3200 Series End Drive Flat and Cleated Belt Conveyors

Transcription

1 00 Series End Drive Flat and Cleated Belt Conveyors Installation, Maintenance & Parts Manual DORNER MFG. CORP. INSIDE THE USA OUTSIDE THE USA P.O. Box Cottonwood Ave. TEL: TEL: Hartland, WI USA FAX: FAX: Rev. G For other service manuals visit our website at:

2 Table of Contents Introduction... Warnings General Safety... Product Description... 4 Specifications... 4 Installation... 6 Required Tools... 6 Recommended Installation Sequence... 6 Conveyors Up to ft (96 mm)... 6 Conveyors Longer Than ft (96 mm)... 6 Mounting Brackets... 7 Return Rollers... 8 Cleated Belt and 4 6 (5 5 mm) Wide Flat Belt Conveyors (0 9 mm) Wide Flat Belt Conveyors... 8 Preventive Maintenance and Adjustment... 9 Required Tools... 9 Standard Tools... 9 Checklist... 9 Lubrication... 9 Maintaining Conveyor Belt... 9 Troubleshooting... 9 Cleaning... 9 Conveyor Belt Replacement... 9 Conveyor Belt Replacement Sequence... 9 Belt Removal for Conveyor Without Stands or Gearmotor Mounting Package... 9 Belt Removal for Conveyor With Stands and Gearmotor Mounting Package... 0 Belt Installation for Conveyor without Stands or Gearmotor Mounting Package... Belt Installation for Conveyor with Stands and Gearmotor Mounting Package... Conveyor Belt Tensioning... Conveyor Belt Tracking... V-Guided Belts... Non V-Guided Belts... Pulley Removal... A Idler Pulley Removal... 4 B Drive Pulley Removal... 5 C Transfer Tail Pulley Removal... 8 Bearing Replacement... 9 A Idler Bearing Replacement... 9 B Drive Bearing Removal and Replacement... 9 Removal... 9 Replacement... 9 C Transfer Tail Bearing Replacement... 9 Pulley Replacement... 9 Idler Pulley... 9 Drive Pulley... 9 Transfer Tail Pulley... 9 Notes... 0 Service Parts... Drive End Tail Assembly... Transfer Tail Assembly... Idler End Assembly... Frame Assembly... 4 Bed Plate and Frame Formulas (76mm) Aluminum Side... 6 Length Formulas... 6 Example (8mm) Aluminum Side... 7 Length Formulas... 7 Example Low to Side Wiper... 8 Length Formulas... 8 Example Low to High Side... 9 Length Formulas... 9 Example (mm) Extruded Plastic... 0 Length Formulas... 0 Example... 0 Adjustable Guiding... 4 Tool-Less Adjustable Guiding....5 (mm) Cleated Guiding... Length Formulas... Example... (5mm) Cleated Guiding... 4 Length Formulas... 4 Example... 4 (5mm) Cleated Guiding... 5 Length Formulas... 5 Example... 5 Flared Side Guiding... 6 Flat Belt Mounting Brackets... 7 Cleated Belt Mounting Brackets... 7 Connecting Assembly without Stand Mount... 8 Flat Belt Connecting Assembly with Stand Mount... 8 Cleated Belt Connecting Assembly with Stand Mount. 9 4 (0mm) to 6 (5mm) Flat Belt Return Roller (0mm) to 48 (9mm) Flat Belt Return Roller. 40 Cleated Belt Return Roller Conveyor Belt Part Number Configuration... 4 Flat Belt Part Number Configuration... 4 Cleated Belt Part Number Configuration... 4 Return Policy Rev. G Dorner Mfg. Corp.

