TOYOTA ADVANCED LOGISTICS Bastian SOLUTIONS Shoe Sorter Manual

Installation and Maintenance Manual
Model: Shoe Sorter
Effective February 2022
Rev. D

Installation and Maintenance Manual: Shoe Sorter
___________________________________________________________________________________
Install ati on a nd Maint ena nce Manual : Sh oe S o rter
Published February 2022
Rev. D
2
Contributions
ROLE
NAME
TITLE
Author Ben Baker Senior Design Engineer
Checker Evan Grimes Customer Service Engineer
Approver Sam Osterhout Design Team Lead
Revisions
DATE
REVISION
REVISION DESCRIPTION
AUTHOR
10/21/2019
A1
Initial document creation
Ben Baker
9/22/2020 B
Added info on sprocket alignment and
replacement; added info about decel
settings; crash gates added to
installation section; added tailshaft
encoder info to Controls section; added
several part numbers to GA drawings.
Changed all references to “ZiPline” to
“BSC” or “Bastian Solutions Conveyor”.
Ben Baker
5/3/2021 C
Updated GA drawing for divert switch;
revised distance recommendations
between knife edge and sorter infeed;
revised torque callouts on shoe bolts.
Ben Baker
10/12/2021
C1
Reformatting and Brand Update
Katie Smith
1/7/2022 Review D MKT final review Mark Fishback
2/18/2022
D
Document Formatting
Andrew W. Jones

Installation and Maintenance Manual: Shoe Sorter
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Install ati on a nd Maint ena nce Manual : Sh oe S o rter
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Term and Acronym Definitions
TERM/ACRONYM
DEFINITION
AC
Alternating current
Accumulation The collection or staging of multiple cartons, cases, or totes of product on
conveyor.
Back pressure Pressure against carton(s) in the direction of carton flow resulting from
weight of densely accumulated cartons.
BF Between frame; this refers to the distance between conveyor bed side
frames.
BHCS Button head cap screw
BOM
Bill of Materials
BRBDC Belted Roller Bed Direct Current; DC roller conveyor format driven by
brushless DC servo motors.
BSC
Bastian Solutions Conveyor
Carton or Case
Term for conveyable items generally contained in cardboard boxes.
CB
Carriage bolt
CCW
Counter-clockwise
CW
Clockwise
DC
Direct current
DC Card
A control card used to power and control the logic used when operating a
MDR in DC conveyor applications.
Diffuse
A photoeye format that houses both the emitter and receiver and senses
an object when the light beam is reflected back to the sensor. This type of
photoeye is a standalone unit and does not use reflectors.
Discharge The point where cartons, cases, or totes exit a conveyor or similar unit
used in a material handling system.
Divert
(noun) A conveyor unit used to change the direction of a carton, case, or
tote in a controlled manner. (verb) To change the direction of a carton,
case, or tote in a controlled manner.
Drive Pulley
A motor-driven pulley used to transmit rotational energy to linear motion in
AC belts.
E-stop A highly visible button or pull cable designed to shut down equipment in
the case of an emergency.
ETO
Engineered to Order; Orders requiring custom Engineering
FAT
Factory Acceptance Testing
Flange A feature in sheet metal consisting of a face and bend connected to an
existing face along a straight edge.
Gapping
The separation of cartons, cases, or totes which are initially in contact with
one another. Generally done by progressively increasing the speed of
consecutive zones, forcing cartons, cases, or totes to "pull a gap."

