Honeywell Intelligrated IntelliSort HS Maintenance Manual
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Honeywell Intelligrated IntelliSort HS Maintenance Manual

Honeywell Intelligrated IntelliSort HS Maintenance Manual

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IntelliSort HS MS
Maintenance Manual
Publication No. 29350703
August 8, 2016

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Summary of Contents for Honeywell Intelligrated IntelliSort HS

  • Page 1 IntelliSort HS MS Maintenance Manual Publication No. 29350703 August 8, 2016...
  • Page 2 Honeywell. © 2016 Honeywell International Inc. All Rights Reserved This document contains confidential proprietary information and trade secrets of Honeywell. This document is distributed with the understanding that it will not be disclosed to any third party, in whole or part, without the prior written consent of Honeywell.

  • Page 3: Table Of Contents

    Table of Contents SAFETY INSTRUCTIONS ....................1 Introduction ......................1 For Your Safety ......................2 Standard Safety Conventions ................... 2 Safety Precautions ....................4 1.4.1 Guards and Guarding ..................4 1.4.2 Headroom ......................5 Controls ........................5 1.5.1 Control Stations ....................5 1.5.2 Safety Devices ....................
  • Page 4 Introduction ......................1 Flight Removal and Installation ................. 2 Chain Adjustment and the Catenary ................. 3 Chain Lubrication ..................... 6 Chain Temperature ....................6 Chain Wear ......................7 Cleaning the Divert and Crossover Switches ............7 Divert Actuator Assembly Replacement..............8 Divert Switch Trigger Replacement ................
  • Page 5 5.2.2 Infeed Belt ......................18 5.2.3 Idler ........................21 5.2.4 Infeed Shaft ......................23 Intermediates ......................24 5.3.1 Divert Profiles ....................24 5.3.2 20° Dual-Sided Soft Touch ................25 5.3.3 20° Dual-Sided Regular Touch .................27 5.3.4 20° Single-Sided Soft Touch Left Hand ............29 5.3.5 20° Single-Sided Regular Touch Left Hand ............31 5.3.6 20°...
  • Page 6 5.6.5 DCM Enclosure ....................56 5.6.6 DCM Board ......................57 5.6.7 Air Switch ......................58 5.6.8 Air Switch Platen ....................59 5.6.9 DDD Kit ......................60 5.6.10 Aluminum Flight ....................61 5.6.11 Tube Flight ....................63 5.6.12 Electric Oiler ....................65 5.6.13 Pneumatic Oiler ....................66 5.6.14 I-Watch System ....................66 TROUBLESHOOTING ......................67 Introduction ......................67 Troubleshooting .......................68...

  • Page 7: Safety Instructions

    Safety Instructions This chapter provides instructions for the safe and productive operation of the equipment. You must read and understand these precautions completely before operating, setting up, installing, running, or performing maintenance on the equipment. Failure to follow this instruction could result in death or serious injury. Introduction These safety precautions are to be used as a guide to supplement the following: All other information pertaining to the equipment.

  • Page 8: For Your Safety

    Safety Instructions Note: Emphasis is placed on the latest edition of the Occupational Safety and Health Standards, which is available from the Department of Labor, Washington, D.C. These standards (found in Part 1910, Title 29 of the Code of Federal Regulations) contain the current, general industry occupational safety and health regulations set forth by federal legislation.
  • Page 9 Safety Instructions Warning signs and labels posted on or near the equipment shall not be removed, painted over, or altered at any time. Reference: ANSI Z535.4. All safety devices, warning lights, and alarms associated with the conveyor system must be regularly tested (at least monthly) for proper operation and serviced as needed.

  • Page 10: Safety Precautions

    Safety Instructions Safety Precautions The success of any safety program depends primarily on the attitudes and training of the installation, maintenance, and operating personnel. The very nature of their work makes it necessary that they develop a complete and firsthand knowledge of each piece of equipment that is within their care.

  • Page 11: Headroom

    Safety Instructions When the equipment passes over a walkway, roadway, or work station, it is considered guarded by location if all moving parts are at least 8 ft. (2.4 m) above the floor or walking surface or are otherwise located so that the employee cannot inadvertently come in contact with hazardous moving parts.

  • Page 12: Safety Devices

    Safety Instructions Equipment that would cause injury when started shall not be started until employees in the area are alerted by a signal, or by a designated person, that the equipment is about to start. When the equipment would cause injury and is automatically controlled or must be controlled from a remote location is started, an audible device shall be provided which can be clearly heard at all points along the conveyor where personnel may be present.

  • Page 13: Operation Safety Precautions

    Safety Instructions Emergency Stops and Restarts The controls shall be arranged so that, in case of emergency stop, manual reset or start at the location where the emergency stop was initiated shall be required of the conveyor(s) and associated equipment to resume operation. Before restarting the equipment that has been stopped because of an emergency, an inspection of the conveyor shall be made and the cause of the stoppage determined.

  • Page 14: Installation And Maintenance Safety

    Safety Instructions Conveyors shall not be newly installed, maintained, or serviced while in operation unless proper installation, maintenance, or service requires the conveyor to be in motion. In this case, personnel shall be made aware of the hazards and how the task may be safely accomplished.

  • Page 15: Lockout / Tagout Guidelines

    Safety Instructions Lockout / Tagout Guidelines Appropriate lockout and tagout policy and procedures shall comply with the Code of Federal Regulations, 29 CFR 1910.147 and the minimum safety requirements outlined in the current publication of the American National Standard Institute’s Control of Hazardous Energy - Lockout/Tagout and Alternative Methods (ANSI Z244.1).

  • Page 17: General Description

    General Description Introduction The IntelliSort® sliding shoe sorters are designed for applications requiring high rate positive sortation of products. The IntelliSort family of sliding shoe sorters is broken into two product classes. • The IntelliSort HS is provided with the I-Watch system when controlled by InControWare®...
  • Page 18 General Description The sorter is shipped to the job site in several assemblies. Every sorter begins with a feeding belt conveyor which is integrated with the sorter infeed terminal end called the idler. This is followed by intermediate sorter sections which contain the divert mechanisms.