3 Introduction IMPORTANT Some illustrations may show guards removed. DO NOT operate equipment without guards. Upon receipt of shipment: Compare shipment with packing slip. Contact factory regarding discrepancies. Inspect packages for shipping damage. Contact carrier regarding damage. Accessories may be shipped loose. See accessory instructions for installation. Dorner s Limited Warranty applies. Dorner 00 series conveyors are covered by Patent Numbers 5,56,60, 6,87,77B, 6,90,57B, 6,97,509B, and corresponding patents and patent applications in other countries. Dorner reserves the right to make changes at any time without notice or obligation. Dorner has convenient, pre configured kits of Key Service Parts for all conveyor products. These time saving kits are easy to order, designed for fast installation, and guarantee you will have what you need when you need it. Key Parts and Kits are marked in the Service Parts section of this manual with the Performance Parts Kits logo. Warnings General Safety A WARNING The safety alert symbol, black triangle with white exclamation, is used to alert you to potential personal injury hazards. A DANGER A WARNING Gearmotors may be HOT. DO NOT TOUCH Gearmotors. Climbing, sitting, walking or riding on conveyor will cause severe injury. KEEP OFF CONVEYORS. A DANGER DO NOT OPERATE CONVEYORS IN AN EXPLOSIVE ENVIRONMENT. A WARNING A WARNING Dorner cannot control the physical installation and application of conveyors. Taking protective measures is the responsibility of the user. When conveyors are used in conjunction with other equipment or as part of a multiple conveyor system, CHECK FOR POTENTIAL PINCH POINTS and other mechanical hazards before system start-up. A WARNING Exposed moving parts can cause severe injury. LOCK OUT POWER before removing guards or performing maintenance. Loosening stand height or angle adjustment screws may cause conveyor sections to drop down, causing severe injury. SUPPORT CONVEYOR SECTIONS PRIOR TO LOOSENING STAND HEIGHT OR ANGLE ADJUSTMENT SCREWS Rev. G Dorner Mfg. Corp.

4 Product Description Refer to Figure for typical components. Typical Components: A Conveyor B Gearmotor Mounting Package C Gearmotor D Guiding & Accessories E Mounting Brackets F Return Rollers G Support Stand H Variable Speed Controller I Drive End J Idler/Tension End Figure B I E G C F A H D E J Figure Specifications Models: Flat Belt 00 Series Conveyor Flat Belt 00 Series Conveyor 0 M WW LLLL A PP BB Belt Type* Conveyor Profile* Output Shaft Position* Conveyor Length Reference Conveyor Width Reference Document Language, M = English 0 = tails = tails = Flat belt with tracking cams and supports = Flat belt with V-guide tracking and supports = Flat belt with tracking cams 4 = Flat belt with V guide tracking Cleated Belt 00 Series Conveyor Cleated Belt 00 Series Conveyor C M WW LLLL A SSSS Cleat Spacing* Output Shaft Position* Conveyor Length Reference Conveyor Width Reference Document Language, M = English Cleat Type* = Flat belt with tracking cams and supports = Flat belt with V-guide tracking and supports = Flat belt with tracking cams 4 = Flat belt with V guide tracking * See Ordering and Specifications Catalog for details. Dorner Mfg. Corp Rev. G

5 Specifications Conveyor Supports: Figure Maximum Distances: K L M K = 4 (60 mm) (Drive End) L = ft (658 mm) M = 6 (94 mm) (Idler End) Figure Specifications: Conveyor Width Reference (WW) Conveyor Belt Width Maximum Conveyor Load* (See NOTE Below) Conveyor Startup Torque* Conveyor Length Reference (LLLL) Conveyor Length Belt Travel Maximum Belt Speed* Belt Takeup (95mm) 00 lb (9kg) 7 in-lb (0.8Nm) 6 (5mm) 50 lb (kg) 8 in-lb (0.9Nm) 8 (0mm) 00 lb (6kg) 0 in-lb (.Nm) * See Ordering and Specifications Catalog for details. 0 (54mm) 50 lb (59kg) in-lb (.5Nm) (05mm) 400 lb (8kg) 5 in-lb (.7Nm) 8 (457mm) 400 lb (8kg) 5 in-lb (.8Nm) 000 to 4000 in 000 increments 4 (609mm) 400 lb (8kg) 0 in-lb (.9Nm) 0 (76mm) 400 lb (8kg) 5 in-lb (.9Nm) ft (94mm) to 40 ft (9mm) in 0. (0.mm) increments 9.7 (46 mm) per revolution of pulley 4 ft/minute (8 m/minute) 6 (95mm) 400 lb (8kg) 8 in-lb (4.Nm) 48 (0mm) 400 lb (8kg) 40 in-lb (4.4Nm).6 (4 mm) of Belt Takeup on Conveyors Under 0 Length.4 (8 mm) of Belt Takeup on Conveyors Over 0 Length NOTE Maximum conveyor loads based on: Non-accumulating product Product moving towards gearmotor Conveyor being mounted horizontal 85-5 Rev. G 5 Dorner Mfg. Corp.