Installation and Maintenance Manual: Shoe Sorter
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TERM/ACRONYM
DEFINITION
Guide Rail Mechanism used to maintain the desired position of conveyable cartons,
cases, or totes on their respective conveying surface.
HHCS
Hex head cap screw
HMI
Human-Machine Interface; an operating console or control panel of a
conveyor system.
HTL High Threshold Logic. In the context of an encoder, a differential push-pull
output intended to operate on 24VDC.
ID
Inner diameter of a circular, cylindrical or arced body.
Idler Roller Cylindrically-shaped material handling component that is unpowered and
used to support a belt.
Infeed The point where cartons, cases, or totes enter a conveyor or similar unit
used in a material handling system.
LOTO
Lockout Tagout
Mark Number
A numeric or alphanumeric term used to uniquely identify a conveyor bed
or collection of beds (of similar model type) within a material handling
system.
Match
A mark made on mating conveyor assemblies to assist in identifying
orientation and placement within a system.
MDR
Motorized drive roller; DC powered conveyor roller with an internally
mounted motor which may be controlled via internal or external
commutation.
MSD Master specification document; a document used to describe a product's
intended capabilities, appearance, and interaction with users.
NO
Normally Open
OAW
Overall width of any given conveyor bed.
OD
Outer diameter of a circular, cylindrical, or arced body.
O-Ring A plastic ring with a circular cross section used for power transmission in
DC conveyor applications.
OSHA Occupational Safety and Health Administration
OTD
On-Time Delivery
Photoeye
Device used to detect the presence of an object-such as a carton, case, or
tote-by use of an emitter and receiver (not necessarily in the same unit as
one another).
PM
Project Management (or Project Manager)
PO
Purchase Order
PPE Personal protective equipment
Proximity Sensor
(“Prox”)
A sensor able to detect the presence of nearby objects without any
physical contact. Typically an inductive sensor that detects nearby
electrically conductive (metal) objects.
Pulley Mechanical device used to change the direction of the belt in a conveyor
system, to drive and/or tension the belt.

Installation and Maintenance Manual: Shoe Sorter
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TERM/ACRONYM
DEFINITION
Reflector A reflective component needed for retroreflective photoeyes to receive
transmitted light or radiation when no object is in front of the photoeye.
Retroreflective Of or relating to a surface or device that reflects light or other radiation
back to its source.
Return Idlers
Belt-routing rollers on the underside of any given AC conveyor.
RLSDC Roller Live Spur Direct Current; DC roller conveyor powered by live MDRs
and configured as a spur.
Roller
Powered or unpowered cylindrically-shaped material handling component
used for mechanical power transmission, a conveying surface, and/or
support for a belted conveying surface.
Shingling
Event in which surfaces of adjacent cartons, cases, or totes are forced to
lift off the conveyor due to elevated uneven carton, case, or tote back
pressure.
Shoe
A sliding element that engages with cartons, cases, or totes to divert from
a shoe sorter onto a spur.
Side Cover A PVC cover used to conceal and protect electrical components and wiring
from foreign debris and moving obstacles.
Side Frame
Structural member used to support rotating components needed for
conveyor beds.
Singulation
The active separation of cartons, cases, or totes.
Skatewheel Small unpowered wheels used to replicate nearly frictionless guidance or
support of conveyable cartons, cases, or totes.
Skew
A format of DC conveyor where one end of all rollers are shifted one roller
position to provide an angled conveying surface for left or right justification
of cartons, cases, or totes.
SKU Stock Keeping Unit; Product and service identification code for a product
(i.e. bar code).
Slug Collection of two or more cartons, cases, or totes that are in contact with
one another.
Snub Roller
A roller or pulley mounted to increase the arc of contact between a belt
and drive pulley. Additionally, this can be used to change the direction of
the return belt travel.
Sorter
Any piece of conveyance equipment used to divert a series of cartons,
cases, or totes simultaneously.
Splice Assembly
A five-component assembly-consisting of a plate (or formed plate), two
bolts, and two nuts-that is used to secure a piece of guide rail to an
adjacent piece of guide rail, or a side frame to an adjacent side frame. This
is used to provide additional structural rigidity and ensure relative position
of components is maintained.
SPST
Single Pole Single Throw; a type of electrical switch.
Spur
A format of DC conveyor used to create linear transitions into intersecting
lines of conveyor positioned at a non-perpendicular angle. Typically
includes 30deg and 22deg configurations.