  • Page 19: Idler Section With Infeed Belt

    General Description Figure 2-2 IntelliSort HS General Layout Idler Section with Infeed Belt The idler section with infeed belt is located at the infeed end of the IntelliSort. The general function of this section is to induct product onto the sorter. The infeed belt is driven by the sorter drive using a Power Take-Off (PTO).

  • Page 20: Intermediate Section With Divert Switch

    General Description Figure 2-3 Idler with Infeed Belt Intermediate Section with Divert Switch 2.3.1 Divert Switch Operator The divert switch assembly is positioned on the side of the sorter opposite the divert location. The shoes then move down the pin guide track to each divert switch assembly.
  • Page 21 General Description The control system determines how many and which specific shoes will be used to divert any item. In general, one divert shoe is sent for every five inches of product length. The lead edge of the divert shoe is timed to connect with the leading edge of the product to be diverted.

  • Page 22: Divert Switch Detail

    General Description 2.3.2 Divert Switch Detail The IntelliSort can be supplied with a pneumatic or electrically actuated divert switch. The divert switch is actuated by a signal from a central control system. The central control system maintains the signal to release the appropriate number of divert shoes needed to guide the product onto predetermined off-ramps, called spurs, which are designed to take product away from the sortation conveyor in a rapid manner.

  • Page 23: Intermediate Section With Catenary

    General Description Intermediate Section with Catenary The catenary is where the carrying chains sag to their lowest point on their return path below the sorter's carrying surface. The catenary is equipped with windows through which maintenance personnel can gauge the amount of sag in the chains and monitor the wear rate of the right and left chains to ensure consistent growth rates.

  • Page 24: Carrying Chain And Drive Unit

    General Description Carrying Chain and Drive Unit Tension on the carrying chain is adjusted during installation and maintained by the catenary take-up section. Carrying chains are driven by drive sprockets located on the drive shaft. The drive shaft is driven by V-belts, which are installed from the drive sheave on the motor to the drive sheave on the shaft mounted reducer.

  • Page 25: Divert Shoes And Flights

    General Description Figure 2-8 Drive Unit Divert Shoes and Flights Streamlined divert shoes are used for both round and flat flights. The IntelliSort is capable of running at speeds up to 650 fpm. Appropriate gap is required between cartons for effective sortation of the product; gap requirements vary based on the product mix and the control system.

  • Page 26: Product Summary

    General Description Figure 2-9 Flight Assemblies and Divert Shoes Product Summary Application Mid to high rate sortation of cartons, totes and a wide variety of items from a single induction conveyor to aftersort conveyors or chutes Minimum Carton Size 6-inches long x 4 inches wide x 3/4 inch high Requirements Infeed Belt Widths 22, 28, and 34 inches...

  • Page 27: Service And Repair

    Service and Repair Introduction This chapter contains instructions for removing, replacing, and adjusting various components on the IntelliSort sliding shoe sorter. Be sure to follow all safety precautions and lockout/tagout procedures when servicing and repairing the conveyor. Before performing any maintenance, follow the lockout/tagout procedure in Safety Instructions to ensure that equipment is safe to work on.

  • Page 28: Flight Removal And Installation

    Repair Service and Flight Removal and Installation Remove the chain cover from the section(s) where you plan to remove the flight. Using screwdrivers or pry bars, lift the chain up and away from the flights. This will allow the chain pins to pull out of the flights. Grasp the flight to be removed and pull it toward you, taking care not to let it fall into the sorter frame.

  • Page 29: Chain Adjustment And The Catenary

    Repair Service and Use screwdriver or pry bar to re-seat the chain in its resting position Chain Adjustment and the Catenary The catenary is equipped with windows through which maintenance personnel can gauge the amount of sag in the carrying chains and monitor the wear rate of the right and left chains to ensure consistent growth rates.
  • Page 30 Repair Service and Figure 3-1 Intermediate Section with Catenary Measure each chain separately, using the window on the corresponding side of the catenary. The amount of sag is the distance from the 0 mark at the top of the catenary window to the top of the chain. Keep in mind, removing 5 inches of chain raises the catenary sag by approximately 8 inches to 10 inches, so ensure there is enough sag before initiating the following procedure.
  • Page 31 Repair Service and To reduce chain sag, adjust chain length as follows: Remove flights, chain covers, and guarding as described in Flight Removal and Installation earlier in this chapter. Remove equal lengths of chain from each side in 5-inch increments (two 2-roller/2- pin links).

  • Page 32: Chain Lubrication

    Repair Service and Chain Lubrication Chain lubrication is the single most important preventive maintenance function on a sliding shoe sorter. Be sure to follow the instructions provided in this chapter to ensure the chain oiler is properly filled and functioning. While improper chain lubrication is not the only possible cause of chain elongation due to pin and bushing wear, proper lubrication and application can extend the life of a chain and save significant costs and downtime associated with chain replacement.

  • Page 33: Chain Wear

    Repair Service and Chain Wear Chain wear is checked by measuring the % elongation over a new chain. Chains should be replaced when they reach a 2.0% elongation over their original length. Elongation can be checked by measuring the center-to-center distance over 25 extended pins (48 chain pitches).

  • Page 34: Divert Actuator Assembly Replacement

    Repair Service and Look for loose or broken parts. Replace as required. Examine the divert trigger, making certain it moves freely and returns to the straight through position. Divert Actuator Assembly Replacement The divert switch actuator assembly consists of the trigger, spacer block, and rotary actuator.

  • Page 35: Divert Switch Trigger Replacement

    Repair Service and Remove the actuator assembly from the divert switch. Install the new actuator assembly into the divert switch. a. Apply Loctite 609 to the threads of the mounting screws. b. Install the screws and washers. c. Torque the screws to 48 in/lbs. Re-connect the cable to the DCM.

  • Page 36: Debris Detection Device Adjustment

    Repair Service and Remove the 1-inch O.D. washer and lock washer. Remove the trigger. There are notches on the bottom of the trigger for a small gear puller, if necessary. Install the new trigger and replace the washers. Apply Locktite 609 to the screw and re-install with 55 in/lbs of torque. Replace the flights to the sorter apron.
  • Page 37 Repair Service and Tighten the bolts that attached the flipper blade to the shaft. Adjust the limit switch, if necessary. • Adjust the trip arm bumper up or down to set the vertical position of the flipper blade. • Loosen the limit switch arm. •...

