Model 2430 SL2 Sorter (DCM) Service Manual

Service Manual Model 2430 SL2 Slat Sorter
Chapter Title is a StyleRef Field
Model 2430
SL2 Slat Sorter
Service Manual
Model 2430 SL2 Slat Sorter Service Manual
© 2017 Dematic Corp. All rights reserved.
No part of this document may be reproduced or transmitted in any form or by

any means, electronic or mechanical, for any purpose, without the express
written permission of Dematic Corp.
Item Description Patent Reference
Positive Displacement Shoe and Slat U.S. Pat. No. US 6,866,136

Sorter Apparatus and Method
Conveyor System with Diverting Track U.S. Pat. No. US 6,923,308 B2
Network U.S. Pat. No. US 7,055,669 B2
Positive Displacement Sorter Shoe U.S. Pat. No. US 7,249,668 B2
U.S. Pat. No. US 7,628,265
Slat Driven Positive Displacement Sorter U.S. Pat. No. US 7,562,761 B2
Tiered Control Architecture U.S. Pat. No. US 7,568,572
Retractable Diverter Nose U.S. Pat. No. US 7,798,306
High Volume Conveyor Sortation System U.S. Pat. No. US 8,060,245
Rotary Actuated Diverter U.S. Pat. No. US 8,469,177
This document contains confidential information, trade secrets and/or know-how

which is the property of Dematic Corp., and may not be disclosed to any third
party without the written permission of Dematic Corp. Product and company
names herein may be the trademarks of their respective owners.
Hereinafter Dematic Corp. shall be written as Dematic and refers to any Dematic
entity within the global Dematic group of companies. Information in this
document is subject to change without notice.
Dematic Corp.
507 Plymouth Avenue
Grand Rapids, MI 49505
616-913-6200
800-530-9153
www.dematic.us
Original Instructions
2 2017-05-11
Contents
1 Safety ............................................................................................. 7
1.1 Danger/Warning/Caution Convention .............................................. 7
1.2 General Safety ................................................................................ 7
1.2.1 Personnel........................................................................................ 8
1.2.2 Equipment....................................................................................... 9
1.2.3 Equipment Labels ........................................................................... 9
1.2.4 CE Declarations .............................................................................. 9
1.2.5 Operation ........................................................................................ 9
1.2.6 Instructions for Safe Clearing of Product Jams................................ 9
1.2.7 Maintenance ................................................................................. 10
1.2.8 Decommissioning and Disposal .................................................... 10
2 Equipment Description ............................................................... 11

2.1 Charge Bed................................................................................... 11
2.2 Framework .................................................................................... 12
2.3 Drives ........................................................................................... 12
2.4 Slat and Shoe Assembly ............................................................... 12
2.5 Divert Assemblies ......................................................................... 13
2.6 Discharge Bed .............................................................................. 13
2.7 Return Sweep ............................................................................... 14
2.8 Environmental Specifications ........................................................ 14
3 Maintenance ................................................................................ 15
3.1 General Safety and Maintenance .................................................. 15
3.2 Periodic Maintenance Schedule .................................................... 16
3.3 Tool Kit ......................................................................................... 17
3.4 Preventive Maintenance ................................................................ 18
3.4.1 Inspections.................................................................................... 18
3.4.2 Creating a Maintenance Window .................................................. 18
3.4.3 Jogging the Sorter......................................................................... 21
3.4.4 Removing Side Panels .................................................................. 23
3.4.5 Cleaning and Care of Powder Coated Components ...................... 23
3.4.6 Checking Tension of the Gas Springs ........................................... 24
3.4.7 Slat Chain ..................................................................................... 25
3.4.8 Clearing Debris from Bottom Covers ............................................. 27
3.4.9 Cleaning Divert Switch and Rail Assemblies ................................. 27
3.4.10 Cleaning the Electrostatic Discharge (ESD) Brush ........................ 27
3.4.11 Cleaning LIM Fans ........................................................................ 28
3.4.12 Cleaning Photoeyes and Reflectors .............................................. 29
3.4.13 Wiring and Cables......................................................................... 29
3.5 Common Maintenance .................................................................. 31
3.5.1 Slat Chain ..................................................................................... 31
3.5.2 Divert Control Module Reseating .................................................. 36
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3.5.3 Slat Sensor Adjustment ................................................................. 36

3.5.4 Electrostatic Discharge (ESD) Brush Adjustment .......................... 39
3.5.5 Return Sweep Bearing Guide Adjustment ..................................... 39
3.5.6 Linear Induction Motor (LIM) Gap Adjustment ............................... 41
3.5.7 Take-Up Sensor Replacement Validation ...................................... 46
3.5.8 Sensor Position Verification ........................................................... 48
3.5.9 Discharge Take-Up Assembly Freedom of Movement ................... 51
3.5.10 Gap Wheel Height Adjustment ...................................................... 52
3.5.11 Transition Bed Belt Calibration ...................................................... 54
3.5.12 Shoe Pin Alarm Recovery.............................................................. 55
4 Troubleshooting .......................................................................... 57
5 Repair ........................................................................................... 63
5.1 Charge Bed ................................................................................... 64
5.1.1 Electrostatic Discharge (ESD) Brushes ......................................... 64
5.1.2 Slat Sensor [Figure 25 – Item (4)] .................................................. 66
5.1.3 Shoe Cap Photoeye [Figure 27 – Item (5)] .................................... 69
5.1.4 Update Photoeye [Figure 28 – Item (2)] ......................................... 71
5.2 Slat Chain ...................................................................................... 76
5.2.1 Slat and Shoe ................................................................................ 76
5.2.2 Link Plate, Carrier Wheel, and Guide Wheel.................................. 79
5.3 Wear Strip ..................................................................................... 82
5.3.1 Upper Frame Rail Wear Strip ........................................................ 82
5.3.2 Lower Frame Rail Wear Strip ........................................................ 85
5.4 Divert Assembly ............................................................................ 91
5.4.1 Slat Sensor, Pin Sensor ................................................................ 91
5.4.2 Retractable Nose [Figure 43 – Item (13)] ....................................... 96
5.4.3 Mechanical Divert Switch (MDS) [Figure 43 – Item (4)] ................. 97
5.4.4 MDS Gate and Bumpers [Figure 46 – Items (2, 12, 14)] ................ 98
5.4.5 Merge Assembly .......................................................................... 100
5.5 Linear Induction Motor (LIM) ........................................................ 101
5.5.1 Upper LIM Assembly ................................................................... 101
5.5.2 Lower LIM Assembly ................................................................... 103
5.5.3 Checking LIM Thrust Direction .................................................... 104
5.5.4 LIM Fan [Figure 50 – Item (6)] ..................................................... 104
5.5.5 Slat Ski Wear Strips [Figure 52 – Item (2)] ................................... 105
5.6 Variable Frequency Drive ............................................................ 107
5.7 Divert Control Module(DCM) ....................................................... 110
5.7.1 DCM Controller............................................................................ 110
5.7.2 DCM Chassis .............................................................................. 110
5.8 Return Pin Sensor [Figure 56 – Item (5)] ..................................... 113
5.9 Discharge Bed ............................................................................. 115
5.9.1 Take-Up Sensor .......................................................................... 115
5.9.2 Take-up Gas Spring [Figure 58 – Item (64)] ................................ 119
5.9.3 Gap Wheels [Figure 58 – Item (62)]............................................. 119
5.10 Taper-Lock Bushings................................................................... 120
5.11 Bearing Setscrews and Cap Screws Torque Specs ..................... 123
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Figures
Figure 1 Model 2430 SL2 Slat Sorter ............................................................ 11

Figure 2 Slat Removal .................................................................................. 19
Figure 3 Slat Installation ............................................................................... 20
Figure 4 Jog Box Connection ....................................................................... 22
Figure 5 Verifying Gas Spring Function ........................................................ 25
Figure 6 Slat Electrostatic Discharge (ESD) Brush ....................................... 28
Figure 7 DCM Cabling .................................................................................. 30
Figure 8 Gas Springs and Take-up Screws .................................................. 33
Figure 9 Removing Slack from the Slat Chain .............................................. 34
Figure 10 Switch Assembly ............................................................................ 37
Figure 11 Electrostatic Discharge (ESD) Brush .............................................. 38
Figure 12 Return Sweep Bearing Guide Detail ............................................... 40
Figure 13 LIM Gap Tool.................................................................................. 41
Figure 14 LIM Gap Adjustment ....................................................................... 42
Figure 15 Bottom Mounted LIM Height Adjustment ........................................ 44
Figure 16 Slat Ski Wear Strip Height Check ................................................... 45
Figure 17 Take-Up Gap .................................................................................. 47
Figure 18 Charge End Slat Sensor ................................................................. 48
Figure 19 Slat Timing Tool.............................................................................. 50
Figure 20 Takeup Indicator ............................................................................. 51
Figure 21 Gap Wheel Height Adjustment........................................................ 53
Figure 22 Charge End Assembly .................................................................... 64
Figure 23 Slat Electrostatic Discharge (ESD) Brush ....................................... 65
Figure 24 Link Plate ESD Brush ..................................................................... 66
Figure 25 Charge End Assembly Slat Sensor ................................................. 67
Figure 26 Charge End Assembly Slat Sensor Gap Verification ....................... 68
Figure 27 Shoe Cap Sensor and Doghouse ................................................... 70
Figure 28 Update Photoeye and Housing ....................................................... 73
Figure 29 Update Photoeye Alignment ........................................................... 74
Figure 30 Slat Timing Tool.............................................................................. 75
Figure 31 Slat Removal .................................................................................. 77
Figure 32 Slat Installation ............................................................................... 78
Figure 33 Slat Shoe ........................................................................................ 79
Figure 34 Preparation for Breaking the Slat Chain .......................................... 80
Figure 35 Slat Chain Links.............................................................................. 81
Figure 36 Wear Strip Tape Replacement........................................................ 83
Figure 37 Wear Strip Transition Points ........................................................... 84
Figure 38 Breaking the Slat Chain .................................................................. 86
Figure 39 Moving the Slat Chain .................................................................... 87
Figure 40 Wear Strip Tape Replacement........................................................ 89
Figure 41 Wear Strip Transition Points ........................................................... 90
Figure 42 20 Degree Parallel Divert Components........................................... 93
Figure 43 20 Degree Parallel Switch Assembly .............................................. 94
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Figure 44 Divert Control Module (DCM) Access.............................................. 95

Figure 45 DCM Front Panel ............................................................................ 95
Figure 46 Mechanical Divert Switch (MDS) ..................................................... 98
Figure 47 Gap between Bumper and MDS Base ............................................ 99
Figure 48 Gap Closed ..................................................................................... 99
Figure 49 20 Degree Parallel Merge Assembly ............................................. 101
Figure 50 Dual LIM Drive .............................................................................. 102
Figure 51 Bottom Guard with Slat Ski Assembly ........................................... 106
Figure 52 Slat Ski Assembly ......................................................................... 107
Figure 53 VFDs in Drive Module ................................................................... 109
Figure 54 Divert Control Module (DCM) ........................................................ 112
Figure 55 DCM Chassis Interface Board Cabling .......................................... 113
Figure 56 Return Pin Sensor......................................................................... 114
Figure 57 Take-Up Sensor ............................................................................ 116
Figure 58 Discharge Bed .............................................................................. 118
Figure 60 Taper-Lock Bushings .................................................................... 120
Figure 61 Dimple the Bushing ....................................................................... 122
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Safety
1 Safety
1.1 Danger/Warning/Caution Convention

This product is furnished with safety guards and warning labels. When this
equipment is applied at your facility, additional guards and warnings may be
required because specific applications might create residual hazards that could
not be anticipated or eliminated when the equipment was designed. Therefore,
examine your installation and provide any additional required safety measures.
Danger, warning, and caution conventions are explained in the following table:
Symbol Description
Danger statements indicate an imminently hazardous situation that, if not avoided, WILL
result in death or serious injury.
Warning statements indicate a potentially hazardous situation that, if not avoided,
COULD result in death or serious injury.
Caution statements indicate a potentially hazardous situation that if not avoided, will
result in minor or moderate injury. It may also be used to alert against unsafe practices.
1.2 General Safety

Never operate this equipment with missing, disabled, or inoperative
safety devices. Operating equipment in this condition will result in
serious injury or death. Immediately remove equipment in this condition
from service.
Severe personal injury or damage to property may occur in the event of:
● Incorrect use or operation of the equipment, including allowing
untrained personnel to interface with or come into contact with the
equipment. Only properly trained and authorized personnel are to
operate this equipment.
● Incorrect or insufficient maintenance of the equipment. Only properly trained
and authorized personnel are to service and maintain this equipment.
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Safety
Do not perform adjustments, maintenance, clearing of jams, or other

work on this equipment without following OSHA Lock-Out/Tag-Out
requirements and state and local requirements. The purpose of this
procedure is to protect all persons involved against unexpected restart.
Personnel should be alerted to the hazard of stored energy which may
exist after the power source is locked out. Refer to ANSI Z244.1 and
OSHA 29 CFR 1910.147 for minimum requirements. Failure to follow
these requirements may result in equipment damage, serious injury, or
death.
If any defects relating to operating safety and reliability are detected or if

any damage occurs, affected parts of the system must be taken out of
operation immediately. Failure to do so may result in serious injury or
death
Climbing, sitting, walking, or riding on equipment at any time may result

in serious injury or death.
Under continuous operation, the external surface of various powered

components might reach temperatures significantly above ambient
temperature. Contact with unprotected skin may cause burns.
Exposure to elevated sound levels can damage hearing. The complete

equipment operating environment should be reviewed and hearing
protection provided if required.
1.2.1 Personnel
● Personnel must be informed about the location and operation of emergency
stops and power disconnect points.
● Personnel must be alerted to potential hazards of entanglement in
conveyors caused by such items as long hair, loose clothing, and jewelry.
These hazards, if not avoided, could result in serious injury or death.
● Personnel must report to a supervisor all unsafe conditions or anything out
of the ordinary that is observed prior to operating the system. Remove
equipment in unsafe conditions from service immediately.
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Safety
1.2.2 Equipment
● Use the equipment exclusively for appropriate loads that it is designed to
handle safely.
● Do not perform any unauthorized conversion or modification of the system,
equipment, or safety devices. Such modifications could degrade safety and
expose personnel to risk of serious injury or death.
● Never connect or disconnect any electrical cables while power is applied to
the equipment as this can result in damage to the equipment or serious
injury or death resulting from electric shock. Lock-out/tag-out equipment
prior to service.
1.2.3 Equipment Labels

Labels for partially completed machinery being used in EU projects requiring CE
conformity are applied after the equipment is incorporated into a conveyor
system to become a complete machine.
Refer to project documentation for equipment label information.
1.2.4 CE Declarations
Refer to project documentation for CE regulatory information such as
Declarations of Incorporation and Declarations of Conformity.
1.2.5 Operation
● Prior to startup, operators are to visually confirm that all personnel are clear
of the equipment.
● During initial equipment startup, personnel must be notified prior to startup
by the operator or via audible and/or visual indications followed by a delay.
● If safety devices are defective or if they do not function reliably, the
equipment must not be put into operation. Notify your supervisor that
equipment is not safe to operate and remove equipment from service.
1.2.6 Instructions for Safe Clearing of Product Jams