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TERM/ACRONYM
DEFINITION
Tail Pulley
A non-driven pulley located at the tail end of the conveyor.
Takeup Pulley Pulley with an adjustable position used to eliminate unnecessary slack in a
belt.
Takeup Screws
Adjustment screw used to adjust the position of a takeup pulley.
TOCS
Top of Conveying Surface; this refers to the elevation of the conveying
surface with respect to the floor on which the conveyor is sitting.
Interchangeable with TOR but applicable to non-roller conveyors as well.
TOR
Top of roller; this refers to the elevation of the conveying surface with
respect to the floor on which the conveyor is sitting.
Track To adjust the position of conveyor components in such a way that
engourages proper belt alignment on a system.
Tracking Bands Thin plastic bands installed on head or secondary drive roller to help keep
DC format conveyor belts tracked.
UHMW
Ultra-high molecular weight polyethylene
VFD Variable Frequency Drive. An electronic variable-speed control for an AC
induction motor.
Waterfall
Method of overlapping guide rail such that cartons, cases, or totes cannot
catch on downstream guide rail.
Wiz Nut A serrated flange nut used to cut into the surface of the component it is
tightened against.

Installation and Maintenance Manual: Shoe Sorter
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Install ati on a nd Maint ena nce Manual : Sh oe S o rter
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Table of Contents
1Introduction........................................................................................................... 12
2OSHA And Safety.................................................................................................. 12
3Model: Shoe Sorter............................................................................................... 12
4Receiving............................................................................................................... 13
4.1 Mark Numbers ......................................................................................................................13
4.2 Skid Contents....................................................................................................................... 14
4.3 Skid Documentation............................................................................................................. 14
5Installation............................................................................................................. 15
5.1 Mechanical Installation ........................................................................................................15
5.1.1 Bed Section Placement ......................................................................................................15
5.1.2 Floor Support Installation....................................................................................................15
5.1.3 Section Fastening and Rail Alignment................................................................................. 16
5.1.4 Spur Installation.................................................................................................................. 18
5.1.5 Chain Installation................................................................................................................20
5.1.6 Slat Installation...................................................................................................................22
5.1.7 Setting Infeed Conveyor .....................................................................................................24
5.1.8Setting Discharge Conveyor ............................................................................................... 28
5.1.9 Installing Debris Sensors .................................................................................................... 29
5.1.10 Installing Guards and Guiderail........................................................................................... 29
5.1.11 Installing Side Covers.........................................................................................................30
5.1.12 Setting Oiler Flow ............................................................................................................... 31
5.1.13 Tailshaft Encoder Installation.............................................................................................. 34
5.1.14 Initial Startup Procedure ..................................................................................................... 35
5.2 Electrical Installation............................................................................................................ 35
5.2.1 Drive Motor Settings ........................................................................................................... 35
5.2.2 Components requiring 3 phase AC power connections ....................................................... 36
5.2.3 Components requiring 24VDC power connections .............................................................. 37
5.2.4 Components requiring 48VDC power connections .............................................................. 37
5.2.5 Knife Edge control wiring for encoder following ................................................................... 37
5.2.6 List of Sensors (discrete) .................................................................................................... 39
5.2.7 Communication between system PLC and divert control box .............................................. 44
6Operation............................................................................................................... 45
6.1 Startup Procedure ................................................................................................................45
6.2 Troubleshooting Faults........................................................................................................ 46
7Maintenance.......................................................................................................... 47
7.1 Slat and shoe repair, replacement, and service.................................................................. 47
7.2 Divert switch repair, replacement, and service................................................................... 48
7.3 Chain Adjustment................................................................................................................. 48
7.4 Sprocket Adjustment and Replacement.............................................................................. 48