  • Page 38: Chain Lubricator Adjustment

    Repair Service and 3.11 Chain Lubricator Adjustment Lubrication directly affects the life and performance of the sorter chains. Proper oil flow and lubrication is the responsibility of the customer. Intelligrated is not responsible for chain damage due to lack of lubrication. Failure to follow this instruction may result in equipment damage.
  • Page 39 Repair Service and Oiler Brushes The bristle tips of the oiler brush should be 1/16 inch lower than the top of the chain side plates. Turn the 5/8 inch nylock nut to adjust the brush height. Fill the oil reservoir with 20 WT NON-DETERGENT OIL. Electric Pump Oiler Priming Instructions Normally, this procedure would only need to be completed during initial installation.

  • Page 40: Orsco Precision Pneumatic Nozzle Style Oiler

    Repair Service and 3.11.2 Orsco Precision Pneumatic Nozzle Style Oiler The Orsco system uses integrated solenoid valves to deliver oil precisely between the sidebars of the chain. One solenoid valve (injector valve) is used to supply air pressure to a positive displacement injector. The other (nozzle valve) feeds a regulator which in turn provides air to the downstream nozzle assembly.
  • Page 41 Repair Service and Orsco Nozzle Adjustment Periodically, the nozzles should be inspected to verify proper position, and proper delivery of oil. The nozzle’s tip should be located directly between the sidebars of the chain. The nozzle tip elevation should be 7/8 of an inch above the top of the chain. Perform a lockout/tagout to ensure the sorter will not start up.

  • Page 42: Carrying Flight Cleaning

    Repair Service and Allow oil to fill the VS manifold until it flows through the bleed valve and close the pet-cock. Manually cycle the injectors by manually firing the injector solenoids. Repeat until lubricant is observed in the nozzle feed line. Repeat process to each injector.

  • Page 43: Electric Switch Removal And Installation

    Repair Service and 3.13 Electric Switch Removal and Installation 3.13.1 Soft Touch Electric Switch Note: If either the Soft Touch Electric Switch or DCM fails, replace both. Electric Switch - Full Assembly Remove the flights at the switch location. Remove four 3/8-16 carriage bolts and nuts that attach the switch to the sorter spreaders.
  • Page 44 Repair Service and Electric Switch - Actuator and Blade Assembly Remove access window at switch location. Remove three #10-24 socket head screws from the bottom of the switch. Pull the actuator and blade assembly out of the sorter through the access window. IntelliSort HS MS | Maintenance Manual | 29350703 August 8, 2016...

  • Page 45: Regular Touch Electric Switch Removal And Installation

    Repair Service and 3.13.2 Regular Touch Electric Switch Removal and Installation Note: If either the regular touch electric switch or DCM fails, the best practice is to replace both. Figure 3-5 Electric Switch Removal Use the following procedure to remove and re-install the regular touch electric switch: Open the window at the switch location.
  • Page 46 Repair Service and Remove four 3/8-16 hex bolts from the bottom of the switch assembly. Pull the switch out of the sorter window. Insert replacement switch and re-install four 3/8-16 hex bolts. Restore power to the conveyor and test the divert switch operation. IntelliSort HS MS | Maintenance Manual | 29350703 August 8, 2016...

  • Page 47: Preventive Maintenance

    Preventive Maintenance Introduction Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage. The satisfactory performance and reliability of this equipment is dependent upon a proficient preventive maintenance (PM) program with scheduled equipment inspections under normal operating conditions.

  • Page 48: Maintenance Precautions

    Maintenance Preventive Preventive maintenance consists of regular service (lubrication, adjustments, cleaning, etc.). Part of preventive maintenance is becoming aware of potential problems by simply using your senses. Use your eyes to see potential component failure. Use your ears to listen for abnormal or louder than normal noises. Use your nose to smell a motor running abnormally warm in time to prevent its burnout.

  • Page 49: Cleaning And Inspection

    Maintenance Preventive 4.2.1 Cleaning and Inspection Generally, there are many reasons for cleaning: To allow heat to dissipate (motors and gearboxes). To prevent wear on moving parts. To prevent binding. For proper operation. Operating personnel will most likely treat clean equipment with more care. Any prescribed cleaning schedule should be modified as experience is gained.
  • Page 50 Maintenance Preventive Daily Weekly Quarterly Date Initials Shoes making contact with the UHMW transitions due to misalignment, improper adjustment, or wear. Visually inspect for wear, improper alignment, or buildup of foreign materials and repair/clean as required. Visually inspect all motors. Make sure the divert switch air pressure is set to 60 psi as read on the digital display mounted by the...
  • Page 51 Maintenance Preventive Daily Weekly Quarterly Date Initials Check the oil level in the chain lubricator reservoir. Add oil to the full level. If the oil level has not changed since the last check, check to make sure the pump is operating correctly.
  • Page 52 Maintenance Preventive Daily Weekly Quarterly Date Initials Skewing of slats that indicates the jump of a sprocket tooth or uneven stretching of the chain. Oil leakage that would indicate faulty motors, reducers, chain oiler, bearings or seals. Ensure that all required guarding and safety devices are in place and functioning properly.
  • Page 53 Maintenance Preventive Daily Weekly Quarterly Date Initials Inspect all divert shoes for any physical damage. Replace any damaged shoes. Verify the shoes slide freely on the carrying flights. Fix any shoe binding problems that are observed. Also look for and correct any shoes that may have jumped out of the pin track.
  • Page 54 Maintenance Preventive Daily Weekly Quarterly Date Initials Inspect the divert switches for presence of any dirt or product spillage. Clean each divert switch as required. Check that the top of the photo-eye is free of any contamination. Inspect the drive unit V-belts for proper tension, wear, and alignment.
  • Page 55 Maintenance Preventive Daily Weekly Quarterly Date Initials Check the physical condition of the black UHMW carrying chain tracks mounted along each side of the sorter. Check the height of the right and left side black UHMW carrying chain guides at points opposite each divert switch.
  • Page 56 Maintenance Preventive Daily Weekly Quarterly Date Initials Check the unit for oil leakage and find the source of the leakage. The most common leak points are pipe plugs, oil seals, and the cover gasket. Rather than waiting for parts during unscheduled down time, you may wish to order replacement parts when the leaks are minor.
  • Page 57 Maintenance Preventive Daily Weekly Quarterly Date Initials After draining, remove debris by thoroughly flushing the inside of the unit with clean oil. Remove and clean the breather plug to ensure that the air passage is clear. Reinstall the drain plug and breather plug after using a threat sealant.