When the products being handled by the conveyor become lodged or jammed,
the following instructions apply:
● Only authorized employees properly trained in the clearing of jammed

products will be allowed to clear jams.
● Turn off and lock out the power to the conveyor before clearing the jam to
prevent unintended motion of equipment. Take precautions to isolate all
sources of energy including hydraulic, pneumatic, gravity, and other
potential or stored energy.
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Safety
DO NOT climb on the conveyor at any time. Falling from the conveyor,
especially from elevated heights, will cause serious injury or death.
● When unable to manually reach the jam with your hands from the walking
surface, select an appropriate and safe method to access the jam. When a
jam is above the walking surface or work level, a lift or ladder may be the
safest method. Be sure to follow applicable manufacturer’s instructions for
safe use requirements and for any personal protection equipment required.
● Take precautions for stored energy of jammed packages, as releasing a jam
may release potential energy.
● Realign product of good quality, and remove product of poor quality (for
example, cartons that are broken, wet, or have open flaps).
● Remove any spilled materials from the conveyor and surrounding area
before restarting conveyors.
● Observe the cause of the jam, and report it to the appropriate supervisor.
Often, jams occur because the conveyables are of poor quality or are
outside specifications, or because the equipment requires maintenance.
● By visual confirmation, be sure all personnel are clear of the conveyor
before restarting.
1.2.7 Maintenance
● A routine safety inspection plan must be implemented before each shift
change and startup of the equipment.
● Maintenance (other than observation) must not be performed while the
equipment is in operation or motion unless proper maintenance or service
requires the equipment to be in motion. In which case, personnel shall be
made aware of all hazards and how the task may be safely accomplished.
1.2.8 Decommissioning and Disposal

Once the SL2 sorter has reached the end of its service life, it must be
decommissioned and disposed of properly. All cables must be cut from the
control panel and the equipment must be disposed of in an environmentally
responsible manner.
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Equipment Description
2 Equipment Description
Figure 1 Model 2430 SL2 Slat Sorter
The Model 2430 SL2 Slat Sorter is available with angle or parallel diverting. The
parallel sorter is capable of processing more than 400 16-inch cartons per
minute. This sorter has no chain other than the chain of slats and link plates, no
sprocket drives, and no catenary take-up. It has extended maintenance intervals.
FlexSort controls are required for Model 2430. They monitor key performance
indicators and report them locally and globally. Any sorting or powering failures
are identified by component and reported through the FlexSort Human Machine
Interface (HMI).
2.1 Charge Bed

The charge bed assembly supports the the slat chain at the charge end of the
sorter. The charge bed is preceded by a transition bed, which is 6 mm (1/4 in)
higher than the sorter. The charge transition bed matches the speed of the sorter
to facilitate the smooth transfer of cartons onto the charge bed of the sorter.
2017-05-11 11
The charge bed includes an update photoeye and an initial slat sensor, which
together match a container to a slat, allowing the sort controller to track the
position of the container on the sorter.
The charge bed also includes a photoeye that detects shoe caps. If a cap is
missing, then the sort controller prevents the shoe on that slat from diverting
product. If the shoe would normally be used to divert a container on that slat,
then the container is not diverted and is recirculated.
2.2 Framework
Frame rails and crossmembers, mounted on floor supports, make up the
structure for the majority of the sorter. Drives, divert switches, and electronic
controls are mounted on this framework. Slats, which make up the surface of the
sorter, roll on tracks that are integrated into the frame rails.
2.3 Drives
Drive assemblies move the slat chain. The 2430 sorter will offer two drive
options, but currently only the linear induction motor is available. Because of
load weight, more upper drives are required than lower, but dual drive
assemblies (upper and lower combined) are preferred where possible. Drives
are spaced along the sorter as evenly as possible, no more than 12.2 m (40 ft)
apart.
Drive motors are controlled by variable frequency drives (VFDs). VFD panels are
available with a single VFD for upper drives or with two VFDs for the dual drives.
A LIM assembly consists of one or two LIMs and an air cooling system. LIM
assemblies are evenly spaced along the length of the sorter. A single upper LIM
assembly is used at the charge end.
2.4 Slat and Shoe Assembly

The conveying surface of the sorter is a continuous chain of interleaved
anodized aluminum slats. Steel plates encased in the slats provide a magnetic
field for LIMs driving the slat chain.
Special reference slats have magnets embedded in them. The magnets trigger a
signal in slat sensors located in the charge bed and in each divert. The slat
sensors communicate this information to the controller to verify slat ID numbers
and to ensure that the correct shoes are diverted. Reference slats include the
primary slat (ID=1), a secondary slat (approximately halfway around the slat
chain), and, for sorters with more than 600 slats, additional index slats placed at
regular increments.
Spring-loaded pins and molded features in the slat end caps mount the slats to
link plates that tie the chain together. These link plates have polyurethane
12 2017-05-11
wheels with sealed precision bearings and carry the slats along tracks built into
the frame rails.
Slat shoes are made of a low-friction, bearing-grade plastic and slide from one
end of a slat to the other to divert product onto take-away conveyors. The shoe
base wraps around the slat. Below the slat, a metal pin and bearing extend from
the base. Divert assemblies engage the pins and and guide the shoes along the
length of the slats. As the shoes move from one side of the sorter to the other
they push cartons from the sorter onto take-away conveyors.
Shoes for a parallel-divert sorter include caps that break free from the shoe base
in the event of a jam. On an angle-divert sorter, the shoe has a fixed top.
2.5 Divert Assemblies

Each divert assembly includes a switch that engages shoe bearings and one or
more tracks that guide the shoes as they divert product. Angle diverts have a
single switch and track, while parallel diverts have three switches and tracks to
divert multiple shoes simultaneously.
Each switch has a slat sensor and two pin sensors and is connected to a divert
control module (DCM). Signals from the slat sensors and pin sensors allow the
sort controller to keep track of the slat IDs. The FlexSort controller
communicates to DCMs which slat shoes to divert, and the DCMs trigger the
switches at precisely the right time to divert the shoes.
Diverted shoes are returned to the switch side of the sorter by a sweep angle on
the bottom of the sorter, near the charge end.
2.6 Discharge Bed

The discharge bed assembly supports the discharge end of the slat and shoe
chain and provides take-up for the slat chain. The discharge bed consists of a
stationary base frame and a movable discharge end, which travels on rails to
accommodate changes in slat chain tension and length. Gas springs provide
tension between the frame and the moving end.
A take-up sensor in the discharge bed monitors whether there is too much slack
in the slat chain. The controller posts a warning if the length is out of tolerance.
A discharge transition bed facilitates smooth transfer of unsorted containers from

the discharge bed to the outfeed conveyor. An update photoeye mounted on the
discharge transition bed monitors package position for containers exiting the
sorter.
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2.7 Return Sweep

As slats return from the discharge end to the charge end of the sorter, the shoes
need to be returned to the switch side of the sorter. A sweep angle directs all
diverted shoes from the take-away side to the switch side.
The return sweep includes a pin sensor to ensure that all shoes are lined up on
the switch side of the sorter. If the sensor detects a missing pin, it signals the
sort controller, which immediately stops the sorter to prevent damage.
2.8 Environmental Specifications

● Operating Temperature: 5° - 45° C (41° – 113° F)
● Humidity: 5% - 99% relative, non condensing
● Noise Level: Below 80 dBA
● Indoor use only in a non-explosive atmosphere
14 2017-05-11
Maintenance
3 Maintenance
:INFO: For information related to the controls system used with these
conveyors, refer to FlexSort controller and software documentation.
3.1 General Safety and Maintenance

Do not perform adjustments, maintenance, clearing of jams, or any other
work on this equipment unless you are competent in carrying out the
energy isolation procedure as required by national or local authorities.
The purpose of energy isolation procedure is to protect all persons
involved against unexpected startup of the equipment. Personnel should
be alerted to the hazard of stored energy which may exist after the
source of energy has been isolated. Refer to national, local, or employer
procedures for minimum requirements. Failure to follow these
requirements may result in equipment damage, serious injury, or death.
Proper maintenance of this unit ensures proper operation and promotes

operating personnel safety. Failure to perform maintenance as outlined
compromises the life expectancy of all wearable components. Life expectancy of
the carrier wheels, carrier wheel wear strips, slats, shoes, and switches may be
shortened if proper cleaning procedures are not performed.
:INFO: See individual manufacturer’s product literature for more information.
Refer to and be familiar with all of the proper safety precautions and
procedures outlined in the Product Safety section of this manual before
performing maintenance. Only properly trained and authorized personnel
are to perform maintenance on this equipment.
Climbing, sitting, walking, or riding on equipment at any time may result

in serious injury or death.
1. Replace broken or worn parts as soon as they are detected.

2. Safety guards must be properly attached to the unit before and while
operating the equipment. Do not operate equipment with missing guards.
3. Keep all CAUTION, WARNING, and DANGER safety labels clean and in
plain sight. Replace all missing or damaged safety labels.
4. Do not operate equipment with missing or inoperable safety devices.
Immediately remove such equipment from service.
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Maintenance
3.2 Periodic Maintenance Schedule

The following schedule contains the periodic inspections and services required
to keep this equipment in top operating condition and minimize breakdowns. The
schedule groups inspections and services by component and gives the
frequency at which each inspection/service should occur.
You can adjust inspection and service frequencies as required based on speed,
load, hours of operation (continuous versus intermittent), surrounding
temperatures, humidity, etc. Perform preventive maintenance at shorter intervals
in extreme environmental conditions and when operating hours increase.
Table 1 Periodic Maintenance Schedule
Component Inspection/Service Frequency
Sorter Verify that all guarding and safety labels are in place and Daily
visible prior to operating the equipment. Correct any problems
immediately.
Verify that all Emergency Stop (E-Stop) circuits are operating
properly by activating at least one E-Stop for each E-Stop
circuit. Activate different E-Stops each day. Correct any
problems immediately.
While the equipment is in operation walk through and visually
inspect for loose hardware and general cleanliness. Listen for
any unusual sounds, paying particular attention to the divert
assemblies and return sweep. Correct any problems
immediately.
Replace any missing shoe caps. Inspect the slats, shoes, and
shoe caps for cleanliness. Clean as necessary (see 3.4.7).
Photoeyes and Inspect the photoeyes and reflectors for cleanliness. Clean as 400 hours
Reflectors necessary (see 3.4.12).
Inspect the photoeyes, reflectors, and mounting brackets for
signs of damage. Replace as necessary (see 5.1.3 or 5.1.4).
Gas Springs Check tension of gas springs/slat chain (see 3.4.6) 400 hours
Powder Coated Inspect for cleanliness or damage. Clean or repair as needed 1200 hours
Components (see 3.4.5).
Divert Assemblies Inspect the divert assemblies for cleanliness. Clean as 1200 hours
necessary (see 3.4.9).
Check the retractable noses, divert rails, and merges for
damage and wear. Replace as necessary (see 5.4).
Wear Strips Inspect wear strips for signs of damage, excessive wear, and 1200 hours
separation from the frame rails. Replace as necessary (see
5.3).
16 2017-05-11
Maintenance
Table 1 Periodic Maintenance Schedule
Component Inspection/Service Frequency
Slat and Shoe Verify the shoes slide freely over the slats, and that the shoe 1200 hours
Assemblies caps are securely locked to the bases. Correct any problems
immediately.
Inspect the slats, shoes, and shoe caps for damage and wear.
Replace as necessary (see 5.2.1).
Inspect the slats and engagement pins for proper seating.
Reseat engagement pins as necessary (see 3.4.2.2).
Inspect the carrier and guide wheels for damage and excessive
wear. Replace when the outside diameter of the carrier wheels
wears to less than 46 mm or as necessary (see 5.2.2).
Inspect the link plates for damage and excessive wear.
Replace as necessary (see 5.2.2).
Electrostatic Discharge Inspect the slat ESD brush for cleanliness. Clean as necessary 1200 hours
(ESD) Brush (see 3.4.10).
Inspect the link ESD brushes for damage and wear. Replace as
necessary (see 5.1.1).
Inspect the slat ESD brush for proper contact. Adjust as
necessary (see 1).
Mechanical Divert Inspect the switch gate for wear. If damaged, replace the MDS 4800 hours
Switches (MDS) with a spare (5.4.3) and then replace the gate and bumpers
(see 5.4.4).
Check that switch gate moves freely. If not, check that the
screws holding the bumpers are not tight.
Inspect the the foam bumpers for damage. If the finger
extending from one bumper is missing or torn, replace the
bumpers (see 5.4.4).
Charge End Assembly Inspect the crescent plate assemblies for damage and wear. 4800 hours
Contact Dematic for replacement as necessary.
Discharge Take-Up Inspect the crescent plate assemblies for damage and wear. 4800 hours
Assembly Contact Dematic for replacement as necessary.
Check the discharge take-up assembly for freedom of
movement (see 3.5.9).
Gas Springs Replace every three years (see 5.9.2). 3 years
3.3 Tool Kit

A set of tools is supplied with the sorter (see Table 2). The first four tools listed
below ship in the FlexSort cabinet, while the rest are shipped with the charge
end of the sorter. All tools in the kit should stay at site with the customer.
:INFO: A tachometer is required for installation but it is not part of the customer
tool kit to be left on site.
2017-05-11 17
Maintenance
Table 2 Tool Kit
Description Part/Dwg No. Qty
LIM height tool K0301-7001A thru 01E 1

Tool bag (includes following items) K0318-56AAA 1
● Jog box F0046-00530 1
● Frame gapping plate K0318-5701A 4
● LIM gap tool K0301-7006A 2
● Slat timing tool K0318-5401A 1
● Slat removal tool K0317-53AAA 2
● Sensor calibration flag K0318-6001A 1
● Profibus "fastconnect" cable stripping tool 05253-50025 1
:INFO: Required quantities are per site.
3.4 Preventive Maintenance

3.4.1 Inspections
Many Model 2430 Sorter maintenance inspections require the creation of a
maintenance window (see section 3.4.2) and/or removal of one or more side
panels (see section 3.4.4). To perform these inspections, create the window and
jog the sorter (see section 3.4.3) to access parts.
3.4.2 Creating a Maintenance Window

3.4.2.1 Slat Removal
:INFO: Do not remove reference slats to create a maintenance window.
Reference slats are marked at both ends with stripes.
1. Follow Lock-Out / Tag-Out procedures (see the first page of the
Maintenance section).
Never let a maintenance window of more than 3 slats be jogged around

the end of the sorter.
2. Select three slats located on the top of the sorter between the charge end
assembly and the first divert assembly for removal.
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3. Use the slat removal tool to press in the pins at one end of each slat to be
removed and remove the slat from the chain link plates (see Figure 2).
:INFO: If necessary, use a flat screw driver or small pry bar to help lift the end of
the slat when you press in on the pins. Avoid cracking the slat end by applying
too much force.
Figure 2 Slat Removal
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Maintenance
3.4.2.2 Slat Replacement

1. Place the slat onto the carrier wheel chain so that the pins in the ends of the
slat are located above the holes in the chain links.
2. Use the slat removal tool to depress both pins on one end of the slat.
Figure 3 Slat Installation
3. With pins depressed, push the slat down until the pins are engaged behind
the link plate. Continue to press the slat down and pull it toward the link until
the pins snap into the link plate holes. If necessary, use a small pry bar
between the chain link and the cap angle to pry the link toward the slat end
until the pin-locating rivets on the link plate can fit in the slots in the slat end.
4. Depress the pins on the other end of the slat and snap them into the holes.
5. Repeat for each removed slat.
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3.4.3 Jogging the Sorter
Never let a maintenance window of more than 3 slats be jogged around

the end of the sorter.
1. Verify that the sorter is powered up but not running. Remove any product
from the sorter.
2. At the sorter power cabinet, insert the key into the SORTER MODE
keyswitch and turn the switch to the MAINT position.
:INFO: If maintenance is required, use appropriate lock out/tag out procedures
(see the first page of the Maintenance section).
3. Remove the cover from the receptacle located on the side of the control box
on the LDM assembly (see Figure 4).
4. Connect the jog box cable. Finger-tighten the nut to secure it to the
receptacle.
5. Push the button on the jog box to jog the sorter as necessary.
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Maintenance
Figure 4 Jog Box Connection
Item Description
A VFDs
B Jog box
C Receptacle: attach jog box here
D Disconnect switch
E Control box
To remove the jog box:

1. Disconnect the jog box cable and replace the receptacle cover.
2. At the sorter power cabinet, switch the SORTER MODE keyswitch to RUN.
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3.4.4 Removing Side Panels

Many maintenance and repair procedures require that you remove side panels
to access parts.
To remove a side panel:

1. Use a 4 mm hex wrench to turn the latches counter-clockwise half a turn.
2. Tilt the panel back from the top cover.
3. Lift the panel out of the support brackets at the bottom of the panel.
When finished with the procedure, return the panels to their original locations,
and turn the latches one-half turn clockwise to lock them into place.
3.4.5 Cleaning and Care of Powder Coated Components

Regularly clean conveyor frames and other powder-coated surfaces for
maximum corrosion protection and longevity. Avoid repeatedly exposing these
surfaces to highly abrasive, sharp, corrosive or caustic materials. Particularly if
you cannot avoid such exposure, be sure to regularly clean the surface to help
extend its life and maintain its appearance. If surfaces are cut or deeply
scratched or underlying steel is exposed, use touch-up paint to seal the surface.
3.4.5.1 Frequency of Cleaning

Periodic cleaning extends the useful life of the surface, retains its appearance,
and removes dirt, grime, and other buildup detrimental to powder coatings.
● Start cleaning at installation, taking care to remove foreign matter before it
dries or affects your coating. Failure to remove foreign materials at an early
stage may require later use of aggressive cleaning materials and
techniques, with potential damage to the coated surface.
● The required cleaning frequency depends on factors such as atmospheric
pollution levels, industrial or other contamination such as alkaline and acidic
materials, or any other materials detrimental to the coating. In industrial or
saltwater locations, pay particular attention to regular cleaning due to the
harsher atmosphere. Conduct cleaning routinely at 1200 hours (three
month) intervals; 2400 hours (six months) should be the longest interval.
3.4.5.2 Cleaning Materials and Process

The best cleaning material is a dilute solution of warm water with a non-abrasive,
pH neutral mild liquid detergent. Avoid excessively hot solutions. Automotive-
based car wash detergents can also be used. Be sure to read all of the
manufacturer’s directions to verify it is safe to use on painted surfaces.