Installation and Maintenance Manual: Shoe Sorter
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7.4.1 Tail Sprocket Replacement Procedure................................................................................ 49
7.4.2 Drive Sprocket Replacement Procedure ............................................................................. 51
7.4.3 Tail Shaft Adjustment Procedure ........................................................................................ 53
7.5 Recommended Preventative Maintenance Schedule ......................................................... 54
Appendix 1 Section Weights ................................................................................... 57
Appendix 2 Oiler System Recommended Flow Rates and Lubrication Intervals59
Appendix 3 General Arrangement Drawings.......................................................... 60
Appendix 4 Electrical Schematics for Divert Control Box .................................... 84
List of Figures
Figure 1-Shoe Sorter Section Types and General Arrangement ............................................................. 12
Figure 2-Mark Number Stickers .............................................................................................................13
Figure 3-Skid Sticker .............................................................................................................................14
Figure 4-Floor Support Installation Detail ............................................................................................... 16
Figure 5-Bed Section Fastening Detail...................................................................................................17
Figure 6-Typical Spur Positioning .......................................................................................................... 19
Figure 7-Spur Mounting Detail ...............................................................................................................20
Figure 8-Chain Connection Detail .......................................................................................................... 21
Figure 9-Slat Installation Detail .............................................................................................................. 23
Figure 10-Spring Clip Seating Detail ......................................................................................................24
Figure 11-Knife Edge Installation Positioning ......................................................................................... 25
Figure 12-Knife Edge Nosebar Positioning Detail................................................................................... 26
Figure 13-Side View of Knife Edge Conveyor......................................................................................... 27
Figure 14-Belt Tracking by Adjusting Snub Rollers................................................................................. 27
Figure 15-Discharge Transition Assembly Positioning Detail .................................................................. 28
Figure 16-Chain Guard, Guiderail, and Side Cover Installation............................................................... 31
Figure 17-Oiler Pump and Flow Adjustment Panel ................................................................................. 33
Figure 18-Tailshaft Encoder Installation ................................................................................................. 34
Figure 19-General Arrangement, Shoe Sorter Slat and Chain Exploded View, Sheet 1 of 1.................... 60
Figure 20-General Arrangement, Shoe Sorter Divert Section, Sheet 1 of 2............................................. 61
Figure 21-General Arrangement, Shoe Sorter Divert Section, Sheet 2 of 2............................................. 62
Figure 22-General Arrangement, Shoe Sorter Divert Switch, Sheet 1 of 3.............................................. 64
Figure 23-General Arrangement, Shoe Sorter Divert Switch, Sheet 2 of 3.............................................. 65
Figure 24-General Arrangement, Shoe Sorter Divert Switch, Sheet 3 of 3.............................................. 66
Figure 25-General Arrangement, Shoe Sorter Divert Receiver and Shoe Return, Sheet 1 of 1 ............... 66
Figure 26-General Arrangement, Shoe Sorter Tail, Sheet 1 of 2............................................................. 69
Figure 27-General Arrangement, Shoe Sorter Tail, Sheet 2 of 2............................................................. 69
Figure 28-General Arrangement, Shoe Sorter Drive, Sheet 1 of 2 .......................................................... 70

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Figure 29-General Arrangement, Shoe Sorter Drive, Sheet 2 of 2 .......................................................... 71
Figure 30-General Arrangement, Shoe Sorter Discharge Transition, Sheet 1 of 1 .................................. 74
Figure 31-General Arrangement, Shoe Sorter Oiler, Sheet 1 of 1........................................................... 76
Figure 32-General Arrangement, Shoe Sorter Chain Guide Fastening Detail, Sheet 1 of 1..................... 77
Figure 33-General Arrangement, Shoe Sorter Debris Sensor Detail, Sheet 1 of 1 .................................. 78
Figure 34-General Arrangement, Shoe Sorter Knife Edge, Sheet 1 of 2 ................................................. 80
Figure 35-General Arrangement, Shoe Sorter Knife Edge, Sheet 2 of 2 ................................................. 81
Figure 36-General Arrangement, Shoe Sorter Induction Gapper, Sheet 1 of 1........................................ 83
Figure 37-Electrical Schematic for Divert Control Box, Sheet 1 of 7........................................................ 84
Figure 38-Electrical Schematic for Divert Control Box, Sheet 2 of 7........................................................ 85
Figure 39-Electrical Schematic for Divert Control Box, Sheet 3 of 7........................................................ 86
Figure 40-Electrical Schematic for Divert Control Box, Sheet 4 of 7........................................................ 87
Figure 41-Electrical Schematic for Divert Control Box, Sheet 5 of 7........................................................ 88
Figure 42-Electrical Schematic for Divert Control Box, Sheet 6 of 7........................................................ 89
Figure 43-Electrical Schematic for Divert Control Box, Sheet 7 of 7........................................................ 90
List of Tables
Table 1-Wiring of Knife Edge and AC Gapper IO Cable ......................................................................... 38
Table 2-List of Sensors.......................................................................................................................... 40
Table 3-Divert Box I/O Mapping .............................................................................................................44
Table 4-Recommended Preventative Maintenance Schedule................................................................. 54
Table 5-List of Section Weights ............................................................................................................. 57
Table 6-List of Drive Motor Weights ....................................................................................................... 58
Table 7-Oiler Pump Runtime (in seconds) Per Lubrication Interval ......................................................... 59
Table 8-Recommended Lubricant Flow Rates and Lubrication Intervals................................................. 59
Table 9-BOM for GA-SHOE-36-120-0001 .............................................................................................. 63
Table 10-BOM for GA-SHOE-MW-88-0001............................................................................................ 72
Table 11-BOM for GA-SHOE-MW-88-0002............................................................................................ 75
Table 12-BOM for GA-SHOE-MW-120-0002..........................................................................................79
Table 13-BOM for GA-SHOE-MW-48-0001............................................................................................ 82