  • Page 59: Replacement Parts

    Replacement Parts Illustrated Parts Lists The following pages contain standard assembly and component parts illustrations and parts lists for your equipment. Colors used in these illustrations are for clarification only and may not match the paint colors of your equipment components. These illustrations and parts listings were up-to-date at the time of the printing of this manual.
  • Page 60 Parts Replacement Find the assembly containing the part. Find the part in the assembly's illustration. Note the item number pointing to it. Find the item number in the SEQ column of the associated parts list. Find the part number in the PART NO column. You should also refer to your system spare parts list to verify the part number for your specific project.

  • Page 61: Abbreviations

    Parts Replacement 5.1.2 Abbreviations The following are abbreviations used in the parts lists. 20 Degree Divert Angle Knife Edge 30 Degree Divert Angle Left Hand Divert ADAPT Adaptor LUBR Lubricator Assembly Medium Speed Between Frame Width (in Motor inches) Catenary Photo Eye CBTA Coupled Brushless Torque...
  • Page 62 Parts Replacement Figure 5-2 Sorter Layout IntelliSort HS MS | Maintenance Manual | 29350703 August 8, 2016...

  • Page 63: Idlers And Infeed Belts

    Parts Replacement Idlers and Infeed Belts 5.2.1 Belt End Idler Assembly Name: ISS 2.25 KE END ID SB ASY 18-29” Assembly Number: 303541 Seq. Qty. Part Number Description 41038902 KNIFE EDGE ROLLER 2.25OD X 22L 41038903 KNIFE EDGE ROLLER 2.25OD X 28L 41038904 KNIFE EDGE ROLLER 2.25OD X 34L 41038908...

  • Page 64: Infeed Belt

    Parts Replacement Seq. Qty. Part Number Description 140027340 ROL G251AB DP CUP 34.00BF NO AXLE 140027380 ROL G251AB DP CUP 38.00BF NO AXLE 140307220 11/16 HEX AXLE PINNED 22.00 BF 140307280 11/16 HEX AXLE PINNED 28.00 BF 140307340 11/16 HEX AXLE PINNED 34.00 BF 140307380 11/16 HEX AXLE PINNED 38.00 BF 5.2.2 Infeed Belt...
  • Page 65 Parts Replacement Seq. Qty. Part Number Description 140027380 ROL G251 AB DP CUP 38.00"BF NO AXLE 140307220 11/16 HEX AXLE PINNED 22.00"BF 140307280 11/16 HEX AXLE PINNED 28.00"BF 140307340 11/16 HEX AXLE PINNED 34.00"BF 140307380 11/16 HEX AXLE PINNED 38.00"BF 41007003 200 PULY RD S 3"...
  • Page 66 Parts Replacement Seq. Qty. Part Number Description 30392001 ISS IDLER PTO TRANS ROLR 22.5W 30392002 ISS IDLER PTO TRANS ROLR 28.5W 30392003 ISS IDLER PTO TRANS ROLR 34.5W 305057 O-BELT .188 X 9.438 LG 83A DUROMETER (3"CTRS) 30393101 ISS IDLER PTO TRANS ROLR SLIDE PLATE WLDMT 22.5W 30393102 ISS IDLER PTO TRANS ROLR SLIDE...

  • Page 67: Idler

    Parts Replacement 5.2.3 Idler Assembly Name: ISS MH-ID ASSY_EW_BF_H-PTO Assembly Number: 304095 Seq. Qty. Part Number Description 30407601 ISS MH-ID PULY BELT LAG & FLAT 22W 30407602 ISS MH-ID PULY BELT LAG & FLAT 28W 30407603 ISS MH-ID PULY BELT LAG & FLAT 34W 30407605 ISS MH-ID PULY BELT LAG &...
  • Page 68 Parts Replacement Seq. Qty. Part Number Description 30225501 ISS SHAFT IDLER ASY 22EW 43BF CONFIG A 30225502 ISS SHAFT IDLER ASY 28EW 49BF CONFIG A 30225503 ISS SHAFT IDLER ASY 34EW 55BF CONFIG A 30225510 ISS SHAFT IDLER ASY 38EW 59BF CONFIG A 30225504 ISS SHAFT IDLER ASY 22EW 43BF CONFIG B 30225505...

  • Page 69: Infeed Shaft

    Parts Replacement 5.2.4 Infeed Shaft Seq. Qty. Part Number Description 30219901 ISS SHAFT IDL 2 15/16 X 43BF 30219902 ISS SHAFT IDL 2 15/16 X 49BF 30219903 ISS SHAFT IDL 2 15/16 X 55BF 30219904 ISS SHAFT IDL 2 15/16 X 59BF 30220300 ISS SPKT 100C36 ASY W/2.94 BU 30220000...

  • Page 70: Intermediates

    Parts Replacement Intermediates 5.3.1 Divert Profiles IntelliSort HS MS | Maintenance Manual | 29350703 August 8, 2016...

  • Page 71: 20° Dual-Sided Soft Touch

    Parts Replacement 5.3.2 20° Dual-Sided Soft Touch Assembly Name: ISS IS ST 20D DSD__BF__ Seq. Qty. Part Number Description See Switch Details later in this chapter. See Switch Details later in this chapter. 30324101 ISS KIT BLOCK UHMW ST 20D RHD 30324102 ISS KIT BLOCK UHMW ST 20D LHD 30448100...
  • Page 72 Parts Replacement Seq. Qty. Part Number Description 30390324 ISS ST DSD RAIL ASY 21.08L (55B-20D) 30390319 ISS RT DSD RAIL ASY 22.72L (43D-20D) 30390320 ISS RT DSD RAIL ASY 31.52L (49D-20D) 30390321 ISS RT DSD RAIL ASY 40.28L (55D-20D) SPARE 304454400 ISS UHMW PG EXTR 150.00L SPARE...