2. Check a small test area first to ensure it does not mar the surface.
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Maintenance
3. Clean all surfaces using a soft cloth, sponge, or soft natural bristle brush; do
not use abrasive tools on the coating.
4. Rinse cleaned surfaces well with fresh water.
:INFO: A mixture of 25% bleach and 75% warm water can also be used on
“white” powder coat to brighten the finish.
5. Lightly scrub with a soft bristle brush.
6. Rinse cleaned surfaces well with fresh water. Make sure no other items
come into contact with the bleach.
Do not use strong solvents such as thinners or solutions containing

chlorinated hydrocarbons, esters, ketones, or strong pH solutions such
as acids or alkaline-based solutions. Do not use acetates, Dulon
thinners, methyl ethyl ketone (MEK), petroleum products, or highly acidic
cleaners. Always follow the recommendations of the cleaner
manufacturer as to the proper concentration. Test a small area first if in
doubt to verify that the cleaner does not damage the coating.
Make sure that water, bleach, and solvents are kept away from conveyor
components that could be damaged, such as motors, rollers, and control
boxes, and that applicable safety practices are observed.
Where solvent is required, such as for cleaning paint spills, use only denatured
alcohol. Minimize contact time, and rinse the solvent cleaner thoroughly from the
surface with large amounts of fresh water. Be sure to check a small test area
first, to ensure that no damage will occur to the whole area.
3.4.6 Checking Tension of the Gas Springs

To determine if the gas springs on the discharge bed are providing proper slat
tension, check as follows:
2. Firmly push (with all your weight) on the discharge end crescent plate,
toward the charge end (see Figure 5).
a. If the discharge end moves easily, has changed significantly from last
PM check, or moves more than 20 mm (3/4 in), replace both gas
springs.
b. If the discharge end does NOT move easily, the gas springs do not
require replacement.
3. The gas springs must be replaced every three years.
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Figure 5 Verifying Gas Spring Function
3.4.7 Slat Chain

3.4.7.1 Routine Maintenance Cleaning
Do not use etching cleaners (alkali and acid based cleaners) to clean
slats and shoes. Also avoid heavy duty abrasive cleaners, which are sold
under various generic descriptions including (but not limited to) polish,
cleaner, cleaner-polish, wax-cleaner, wax-polish, metal brightener, and
scouring powder.
Do not use products containing benzene, toluene, aldehydes, ketones,

tetrahydrofurans, or gasoline, etc. to clean slats and shoes.
Use care to prevent water from getting into the sorter.

2. Use a cloth dampened with mild soap and water to clean slats and shoes.
3. Remove all dirt, tape, labels, etc. from slats and shoes.
:INFO: If necessary, remove slats from the sorter to thoroughly clean them,
making sure to return reference slats to their same location in the chain.
4. Wipe off any soap residue using a clean cloth dampened with water.
5. Dry slats and shoes thoroughly when finished.
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3.4.7.2 Spilled Contaminant Cleaning
Do not use etching cleaners (alkali and acid based cleaners) to clean
slats and shoes. Avoid also heavy duty abrasive cleaners, which are sold
under various generic descriptions including (but not limited to) polish,
cleaner, cleaner-polish, wax-cleaner, wax-polish, metal brightener, and
scouring powder.
Do not use products containing benzene, toluene, aldehydes, ketones,

tetrahydrofurans, or gasoline, etc. to clean slats and shoes.
Use care to prevent water from getting into the sorter.
1. Follow Lock-Out / Tag-Out procedures (see the first page of the Preventive
2. Jog the sorter so that the contaminated slats are located between the
charge end assembly and the first divert assembly (see section 3.4.3).
Do not allow a maintenance window with more than three slats removed
to travel into the discharge take-up assembly.
3. Use a shop vacuum to remove loose particles or pooled liquid from the
sorter.
:INFO: Up to six slats can be removed for cleaning at one time.
4. Use the steps for creating a maintenance window to remove contaminated
slats from the sorter (see section 3.4.2).
5. Remove the shoes from the slats.
6. Thoroughly clean slats and shoes, depending on material spilled, as follows:
■ For sugary liquid spills (such as BBQ sauce, ketchup, fruit juice, soft
drinks) use the following solution (should be 21° C (70° F) or warmer):
o Three quarts carbonated water.
o One quart vinegar, citric acid, or ammonia.
o One teaspoon Joy or similar degreaser.
■ For dry spills (such as kitty litter, flour, accumulated dust), use cloths
that are dry or dampened with a low caustic, non-grit content citrus
based cleaner such as “Goo Gone”.
■ For reactive liquid spills (such as bleach, paint, detergents), use clean
cloths dampened with a low caustic, non-grit content citrus based
cleaner such as “Goo Gone.”
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7. Use a brush dipped in the cleaning solution to clean dried liquids or hard-to-
reach sorter sections.
8. Wipe down all cleaned parts with clean, dry cloths and make sure they are
thoroughly dry.
9. Replace the shoes on the slats and the slats in the sorter.
3.4.8 Clearing Debris from Bottom Covers

2. Remove slats from the sorter to create a maintenance window (see section
3.4.2).
3. Remove side panels.
4. Jog the sorter (see section 3.4.3) until the maintenance window is at the
bottom of the sorter near the discharge end.
5. Remove any debris through the maintenance window in the slat chain.
6. Jog the chain along the length of the sorter and remove any debris from the
bottom covers.
7. Replace side panels and replace the slats in the maintenance window.
3.4.9 Cleaning Divert Switch and Rail Assemblies

2. Remove slats from the sorter to create a maintenance window (see section
3.4.2). Jog the sorter to access the divert assemblies (see section 3.4.3).
3. Remove debris from the switches, divert rails, and merges.
4. Use a soft, lint-free cloth to wipe clean the bearing path through the
switches, divert rails, and merges.
5. Replace the slats.
3.4.10 Cleaning the Electrostatic Discharge (ESD) Brush

2. Remove three slats from the sorter to create a maintenance window (see
section 3.4.2) on the charge bed.
3. Remove dried, loose debris from the ESD brush with compressed air.
4. Remove sticky, clotted debris:
a. Mark the position of the brush assembly on its bracket.
b. Remove the brush from its bracket.
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Maintenance
c. Thoroughly clean the brush using water and dish detergent (Joy or
similar degreaser; solution should be 21°C (70°F) or warmer).
d. Thoroughly dry the brush and replace it on the bracket.
Figure 6 Slat Electrostatic Discharge (ESD) Brush
Callout Description
C Electrostatic discharge brush
3.4.11 Cleaning LIM Fans

2. Remove side panels as necessary to access the LIMs.
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3. Remove dust and debris from the fan, housing, and heat sink fins with a soft
brush and a vacuum cleaner.
4. Verify that the fan is not binding or rubbing on the housing. The fan should
spin very freely by hand. If it does not, replace the fan (see section 5.7.1).
5. Replace the side panels.
3.4.12 Cleaning Photoeyes and Reflectors

2. Clean photoeyes and reflectors with a soft cloth, mild soap, and water.
3. Dry photoeyes and reflectors with a soft cloth after cleaning.
3.4.13 Wiring and Cables

Refer to the system electrical drawings for location, routing, and termination
details for all wiring and cables.
3.4.13.1 Cabling Considerations

Take the following into account when installing cables:
● Route and secure all cables so they do not contact moving components.
● Secure cables so that the weight of the cable is relieved immediately upon
exiting a device. As the cable exits a device, provide a small loop of cable
and secure the cable to a suitable attachment point.
● Use care when installing cables to avoid kinking, compressing, or stressing
of the cable. Observe a minimum bend radius of 76 mm (3 inches).
● Route data cables a minimum of 50 mm (2 inches) from power cables.
● Avoid long parallel runs of data cables in close proximity to power cables.
● If a data cable must cross a power cable, it should cross at 90°.
● Do not tie wrap data cables to power cables.
3.4.13.2 DCM Cabling Considerations

Take the following into account when installing DCM cables:
● Secure the divert assembly’s cable harness so that the weight of the cable
is relieved at the DCM. As the cable exits the DCM, provide a small loop of
cable, and then secure the cable to a suitable attachment point. The cable
harness may be coiled to take up excess slack.
● Route the DCM cable harness and pin sensor cables a minimum of 50 mm
(2 inches) from LIM power cables.
● Do not tie wrap DCM cables to power cables.
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Maintenance
3.4.13.3 DCM Cable Attachment
Do not loosen or remove the back cover on the DCM chassis.
1. Using a long shaft #1 Phillips screwdriver (part # 01800-01010) loosen the

two screws at the top of the interface board that secure it to the DCM
chassis. Fold the interface board down.
2. Attach the divert assembly’s cable harness to the chassis (see Figure 7).
Figure 7 DCM Cabling
3. Place the divert assembly cables in the retaining slots as indicated on the
back cover label. Pull the cables taut to seat the strain relief rings on the
retaining bracket.
4. Position the divert assembly cables so that they lie as flat to the interface
board as possible and do not bind against the back cover when the interface
board is lifted into position. Connect the cables to the interface board as
indicated on the schematic drawings.
5. Place the power cable in the retaining slots as indicated on the back cover
label. Pull the cable taut to seat the strain relief ring on the retaining bracket.
Connect the cable to the interface board.
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6. Place the divert pin out cable in the retaining slots as indicated on the back
cover label. Pull the cable taut to seat the strain relief ring on the retaining
bracket. Connect the cable to the interface board.
:INFO: Profibus cable connectors have a switch. If the associated DCM is at the
physical end of the network, set the switches to On. If it is not, set the switches
to Off.
7. Attach the Profibus cables to the connector. Route Profibus cables
separately from LIM power cables.
:INFO: Profibus cables do not have strain relief rings.
8. Place the Profibus cables in the retaining slots as indicated on the back
cover label. Pull the cables taut and seat them in the retaining bracket, but
do not connect the Profibus cables to the interface board. Leave the
interface board lying flat, unattached to the top of the chassis.
3.5 Common Maintenance

Many maintenance procedures require the creation of a maintenance window
(section 3.4.2), jogging the sorter (section 3.4.3), and removal of one or more
side panels (section 3.4.4).
3.5.1 Slat Chain

If the gap between the discharge plate and the frame rail on the discharge bed is
less than 83 mm (3-1/4 in) or more than 222 mm (8-3/4 in) from the frame rail,
the slat chain needs to be broken and a slat needs to be added or removed.
:INFO: Contact Dematic Customer Service for support prior to adding or

removing a slat from the slat chain.
Loosen the gas springs that tension the slat chain before breaking the slat chain
to permananently add or remove a slat. (Detensioning the chain is also
necessary for replacing multiple chain links (section 5.2.2) and for replacing the
gas springs (section 5.9.2).)
3.5.1.1 Relieving Tension on the Slat Chain

2. Remove two or three slats above the take-up screws in the discharge bed
for better access and view.
3. Remove the screws (item K in Figure 8) that fasten the take-up block (item
D) to the discharge plates.
:INFO: If working alone or sharing one tool, alternate from side to side and turn
screws in increments of 2 inches or less.
4. Use an impact wrench or a drill and socket to turn the take-up screws (item
E) clockwise.
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Maintenance
5. Continue to turn the take-up screws simultaneously (or alternately) until the
take-up blocks stop against the jam nuts.
6. Remove slats to make a maintenance window as needed where the chain
links are to be removed or added.
7. Use two ratchet straps, located near the ends of the slats, to remove slack
from the chain. (See Figure 9.) Check to make sure the gap between the
discharge plate and the frame rail is closed.
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Figure 8 Gas Springs and Take-up Screws
Item Description
A Take-up sensor
B Gas spring
C Bracket
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Maintenance
Item Description
D Take-up block
E Take-up screw
F Jam nuts
G Discharge plates
H Top cover
I Discharge frame crossmember
J Gap between discharge plate and frame rail
K Take-up block screws
L Discharge assembly
Figure 9 Removing Slack from the Slat Chain
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Maintenance
Callout Description
A Ratchet straps
B Cap angle
3.5.1.2 Removing Slats (Permanent Removal)

:INFO: Contact Dematic Customer Service for support prior to removing a slat
from the slat chain.
2. Jog the sorter so that the primary slat is located between the charge end
assembly and the first divert assembly (see section 3.4.3).
3. Mark the primary-slat chain links for easy to identification.
4. Relieve tension on the slat chain (see section 3.5.1.1).
5. Remove two slats upstream from the primary slat, the primary slat, and
three slats downstream.
6. Remove the snap rings and wheels from the chain links immediately
downstream from the primary slat, opposite each other near the middle of
the maintenance window to break the chain of links.
7. Remove the first pair of chain links downstream of those for the primary slat.
8. Reconnect the chain links.
9. Replace the slats. Make sure the primary slat goes in the marked links.
10. Retension the slat chain (see section 3.5.1.4).
11. Follow programming steps as outlined by Dematic Customer Service
support staff.
3.5.1.3 Adding Slats (Permanent Addition)

:INFO: Contact Dematic Customer Service for support prior to adding a slat to
the slat chain.
2. Jog the sorter so that the primary slat is located between the charge end
assembly and the first divert assembly (see section 3.4.3).
3. Mark the primary-slat chain links for easy identification.
4. Relieve tension on the slat chain (see section 3.5.1.1).
5. Remove two slats upstream from the primary slat, the primary slat, and two
slats downstream.
6. Remove the snap rings and wheels from the chain links immediately
downstream from the primary slat to break the chain of links.
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Maintenance
Guide wheels must be included at least every other link. Normally, add
chain links that have guide wheels.
7. Add a pair of chain links immediately downstream from the primary slat (see
section 5.2).
8. Reconnect the chain links.
9. Replace the slats. Make sure the primary slat goes in the marked links.
11. Follow programming steps as outlined by Dematic Customer Service
support staff.
3.5.1.4 Tensioning the Slat Chain