6 Installation Figure NOTE Conveyor MUST be mounted straight, flat and level within confines of conveyor. Use a level (Figure, item N) for setup. N Conveyors Longer Than ft (96 mm) Installation Component List: O P Conveyor frame Section Label. Locate and arrange conveyor sections by section labels (Figure 4, item P). Figure 4 Required Tools Hex-key wrenches: - 4 mm, 5 mm Level Torque wrench Figure Recommended Installation Sequence Figure 4. On tension end of the conveyor, identified by the pinion locking screw (Figure 5, item S), push in head plate assembly (U): Loosen the pinion locking screw (S), adjust the pinion torque screw (Figure 6, item V). On both sides of conveyor, loosen the two tail clamp bolts (Figure 5, item T), and push head plate assembly (U) inward. Figure 5 O P P Install support stands (see accessory instructions) Assemble conveyor (if required) Attach mounting brackets to conveyor S Attach conveyor to stands Install return rollers on conveyor (optional) Mount gearmotor mounting package (see accessory instructions) Attach guides/accessories (see page through 5 of Service Parts section for details) Conveyors Up to ft (96 mm) No assembly is required. Install mounting brackets and return rollers. Refer to Mounting Brackets on page 7 and Return Rollers on page 8. T U Figure 5 Dorner Mfg. Corp Rev. G

7 Installation Figure 6 Figure 9 AR Figure 6. Roll out conveyor belt and place conveyor frame sections (Figure 7, item O) into belt loop. Figure 7 V Figure 9 5. Tighten conveyor belt, refer to Conveyor Belt Tensioning on page. 6. Install mounting brackets and return rollers. Refer to Mounting Brackets on page 7 and Return Roller on page 8. O O Mounting Brackets. Locate brackets. Exploded views shown in Figure 0 & Figure. Figure 0 Figure 7 4. Join conveyor sections and install connector brackets (Figure 8, item W) or connector/mount brackets (WA) and screws (X) on both sides as indicated. Tighten screws to 60 in-lb (7 Nm). Y AC AB Figure 8 W AA Z X Figure 8 WA Figure Mounting Brackets for Flat Belt Conveyor Figure 0 NOTE For Conveyors longer than 0 ft (6096 mm) use the process outlined in the Conveyor Belt Tensioning section on page. Extend the Drive End Tail Assembly to the zero mark of the tension indicator (Figure 9, item AR) before proceeding to step 5. The zero mark for the tension indicator is when the indicator begins to turn black. Y AA AB AC Z Mounting Brackets for Cleated Belt Conveyor Figure 85-5 Rev. G 7 Dorner Mfg. Corp.

8 Installation. Remove screws (Figure 0, item Y & Z) & (Figure, item Y & Z), washers (AA), nuts (AB) and T-bars (AC) from brackets.. Insert T-bars (Figure 0, item AC) & (Figure, item AC) into conveyor side slots (Figure, item AC). Fasten brackets (Figure, item AD) to conveyor with mounting screws (Y). Figure Y AC Z AA AB Figure 4 Figure 4. Remove screws (Figure, item AE) & (Figure 4, item AE) and clips (AF) from roller assembly.. Install roller assemblies (Figure 5, item AG) as shown. Tighten screws (AE) to 60 in-lb (7 Nm). Figure 5 AE AE AF AF AE AG Figure 4. Fasten brackets to support stand with mounting screws (Figure, item Z), washers (AA) and nuts (AB). 5. Tighten screws (Figure, item Y & Z) to 60 in-lb (7 Nm). Return Rollers Cleated Belt and 4 6 (5 5 mm) Wide Flat Belt Conveyors. Locate return rollers. Exploded views shown in Figure & Figure 4. Figure AD NOTE Mounting brackets for flat belt conveyors shown. AF AE Figure (0 9 mm) Wide Flat Belt Conveyors. Locate return rollers. Exploded view shown in Figure 6. Figure 6 AH AI Figure 6. Remove screws (Figure 6, item AH) and clips (AI) from roller assembly.. Install roller assembly as shown (Figure 7, item AJ). Tighten screws (AH) to 60 in-lb (7 Nm). AI AG AH Figure 7 AE AF Return Rollers for Flat Belt Conveyor Figure AH AJ Figure 7 Dorner Mfg. Corp Rev. G