  • Page 73: 20° Dual-Sided Regular Touch

    Parts Replacement 5.3.3 20° Dual-Sided Regular Touch Assembly Name: ISS IS RT 20D DSD__BF__ Seq. Qty. Part Number Description See Switch Details later in this chapter. See Switch Details later in this chapter. 30448100 ISS CROSS-OVER 20D DUAL SIDED ASY 30276101 ISS BLOCK UHMW DIV RE-ENTRY 20D RHD 30468901...
  • Page 74 Parts Replacement Seq. Qty. Part Number Description 30468902 ISS 21D RE-ENTRY (SPCC) LH 30324001 ISS RT DS DIV RAIL KIT 113.00L (43BF) (20D) 30324002 ISS RT DS DIV RAIL KIT 129.50L (49BF) (20D) 30324003 ISS RT DS DIV RAIL KIT 146.00L (55BF) (20D) 30390385 ISS RT DIV RAIL ASY 45.63L (59BF) 30390386...

  • Page 75: 20° Single-Sided Soft Touch Left Hand

    Parts Replacement 5.3.4 20° Single-Sided Soft Touch Left Hand Assembly Name: ISS IS ST 20D LHD S1-R1__BF__ Seq. Qty. Part Number Description See Switch Details later in this chapter. 30324102 ISS KIT BLOCK UHMW ST 20D LHD 30316801 ISS ST DIVERT RAIL ASY 47.13L (43BF 20D) 30316802 ISS ST DIVERT RAIL ASY 64.69L (49BF...
  • Page 76 Parts Replacement Seq. Qty. Part Number Description 30276102 ISS BLOCK UHMW DIV RE-ENTRY 20D 30468902 ISS 21D RE-ENTRY (SPCC) LH (59BF) SPARE 304459400 ISS UHMW PG EXTR 150.00L SPARE 304458400 ISS ALUM PG EXTR 150.00L IntelliSort HS MS | Maintenance Manual | 29350703 August 8, 2016...

  • Page 77: 20° Single-Sided Regular Touch Left Hand

    Parts Replacement 5.3.5 20° Single-Sided Regular Touch Left Hand Assembly Name: ISS IS RT 20D LHD S1-R1__BF__ Seq. Qty. Part Number Description See Switch Details later in this chapter. 30390301 ISS RT DIV RAIL ASY 66.34L (43B-20D) 30390302 ISS RT DIV RAIL ASY 83.09L (49B-20D) 30390303 ISS RT DIV RAIL ASY 101.45L (55B-20D) 30390389...

  • Page 78: 20° Single-Sided Regular Touch Right Hand

    Parts Replacement Seq. Qty. Part Number Description 30468902 ISS 21D RE-ENTRY (SPCC) RH (59BF) SPARE 304459400 ISS UHMW PG EXTR 150.00L SPARE 304458400 ISS ALUM PG EXTR 150.00L 5.3.6 20° Single-Sided Regular Touch Right Hand Assembly Name: ISS IS RT 20D RHD S1-R1__BF__ Seq.
  • Page 79 Parts Replacement Seq. Qty. Part Number Description 30390302 ISS RT DIV RAIL ASY 83.09L (49B-20D) 30390303 ISS RT DIV RAIL ASY 101.45L (55B-20D) 30390389 ISS RT DIV RAIL ASSY 108.94L (59B-20D) 30276101 ISS BLOCK UHMW DIV RE-ENTRY 20D 30468901 ISS 21D RE-ENTRY (SPCC) RH (59BF) SPARE 304459400 ISS UHMW PG EXTR 150.00L SPARE 304458400...

  • Page 80: 30° Single-Sided Regular Touch Left Hand

    Parts Replacement 5.3.7 30° Single-Sided Regular Touch Left Hand Assembly Name: ISS IS RT 20D RHD S1-R1__BF__ Seq. Qty. Part Number Description See Switch Details later in this chapter. 30390301 ISS RT DIV RAIL ASY 66.34L (43B-20D) 30390302 ISS RT DIV RAIL ASY 83.09L (49B-20D) 30390303 ISS RT DIV RAIL ASY 101.45L (55B-20D) 30276302...

  • Page 81: 30° Single-Sided Regular Touch Right Hand

    Parts Replacement 5.3.8 30° Single-Sided Regular Touch Right Hand Assembly Name: ISS IS RT 30D RHD S1-R1__BF__ Seq. Qty. Part Number Description See Switch Details later in this chapter. 30390301 ISS RT DIV RAIL ASY 66.34L (43B-20D) 30390302 ISS RT DIV RAIL ASY 83.09L (49B-20D) 30390303 ISS RT DIV RAIL ASY 101.45L (55B-20D) 30276302...

  • Page 82: 30° Single-Sided Regular Touch Right Hand

    Parts Replacement 5.3.9 30° Single-Sided Regular Touch Right Hand Assembly Name: ISS IS RT 30D RHD S1-R1__BF__ Seq. Qty. Part Number Description See Switch Details later in this chapter. 30276301 ISS BLOCK UHMW DIV RE-ENTRY 30D RHD 30390301 ISS RT DIV RAIL ASY 66.34L (43B-20D) 30390302 ISS RT DIV RAIL ASY 83.09L (49B-20D) 30390303...

  • Page 83: 20° Single-Sided Soft Touch Right Hand

    Parts Replacement 5.3.10 20° Single-Sided Soft Touch Right Hand Seq. Qty. Part Number Description See Switch Details later in this chapter. 30318601 ISS KIT BLOCK UHMW ST 20D RHD 30316804 ISS ST DIV RAIL ASY 22.46L (43B-30D) 30316805 ISS ST DIV RAIL ASY 34.44L (49B-30D) 30316806 ISS ST DIV RAIL ASY 46.43L (55B-30D) 30390388...