To compress the gas springs:
1. Use an impact wrench or a drill and socket to turn the take-up screws
counterclockwise just enough to begin to move the discharge plates.
:INFO: If working alone or sharing a single tool, alternate sides and turn screws
in increments of 2 inches or less.
2. Continue to turn the take-up screws simultaneously until the take-up blocks
(Figure 8 – item D) stop against the brackets (item C).
3. Jog the sorter and confirm that the gap between the discharge plate and the
frame rail is more than 83 mm (3-1/4 in) and less than 222 mm (8-3/4 in).
4. Insert the two screws (item K) that lock the take-up block to the side of the
discharge assembly frame.
3.5.2 Divert Control Module Reseating

2. Remove the side panels adjacent to the DCM (see 3.4.4).
3. Remove the mounting hardware securing the DCM controller in the chassis
and remove the DCM controller.
4. Insert the DCM controller into the chassis, grasping the right-hand back of
the chassis and pressing firmly on the right side of the controller’s cover to
seat.
5. Tighten the mounting hardware.
3.5.3 Slat Sensor Adjustment

To adjust the slat sensor gap:
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Maintenance
section 3.4.2).
3. Jog the sorter (see section 3.4.3) to position a slat just downstream of the
charge end or switch slat sensor while leaving the sensor exposed.
4. If the gap between the slat sensor cover, Figure 10 – (15), and the slat is
less than 2.5 mm or greater than 5.5 mm, continue with the following steps.
5. Remove the hex head cap screws, washers, and slat sensor cover from the
switch assembly.
Figure 10 Switch Assembly
6. Unplug the slat sensor cable and remove the slat sensor (6).
7. Remove the slat sensor support block (5).
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Maintenance
8. If the slat sensor is too low, insert a slat sensor shim (18) on top of the
existing slat sensor spacers. If the sensor is too high, remove one of the slat
sensor spacers.
9. Replace the slat sensor support block, reattach the slat sensor cable, and
seat the sensor on the support.
10. Replace the slat sensor cover, washers, and the hex head cap screws.
11. Using metric hex wrenches as feeler gauges, verify that the gap between
the slat sensor cover and the slat is between 2.5 and 5.5 mm (see Figure
11).
12. Replace the three slats.
Figure 11 Electrostatic Discharge (ESD) Brush
Item Description
A Metric hex wrench (used as feeler gauge)

B Slat sensor
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Item Description
3.5.4 Electrostatic Discharge (ESD) Brush Adjustment

3.5.4.1 Adjusting Link Plate ESD Brushes
1. Follow lockout/tagout procedures (see the first page of the Maintenance
section).
2. Remove slats above the ESD link brush (see section 3.4.2).
3. Remove the ESD brush bracket from the crossmember.
:INFO: If the brush is already at the top of the adjustment slots, replace the
brush (section 5.1.1.2).
4. Loosen the nuts holding the brush to the bracket and adjust the brush so
that when mounted it will lightly touch the link plate; tighten the nuts.
5. Remount the brush bracket on the crossmember.
3.5.4.2 Adjusting Slat ESD Brush

2. Remove slats on the charge bed above the ESD brush to create a
maintenance window (see section 3.4.2).
3. Loosen the hardware attaching the ESD brush to the brush bracket (see
Figure 11).
4. Adjust the brush so that it lightly touches the slats and tighten the hardware.
3.5.5 Return Sweep Bearing Guide Adjustment

The bearing guide exits the merge end of the return sweep parallel to the
direction of flow until it has passed all DCMs. Then it angles toward the switch
side to connect to the lower bearing guide on the charge bed.

2. Remove side panels adjacent to the return sweep.
section 3.4.2). Jog the sorter to move the maintenance window to the
bottom of the sorter above the return sweep (see section 3.4.3).
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Maintenance
4. Loosen the mounting hardware and reposition the bearing guides as

necessary for proper alignment (see Figure 12). At each transition point,
bearing guides should be offset 0.5 mm to prevent bearings from bumping
the guide.
Figure 12 Return Sweep Bearing Guide Detail
Item Description
A Bearing guide
B Mounting clip (K0309-61AAA)
C Splice connector (K0309-61AAB)
5. Tighten the hardware.

7. Jog the maintenance window to the top of the sorter and replace the three
slats.
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3.5.6 Linear Induction Motor (LIM) Gap Adjustment

The top surface of the LIM is tapered along each side. The middle is flat and
level. When adjusting the gap, measure from the flat surface and not from the
tapered sides. LIM “corners” in the following instructions refer to where the flat
and tapered surfaces meet at the front and back edges of the LIM.
3.5.6.1 Top Mounted LIM

section 3.4.2).
3. Jog the sorter to access the LIM, positioning a slat over the upstream edge
of the LIM while leaving the mid section exposed (see section 3.4.3).
Verify that the carrier wheels on the slat used for gap measurement are
in firm contact with the frame rail wear strips.
4. Position the LIM gap tool (see Figure 13) beneath the slat and above an
upstream corner of the top mounted LIM.
5. Adjust the LIM so that the corner just touches the second step of the LIM
gap tool when it is held up tight to the bottom of the slat. Adjust the LIM
corners as follows (see Figure 14):
a. Loosen the jam nut.
b. Turn the adjustment nut until the LIM corner you are adjusting contacts
the second step of the LIM gap tool.
c. Tighten the jam nut.
Figure 13 LIM Gap Tool
Item Description
A LIM “No go”

B LIM “Go”
C Wear strip “No go”
D Wear strip “Go”
6. Jog the sorter and adjust the downstream LIM corners.
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Maintenance
7. When all four LIM corners are adjusted, recheck each corner. Verify that the
second step of the LIM gap tool just fits between each corner and the slat,
while the third step will not. Adjust as necessary.
Figure 14 LIM Gap Adjustment
Item Description
A Slats
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Item Description
B Top mounted LIM

C Slat retainer bolt
D Adjustment nut
E Jam nut
F LIM gap tool; adjust gap to middle step (see Figure 13)
G LIM “corner”
H LIM ski wear strip
3.5.6.2 Bottom Mounted LIM

2. Remove the side panel by the LIM on the take-away side of the sorter. On
the switch side of the sorter, remove the side panels adjacent to the VFD
assembly.
3. Create two maintenance windows of three slats each with a single slat
between them (see section 3.4.2).
4. Jog the sorter (see section 3.4.3) to move the maintenance windows to the
bottom of the sorter below the LIM drive, with the slat between windows
near one end of the LIM.
Verify that the carrier wheels on the slat being used for gap
measurement are in firm contact with the frame rail wear strips.
5. Position the LIM gap tool (see Figure 13) on top of the slat and under a
corner of the bottom mounted LIM.
6. Adjust the LIM corners as follows:
a. Loosen the jam nut on the LIM bolt.
b. Turn the adjustment nut on the LIM bolt until the LIM corner you are
adjusting contacts the second step of the LIM gap tool.
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Maintenance
Figure 15 Bottom Mounted LIM Height Adjustment
Item Description
A Top mounted LIM

B Bottom mounted LIM
C LIM corner
D Adjustment nut
E Jam nut
F LIM bolt
G Lower LIM guard
7. After checking both corners at one end of the LIM, jog the sorter until the
slat is at the other end of the LIM, and check the corners at that end.
8. When all four LIM corners are adjusted, recheck each corner. Verify that the
second step of the LIM gap tool just fits between each corner and the slat,
while the third step does not. Adjust as necessary.
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9. Position the LIM gap tool on top of the slats and under one end of a wear
strip on the ski assembly. Adjust the wear strips so that each corner just
touches the first step of the LIM gap tool (see Figure 16):
a. Loosen the jam nut on the ski adjustment bolt.
b. Turn the adjustment nut on the slat retainer bolt until the wear strip
corner you are adjusting just touches the first step of the LIM gap tool.
Figure 16 Slat Ski Wear Strip Height Check
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Maintenance
Item Description
A Slat and shoe assembly

B Top mounted LIM
C Lower LIM guard
D LIM gap tool
E Bottom mounted LIM
F Ski adjustment bolt
G Jam nut
H Bottom LIM ski assembly
I Adjustment nut
10. When both ends of each ski wear strip are adjusted, recheck. Verify that the
first step of the LIM gap tool just fits between each wear strip and the slat,
while the second step does not. Adjust as necessary.
11. Repeat steps for each bottom mounted LIM and each slat ski wear strip.
3.5.7 Take-Up Sensor Replacement Validation

Follow Lock-Out / Tag-Out procedures (see the first page of the
If an over-travel alarm displays on the FlexSort HMI, verify that there is power to
the sensor. Then remove a top cover from the discharge bed and measure the
gap between the end of the top frame rail and and the discharge side plate (see
Figure 17, item J).
46 2017-05-11
Maintenance
Figure 17 Take-Up Gap
Item Description
A Take-up sensor
B Gas spring
C Bracket
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Maintenance
Item Description
D Take-up block
E Take-up screw
F Jam nuts
G Discharge plates
H Top cover
I Discharge frame crossmember
J Gap
K Take-up block screws
L Discharge assembly
If the distance is less than 222 mm (8-3/4 in), replace the sensor (see 5.9.1). If it
is greater than 222 mm, remove a slat (see 3.5.1).
3.5.8 Sensor Position Verification

:INFO: The relationship of the charge end slat sensor and the shoe cap
photoeye to the return pin sensor is critical to the operation of the sorter. The
locations of the slat sensor and shoe cap photoeye are fixed. If the relationship
of the charge end slat sensor to the return pin sensor needs adjustment, the
return pin sensor must be repositioned. Any time the shoe cap photoeye is
replaced or the charge end slat sensor is moved, the sorter must be recalibrated.
1. Jog the sorter so that the charge end slat sensor is sensing a gap between
slats. The yellow LED depicted in Figure 18 will be illuminated.
Figure 18 Charge End Slat Sensor
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Maintenance
2. Verify that the shoe cap photoeye beam is properly adjusted to be centered
over a gap between slats for the entire length of the slats. Adjust as needed.
3. Verify that the return pin sensor is centered between two shoe pins +/- 13
mm (1/2 in). Adjust as needed.
4. Check the return pin sensor gap. Jog the sorter to position a shoe pin below
the sensor. Verify that the sensor’s indicator LED is illuminated and that the
gap between the sensor and the shoe pin is 5-7 mm. Adjust as necessary.
5. Check the location of the shoe cap photoeye beam on the shoe caps. Jog
the sorter to position a shoe cap in front of the photoeye. Verify that the
photoeye beam is interrupted by a shoe cap but not by a shoe. Adjust as
necessary.
6. If the update photoeye is replaced or the charge end slat sensor is moved,
calibrate the sorter:
a. On the FlexSort HMI, go to the System Mode page (under Status) and
start diagnostic mode.
b. Go to the Jog To Slat page (under Diagnostic Mode).
c. Enter “1” in the Jog To Slat entry box and run the test.
:INFO: If the primary slat is on a link plate with a guide wheel, remove the guide
wheel before installing the slat timing bracket on the slat.
d. Remove the primary slat (slat number one) and install the slat timing
bracket on the take-away side (see Figure 19). (The first time the
bracket is installed the tabs bend out as the bracket is pressed over the
end of the slat.)
e. On the FlexSort HMI, go to the Slat Sensor Calibration page.
f. Follow the instructions to calibrate the slat sensor, referring to the on-
screen Help file as necessary.
g. Remove the slat timing tool.
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Maintenance
Figure 19 Slat Timing Tool
Item Description
A Slat timing tool

B Reflector
C Update photoeye
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Maintenance
3.5.9 Discharge Take-Up Assembly Freedom of Movement

The discharge bed includes an indicator showing whether the take-up is in the
safe range (Figure 20).
Figure 20 Takeup Indicator
If the edge of the discharge plate is aligned with the green on the indicator, the
take-up is within range. If it is not, or to to do a more accurate maintenance
check, use the following procedure.

2. Remove the top cover to access the gap between the discharge plate and
the frame rail on both sides of the bed.
3. Measure the gap between the discharge plate and the upper frame rail.
4. If the gap is less than 83 mm (3-1/4 in), add a slat to the slat chain (see
3.5.1.3). If the gap is more than 222 mm (8-3/4 in), remove a slat (see
3.5.1.2).
5. Replace the top covers.
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Maintenance
3.5.10 Gap Wheel Height Adjustment

1. Remove plastic plugs, Figure 21 (item G), from adjustment windows on both
sides of the discharge bed.
2. Loosen the four bolts that fasten the gap wheel support frame (item H) to
the discharge end side plates.
3. Loosen the jam nuts.
:INFO: Always adjust gap wheel assemblies on both sides equally. This
assumes previous adjustments have been equally applied. If you suspect
otherwise, break the slat chain and use the LIM height tool to reset the height
adjustment (Figure 21).
4. Adjust up to the bottom of the slats.
5. Check that the carrier wheels for the supported slat drag on the wheel-
carrying surfaces but turn easier than wheels not supported by gap wheels.
6. Tighten jam nuts and replace hole plugs.
7. Tighten the slat support mounting bolts.
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Figure 21 Gap Wheel Height Adjustment
Item Description
A Gap wheel
B Slat support weldment
C LIM height tool (Adjust wheel height to bottom of slat, rather than using
this tool)
D Adjustment nut
E Jam nut
F Adjustment bolt
G Adjustment hole plug
H Slat support mounting bolts
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Maintenance
3.5.11 Transition Bed Belt Calibration

1. Using the FlexSort HMI, go to the Conveyor Speed Test screen (under
Diagnostic Mode) and select the charge transition bed.
2. Set the bed to run at 0.5 m/sec and start the test.
3. Verify that the transport belt is tracking properly.
4. Calibrate the charge transition bed belt speed:
a. Set the conveyor speed to 2.0 m/sec and start the test.
b. Use a tachometer to verify the belt speed. If the tachometer speed
does not closely equal the current speed displayed (± 0.5 m/sec), verify
that the PPI is set to the right resolution and is undamaged.
c. Go to the Calibrate Conveyor Speed screen. Run the conveyor at 2.0
m/sec and click the copy icon to copy the value displayed under current
speed into the measured speed entry field. Click the calibrate icon to
achieve calibration.
d. Verify that the measured speed displayed equals the current speed
displayed. If it does not, repeat step c.
5. On the FlexSort HMI, go to the Conveyor Speed Test page and select the
sorter.
6. Calibrate the sorter speed:
b. Use a tachometer to verify the speed.
c. If the tachometer speed does not closely equal the current speed
displayed (± 0.5 m/sec), go to the Calibrate Conveyor Speed page and
run the conveyor at 2.0 m/sec.
d. Click the copy icon to copy the value displayed under current speed
into the measured speed entry field.
e. Click the calibrate icon to achieve calibration.
f. Verify that the measured speed displayed equals the current speed
displayed. If it does not, repeat steps c - e.
7. On the FlexSort HMI, go to the Conveyor Speed Test screen and select the
discharge transition bed. Set the bed to run at 0.5 m/sec and start the test.
8. Verify that the transport belt is tracking properly.
9. Calibrate the discharge transition bed belt speed:
b. Use a tachometer to verify the belt speed. If the tachometer speed
does not closely equal the current speed displayed (± 0.5 m/sec), verify
that the PPI is set to the right resolution and is undamaged.
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Maintenance
c. Go to the Calibrate Conveyor Speed screen. Run the conveyor at 2.0

m/sec and click the copy icon to copy the value displayed under current
speed into the measured speed entry field. Click the calibrate icon to
achieve calibration.
d. Verify that the measured speed displayed equals the current speed
displayed. If it does not, repeat step c.
3.5.12 Shoe Pin Alarm Recovery

FlexSort reports broken shoe pins detected by pin sensors located in the return
sweep and in the diverts. To recover from a broken shoe pin alarm, use the
following procedures and refer to the Model 3633 FlexSort Software online help
or Operator Manual as required.
3.5.12.1 Inspecting for Broken Pins