9 Preventive Maintenance and Adjustment Required Tools Standard Tools Hex-key wrenches: -.5 mm, 4 mm, 5 mm Checklist Keep service parts on hand (see Service Parts section for recommendations) Keep supply of belt cleaner (part # 6569) Clean entire conveyor and knurled pulley while disassembled Replace worn or damaged parts Lubrication Cleaning IMPORTANT Do not use belt cleaners that contain alcohol, acetone, Methyl Ethyl Ketone (MEK) or other harsh chemicals. Use Dorner Belt Cleaner (part # 6569). Mild soap and water may also be used. Do not soak the belt. For /05 woven polyester and /06 black anti-static belts, use a bristled brush to improve cleaning. Conveyor Belt Replacement A WARNING No lubrication is required. Replace bearings if worn. Maintaining Conveyor Belt Troubleshooting Inspect conveyor belt for: Surface cuts or wear Stalling or slipping Damage to V-guide Surface cuts and wear indicate: Sharp or heavy parts impacting belt Jammed parts Improperly installed bottom wipers (if installed) Accumulated dirt in wipers (if installed) Foreign material inside the conveyor Improperly positioned accessories Bolt-on guiding is pinching belt Stalling or slipping indicates: Excessive load on belt Conveyor belt or drive timing belt are not properly tensioned Worn knurl or impacted dirt on drive pulley Intermittent jamming or drive train problems Damage to V-guide indicates: Twisted or damaged conveyor frame Dirt impacted on pulleys Excessive or improper side loading Exposed moving parts can cause severe injury. LOCK OUT POWER before removing guards or performing maintenance. Conveyor Belt Replacement Sequence Remove old conveyor belt: -Conveyor without Stands or Gearmotor Mounting Package -Conveyor with Stands and Gearmotor Mounting Package Install new conveyor belt Tension conveyor belt Belt Removal for Conveyor Without Stands or Gearmotor Mounting Package. If equipped, remove return rollers and guiding and accessories from one side of conveyor Rev. G 9 Dorner Mfg. Corp.

10 Preventive Maintenance and Adjustment. On tension end of the conveyor, identified by the pinion locking screw (Figure 8, item S), push in head plate assembly (U): Loosen the pinion locking screw (S), adjust the pinion torque screw (Figure 9, item V). On both sides of conveyor, loosen the two tail clamp bolts (Figure 8, item T), and push head plate assembly (U) inward. Figure 8 Figure 9 T U S Figure 8 Figure 0 AL AM AK AK AM Figure 0. Remove mounting brackets (Figure 0, item AM) from one side of conveyor. (Reverse steps & 4 of Mounting Brackets section on page 7).. If equipped, remove return rollers, guiding and accessories from side opposite drive cover. 4. On tension end of the conveyor, identified by the pinion locking screw (Figure, item S), push in head plate assembly (U): Loosen the pinion locking screw (S), adjust the pinion torque screw (Figure, item V). On both sides of conveyor, loosen the two tail clamp bolts (Figure, item T), and push head plate assembly (U) inward. Figure S V Figure 9. Remove conveyor belt. T U Belt Removal for Conveyor With Stands and Gearmotor Mounting Package A WARNING Figure Figure V Removing mounting brackets without support under gearmotor will cause conveyor to tip, causing severe injury. PROVIDE SUPPORT UNDERNEATH THE GEARMOTOR WHEN CHANGING THE BELT. Place temporary support stands (Figure 0, item AK) at both ends of the conveyor. Place an additional support stand under the drive motor (AL), if equipped. See WARNING. Figure 5. Remove belt (Figure, item AN) from conveyor. Figure AN AN Figure Dorner Mfg. Corp Rev. G

11 Preventive Maintenance and Adjustment Belt Installation for Conveyor without Stands or Gearmotor Mounting Package. Orient belt so splice leading fingers (Figure 4, item AO) point in the direction of belt travel as identified by the conveyor directional label (AP). Belt Installation for Conveyor with Stands and Gearmotor Mounting Package A WARNING Figure 4 AO AP Removing mounting brackets without support under gearmotor will cause conveyor to tip, causing severe injury. PROVIDE SUPPORT UNDERNEATH THE GEARMOTOR WHEN CHANGING THE BELT Figure 4. Slide belt onto the conveyor frame assembly.. Tension belt. Refer to Conveyor Belt Tensioning on page. 4. If equipped, install wipers, return rollers and guiding. Ensure temporary support stands (Figure 0, item AK) are placed at both ends of the conveyor. Place an additional support stand under the drive motor (AL), if equipped. See WARNING.. Orient belt so splice leading fingers (Figure 4, item AO) point in the direction of belt travel as identified by the conveyor directional label (AP).. Install belt (Figure 5, item AN) on conveyor. Lift conveyor slightly to avoid pinching belt on temporary support stands. Figure 5 AN AN Figure 5 4. Re-install conveyor mounting brackets. Refer Mounting Brackets on page 7, steps through Tension belt. Refer to Conveyor Belt Tensioning on page. 6. If equipped, re-install return rollers and guiding Rev. G Dorner Mfg. Corp.