  • Page 84: 30° Single-Sided Soft Touch Left Hand

    Parts Replacement Seq. Qty. Part Number Description SPARE 304459400 ISS UHMW PG EXTR 150.00L SPARE 304458400 ISS ALUM PG EXTR 150.00L 5.3.11 30° Single-Sided Soft Touch Left Hand Assembly Name: ISS IS ST 30D LHD S1-R1__BF__ Seq. Qty. Part Number Description See Switch Details later in this chapter.
  • Page 85 Parts Replacement Seq. Qty. Part Number Description 30316805 ISS ST DIVERT RAIL ASY 34.44L (49BF 30D) 30316806 ISS ST DIVERT RAIL ASY 46.43L (55BF 30D) 30276302 ISS BLOCK UHMW DIV RE-ENTRY 30D SPARE 304459400 ISS UHMW PG EXTR 150.00L SPARE 304458400 ISS ALUM PG EXTR 150.00L IntelliSort HS MS | Maintenance Manual | 29350703 August 8, 2016...

  • Page 86: 30° Single-Sided Soft Touch Right Hand

    Parts Replacement 5.3.12 30° Single-Sided Soft Touch Right Hand Assembly Name: ISS IS ST 30D RHD S1-R1__BF__ Seq. Qty. Part Number Description See Switch Details later in this chapter. 30318601 ISS KIT BLOCK UHMW ST 30D RHD 30316804 ISS ST DIVERT RAIL ASY 22.46L (43BF 30D) 30316805 ISS ST DIVERT RAIL ASY 34.44L (49BF...

  • Page 87: Catenaries

    Parts Replacement Seq. Qty. Part Number Description SPARE 304459400 ISS UHMW PG EXTR 150.00L SPARE 304458400 ISS ALUM PG EXTR 150.00L Catenaries 5.4.1 150DP Electric Oiler Catenary Kit Assembly Name: ISS CAT KIT 15DP_BF_L 303378__ Assembly Number: 303378 Seq. Qty. Part Number Description 30233301...

  • Page 88: Pneumatic Oiler Catenary

    Parts Replacement 5.4.2 Pneumatic Oiler Catenary Assembly Name: ISS CH CARE CAT ASY_BF_D 303764__ Assembly Number: 303764 Seq. Qty. Part Number Description 30376701 ISS GD BLK CAT-IN UHMW CHAIN RH 30376702 ISS GD BLK CAT-IN UHMW CHAIN LH 30378101 ISS BLOCK ASY CHGD CAT OUT 48R RH 30378102 ISS BLOCK ASY CHGD CAT OUT 48R LH 30376601...

  • Page 89: Drives And Discharge Belts

    Parts Replacement Drives and Discharge Belts 5.5.1 Drive Assembly Name: ISS MH-DR__BF_H-DR__EW_H-DIV 304100 Assembly Number: 304100 Seq. Qty. Part Number Description 21030608 MOTOR REL 5HP #P18G7403 184T 21030607 7.5HP,1770RPM,3PH,60HZ,213,T,0735M,TEFC, BALDOR EM3770T 21287400 MTR BALDOR 10HP 215FR TEFC-XE EM3774T IntelliSort HS MS | Maintenance Manual | 29350703 August 8, 2016...
  • Page 90 Parts Replacement Seq. Qty. Part Number Description 21030601 EM2333T MOTOR, 15HP 254T FRAME 230/460V 1765 RPM 21299000 MTR REL 20HP BALDOR #EM2334T 21030603 MOTOR BALDOR 25HP #EM4103T 284T 21030604 MOTOR BALDOR 30HP #EM4104T 286T 21030605 MOTOR BALDOR 40HP #EM4110T 324T 21030606 MOTOR BALDOR 50HP #EM4115T 326T 22484217...
  • Page 91 Parts Replacement Seq. Qty. Part Number Description 22484110 SPLIT TAPER SHEAVE 3 GROOVE USES BUSHING B, OD 6.28 22484104 SPLIT TAPER SHEAVE 3 GROOVE USES BUSHING B, OD 12.68 22596804 SPLIT TAPER SHEAVE 3 GROOVE USES BUSHING B, OD 12.68 22596803 SPLIT TAPER SHEAVE, 2 GROOVE, USES BUSHING B, OD 15.68...

  • Page 92: Shaft Drive

    Parts Replacement 5.5.2 Shaft Drive Assembly Number: 302254 Seq. Qty. Part Number Description 30218101 ISS SHAFT DR 3 7/16 X 1.938 43BF 30218102 ISS SHAFT DR 3 7/16 X 1.938 49BF 30218103 ISS SHAFT DR 3 7/16 X 1.938 55BF 30218110 ISS SHAFT DR 3 7/16 X 1.938 59BF 30218104...

  • Page 93: Discharge Belt

    Parts Replacement Seq. Qty. Part Number Description 30218200 ISS SPKT 100A48 ADJ ASY W/R2 BU 30219600 ISS SPKT 100R48 ASY W/R1 BU 5.5.3 Discharge Belt Assembly Name: ISS MH-DR BELT FRAME_BF_H_DR__304135 Assembly Number: 304135 Seq. Qty. Part Number Description 30412401 ISS MH-DR PULY BELT LAG &...
  • Page 94 Parts Replacement Seq. Qty. Part Number Description 30414502 ISS EX PWR UNIT 2HP ___V BAL XE MTR/DGE RD __Q05HA__ LH BLT DR 30414503 ISS EX PWR UNIT 3HP ___V BAL XE MTR/DGE RD __Q05HA__ RH BLT DR 30414504 ISS EX PWR UNIT 3HP ___V BAL XE MTR/DGE RD __Q05HA__ RH BLT DR 23096500 PRS SW M12X1...