The Human Machine Interface (HMI) generates an alarm if a pin sensor detects
that a shoe is missing a pin. The HMI identifies which slats have broken pins. It
also indicates which pin sensor(s) detected the missing pins:
● If a pin sensor in a divert generated the alarm, the ID number of the DCM
associated with that divert is shown in parentheses following the slat ID.
● If the return pin sensor detected the broken pin, no ID is listed in
parentheses after the slat ID.
1. Determine the origin of the shoe pin alarm.

a. Go to the FlexSort Human Machine Interface (HMI) and select the
System Status page.
b. Click to view details on the faulted sorter subsystem, then on the
Conveyor component, and then on the Slats component. The SlatIDs
column lists slats with broken pins.
:INFO: To minimize the number of lost packages when jogging the sorter,
remove packages only after they exit the discharge transition bed. Allow
packages to move along the surface of the sorter as you jog the sorter.
2. If the alarm was generated by the return pin sensor (no DCM ID listed):
a. Remove the side panels on the switch side of the sorter between the
charge end and the return pin sensor (located approximately 35 feet
downstream of the charge end).
:INFO: Verify that all shoes are justified to the switch side. Any shoes not
justified are likely damaged.
b. Visually inspect the shoe pins between the pin sensor and the charge
end for damage.
c. If a broken shoe pin is found, remove the broken shoe pin and related
debris.
3. If the alarm was generated by a DCM:
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a. Remove the slat indicated by the FlexSort HMI and, if the pin is missing
or loose or if the shoe is cracked, remove the shoe.
b. Check nearby shoe pins—two slats on either side of the removed slat—
and, if any are broken, remove the slat and the shoe.
4. If no broken shoe pin is found, continue to troubleshoot the alarm as
indicated in the on-screen help on the HMI (or you can restart the system).
Troubleshooting may reveal the cause of the inaccurate alarm.
3.5.12.2 Replacing the Broken Shoe

2. Locate and remove the broken shoe pin and related debris.
3. If necessary, jog the sorter to position the slat indicated by the FlexSort HMI
on the top of the sorter in an accessible location (see section 3.4.3).
4. Remove the slat with the broken pin and remove the shoe.
5. Inspect the shoe. If pieces have not yet been found, attempt to locate them.
It may be necessary to remove slats and side panels upstream to locate the
missing pieces.
6. Replace the damaged shoe.
7. Replace the slat and close up the sorter.
3.5.12.3 Restarting the Sorter

1. If the sorter has been jogged, change the SORTER MODE switch on the
FlexSort control cabinet to RUN.
2. On the HMI:
a. Go to the System Status | Sorter | Conveyor (sorter) | Slat Status page.
b. Click to clear any alarms.
c. Go to the System Mode page, enter Diagnostic Mode, and then enter
Run Mode.
3. Reset any active system faults.
4. Restart the system.
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4 Troubleshooting
The Model 2430 Sorter is integrated with the FlexSort Human-Machine Interface
(HMI). The HMI provides a variety of fault messages and alarms and suggests
causes, diagnoses, and solutions. The following troubleshooting information is in
addition to that from the HMI.
The troubleshooting table below is provided to assist in diagnosing and resolving

symptoms that might occur during the normal operation of the sorter.
:INFO: See individual manufacturer’s product literature for more information.
To use the troubleshooting table:

1. Identify the symptom in the left most column in the table.
2. Identify the most likely possible cause in the center column.
3. Apply the solution outlined in the far right column.
Table 3 General Troubleshooting
Symptom Possible Cause Solution
Divert Shoes
Shoes jump divert guides or Slat and shoe are sticky. Clean slat and shoe (see 3.4.7).
switch Shoe is missing bottom roller Replace shoe (see 5.2).
bearing.
Shoe is jammed on slat. Replace shoe and/or slat (see 5.2).
Divert shoes making a loud Misaligned divert angle or Re-align the divert rails with the
rapping or metallic noise shingling of divert guide into merge/shingle in the direction of flow
passing along a merge at the merge. (see 5.4).
end of a divert angle
Divert shoes making a rapping Divert switch mechanism is not Replace mechanical divert switch with a
or metallic noise at a divert functioning properly. spare and send defective switch to
switch when the divert switch is Dematic for rebuild (see 5.4.1).
turned on
Divert shoes making noise at Divert controller is not functioning Re-seat divert controller (see 3.5.2).
divert nose or deep marking properly. Replace divert controller (see 5.7.1).
appears on the surface of a
divert nose Divert switch dirty and sticky. Clean switch gate and bumpers.
Divert switch mechanism is not Replace switch with a spare and send
functioning properly. defective switch to Dematic for rebuild
(see 5.4.1).
Retractable nose damaged. Replace nose (see 5.4.2).
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Troubleshooting
Shoes are diverted when not Divert switch is dirty and sticky. ● Clean switch gate and bumpers.
supposed to ● Clear the missing pin fault and restart
:INFO: This is reported as a the sorter (3.5.12)
broken pin, because the shoe
pin is not detected by the Divert switch bumper or gate is Replace switch with a spare (see 5.4.3)
damaged. and repair switch with new gate and/or
switch-out pin sensor.
bumpers (see 5.4.4).
Frequent broken pins at the Debris on the bottom covers Clear debris from the bottom covers (see
return photoeye diverts pins into the nose of the 3.4.8).
return sweep.
Product movement
Product jams (at shoe Broken shoe cap is jamming the ● Check for missing or broken shoe
assembly) slat or track. cap.
● Remove broken shoe cap.
● Replace shoe cap.
Package weight exceeds Remove packages that exceed the
maximum weight specification. maximum weight.
Product misdiverted or Debris in divert assembly. Remove debris (see 3.4.9).
excessive recirculation Mechanical divert switch Test by pushing Manual Divert buttons 1,
mechanism is faulty. 2, and 3 on the DCM to determine which
switch mechanism is causing the
problem. Replace the mechanical divert
switch with a spare and send defective
switch to Dematic for rebuild (see 5.4.3).
Divert controller is not functioning Re-seat divert controller (see 3.5.2)
properly. Replace divert controller (see 5.7.1).
HAS is not functioning properly. Refer to the Troubleshooting section of
the Horizontal Array Sensor Service
Manual.
Sorter does not start Long range photoeye is blocked or Clear photoeye or align properly.
misaligned.
Emergency pull cord actuated. Find reason emergency stop was
actuated, fix problem, reset actuator, and
restart system.
Sorter stops or loses speed Object jammed between slat link Inspect for and remove object jammed
plates and side of sorter. between slat link plates and side of
sorter.
Long range photoeye is blocked or Clear photoeye or align properly.
misaligned.
Emergency stop is actuated. Find reason emergency stop was
actuated, fix problem, reset actuator, and
restart system.
Recirculation line is full. Clear line (or clean line-full photoeye)
and restart system.
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Product spins off the front or Product is out of specification. Route out-of-specification product off the
back of shoes during diverting sorter.
Photoeyes
Long range photoeye not Photoeye dirty or out of alignment. 1. Confirm photoeye power indicator
working light is on.
2. Block photoeye.
3. If photoeye indicator light does not
change status, clean and align
photoeye.
Photoeye cable faulty. If photoeye power indicator is not lit:
1. Disconnect the photoeye cable.
2. With a voltmeter connected to ground,
probe the photoeye cable for 24 VDC
on pins 1 (+) and 3 (-).
3. If 24 VDC is not present, check power
supply.
4. If power supply is OK, replace faulty
cable.
I/O module faulty. 1. Locate photoeye I/O module in control
cabinet.
2. Check to see if input LED on I/O
module turns ON.
3. If LED does not turn on, connect
voltmeter to ground and probe the
input terminals at I/O module.
4. Alternately block and unblock the
photoeye.
5. If voltmeter fluctuates between
approx. 0 VDC and 24 VDC, replace
faulty I/O module.
Photoeye faulty. ● Verify the photoeye power indicator
light is on. Interrupt the photoeye
beam with a card. If no red dot is
apparent on card, replace photoeye.
● If photoeye green indicator light is not
on but 24 VDC power is present when
you probe the cable, replace
photoeye.
● If photoeye is clean and properly
aligned, replace photoeye.
● If the I/O module is not faulty, replace
photoeye.
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Troubleshooting
Sorter update or shoe cap Photoeye dirty. ● Confirm green and amber photoeye
photoeye not working indicator lights are on.
● Block photoeye with a card.
● If a red laser dot is not visible on
card, clean photoeye with a lint-free
Do not look directly into the cloth (see 3.4.12).
photoeye laser beam. Photoeye not aligned with ● Confirm green and amber photoeye
Prolonged exposure can reflector. indicator lights are on.
damage your eyes.
● Block photoeye with a card.
● If a red laser dot is visible on card,
align photoeye with reflector (see
5.1.3 or 5.1.3).
Photoeye cable faulty. ● If photoeye green indicator light is not
on, disconnect the photoeye cable.
● With a voltmeter connected to ground,
probe the photoeye cable for 24 VDC
on pins 1 (+) and 3 (-).
● If 24 VDC is not present, check power
supply.
● If power supply is OK, replace faulty
cable (see 5.1.3 or 5.1.3).
I/O module faulty. ● Confirm green and amber photoeye
indicator lights are on.
● Block photoeye.
● If amber indicator light turns off, locate
SORT PE I/O module in control
cabinet.
● Block photoeye and check to see if
red input LED on I/O module turns on.
● If LED does not turn on, connect volt
meter to ground and probe the input
terminals at SORT PE I/O module.
● Alternately block and unblock the
photoeye.
● If voltmeter fluctuates between
approx. 0 VDC and 24 VDC, replace
I/O module.
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Troubleshooting
Sorter update or shoe cap Photoeye faulty. ● Verify the photoeye power indicator
photoeye not working light is on. Interrupt the photoeye
(cont.) beam with a card. If no red dot is
apparent on card, replace photoeye.
● If photoeye green indicator light is not
on but 24 VDC power is present when
you probe the cable, replace
photoeye.
● If photoeye is clean and properly
aligned, replace photoeye.
● If the I/O module is not faulty, replace
photoeye (see 5.1.3 or 5.1.3).
General
Take-up over travel alarm Slat chain length too great. Remove a slat to the sorter (see 3.5.1).
displayed on the FlexSort HMI Faulty takeup sensor cable. Check cable and replace if damaged
(see 5.9.1).
Faulty takeup sensor. Verify that the distance between the
sensor and the sensed surface is within
the prescribed parameters (see 3.5.7). If
it is, replace the sensor (see 5.9.1).
Discharge take-up assembly Slat chain length too great. Remove a slat (see 3.5.1.2).
surging and near end of travel
limit
Take-up under travel alarm Take-up sensor dirty or obstructed Clean the take-up sensor and make sure
displayed on the FlexSort HMI there are no obstructions between the
sensor and the slat support bracket.
Speed regulation fault Gap between LIMs and slats is too Check gaps and adjust as needed (see
displayed on FlexSort HMI great 3.5.6).
One or more VFDs offline Verify that all VFDs are online and in
Auto mode.
Direction of force is reversed on ● Check direction of force (see 5.5.3).
one or more LIMs ● If reversed, check wiring polarity and
correct as needed.
Slat chain movement impeded by Check for a damaged or misadjusted
mechanical binding components (examples: seized wheel
bearings; slat skis on lower LIMs
dragging on slats).
Wrong parameters on VFD Contact Dematic Customer Service for
setting parameters or replace VFD with a
spare.
Slat chain noisy Loss of slat tension, failed gas Replace gas spring (see 5.9.2).
spring cylinder.
Gap wheels too high or too low. Adjust gap wheels (see 3.5.10).
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5 Repair
This section provides removal and replacement procedures for replaceable parts
and assemblies. As you follow the removal steps to reach the part that is to be
replaced, you might have to remove other parts. Inspect these parts for wear or
other problems and replace them at this time if necessary.
:INFO: Use care not to damage good parts when trying to reach a particular
part.
The heading for each procedure references the part or parts to replace. The
reference following the part name [Figure 8 - Item (25)] directs you to the
illustration containing that part for a visual reference.
In the procedure, when applicable, the number adjacent to the part referenced in
that step refers to a Figure and Item number, as in Figure 5-(9). If the figure
number is not listed, the item number refers to the last figure that was
referenced.
Do not perform adjustments, maintenance, clearing of jams, or any other

work on this equipment unless you are competent in carrying out the
energy isolation procedure as required by national or local authorities.
The purpose of energy isolation procedure is to protect all persons
involved against unexpected startup of the equipment. Personnel should
be alerted to the hazard of stored energy which may exist after the
source of energy has been isolated. Refer to national, local, or employer
procedures for minimum requirements. Failure to follow these
requirements may result in equipment damage, serious injury, or death.
Refer to and be familiar with all of the proper safety precautions and
procedures outlined in the Safety section of this manual before
performing maintenance. Only properly trained and authorized personnel
are to perform maintenance on this equipment.
Follow standard shop practices and safety procedures whenever you remove or
replace parts.
1. Make certain the system is locked out before performing any maintenance
activities.
2. Secure all hardware during installation.
3. Clean parts and assemblies after installation.
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Repair
4. Before starting the conveyor, install all guards and covers removed during
maintenance or repair activities.
5.1 Charge Bed

5.1.1 Electrostatic Discharge (ESD) Brushes
Figure 22 Charge End Assembly
5.1.1.1 Slat ESD Brush [Figure 22 – Item (13)]
Removal
1. Follow Lock-Out / Tag-Out procedures (see the first page of the Repair
section).
64 2017-05-11
Repair
section 3.4.2) above the ESD brush on the charge assembly.
3. Mark the position of the ESD brush Figure 23 – (2), on the bracket (1).
4. Remove the brush.
Replacement
:INFO: Be sure to use star washers when installing the ESD brush to ensure a
good ground.
1. Install the new ESD brush on the bracket.
2. Verify the brush lightly touches the slats.
Figure 23 Slat Electrostatic Discharge (ESD) Brush
5.1.1.2 Link Plate ESD Brush [Figure 22 – Item (11)]
Removal
section).
section 3.4.2) in the charge bed.
3. Remove the ESD brush, Figure 24 – (2), from its bracket on the charge bed
frame crossmember.
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Repair
Replacement
:INFO: Be sure to use star washers when installing the ESD brush to ensure a
good ground.
1. Install the ESD brush.
2. Confirm that the brush lightly touches the chain links.
:INFO: Link plate brushes are not adjustable. If the brush is not touching the link
plates, the bracket may be bent.
Figure 24 Link Plate ESD Brush
5.1.2 Slat Sensor [Figure 25 – Item (4)]

Removal
Do not move the sensor bracket. The location of this sensor is key to
proper sorter performance. If moved, sorter sensor positions must be
verified (see section 3.5.8).
section).
66 2017-05-11
Repair
section 3.4.2) on the charge bed above the slat sensor assembly, Figure
22 – (10).
3. Remove the slat sensor cover, Figure 25 – (3).
4. Disconnect the cable (5) and remove the slat sensor (4).
Replacement
1. Install the slat sensor and connect it to the cable.
2. Replace the slat sensor cover.
3. Using metric hex wrenches as feeler gauges, verify that the gap between
the slat sensor cover and the slat is between 2.5 and 5.5 mm (see Figure
26).
5. Jog the sorter until a minimum of 200 slats have passed the slat sensor (see
section 3.4.3).
Figure 25 Charge End Assembly Slat Sensor
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Repair
Figure 26 Charge End Assembly Slat Sensor Gap Verification
Callout Description
A Metric hex wrench (used as feeler gauge)

B Slat sensor
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Repair
5.1.3 Shoe Cap Photoeye [Figure 27 – Item (5)]