Installation and Maintenance Manual: Shoe Sorter
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Install ati on a nd Maint ena nce Manual : Sh oe S o rter
Published February 2022
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10
Reference Documents
MANUFACTURER
DOCUMENT
TITLE
DOCUMENT
NUMBER URL
Teknic, Inc.
ClearPath MC/SD
User Manual
Rev.3.05
N/A https://www.teknic.com/files/download
s/clearpath_user_manual.pdf
Teknic, Inc.
AC ClearPath-
MC/SD User
Manual Rev.3.06
N/A https://www.teknic.com/files/download
s/ac_clearpath-sc_manual.pdf
The Diamond
Chain Company
Diamond Chain
Maintenance
Guide
11255_201903
https://www.diamondchain.com/wp-
content/uploads/2017/03/catalogs/mai
ntenance-guide/maintenance-
guide.pdf
The Diamond
Chain Company
Diamond Series
Product Catalog
DC1000-
201905
https://www.diamondchain.com/wp-
content/uploads/2018/01/2019_Diamon
d_Chain_Catalog_links.PDF
The Diamond
Chain Company
Roller Chain Wear
Gauge Instructions DCWG-2013 N/A
ABB Motors and
Mechanical, Inc.
(formerly Baldor
Electric
Company)
Instruction Manual
for DODGE®
Setscrew,
Eccentric Collar,
D-Lok, H-E Series,
E-Z Kleen, Ultra
Kleen and Food
Safe Mounted Ball
Bearings
MN3016 https://www.baldor.com/mvc/Downloa
dCenter/Files/MN3016
ifm Efector, Inc.
Operating
instructions Retro-
reflective sensor
(OGP7xx)
80284283 / 00 https://www.ifm.com/mounting/802842
83UK.pdf
Insight
Automation
EZ24 Family
Reference Manual PR-1100
https://www.pulseroller.com/files/NA/C
ontrol%20Literature%20&%20Drawing
s/EZ-
24/Users%20Manual%20and%20Specif
ications/Users_Guide.pdf
SEW Eurodrive
Operating
Instructions (AC
Motors DR..71-
315, DRN63-315,
DR2..63-80)
24745332/EN
https://download.sew-
eurodrive.com/download/pdf/24745332
.pdf
SEW Eurodrive
Assembly and
Operating
Instructions (Gear
unit series R..7,
F..7, K..7, K..9,
21932786/EN
https://download.sew-
eurodrive.com/download/pdf/21932786
.pdf