  • Page 95: Knife Edge End Idler Sb

    Parts Replacement 5.5.4 Knife Edge End Idler SB Assembly Name: ISS 2.25 KE END ID SB ASY 18-29” 303541 Assembly Number: 303541 Seq. Qty. Part Number Description 41038902 KNIFE EDGE ROLLER 2.25OD X 22L 41038903 KNIFE EDGE ROLLER 2.25OD X 28L 41038904 KNIFE EDGE ROLLER 2.25OD X 34L 41038908...
  • Page 96 Parts Replacement Seq. Qty. Part Number Description 140307220 11/16 HEX AXLE PINNED 22.00 BF 140307280 11/16 HEX AXLE PINNED 28.00 BF 140307340 11/16 HEX AXLE PINNED 34.00 BF 140307380 11/16 HEX AXLE PINNED 38.00 BF IntelliSort HS MS | Maintenance Manual | 29350703 August 8, 2016...

  • Page 97: Component Details

    Parts Replacement Component Details 5.6.1 20° and 30° Soft Touch Electric Switch Assembly Name: ISS ELEC SW ASY 20D & 30D ST__H 304539__ Assembly Number: 304539 Seq. Qty. Part Number Description 30457601 ISS ELEC SW BLOCK ASY 20/30 ST RH 30457602 ISS ELEC SW BLOCK ASY 20/30 ST LH 30453801...

  • Page 98: 20° And 30° Soft Touch Electric Switch

    Parts Replacement Seq. Qty. Part Number Description 30453401 ISS ELEC SW BLADE 20/30 ST RH 30453402 ISS ELEC SW BLADE 20/30 ST LH 7085793 GUARD, FRMD, CBTA, 16GA 5.6.2 20° and 30° Soft Touch Electric Switch Assembly Name: ISS ELEC SW ASY ST__H 303948__ Assembly Number: 303948 Seq.
  • Page 99 Parts Replacement Seq. Qty. Part Number Description 7085885 SWITCH, DVT, GNECK, CBTA, 160, RH 7085886 SWITCH, DVT, GNECK, CBTA, 160, LH 7071447 BRIDGE,SW,GSNECK,UXV,16O,OP,LH 7071446 BRIDGE,SW,GSNECK,UXV,16O,SH,RH 7085864 TRIGGER,SW,GSNECK,HVY,LH,NYCST 7085863 TRIGGER,SW,GSNECK,HVY,RH,NYCST 7001128 LENS,LEXAN,.080, .928X .50LG 7085897 PE,CONNECTOR ASSY,AB 7085791 ACTUATOR ASSY COUPLED BTA LH 7085790 ACTUATOR ASSY COUPLED BTA RH IntelliSort HS MS | Maintenance Manual | 29350703...

  • Page 100: 20° Regular Touch Electric Switch

    Parts Replacement 5.6.3 20° Regular Touch Electric Switch Assembly Name: ISS ELEC SW ASY 20D RT__H 304281__ Assembly Number: 304281 Seq. Qty. Part Number Description 30394500 ISS ELEC SW ADAPT BLOCK IN UHMW 30428001 ISS ELEC SW ADAPT BLOCK OUT UHMW 20D RT RH 30428002 ISS ELEC SW ADAPT BLOCK OUT UHMW...

  • Page 101: 30° Regular Touch Electric Switch

    Parts Replacement Seq. Qty. Part Number Description 7085897 PE,CONNECTOR ASSY,AB 7085791 ACTUATOR ASSY COUPLED BTA LH 7085790 ACTUATOR ASSY COUPLED BTA RH 5.6.4 30° Regular Touch Electric Switch Assembly Name: ISS ELEC SW ASY 30D RT_H 304283__ Assembly Number: 304283 Seq.

  • Page 102: Dcm Enclosure

    Parts Replacement Seq. Qty. Part Number Description 7001422 BRIDGE,SW,GSNECK,UXV,21O,LH 7001421 BRIDGE,SW,GSNECK,UXV,21O,RH 7085864 TRIGGER,SW,GSNECK,HVY,LH,NYCST 7085863 TRIGGER,SW,GSNECK,HVY,RH,NYCST 7001128 LENS,LEXAN,.080, .928X .50LG 7085897 PE,CONNECTOR ASSY,AB 7085791 ACTUATOR ASSY COUPLED BTA LH 7085790 ACTUATOR ASSY COUPLED BTA RH 5.6.5 DCM Enclosure Assembly Number: 23433600 Seq.

  • Page 103: Dcm Board

    Parts Replacement 5.6.6 DCM Board Assembly Number: 23434000 Seq. Qty. Part Number Description 23434000 DCM BOARD The DCM (23433600) includes all required cord sets and this circuit board. The circuit board can be replaced independently when necessary. IntelliSort HS MS | Maintenance Manual | 29350703 August 8, 2016...

  • Page 104: Air Switch

    Parts Replacement 5.6.7 Air Switch Assembly Name: ISS I-SWITCH W/CYL-VAL_HD 302824 Assembly Number: 302824 Seq. Qty. Part Number Description 30234800 BRG 6203 LT-SEALS 40MM X 17BR 30315800 ISS I-SWITCH AL PIVOT BRKT 30263901 ISS I-SWITCH UHMW DIV BAR RHD 30263902 ISS I-SWITCH UHMW DIV BAR LHD 30281505 ISS SW VAL/CYL MTG ASY W/O CABLE...

  • Page 105: Air Switch Platen

    Parts Replacement Seq. Qty. Part Number Description 30280300 BUSHING URE 5/16T X 1 1/2OD X 17/32B X 5/8PILOT 30255001 ISS I-SWITCH BUMPER ASY 5.6.8 Air Switch Platen Assembly Name: ISS I-SW ST ISO PLATEN 303160 Assembly Number: 303160 Seq. Qty. Part Number Description 30315901...

  • Page 106: Ddd Kit

    Parts Replacement Seq. Qty. Part Number Description 30278401 ISS I-SWITCH UHMW WEDGE-BAR RHD 30278402 ISS I-SWITCH UHMW WEDGE-BAR LHD 23096700 PHOTO EYE 24VD A-B #42KB-T1LPSQ-Y3 W/PICO QD 5.6.9 DDD Kit Assembly Name: ISS DDD KIT TYP_HD ASY 302957__ Assembly Number: 302957 Seq.