:INFO: Verify that you select the correct photoeye when replacing this part (see
Figure 27). Both charge-end photoeyes are numbered the same in the drawings.
Removal
section).
2. Remove the sensor doghouse from the charge end assembly.
3. Remove the shoe cap photoeye, Figure 27 – (5), from the support angle (3).
4. Remove the cable connector (6) from the photoeye.
Replacement
1. Connect the cable connector to the shoe cap photoeye.
2. Install the shoe cap photoeye on the support angle.
3. Replace the sensor doghouse on the charge end assembly.
4. Align the photoeye with the reflector and verify that the yellow and green
LEDs are illuminated.
5. Verify that a shoe cap interrupts the photoeye beam, but a shoe does not.
6. Locate the teach-in button on the top of the photoeye, on the same end as
the LEDs.
:INFO: Do not hold the teach-in button for more than five seconds. Release the
button as soon as the yellow LED turns off.
7. Press and hold the teach-in button until the yellow LED turns off (between
two and five seconds). The LED turns off momentarily and then back on,
indicating that teach-in is initiated.
8. When both the yellow and green LEDs begin to flash, press the teach-in
button once to store the sensitivity setting.
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Repair
Figure 27 Shoe Cap Sensor and Doghouse
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Repair
5.1.4 Update Photoeye [Figure 28 – Item (2)]

Removal
section).
2. Remove the cover, Figure 28 – (9), from the update sensor housing (1).
3. Mark the location of the sensor mounting bracket (8) on the angle bracket
(7).
4. Remove the sensor bracket from the support angle.
5. Mark the location of the update photoeye (2) on the sensor bracket.
6. Remove the update photoeye from the sensor bracket.
7. Remove the cable connector (6) from the update photoeye.
Replacement
Installing the photoeye:
1. Connect the cable connector to the update photoeye.
2. Install the update photoeye on the sensor bracket.
3. Install the sensor bracket on the angle bracket.
4. Align the photoeye with the reflector and verify that the yellow and green
LEDs are illuminated.
5. Interrupt the photoeye beam with a card roughly 150 mm (six inches) from
the photoeye.
6. Position the card at a 90 degree angle to the slat and align the edge of the
card with the edge of the slat. Mark the location of the photoeye beam on
the card.
7. Move the card roughly 150 mm (six inches) further from the photoeye. Edge
align the card to the slat at a 90 degree angle and mark the location of the
photoeye beam on the card.
8. Repeat step 7 until you reach the opposite side of the sorter.
9. If the location of the photoeye beam on the card is consistent across the
sorter, continue with storing the sensitivity setting. If not, adjust the
photoeye accordingly and go to step 5.
Storing the sensitivity setting:

1. Locate the teach-in button on the top of the photoeye, on the same end as
the LEDs.
:INFO: Do not hold the teach-in button for more than five seconds. Release the
button as soon as the yellow LED turns off.
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Repair
2. Press and hold the teach-in button until the yellow LED turns off (between
two and five seconds). The LED turns off momentarily and then back on,
indicating that teach-in is initiated.
3. When both the yellow and green LEDs begin to flash, press the teach-in
button once to store the sensitivity setting.
Calibrating the offset between charge end slat sensor and update photoeye:
1. On the FlexSort HMI, go to the System Mode page (under Status) and start
diagnostic mode.
2. Go to the Jog To Slat screen (under Diagnostic Mode).
3. Enter “1” in the Jog To Slat entry box and run the test.
4. Install the slat timing bracket on the primary slat (slat number one) on the
take-away side of the sorter (see Figure 30).
a. Remove the primary slat from the slat chain (see section 3.4.2.1).
b. Press the slat timing bracket onto the take-away end of the slat.
:INFO: The first time that the slat timing bracket is used, the tabs bend to hold
the bracket upright on the slat. If the bracket fits too loosely, bend the tabs
lightly.
c. Replace the primary slat (see section 3.4.2.2).
5. On the FlexSort HMI, go to the Slat Sensor Calibration screen.
6. Follow the instructions to calibrate the slat sensor, referring to the on-screen
Help file as necessary.
7. Remove the slat timing tool from the primary slat.
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Figure 28 Update Photoeye and Housing
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Figure 29 Update Photoeye Alignment
Item Description
A Sensor doghouse
B Cardboard
C Photoeye beam
D Update photoeye
E Edge align
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Figure 30 Slat Timing Tool
Item Description
A Slat timing tool

B Reflector
C Update photoeye
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5.2 Slat Chain

Slats on the SL2 sorter are easy to remove (see section 5.2.1). However, to
replace link plates or wheels (5.2.2), you need to relieve tension on the slat
chain (3.5.1.1) and break the slat chain.
5.2.1 Slat and Shoe

Verify the type of slat to be replaced prior to starting this procedure. Reference
slats are marked at both ends with colored stripes and must be tested for proper
polarity with the magnet polarity testing tool prior to installation.
● The primary slat has white stripes on either end; the polarity of both
magnets at the bottom of the slat should be north.
● The secondary slat has green stripes; the polarity of the magnets at the
bottom of the slat should be one north and one south.
● Index slats have orange stripes; the polarity of both magnets at the bottom
of the slat should be south.
Removal
Slat
Shoe [Figure 33 – Item (1)]
section).
2. Use the slat removal tool to press in the pins at one end of the slat and
remove the slat from the chain link plates (see Figure 31).
:INFO: If necessary, use a flat screw driver or small pry bar to help lift the end of
the slat when you press in on the pins.
3. Slide the shoe, Figure 33 – (1), off the slat.
4. If replacing only the bearing, (4), remove it from the shoe and replace it.
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Figure 31 Slat Removal
Replacement
Slat
Shoe [Figure 33 – Item (1)]
1. If the slat being replaced is numbered, use a permanent marker to match
the number on the new slat.
2. Place the shoe on the slat.
3. Place the slat onto the carrier wheel chain so that the pins in the ends of the
slat are located above the holes in the chain link plates.
4. Use the slat removal tool to depress both pins on one end of the slat (see
Figure 32).
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Figure 32 Slat Installation
:INFO: Do not use excessive force in pressing the slats down over the locating
pins. Too much force can damage the ends of the slats.
5. With pins depressed, push the slat down and pull it toward you until the pins
are engaged behind the link plate. Continue to press the slat down until the
pins snap into the link plate holes. If the slat ends do not slide over the
locating pins on the link plate, use a small pry bar to press the plate toward
the slat end.
6. Depress the pins on the other end of the slat, pull the slat toward you, and
push down until the pins snap into the holes.
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Figure 33 Slat Shoe
5.2.2 Link Plate, Carrier Wheel, and Guide Wheel

Removal
Link Plate [Figure 35 – Item (1)]
Carrier Wheel [Figure 35 – Item (4)]
Guide Wheels [Figure 35 – Item (2)]
section).
2. Remove slats from the link plate or plates to be replaced.
3. Relieve tension on the slat chain by loosening the gas springs (see section
3.5.1.1).
4. Place ratchet straps around slats at either end of the section of removed
slats and draw them taut (see Figure 34).
5. Remove the snap ring, Figure 35 – (5), and wheel (4) from the axle on the
farthest downstream chain link (1) to be replaced.
6. Lift the chain above the rim of the frame rail until you can remove the axle
from the next downstream link plate.
:INFO: If necessary tighten the ratchet strap to provide the necessary slack to
remove the section of chain.
7. Remove the snap ring from the axle on the link plate upstream from the link
plates to be replaced.
8. Remove the section of links to be replaced.
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9. If replacing a guide wheel (2), remove the socket head cap screw (3) and
remove the wheel from the link plate.
Figure 34 Preparation for Breaking the Slat Chain
Callout Description
A Ratchet straps
B Cap angle
Replacement
Link Plate [Figure 35 – Item (1)]
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Carrier Wheel [Item (4)]

Guide Wheels [Item (2)]
1. Replace guide wheels, carrier wheels, or link plates as needed. Tighten
guide-wheel socket head cap screws to 5.4 nm (48 in lb).
2. Insert the axle of the first link plate into the bushing of the next downstream
link plate.
3. Place the wheel on the axle and fasten it with the snap ring.
4. Place the bushing of the last replacement link plate over the axle of the next
upstream link plate and fasten it with the snap ring.
5. Replace the cap angles.
6. Replace the removed slats.
7. Retension the slat chain (see section 3.5.1.4)
Figure 35 Slat Chain Links
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5.3 Wear Strip

5.3.1 Upper Frame Rail Wear Strip
Due to the degree of difficulty and potential hazards of performing the
following repair procedure, it is strongly recommended that frame rail
wear strips be replaced only by Dematic service personnel.
Removal
section).
2. Verify that at least every tenth slat and all reference slats are numbered
legibly.
3. Remove the cap angles (Figure 34 – item B) located above the wear strip to
be replaced.
3.5.1.1).
5. Remove all the slats above the wear strip to be replaced.
6. Place ratchet straps around slats at either end of the removed slats and
draw it taut (see Figure 34).
7. Remove snap rings Figure 35 – (5) and wheel (4) from the axle on a chain
link to break the chain near the middle of the window created by removing
slats.
8. Lift the ends of the chain off the wear strip and fold them back onto the
surface of the sorter.
:INFO: Remove the entire damaged wear strip. Do not attempt to replace a
portion of a wear strip.
9. Remove the damaged wear strip from the frame rail with a putty knife.
:INFO: Apply Goo Gone Spray Gel solvent only to the frame rail. Avoid contact
with other sorter parts.
10. Clean the frame rail with Goo Gone Spray Gel solvent.
a. Saturate the tape remnants on the frame rail with the solvent.
b. Allow the solvent to soak in.
c. Remove tape remnants with a putty knife.
d. Wipe the frame rail clean with a soft rag.
Replacement
:INFO: Use only parts supplied by Dematic for wear strip replacement.
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1. Put down the two-sided tape, leaving the backing on the top surface. Trim
the tape to fill the entire exposed frame rail surface (see Figure 36).
Figure 36 Wear Strip Tape Replacement
Callout Description
A New wear strip

B Frame rail joint
C Non-conductive two-sided tape (blue)
D Conductive two-sided tape (white)
E Existing wear strip
2. Lay the wear strip in place on the frame rail to check length. Trim as
necessary to fill the entire exposed frame rail surface.
Do not grind, machine, or otherwise alter the exposed wheel-running

surface of the wear strip.
3. Check the transition point on the upstream end of the wear strip (the point at
which it meets the charge end assembly or existing wear strip). Perform
alterations as necessary (see Figure 37):
● If the wear strip is lower than the existing wheel-running surface but
within one millimeter, no alteration is necessary.
● If the wear strip is higher than the existing wheel-running surface, grind
the bottom of the wear strip on that end until the transition point is flush
or there is a small step (less than one millimeter) down to the wear
strip.
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● If the wear strip is more than one millimeter below the existing wheel-
running surface, contact Dematic customer service for further
instruction.
Figure 37 Wear Strip Transition Points
Callout Description
A Wear strip
B Grind here as necessary
C Existing wheel-running surface
D Frame rail
4. Check the transition point on the downstream end of the wear strip (the
point at which it meets the discharge take-up assembly or existing wear
strip). Perform alterations as necessary:
● If the wear strip is higher than the adjacent wheel-running surface but
● If the wear strip is more than one millimeter higher than the existing
wheel-running surface, grind the bottom of the wear strip on that end
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until the transition point is flush or there is a small step (less than one
millimeter) down to the existing wheel-running surface.
● If the wear strip is lower than the existing wheel running surface,
contact Dematic customer service for further instruction.
Prevent dirt or any foreign material from coming in contact with the
exposed tape.
5. Remove the backing on the two-sided tape.

:INFO: Position the wear strips so that the breaks in the strips never coincide
with the gaps in the frame rails.
6. Place the wear strip in place and press down firmly.
7. Reconnect the ends of the slat chain.
8. Replace the slats in their original numbered positions. Double-check the
positions of all reference slats.
:INFO: Frequent removal of cap angle can cause deformation of the mounting
holes. Replace cap angle if it becomes fatigued or deformed.
5.3.2 Lower Frame Rail Wear Strip

Due to the degree of difficulty and potential hazards of performing the
following repair procedure, it is strongly recommended that frame rail
wear strips be replaced only by Dematic service personnel.
Removal
section).
2. Verify that every tenth slat and all reference slats are numbered legibly.
3. Remove side panels adjacent to the discharge bed (see section 3.4.4).
3.5.1.1).
5. Remove the cap angles (Figure 38 – item B) between the last downstream
take-away and the discharge bed.
6. Just downstream from the last downstream take-away, remove a slat at a
link with a guide wheel. Leave the next slat downsteam in place, and then
remove the rest of the slats downstream to the discharge bed.
7. Where the one slat was removed use wood clamps to clamp the chain to
the frame rail.
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8. Place a ratchet strap around slats at either end of the removed slats and
draw it taut.
Figure 38 Breaking the Slat Chain
Callout Description
A Ratchet straps
B Cap angle
9. Remove snap rings Figure 35 – (5) and wheels (4) from axles on chain links
on both sides and at both ends of the exposed chain and remove the
sections of chain.
10. Release the tension and remove the ratchet strap from the downstream end
of the slat opening.
11. Anchor a winch downstream of the sorter, such that the cable can be
attached to the pull straps without contacting any other portion of the sorter
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(see Figure 39). The height of the winch must be such that the carrier
wheels on the slats remain in contact with the frame rails.
12. Place pull straps around the slat downstream from the clamp.
13. Attach the winch to the straps and remove slack from the winch cable.
14. Remove the clamps.
15. Use the winch to pull the slat chain as far as possible toward the discharge
end.
16. Just downstream from the last downstream take-away, remove a slat at a
link with a guide wheel and clamp the chain link to the frame rail.
Figure 39 Moving the Slat Chain
Callout Description
A Winch
B Winch cable
C Pull straps
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Callout Description
D Guide wheel
E Clamp
F Direction of flow
17. Leave the next slat downstream in place and then remove the rest of the
slats downstream.
18. Remove the corresponding section of chain links.
19. Repeat steps 12 through 18 as necessary until the section of wear strip to
be replaced is nearly exposed and then follow steps 12 through 16 to
completely expose the wear strip to be replaced.
20. Remove side panels as necessary to access the wear strip.
:INFO: Remove the entire damaged wear strip. Do not attempt to replace a
portion of a wear strip.
21. Remove the damaged wear strip from the frame rail with a putty knife.
:INFO: Apply the Goo Gone Spray Gel solvent only to the frame rail. Avoid
contact with other sorter parts.
22. Clean the frame rail with Goo Gone Spray Gel.
a. Saturate the tape remnants on the frame rail with the solvent.
b. Allow the solvent to soak in.
c. Remove the tape remnants with a putty knife.
d. Wipe the frame rail clean with a soft rag.
Replacement
:INFO: Use only parts supplied by Dematic for wear strip replacement.
1. On either side of each joint between frame rails, put a 3-inch piece of
conductive two-sided tape.
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2. Put down non-conductive two-sided tape to fill the entire remaining exposed
frame rail surface (see Figure 40). Trim the tape to fill the remaining surface.
Figure 40 Wear Strip Tape Replacement
Callout Description
A New wear strip

B Frame rail joint
C Non-conductive two-sided tape (blue)
D Conductive two-sided tape (white)
E Existing wear strip
3. Before removing the tape backing, lay the wear strip in place on the frame
rail to check length. Trim as necessary to fill the entire exposed frame rail
surface.
Do not grind, machine, or otherwise alter the exposed wheel-running

surface of the wear strip.
4. Check the transition point on the upstream end of the wear strip (the point at
which it meets the discharge take-up assembly or existing wear strip).
Perform alterations as necessary (see Figure 41):
● If the wear strip is lower than the existing wheel-running surface but
● If the wear strip is higher than the existing wheel-running surface, grind
the bottom of the wear strip on that end until the transition point is flush
or there is a small step (less than one millimeter) down to the wear
strip.
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● If the wear strip is more than one millimeter below the existing wheel-
running surface, contact Dematic customer service for further
instruction.
Figure 41 Wear Strip Transition Points
Callout Description
A Wear strip
B Grind here as necessary
C Existing wheel-running surface
D Frame rail
5. Check the transition point on the downstream end of the wear strip (the
point at which it meets the charge end assembly or existing wear strip).
Perform alterations as necessary:
● If the wear strip is higher than the existing wheel-running surface but
● If the wear strip is more than one millimeter higher than the existing
wheel-running surface, grind the bottom of the wear strip on that end
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until the transition point is flush or there is a step down of less than one
millimeter to the existing surface.
● If the wear strip is lower than the existing wheel running surface,
contact Dematic customer service for further instruction.
Prevent dirt or any foreign material from coming in contact with the
exposed tape.
6. Remove the backing from the two-sided tape.