Installation and Maintenance Manual: Shoe Sorter
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11
MANUFACTURER
DOCUMENT
TITLE
DOCUMENT
NUMBER URL
S..7,
SPIROPLAN® W)
Bijur Delimon
International
SureFire II
Lubricator
Automatic, Oil &
Fluid Grease,
Single Phase
36410
http://www.bijurdelimon.com/fileadmin
/products/docs/bdius/Datasheets/3641
0_LUB_SureFire-II-PDI-SLR_DS-R2.pdf
Bijur Delimon
International
Operators Manual
Controller,SureFire
II (Single Phase
PDI - SLR(24VDC,
115VAC &
230VAC))
36412
http://www.bijurdelimon.com/fileadmin
/bdide/downloads/36412_SureFire-
II_Controller_OM_2017_1_GB.pdf
Bijur Delimon
International
SureFire II
Lubricator Quick
Start Manual
71070
http://www.bijurdelimon.com/fileadmin
/products/docs/bdius/Operator-
Manuals/71070_SureFire-II-
Quick_Start_QS-R3.pdf

Installation and Maintenance Manual: Shoe Sorter
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Install ati on a nd Maint ena nce Manual : Sh oe S o rter
Published February 2022
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1 Introduction
Thank you for choosing Bastian Solutions conveyor. The following manual serves as a guide for
installation, part replacement, and general maintenance for your material handling equipment. It is
important to read the manual and follow any instructions as it provides important safety information for
personnel and will maximize the longevity of the conveyor.
The information contained in this manual applies only to the products described. Uses, activities, or
processes related to installing or maintaining the equipment that are not explicitly described in this
manual are considered out of scope. Please contact Bastian Solutions for any questions or support that is
not clearly addressed in this document. Bastian Solutions is not responsible for misuse of the equipment
described in this manual or misuse of information in this manual. If you have any questions, contact
Bastian Solutions Customer Service at [e-mail].
2 OSHA And Safety
BSC is not responsible for ensuring that conveyors used in a system abide by OSHA standards. Safety is
of primary importance to our company, but as a product distributor we ask that system integrators and
end users conform with all applicable OSHA standards. We encourage that all warnings in this manual
are followed to avoid unnecessary risk.
3 Model: Shoe Sorter
The BSC Shoe Sorter is a slat conveyor with movable shoes that slide laterally on the slats when diverted
by rails below the conveying surface. The shoe sorter is used for high-speed, high-volume primary
sortation, and is optimized for conveyance of cartons and totes.
Figure 1-Shoe Sorter Section Types and General Arrangement
Figure 1 shows a side view of an example shoe sorter. Product flows over an induction conveyor,
containing at least a knife edge transition belt, but commonly also containing one or more gapper
conveyors to set correct product spacing. The product then flows across the sorter, which contains one or
more divert sections. Each divert section will mate to a spur and a takeaway conveyor line. Products that
do not get diverted will continue down the length of the sorter onto discharge conveyor.

Installation and Maintenance Manual: Shoe Sorter
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4 Receiving
Upon delivery of any Bastian Solutions conveyor, please review and check the following:
•The quantity of items received against the Bill of Lading.
•Complete a visual inspection of equipment to determine any damage that may have occurred
during shipping. If damage is present, document with pictures.
•Review Mark Number information and layout locations. More information can be found in
subsection 4.1.
If there are any missing or damaged components contact your Bastian Solutions’ conveyor
representative with as much detail as possible. If you are unsure of your Bastian Solutions’ conveyor
representative, please contact Bastian Solutions Customer Service at
[e-mail].
4.1 Mark Numbers
A mark number is a specific number given to a piece of equipment. A mark number is usually made up of
a single product line (RZPDC, RLVDC, BZPDC, etc.) but can contain many bed section lengths. They can
range from two inches to hundreds of feet in length. The mark number is used to help identify where the
piece of equipment will go within the system layout.
Every bed section of conveyor will have (2) stickers. One sticker on the infeed end of the bed, and one
sticker on the discharge end of the bed. Each sticker will contain the following information:
•Project Number and Name
•Model Type
•Mark Number
•Match
•Piece
•Flow
Figure 2 shows the stickers that would appear on an RZPDC that has two bed sections.
The match field on the stickers is used to indicate if two bed sections are to be spliced to one another.
As shown in Figure 2 the stickers where the two beds splice together both contain “Match: 1”. The
piece field defines the bed section number within the mark. The flow refers to the direction of product
flow along the conveyor system.
Figure 2-Mark Number Stickers