12 Preventive Maintenance and Adjustment Conveyor Belt Tensioning A WARNING NOTE On pinion gear, do not exceed a torque of 00 in-lb (. N m). Over tensioning the conveyor belt could cause excessive pulley bearing load and early failure. Exposed moving parts can cause severe injury. LOCK OUT POWER before removing guards or performing maintenance.. Extend head plate assembly until proper tension in the belt is achieved. If proper tensioning can not be obtained before the belt life indicator is all black (Figure 8, item AR) the belt must be replaced. Figure 8. On tension end of the conveyor, identified by the pinion locking screw (Figure 6, item S), loosen the two tail clamp bolts (T), on both sides of conveyor. Figure 6 NOTE For conveyors longer than 0 ft (6096 mm) the belt tensioning procedure outlined below may be preformed on both the Drive and Idler Ends of the conveyor. T S U Figure 6. With 5mm hex wrench, hold pinion torque screw (Figure 7, item V). Loosen the pinion locking screw (Figure 6, item S) and turn the pinion torque screw (V) to extend head plate assembly. Figure 8 4. After adjusting proper tensioning, tighten the pinion locking screw (Figure 6, item S) to 69 in lbs (7.8 N m), and tighten tail clamp bolts (Figure 6, item T) on both sides of conveyor to 46 in-lb (6.5 N m). 5. If belt tracking is necessary, refer to Conveyor Belt Tracking on page. Conveyor Belt Tracking V-Guided Belts V-guides on belts help maintain proper belt tracking. Track as needed to reduce belt bulge from center of belt (Figure 9). See steps below in Non V-guided Belts procedure for adjusting for any belt bulging. Belt bulge will be minimal when belt is properly tracked. Figure 9 AR Figure 7 V Figure 9 Figure 7 Dorner Mfg. Corp Rev. G

13 Preventive Maintenance and Adjustment Non V-Guided Belts Figure Non V-guided belt conveyors are equipped with belt tracking assemblies. When adjusting belt tracking, always adjust the discharge end of the conveyor first. To adjust belt tracking:. Ensure tensioning racks are extended and touching the idler pulley headplates: loosen the pinion locking screw (Figure 6, item S) and rotate the pinion torque screw (Figure 7, item V) clockwise until contact with the head plate is made, then tighten the pinion locking screw (S) to 69 in lbs (7.8 N m). On the side of conveyor to be adjusted, loosen two () tail clamp screws (Figure 0, item T). AT Figure 0 S Figure 4. Re-tighten the head plate fastening screws (Figure, item T) with a 5 mm hex-key wrench to 46 in-lb (6.5 Nm). Figure T Figure 0. With the conveyor running, use wrench (Figure, item AS) to rotate the tracking screw (Figure, item AT) in small increments until the belt tracks in the center of the conveyor. T Figure AS Pulley Removal Figure A WARNING Figure Exposed moving parts can cause severe injury. LOCK OUT POWER before removing guards or performing maintenance. Remove conveyor belt to access pulley(s). See Conveyor Belt Replacement on page 9. Remove the desired pulley following the corresponding instructions below: A Idler Pulley Removal B Drive Pulley Removal C Transfer Tail Pulley Removal 85-5 Rev. G Dorner Mfg. Corp.