:INFO: Position the wear strips so that the breaks in the strips never coincide
with the gaps in the frame rails.
7. Place the wear strip in place and press down firmly.
8. Remove the clamps from the chain by the last take-away.
9. Unwind the winch to relieve tension on the slat chain, allowing the slat chain
to roll backwards until there is room to install the sections of chain links that
were removed.
10. Re-clamp the slat chain, disconnect the winch, and remove the pull straps.
11. Reconnect the last pair of chain-link sections to be removed.
12. Install slats in the replaced sections of chain links.
13. Repeat steps 8 through 12 until all chain-link sections have been replaced in
the sorter.
14. Place a ratchet strap around slats at either end of the removed slats, draw it
taut, and connect the ends of the slat chain.
15. Replace all remaining slats.
16. Re-tension the gas spring (see section 3.5.1.4).
:INFO: Frequent removal of cap angle can cause deformation of the mounting
holes, resulting in difficulty creating the shingling as required. Replace cap angle
when it becomes fatigued or deformed.
5.4 Divert Assembly

5.4.1 Slat Sensor, Pin Sensor
Each divert has one slat sensor and three pin sensors. The pin sensors are:
● Pin-in: senses each shoe bearing as it first enters the divert switch
● Pin-out: senses the bearing on each shoe that has not been diverted as it
leaves the divert switch
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● Pin-divert-out: senses the bearing on each shoe that has been diverted as it
leaves the divert merge assembly on the opposite side of the sorter from
where from where it entered the switch
:INFO: All pin sensors are numbered the same in the drawings.
Removal
Slat Sensor [Figure 43 – Item (6)]
Pin Sensor [Figure 43 – Item (16)]
section).
2. Remove three slats from the sorter to create a maintenance window above
the divert switch (see section 3.4.2).
3. Remove the side panel adjacent to the relevant switch assembly and
expose the Divert Control Module (DCM) (see Figure 44).
4. Remove the slat sensor cover, Figure 43 – (15).
5. Disconnect the slat sensor (6) from the attached cable and remove it.
6. Remove the pin sensor cover (10).
7. Disconnect the pin sensor (16) from the attached cable and remove it.
Replacement
Slat Sensor
Pin Sensor
1. Install the pin sensor and connect it to the cable.
2. Replace the pin sensor cover.
3. Install the slat sensor and connect it to the cable.
4. Replace the slat sensor cover.
5. Use metric hex wrenches a feeler gauges to verify that the gap between the
slat sensor cover and the slat is between 2.5 and 5.5 mm. Adjust as
necessary (see section 3.5.3).
7. Using the HMI, set the sorter to run at 20 percent of maximum operating
speed and start the sorter.
8. Verify the sensor functionality at the DCM (see Figure 45):
a. Verify that the 15 V Power, 5 V Power, and Profibus LEDs are
illuminated.
b. Verify that the Pin In 1, Switch Pin Out, and Slat Sensor LEDs are
illuminating as each slat cycles by.
c. Verify that the Index Mag LED illuminates as each index slat cycles by.
9. Replace the side panel.
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Figure 42 20 Degree Parallel Divert Components
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Figure 43 20 Degree Parallel Switch Assembly
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Figure 44 Divert Control Module (DCM) Access
Callout Description
A Divert Control Module
Figure 45 DCM Front Panel
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5.4.2 Retractable Nose [Figure 43 – Item (13)]

Removal
section).
a switch assembly (see section 3.4.2).
3. Remove the socket head cap screws and flat washers from the retractable
noses, Figure 43 – Item (13).
4. Remove the retractable noses, spacers (7, 8), and springs (17).
Replacement
1. Place the spring in the pockets on the retractable nose and the fixed nose
(9, 12). Position these parts together on the divert deck plate.
2. Insert the nose spacer (8) through the retractable nose and the fixed nose.
3. Apply Loctite 222 (purple) to a socket head cap screw. Slide the screw
through the upstream hole on the fixed nose and then through the spacer,
and retractable nose. Thread the screw into the switch assembly far enough
to hold the pieces in place.
4. Install the spacer (7).
5. Apply Loctite to the socket head cap screw and install it.
6. Torque the socket head cap screws to 4 nm.
7. Push on the retractable part of the nose and verify that it retracts when
pressed and extends when released.
11. Test the divert functionality at the DCM (see Figure 45):
a. Press and hold the Divert 1 button. Listen for smooth movement of the
shoes through the divert and verify that the Div Pin Out and Divert 1
LEDs illuminate.
b. Press and hold the Divert 2 button. Listen for smooth movement of the
LEDs illuminate.
c. Press and hold the Divert 3 button. Listen for smooth movement of the
LEDs illuminate.
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12. Increase the speed of the sorter to the maximum operating speed for the
system and repeat step 11.
5.4.3 Mechanical Divert Switch (MDS) [Figure 43 – Item (4)]

Removal
section).
2. Remove two or three slats to create a maintenance window above the
switch assembly (see section 3.4.2).
3. Remove the side panel adjacent to the relevant switch assembly ( see
section 3.4.4) and expose the Divert Control Module (DCM) (see Figure 44).
4. Remove the switch cover, Figure 43 – (29), from the MDS.
5. Remove the screws that fasten the outer guide (11) to the switch.
6. Remove the screws that fasten the MDS (4) to the deck plate (1).
7. Lift the MDS that needs to be replaced and unplug the cable.
8. Remove the MDS.
Replacement
1. Plug in the cable.
2. Place the new MDS in position on the deck plate under the outer guide.
3. Replace the screws that fasten the MDS to the deck plate and the outer
guide to the switch.
4. Replace and fasten the switch cover.
7. Test the divert functionality at the DCM:
LEDs illuminate.
LEDs illuminate.
LEDs illuminate.
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5.4.4 MDS Gate and Bumpers [Figure 46 – Items (2, 12, 14)]
For quickest repairs to the sorter, the entire MDS mechanism is normally
replaced with a spare (see section 5.4.3). However, bench repairs can be made
to replace the gate, Figure 46 – (2), and the bumpers (12, 14). Bumpers should
be replaced whenever a gate is replaced. If bumpers are being replaced, there is
no need to replace the gate if it is in good shape.
Removal
:INFO: The following instructions assume that the MDS being repaired has
already been removed from the divert (see 5.4.3).
1. Remove the socket head cap screw that serves as the axle for the gate and
remove the gate.
2. Remove the two screws that hold the bumpers in place and remove the
bumpers.
Figure 46 Mechanical Divert Switch (MDS)
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Replacementl
1. Place the bumpers in the slot of the switch base (1).
2. Insert the two screws that hold the bumpers in place.
3. Attach locknuts until at least one thread emerges from each nut, but do not
tighten.
:INFO: When fastening, the screw threads may draw the bumper away from the
base (see Figure 47).
4. Spin the screws and nuts counter-clockwise until the bumper is flush with
the base (see Figure 48).
5. Insert socket head cap screw through the gate and fasten with the locknut to
the base. Do not overtighten.
6. Check that the gate moves freely and that all wires are firmly connected.
Figure 47 Gap between Bumper and MDS Base
Figure 48 Gap Closed
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5.4.5 Merge Assembly

Removal
Merge Component [Figure 49 – Item (2)]
section).
the merge assembly (see section 3.4.2).
3. Remove the pin sensor cover, Figure 49 – (4).
4. Disconnect the pin sensor (6) from the attached cable and remove it.
5. Remove the merge (2) from the deck (1).
Replacement
Merge Component [Figure 49 – Item (2)]
1. Install the merge.
2. Install the pin sensor and connect it to the cable.
3. Replace the pin sensor cover.
7. Test the divert functionality at the DCM (see Figure 45):
LEDs illuminate.
LEDs illuminate.
LEDs illuminate.
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Figure 49 20 Degree Parallel Merge Assembly
5.5 Linear Induction Motor (LIM)

Dematic recommends replacing an entire LIM assembly, which consists of the
motor itself, the heat sink, and the mounting plate, not just the individual motors.
5.5.1 Upper LIM Assembly

Removal
1. Follow lockout/tagout procedures (see the first page of the Repair section).
2. Remove slats to make a maintenance window above the LIM.
3. Disconnect the LIM cables.
4. Remove the upper LIM guard, Figure 50 – (2).
5. Carefully remove the upper LIM assembly (5).
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Replacement
1. Place the LIM assembly into position on the LIM mount weldment (1).
2. Replace the upper LIM guard.
3. Replace and tighten hardware.
4. Connect the LIM cables.
5. Adjust the LIM gaps (see section 3.5.6).
Figure 50 Dual LIM Drive
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5.5.2 Lower LIM Assembly

Removal
1. Follow lockout/tagout procedures (see the first page of the Repair section).
2. Make three maintenance windows with a single slat between the windows
(section 3.4.2).
3. Remove side panels adjacent to the LIM assembly being replaced (section
3.4.4).
4. Jog the sorter until the maintenance windows are centered under the LIM
assembly (section 3.4.3).
5. Disconnect the LIM cables.
6. Carefully remove the two slats between the maintenance windows.
7. Loosen hardware fastening the lower LIM guard assembly, Figure 50 – (3),
to the crossmembers and remove the guard assembly.
8. Support the lower LIM assembly (5) and then remove the nuts holding the
assembly to the LIM frame weldment (1) and remove the LIM assembly.
Replacement
1. Replace the LIM assembly on the LIM frame.
2. Replace the LIM guard assembly on the crossmembers.
3. Replace the two slats so that there are three maintenance windows, none
larger than three slats.
4. Connect the LIM cables.
5. Adjust the LIM gaps (see section 3.5.6.2).
6. Jog the sorter until the maintenance windows are on the top of the sorter.
7. Replace the remaining slats.
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5.5.3 Checking LIM Thrust Direction

After installing a new LIM, check to make sure the direction of thrust is correct.
Before starting, power must be applied to the power cabinet and therefore to all
VFD assemblies.
1. Turn off all VFD assembly (LDM) disconnect switches except that for the
replaced LIM.
2. Set the keyed switch on the sorter power cabinet door to Maintenance
mode.
3. Remove the jog box receptacle cover on the VFD assembly for the replaced
LIM and plug the jog box into the receptacle (Figure 4).
4. If the LIM is driven by a dual VFD assembly
a. Turn off the disconnect switch.
b. Open the box cover.
c. Turn off the motor switch for the LIM not being tested.
d. Replace the box cover.
e. Turn the disconnect switch back on.
:INFO: Jogging a single LIM does not start the sorter, but you can observe
slight movement of the slats above or below the LIM. You may want to place
your hand on the slats to also feel the movement.
5. Closely watch the slats by the replaced LIM while pressing and releasing
the jog pushbutton.
■ Upper LIM: when jogged, the slats above the LIM move slightly toward
discharge end of sorter.
■ Lower LIM: when jogged, the slats below the LIM move slightly toward
charge end of sorter.
6. If the direction of thrust is wrong, check that the LIM is installed so the
power cables exit in the direction of desired travel.
7. For dual LIM assemblies, make sure both LIM motor switches inside the
VFD control box are turned on.
5.5.4 LIM Fan [Figure 50 – Item (6)]

Removal
section).
2. Remove slats from the sorter to create a maintenance window above the
LIM drive (see section 3.4.2).
3. Remove the fan shroud Figure 50 – (7).
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4. Disconnect the fan cable.

5. Remove the fan (6).
Replacement
1. Install the fan and connect the cable.
2. Replace the fan shroud.
5.5.5 Slat Ski Wear Strips [Figure 52 – Item (2)]

Removal
Replace the slat retainer wear strips as a pair.
section).
2. Remove the side panel by the LIM on the take-away side of the sorter. On
the switch side of the sorter, remove the side panels adjacent to the VFD
drive module.
3. Create two maintenance windows of three slats each with a single slat
between them (see section 3.4.2).
4. Jog the sorter (see section 3.4.3) to move the maintenance windows to the
bottom of the sorter below the LIM drive.
5. Remove the slat ski assembly, Figure 51 – (2), from the bottom guard (16).
6. Remove the slat retainer wear strips, Figure 52 – (2), from the ski assembly
(1).
Replacement
1. Install new wear strips on the ski assembly.
2. Install the ski assembly on the bottom guard.
Verify that the carrier wheels on the slat used for gap measurement are
in firm contact with the frame rail wear strips.
3. Adjust the gaps between the wear strips and the slats (see section 5.5.5).
4. Jog the maintenance windows to the top of the sorter and replace the slats.
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Figure 51 Bottom Guard with Slat Ski Assembly
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Figure 52 Slat Ski Assembly
5.6 Variable Frequency Drive

Removal
section).
2. Remove the louvered VFD cover panel, if present.
3. Turn off the disconnect switch on the Profibus enclosure and wait 3 minutes
before removing the VFD cover.
4. Remove slats to make a maintenance window above the VFD.
5. Loosen screws holding the cover (containing the communications option
board) and the metal plate at the bottom front of the VFD.
6. Remove the cover and the metal plate together and turn the cover over
without disconnecting or straining the ribbon cable to the option board.
7. Note the DIP switch settings.
8. Label and remove the Profibus cable and power cables from the bottom of
the VFD.
:INFO: Be careful not to lose the screws from the back side of the mounting
plate when removing the VFD.
9. Remove the screws holding the VFD to the mounting plate and remove the
VFD.
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Replacement
1. Install the VFD on its mounting plate.
2. Loosen screws holding the cover (containing the communications option
board) and the metal plate at the bottom front of the VFD.
3. Remove the cover and the metal plate together and turn the cover over
without disconnecting or straining the ribbon cable to the option board.
4. Use a small screwdriver to set the Profibus address DIP switch.
■ Switch 8 is always open (up).
■ Set switches 1-7 as a binary number.
■ Example: for address 87: Set switches 4 and 6 to closed (down). Set
switches 1,2,3,5,and 7 to open (up).
Values of open switches: 1+2+4+16+64 = 87.
5. Connect the Profibus and power cables.
6. Replace the front cover and metal plate.
8. Turn on the disconnect.
9. Replace the louvered cover panel (if any).
11. Locate the Devices sub-group on the navigation tree and launch the Motors
page.
12. Identify the row displaying data for the newly replaced VFD. Compare the
columns for Hertz, amps, and volts of the new VFD with the other VFDs in
the sorter. Verify that the values displayed are similar.
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Figure 53 VFDs in Drive Module
Item Description
A VFDs
B Jog box
C Jog box receptacle
D Disconnect switch
E Control box
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5.7 Divert Control Module(DCM)

5.7.1 DCM Controller
Removal
section).
2. Remove the side panel that covers the DCM.
3. Remove the DCM controller from the chassis (see Figure 54).
Replacement
1. Reference the Profibus address placard located at the DCM location on the
sorter (or the project Electrical Physical Layout drawing for the FlexSort
control cabinet) to determine the correct Profibus address for the DCM.
2. Locate the rotary switches, X16 and X1, found on the DCM controller
interface board.
3. Use a small screwdriver to set the Profibus address as a Hex number. For
example, to set address 3D Hex, set the X16 pointer to "3", and the X1
pointer to "D".
4. Insert the DCM controller into the chassis, grasp the right-hand back of the
chassis, and firmly press on the right side of the controller’s cover to seat.
Tighten the mounting hardware.
6. Clear any faults related to the DCM on the FlexSort HMI.
5.7.2 DCM Chassis