  • Page 107: Aluminum Flight

    Parts Replacement Seq. Qty. Part Number Description 22612702 WHEEL PLASTIC 2.5 O.D. BUSHING REMOVED 5.6.10 Aluminum Flight Assembly Name: ISS FLIGHT ASSY ASY SLAT ZGS-LS__BF__D_H 304245 Assembly Number: 304245 Seq. Qty. Part Number Description 30424501 ISS FLIGHT ASY SLAT ZGS-LS 43BF 20D 30424502 ISS FLIGHT ASY SLAT ZGS-LS 43BF 20D 30424503...
  • Page 108 Parts Replacement Seq. Qty. Part Number Description 30424507 ISS FLIGHT ASY SLAT ZGS-LS 49BF 30D 30424508 ISS FLIGHT ASY SLAT ZGS-LS 49BF 30D 30424509 ISS FLIGHT ASY SLAT ZGS-LS 55BF 20D 30424510 ISS FLIGHT ASY SLAT ZGS-LS 55BF 20D 30424511 ISS FLIGHT ASY SLAT ZGS-LS 55BF 30D 30424512 ISS FLIGHT ASY SLAT ZGS-LS 55BF 30D...

  • Page 109: Tube Flight

    Parts Replacement Seq. Qty. Part Number Description 30424401 ISS PUSHER ASY SLAT ZG-LS 30D DS 30227903 ISS ENDCAP ASY SLAT ZG RH 30227904 ISS ENDCAP ASY SLAT ZG LH 5.6.11 Tube Flight Assembly Name: ISS FLIGHT ASSY ASY TUBE__BF__D_H 302300 Assembly Number: 302300 Seq.
  • Page 110 Parts Replacement Seq. Qty. Part Number Description 30230011 ISS FLIGHT ASY TUBE 55BF 30D RH 30230012 ISS FLIGHT ASY TUBE 55BF 30D LH 30274900 ISS PUSHER ASY TUBE 20D RH 30275000 ISS PUSHER ASY TUBE 20D LH 30275100 ISS PUSHER ASY TUBE 30D RH 30275200 ISS PUSHER ASY TUBE 30D LH 30253300...

  • Page 111: Electric Oiler

    Parts Replacement 5.6.12 Electric Oiler Assembly Name: ISS KIT CHAIN OILER W/LIGHT 30456600 Assembly Number: 30456600 Seq. Qty. Part Number Description Full 30456600 ISS STANDARD CHAIN OILER Assy 30456000 ISS STANDARD OILER POLE LIGHT 30293001 ISS OILER 2QT RESERVOIR W/39" LEADS IntelliSort HS MS | Maintenance Manual | 29350703 August 8, 2016...

  • Page 112: Pneumatic Oiler

    Parts Replacement 5.6.13 Pneumatic Oiler Assembly Name: ISS CHAIN OILER W/MTG STRUT__V_C (__BF__D) Assembly Number: 304322, 303776 Assembly Name: ISS CHAIN CARE NOZZLE KIT Assembly Number: 303776 Seq. Qty. Part Number Description Oiler 7088009 LUBRICATOR,ORSCO, VSR-0039-4-AC 110VAC 7088010 LUBRICATOR CHN VLV STK W RSVR 24VDC Nozzle Kit 30357000...

  • Page 113: Troubleshooting

    Troubleshooting Introduction Before performing any maintenance or lubrication services, follow the lockout/tagout procedure in the Safety Instructions chapter to ensure that the equipment is safe to work on. Failure to follow this instruction may result in serious personal injury and/or equipment damage. When troubleshooting equipment problems, it is essential to completely understand how the system functions during normal operation.
  • Page 114 Troubleshooting List short and long term solutions. Select a solution or possible solutions. Implement and document one solution at a time. Troubleshooting Symptom Probable Cause Corrective Action No line voltage. Check emergency stops and Motor will not start or reset. it is slow to start.
  • Page 115 Troubleshooting Symptom Probable Cause Corrective Action Low line voltage. Check for proper supply voltage Motor will not start or and proper motor wiring. it is slow to start. Correct as necessary. Conveyor overloaded Remove load from conveyor or jammed. and reset. Check for foreign material in chain or sprockets and remove.
  • Page 116 Troubleshooting Symptom Probable Cause Corrective Action Lack of lubrication in Replace reducer with spare. Motor emits reducer. excessive noise, hum, or vibration. Worn or damaged Replace motor or reducer with motor or reducer. spare. Defective bearing. Replace motor or reducer with spare.
  • Page 117 Troubleshooting Symptom Probable Cause Corrective Action Refer to “Possible See “Corrective Action for Excessive noise. Excessive wear” listed above. Causes for Excessive wear” listed above. Dirty chain. Remove and clean chain in solvent; clean sprockets, replace chain and lubricate as instructed.

  • Page 118: Troubleshooting Help

    Troubleshooting Symptom Probable Cause Corrective Action Spur lane full. Clear lane. Divert switch not working. Photo-eye defective. Replace. Broken wire or loose Repair or replace. connection. DCM board defective Replace. Sorter in calibrate Exist calibrate mode in control Sorter running at the mode.
  • Page 119 Index chain wear, 70 cleaning, 3 cleaning crossover switches, 7 abbreviations, 15 cleaning the divert, 7 actuator assembly, 18 Code of Federal Regulations, 2 adjusting debris detection device, 10 controls, 5 adjusting Orsco nozzle, 15 conveyor start adjusting the chain, 3 delay, 70 adjusting the chain lubricator, 12 conveyor stop...
  • Page 120 soft touch, 17 troubleshooting, 68, 69 elevation minimum, 10 emergency restart, 7 noise, 3 emergency stop, 6, 7, 6 troubleshooting, 71 nozzle adjusting, 15 nozzle style oiler, 14 fasteners, 7 finish, 10 flight, 9, 7 cleaning, 16 oil, 6, 12, 13, 5, 6, 8, 9, 10, 11, 23, 66 installation, 2 oil leak, 70 removal, 2...
  • Page 121 operation precautions, 7 sliding shoe, 9 precautions, 4 sorter frame width, 10 signs, 9 spur, 6, 7 safety conventions, 2 safety instructions, 1 sag, 7, 3, 4, 70 trigger, 8, 9, 53, 54 reducing, 5 sag range, 7 IntelliSort HS MS | Maintenance Manual | 29350703 August 8, 2016...

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