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4.2 Skid Contents
Skids will contain varying combinations of conveyor sections, support structures, accessories, and
pertinent hardware. For protection of product integrity during shipping, accessories and supports may be
delivered on separate, but labeled skids.
4.3 Skid Documentation
All shipments will contain a Bill of Lading for the delivery company, a skid label, and a skid manifest. Skid
labels have the contents of each shipped item located on the skid. Figure 3 shows a sample of a skid
label. These stickers are placed on the surface of each skid.
Figure 3-Skid Sticker

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5 Installation
Ensure that your conveyor equipment has been securely fastened to the floor or other mounting surface
before full operation occurs.
Consideration should be given to floor point loading prior to installation to
ensure proper support of equipment. See Appendix 1 for section weights.
5.1 Mechanical Installation
5.1.1 Bed Section Placement
1. Lay out chalk lines on floor for placement – See the system layout/installation drawings.
3. Set the drive section in position. Refer to the system layout/installation drawing and Figure 1.
DO NOT pick up or move drive section using the lifting eyes on the motor
or gearbox. Damage to the gearbox or drive shaft may result.
On larger units, the motor may be shipped separate from the drive unit.
See SEW Eurodrive Gear Unit Assembly and Operating Instructions
section 4 for installation instructions.
Secure the drive unit to the floor before installing the motor. Heavy
gearmotors may cause the drive unit to become unbalanced or tip during
installation.
4. Adjust the foot bolts on the drive so all four feet are in contact with the floor and the drive section is
level and aligned to the chalk lines.
5. Check that the height of the drive section matches the specified height on the system layout drawing
(the top of the frame is 3/8” below the final slat surface)
6. If the drive section is out of square, use the provided tension rod for squaring adjustment
7. Set each section and bolt them together, working backwards from the drive to the tail. See Figure 5
for details on fastening the sections together. Hand tighten only at this stage.
8. Check square on each section and check the straightness of the sorter before securing to the floor.
1. See Figure 4
2. Place a thin black neoprene washer between the bolt head and the flange of the sideframe.
3. Place a green urethane vibration damper between the sideframe and the floor support.

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Figure 4-Floor Support Installation Detail
4. Adjust the urethane vibration damper to 3/8” to 7/16” tall (1/8” to 1/16” compression).
5. Adjust the top of conveying surface height by adjusting the floor support.
Do not use vibration dampers for height adjustment. Excessive
compression can damage the vibration dampers and will increase
vibrations transmitted into the floor supports.
5.1.3 Section Fastening and Rail Alignment
1. See Figure 5 for details on fastening sections together.
2. Use of a laser level is recommended to set the sorter straight and level.
The sorter must be level front-to-back, side-to side, and all sections must be
aligned straight to within the tolerances specified in step 3. Misalignment
can cause noisy operation and/or damage to the chain, bearings, and slats.
3. Lateral straightness tolerances must be within +/- 1/2 inch per 100 feet. Check each bed section joint
to ensure there are no bumps or discontinuities (use a laser to sight from the drive to the tail).

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4. Twist in the sorter bed must be limited to +/- 1/4 inch per 10 feet of sorter length, with no bumps or
discontinuities and no section out-of-level by more than +/- 1/2 inch across its width.
5. Ensure the drive and tail shafts are level by placing a precision level directly on the respective shafts.
See Diamond Chain Maintenance Guide section 1 for chain alignment tolerances.
Figure 5-Bed Section Fastening Detail
6. Place a straightedge across the gap in the bearing rail between each bed section and install the
bearing rail splice so that it mates with the installed bearing rail on both the upstream and
downstream ends.
a. If there are any bumps created by misalignment where the bearing rail ends meet, it will cause
excessive noise during operation and, if the misalignment is severe, can damage the chain mount
bearings over time.
The bearing rail splice can also be used for pulling sections together
(aligning) left-to-right. Ensure the section splice bolts are loose enough to
allow movement before pulling the sections together.
7. Place a straightedge across the gap in the pin guide between bed sections and install the pin guide
splice so that it mates with the installed pin guide on both the upstream and downstream ends. The
pin guide and pin guide splices should be approximately centered in their mounting slots.