Removal
section).
2. Remove the side panel that covers the DCM.
3. Remove the DCM controller from the chassis (see Figure 54).
4. Using a long blade #1 Phillips screwdriver (part # 01800-01010) loosen the
two screws at the top of the interface board that secure it to the DCM
chassis. Fold the interface board down.
5. Disconnect the power cable from the interface board (see Figure 55).
6. Disconnect the remaining cables from the interface board and remove all
cables from the retaining slots.
7. Remove the DCM chassis and mounting brackets.
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Replacement
1. Position the DCM chassis on the sorter in the same location as the chassis
that has been removed, taking the following into account:
● Do not loosen the mounting brackets that come pre-assembled to the
chassis.
● Position upstream of the divert assembly that the DCM is controlling,
when possible.
● Allow a minimum of 50 mm of space on both sides of the chassis when
possible, especially the open side, for air circulation.
● Center the chassis vertically between the upper and lower frame rails.
Do not loosen or remove the back cover on the DCM chassis.
2. Using the long blade #1 Phillips screwdriver, loosen the two screws at the
top of the interface board that secure it to the DCM chassis. Fold the
interface board down.
3. Attach the divert assembly’s cable harness to the chassis (see Figure 55).
4. Place the divert assembly cables in the retaining slots as indicated on the
back cover label. Pull the cables taut to seat the strain relief rings on the
retaining bracket.
5. Position the divert assembly cables so that they lie as flat to the interface
board as possible, such that they do not bind against the back cover when
the interface board is lifted into position.
6. Place the power cable in the retaining slots as indicated on the back cover
label. Pull the cable taut to seat the strain relief ring on the retaining bracket.
Connect the cable to the interface board.
7. Place the divert pin out cable in the retaining slots as indicated on the back
cover label. Pull the cable taut to seat the strain relief ring on the retaining
bracket. Connect the cable to the interface board (refer to system wiring
diagrams).
8. Verify that the Profibus cable connector switches are correctly set. If the
associated DCM is at the physical end of the network, set the switches to
on. If it is not, set the switches to off.
:INFO: The Profibus cables do not have strain relief rings.
9. Place the Profibus cables in the retaining slots as indicated on the back
cover label. Pull the cables taut and seat them in the retaining bracket.
Connect the cables to the interface board.
10. Lift the interface board in the DCM chassis. Tighten the two screws at the
top of the interface board that secure it to the chassis.
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:INFO: If installing a new DCM controller, set the address switches on the
controller as indicated on the Profibus address placard mounted at the DCM
location on the sorter.
11. Insert the DCM controller into the chassis, grasping the right-hand back of
the chassis and pressing firmly on the right side of the controller’s cover to
seat. Tighten the mounting hardware.
Figure 54 Divert Control Module (DCM)
Callout Description
A Mounting Plate
B Divert Control Module
C Upper frame rail
D T-bolt
E Lower frame rail
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Figure 55 DCM Chassis Interface Board Cabling
5.8 Return Pin Sensor [Figure 56 – Item (5)]

The return pin sensor is located in the merge end of the return sweep assembly.
The sensor is located between 10.29 m and 12.70 m (405 in and 500 in) from
the upstream end of the charge bed.
Removal
Return Pin Sensor
When replacing the sensor, do not move the sensor bracket. The
location of this sensor is key to proper sorter performance. If moved
inadvertently, sorter sensor positions must be verified (see section
3.5.8).
section).
2. From the upstream end of the charge bed, measure downstream about 10.5
m (35 ft) on the switch side of the sorter. Remove the side panel and locate
the return pin sensor. Remove other side panels as needed.
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3. Disconnect the return pin sensor, Figure 56 – (5), from the attached cable.
4. Remove the return pin sensor from the sensor bracket (4).
Replacement
Return Pin Sensor
1. Replace the return pin sensor on the sensor bracket.
2. Connect the return pin sensor to the cable.
3. Use a 5 mm hex wrench as a feeler gauge to verify that the gap between
the return pin sensor and slat shoe pins is 5 mm. Adjust as necessary.
Figure 56 Return Pin Sensor
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5.9 Discharge Bed

5.9.1 Take-Up Sensor
Removal
section).
2. Remove three slats from the sorter to create a maintenance window at the
center of the discharge bed (see section 3.4.2).
3. Locate the take-up sensor on the right side (facing downstream) of the
discharge frame under the crossmember (item A in Figure 57).
4. Disconnect the take-up sensor from the attached cable.
5. Remove the take-up sensor from the sensor bracket.
Replacement
1. Replace the take-up sensor in the bracket.
2. Locate the face of the sensor 10 mm from the bracket.
3. Connect the cable to the take-up sensor.
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Figure 57 Take-Up Sensor
Item Description
A Take-up sensor
B Gas spring
C Bracket
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Item Description
D Take-up block
E Take-up screw
F Jam nuts
G Discharge assembly
H Discharge plates
I Top cover
J Gap
K Discharge frame crossmember
L Take-up block screws
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Figure 58 Discharge Bed
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5.9.2 Take-up Gas Spring [Figure 58 – Item (64)]

Gas springs keep tension on the slat chain. Replace gas springs every three
years to ensure correct tension.
Removal
Make sure tension on the gas spring is fully relieved before removing
from the ball studs. The springs are under high pressure.
1. Relieve tension on the gas spring (see section 3.5.1.1).

2. Use a small flat screw driver to pry the snap ring out from the back of the
end fitting. Continue to pry while sliding the snap ring off center, so it holds
in the open position.
3. Repeat for the fitting on the other end of the spring.
4. Pull each end of the spring away from the ball studs.
Replacement
1. Use a small flat screw driver to pry the snap ring out from the back of the
end fitting. Continue to pry and slide the snap ring off center, so it holds in
the open position.
2. Press the cylinder end of the spring onto the ball stud on the take-up block.
3. Press the rod end of the spring onto the ball stud on the discharge plate.
4. Use a flat screw driver to slide the snap rings over the ball studs. Check to
make sure they are firmly secured on the ball studs.
5. Tension the gas springs (see section 3.5.1.4).
5.9.3 Gap Wheels [Figure 58 – Item (62)]

Wheels support the slat chain at the gap between the upper frame rail and the
wheel-running surface on the discharge bed side plates.
Removal
section).
the gap wheels on the discharge bed (see section 3.4.2).
3. Remove the axles and spacers, Figure 58 – (55).
4. Remove the wheels (62).
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Repair
Replacement
1. Insert a spacer in the gap wheel and hold the wheel in place in the support
frame.
2. Insert axles and fasten with hardware.
3. Adjust the wheel support frame down so that the wheel height is below the
bottom surface of the slats.
5. Adjust the wheel height (see section 3.5.10)
5.10 Taper-Lock Bushings

The charge transition bed uses taper-lock bushings in the drive train to attach
sprockets to the shafts. This is a generic procedure that applies to all taper-lock
bushings with setscrews.
Make sure that a Taper Lock bushing is not under belt tension when the
bushing is being removed. Otherwise, Taper Lock bushing threads will
be damaged, making the bushing unusable, and other equipment
damage could occur.
Removal
1. Remove all screws holding the bushing(s) in place.
2. Insert screws in the bushing holes as indicated by a blackened circle (see
Figure 59). Loosen the bushing by alternately tightening the screws.
Figure 59 Taper-Lock Bushings
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Replacement
3. Clean the shaft, bore of bushing, outside of bushing, and hub bore of all oil,
paint, and dirt, and file away any burrs.
4. Insert the bushing into the hub. Match the hole pattern, not the threaded
holes (each completed hole will be threaded on one side only).
:INFO: If two bushings are used on the same component and shaft, fully tighten
one bushing before working on the other.
Do not lubricate the bushing taper, bushing bore, hub taper, or the shaft.
Doing so could result in breakage of the product.
5. Lightly oil the setscrews, and thread them loosely into the half-threaded
holes indicated by a clear circle within a circle (see Figure 60).
6. With the key on the shaft, position the assembly on the shaft, allowing for
the small axial movement that occurs during the tightening procedure.
Stake the key behind the bushing by marking the key with a chisel. If the
key goes through the bushing, repeat on other side. Do not mar shaft.
Do not use worn hex key wrenches. Doing so might result in a loose
assembly or might damage the screws.
7. Alternately and progressively torque the setscrews to the recommended

torque settings (see Table 4).
:INFO: When installing a bushing in sintered steel product (such as a sheave or
coupling), follow the torque recommendations on the product hub if present.
Where bushings are used with lubricated products such as chains,

gears, or grid couplings, be sure to seal all pathways (where lubrication
could leak) with RTV or a similar material.
8. Without hitting the bushing directly with a hammer, dimple the face of the
bushing in four places using a drift punch or sleeve. Also dimple around the
key as shown in Figure 60 to help lock the key in place.
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Figure 60 Dimple the Bushing
Table 4 Taper-Lock Bushing Torques
Bushing No. Torque (lb/in) Torque

(lb/ft)
1008, 1108 55 4.6

1210, 1215, 1310 175 14.6
1610, 1615 175 14.6
2012 280 23.3
2517, 2525 430 35.8
3020, 3030 800 66.7
3535 1,000 83.3
4040 1,700 141.7
4545 2,450 204.2
5050 3,100 258.3
6050, 7060, 8065 7,820 651.7
10085, 120100 13,700 1,141.7
9. Repeat hammering and re-torque until the recommended torque no longer

turns the setscrews.
The bushing must be square with the hub after installation is complete.
Any deviation greatly weakens the bushing’s holding ability.
10. Re-inspect screw tightness with a torque wrench after initial run-in, and
periodically thereafter. Repeat steps 7, 8 and 9 if a bushing is loose.
11. Install all guards that were removed to gain access to the bushing.
Make sure all guards removed to gain access to the bushing have been
re-installed before restarting the conveyor, or serious injury could result.
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5.11 Bearing Setscrews and Cap Screws Torque Specs

When replacing sprocket, sheave, and bearing collar setscrews, tighten to the
setscrew torques listed in Table 5, using a torque wrench.
When replacing Dodge D-LOK mounted bearings and Sealmaster Skwezloc

bearings, tighten the cap screws to the torque listed in Table 6, using a torque
wrench:
Table 5 Bearing Setscrew Torques
Setscrews
Setscrew Thread Hex Wrench Size Torque

Pound -Inches Pound - Feet
#10 3/32” 36 3.0
1/4” 1/8” 87 7.3
5/16” 5/32” 165 13.8
3/8” 3/16” 290 24.2
7/16” 7/32” 430 35.8
1/2” 1/4” 630 51.7
5/8” 5/16” 1270 105.8
Setscrew Thread Hex Wrench Size Torque (nm)
(mm) (mm)
M6 3 7
M8 4 16
M10 5 28.5
Table 6 Bearing Cap Screw Torques
D-LOK and Skwezloc Cap Screws
Cap Screw Hex Wrench Torx Wrench Torque

Thread Size Size Pound - Inches Pound - Feet
#8 1/8” T-25 66 5.5
#10 5/32” T-27 86 7.2
1/4” 3/16” T-30 171 14.3
5/16” 1/4” T-45 380 31.2
:INFO: Skwezlock bearings use Torx cap screws.
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When replacing such bearings, please also note the following:

● Clean the shaft and bearing bore thoroughly, as necessary.
● Be sure that the bearing is not on a worn section of the shaft.
● For tighter fits, tap the inner ring face only, but DO NOT hammer on the
housing.
● The bearing outer ring OD is spherical and swivels in the housing to
accommodate misalignment. Snug hold-down bolts, and use the shaft to
swivel each bearing until the final position is in the center, with free
movement top-to-bottom as well as side-to-side. Pass the shaft through
both bearings without forcing. This prevents pre-loading of the bearings.
● If applicable, tighten hold-down bolts. Turn the shaft by hand.
:INFO: Resistance to turning should be the same as before full tightening of
hold-down bolts.
● Replace any setscrews with knurled-cup screws with a locking patch.
● For setscrew-mounted bearings, tighten the setscrew alternately, using the
appropriate hex wrench. Do not over tighten. Install the setscrew either by
tightening the setscrew and backing it off 1/2 turn or by tightening until the
setscrew meets the shaft or key, and complete the tightening with a torque
wrench.
:INFO: Do not drill through the setscrew holes for spot drilling of the shaft.
● For eccentric collar-mounted bearings, slide the collar against the cam end
of the inner race. Use a punch in the hole provided in the collar; tap the
collar smartly in the direction of shaft rotation.
● For D-LOK and Skwezloc collar-mounted bearings, be sure the collar is
square and tight against the shoulder on the inner ring. Tighten the cap
screw using the appropriate hex wrench.
● For cap screw-mounted bearings, do not over tighten. Install the cap screw
either by tightening and backing it off 1/2 turn or tighten until the cap screw
is snug, and complete the tightening with a torque wrench.
● For expansion bearings (H-E Series), locate the inner unit in the housing to
allow expansion in the desired direction before locking it to the shaft.
124 2017-05-11

Model 2430 SL2 Sorter (DCM) Service Manual

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Service Manual Model 2430 SL2 Slat Sorter

Chapter Title is a StyleRef Field

© 2017 Dematic Corp. All rights reserved.

No part of this document may be reproduced or transmitted in any form or by

Item Description Patent Reference

Positive Displacement Shoe and Slat U.S. Pat. No. US 6,866,136

This document contains confidential information, trade secrets and/or know-how

2 Equipment Description ............................................................... 11

3.5.3 Slat Sensor Adjustment ................................................................. 36

Figure 1 Model 2430 SL2 Slat Sorter ............................................................ 11

Figure 44 Divert Control Module (DCM) Access.............................................. 95

1.1 Danger/Warning/Caution Convention

1.2 General Safety

Do not perform adjustments, maintenance, clearing of jams, or other

If any defects relating to operating safety and reliability are detected or if

Climbing, sitting, walking, or riding on equipment at any time may result

Under continuous operation, the external surface of various powered

Exposure to elevated sound levels can damage hearing. The complete

1.2.3 Equipment Labels

Refer to project documentation for equipment label information.

1.2.6 Instructions for Safe Clearing of Product Jams

● Only authorized employees properly trained in the clearing of jammed

1.2.8 Decommissioning and Disposal

Figure 1 Model 2430 SL2 Slat Sorter

2.1 Charge Bed

2.4 Slat and Shoe Assembly

2.5 Divert Assemblies

2.6 Discharge Bed

A discharge transition bed facilitates smooth transfer of unsorted containers from

2.7 Return Sweep

2.8 Environmental Specifications

3.1 General Safety and Maintenance

Proper maintenance of this unit ensures proper operation and promotes

:INFO: See individual manufacturer’s product literature for more information.

Climbing, sitting, walking, or riding on equipment at any time may result

1. Replace broken or worn parts as soon as they are detected.

3.2 Periodic Maintenance Schedule

Table 1 Periodic Maintenance Schedule

Component Inspection/Service Frequency

Table 1 Periodic Maintenance Schedule

Component Inspection/Service Frequency

3.3 Tool Kit

Table 2 Tool Kit

Description Part/Dwg No. Qty

LIM height tool K0301-7001A thru 01E 1

:INFO: Required quantities are per site.

3.4 Preventive Maintenance

3.4.2 Creating a Maintenance Window

Never let a maintenance window of more than 3 slats be jogged around

3.4.2.2 Slat Replacement

3.4.3 Jogging the Sorter

Never let a maintenance window of more than 3 slats be jogged around

Figure 4 Jog Box Connection

To remove the jog box:

3.4.4 Removing Side Panels

To remove a side panel:

3.4.5 Cleaning and Care of Powder Coated Components

3.4.5.1 Frequency of Cleaning

3.4.5.2 Cleaning Materials and Process

1. Follow Lock-Out / Tag-Out procedures (see the first page of the

Do not use strong solvents such as thinners or solutions containing

3.4.6 Checking Tension of the Gas Springs

Figure 5 Verifying Gas Spring Function

3.4.7 Slat Chain