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a. If there are any bumps created by misalignment where the pin guide ends meet, it will cause
excessive noise during operation and, if the misalignment is severe, can damage the pin guide
covers and the slat mounts over time.
The pin guide fixing screw is always on the upstream end with respect to
chain flow. It is important to maintain this orientation, or the plastic cover
could come off and cause damage.
8. Once the sections are straight and level, fully tighten all section splice bolts and secure to the floor or
decking.
a. Tighten 1/4”-20 fasteners to 8.4 ft-lb.
b. Tighten 3/8”-16 fasteners to 31 ft-lb.
c. Fastening hardware to secure the floor supports to the floor or decking is not provided by BSC.
Consult the hardware manufacturer for appropriate torque values.
Ensure the securing method is appropriate for the application. Installations
in seismic zones will generally require an independent seismic review. BSC
does not provide general-purpose recommendations for concrete anchors
or other fastening methods, since fastening requirements depend on the
site-specific details of the mounting surface.
9. Verify straightness and level again once all sections are fully secured and all bolts are tightened.
Adjust the section positioning as needed if any sections have moved out of alignment.
5.1.4 Spur Installation
1. The spur mounting brackets share mounting bolts with the chain guards. Spur locations use a chain
guard piece painted standard silver color instead of safety yellow.
2. Attach the spurs to the sorter by bolting the spur to the slots in the mounting brackets using 3/8”
carriage bolts.
3. Spur locations are adjustable along the length of the sorter using the provided slots.
4. Locate spurs per the system installation drawing. See Figure 6 for typical spur positioning. Spur
alignment is given relative to the divert rail and the positions of installed shoes.
a. In a typical installation, measure off the divert rail, since the slats and shoes are typically installed
only after spurs have been mounted.
b. The critical dimension (1 3/8” in Figure 6) is measured between the face of the divert rail and the
inside of the spur frame, perpendicular to the divert rail. This measurement will locate the spur
correctly on both 30° divert and 22.5° divert sorters.
Spur positioning may need to be modified for certain product types (e.g.
totes with an overhanging lip may require the spur to be moved
downstream so the overhanging lip can clear the downstream spur
guiderail). Check and follow the system installation drawing for exact site-
specific spur positioning.
5. Set spurs approximately 3/8” lower than the sorter TOCS using the spur jack bolts.
6. Tighten spur mounting bolts once spur is in its final position. See Figure 7.
a. Tighten 3/8”-16 fasteners to 31 ft-lb.

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The provided adjustment travel is intended for optimizing the spur location
relative to the divert rail. Moving the spur a large distance may cause
problems diverting large packages, depending on the system layout.
Figure 6-Typical Spur Positioning
2”
1 3/8”

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Figure 7-Spur Mounting Detail
5.1.5 Chain Installation
Run power to the main drive motor and verify the motor rotation direction
before installing the chain. Running the sorter backwards can cause
damage to slats, chain, and sorter internal components.
The “missing bearing” fork sensor on the first divert section is easy to
damage when installing the chain. Remove the sensor during chain install
and replace it after chain installation is completed.
1. Remove the “missing bearing” fork sensor on the first divert. Zip tie the sensor to the underside of the
first divert switch so it won’t get misplaced and will be available for re-installation after the chain is
installed.
a. See Figure 22, Figure 23, and Figure 24 in Appendix 3 for details of the “missing bearing” fork
sensor mounting. The sensor is identified by balloon (6).
2. The chain comes pre-assembled with chain mounts.
3. The chain is shipped and tagged in matched pairs (right and left)
a. Right and left sides of the sorter are determined by facing in the direction of product flow.