14 Preventive Maintenance and Adjustment A Idler Pulley Removal. Temporarily support the idler pulley. Figure 4 4. Slide the idler pulley assembly (Figure 7, item AW) out of the headplate on the opposite side. Figure 7 AW Figure 4. On one side of conveyor, loosen the two () back fastening screws (Figure 5, item T) and remove two () front fastening screws (AU). Figure 5 Figure 7 5. Remove the pulley shaft assembly: remove the clip ring (Figure 8, item AX) and washer (AY) from one side of the pulley assembly. Figure 8 AX T AU AY Figure 5. Pull back the outer headplate (Figure 6, item U) and remove the inner spacer (AV). Figure 6 Figure 8 6. Slide the shaft assembly (Figure 9, item AZ) out of the pulley (AW). Figure 9 U AV AW AZ Figure 6 Figure 9 Dorner Mfg. Corp Rev. G

15 Preventive Maintenance and Adjustment B Drive Pulley Removal A WARNING Figure 4 BC Drive shaft keyway may be sharp. HANDLE WITH CARE.. Remove the gearmotor mounting package: Top and Bottom Mount Packages Side Mount Packages BB BB NOTE Bottom Mount Package shown, Top Mount Package similar. Top and Bottom Mount Packages a. Use a temporary support (Figure 40, item BA) to support Gearmotor. Figure 4 Figure 4 c. Loosen tensioner (Figure 4, item BD). BE Figure 40 BD BA Figure 40 b. Remove four (4) screws (Figure 4, item BB) and remove cover (BC). Figure 4 Figure 4 d. Remove taper-lock screws (Figure 4, item BF) on the driven pulley (Figure 4, item BE). Insert one () of taper lock screws (Figure 4, item BF) in remaining hole (BG). Tighten screw (BF) until pulley is loose. Remove pulley, taper hub assembly and timing belt. BG BF Figure Rev. G 5 Dorner Mfg. Corp.

16 Preventive Maintenance and Adjustment e. Remove four (4) M5 mounting screws (Figure 44, item BH) and two () M8 mounting screws (BI). Figure 47 d. Remove the four (4) lock screws (Figure 47, item BK) and the short side drive guard (BM). Figure 44 BI BM BK BJ BH BN BO Figure 44 f. Remove gearmotor and mounting plate assembly (Figure 44, item BJ). Side Mount Package a. Temporarily support Gearmotor. b. Loosen the four (4) lock screws (Figure 45, item BK). Figure 47. Loosen set screw (Figure 47, item BN) and remove jaw coupling (BO).. Temporarily support the drive pulley. Figure 48 Figure 45 Figure 46 Figure 45 c. Rotate and remove the gear motor and guard assembly (Figure 46, item BL). BL Figure Remove four shaft cover screws (Figure 49, item BP). Remove the shaft cover (BQ). Figure 49 BP BQ Figure 46 Figure 49 Dorner Mfg. Corp Rev. G

17 Preventive Maintenance and Adjustment 5. Loosen the bearing collar set screw (Figure 50, item BR) and remove bearing collar (BS). Repeat on drive shaft side of pulley (Figure 5, item BR and BS). 6. On the drive headplate, remove two () screws (Figure 5, item T). 60 in-lb (7 Nm) Figure 5 Figure 50 BS T BR Figure 5 BS Figure 50 Figure 5 7. Remove the outer headplate assembly (Figure 5, item BT), and inner spacer (AV). Figure 5 BR BT AV Figure 5 NOTE When reassembling, tighten the bearing collar set screws to 5 in-lbs (6 Nm). Check after 4 hours of conveyor use. Figure 5 8. Slide the drive pulley (Figure 54, item BU) out of the headplate on the opposite side. Figure 54 BU Figure Rev. G 7 Dorner Mfg. Corp.

18 Preventive Maintenance and Adjustment C Transfer Tail Pulley Removal. Temporarily support the transfer tail assembly. Figure Slide the transfer tail pulley assembly (Figure 58, item BV) out of the headplate on the opposite side. Figure 58 BV Figure Remove hex nuts (Figure 59, item BW). Figure 59 Figure 55. On one side of conveyor, remove the two () back fastening screws (Figure 56, item T), and the two () front fastening screws (AU) BW Figure 56 T Figure Remove support plates (Figure 60, item BX) and washers (BY). Figure 60 BY BX AU Figure 56. Remove the inner spacer (Figure 57, item AV). Figure 57 AV U Figure Remove pulleys (Figure 6, item BZ) and additional washers (CA). Figure 6 BZ Figure 57 CA Figure 6 8. To remove additional pulleys, repeat steps 6 through 7. Dorner Mfg. Corp Rev. G

19 Preventive Maintenance and Adjustment Bearing Replacement A WARNING Replacement. Inspect bearing housing bearing surface. If worn or damaged, replace. See Service Parts on page.. Insert bearing (Figure 6, item CB) into housing slot (CC). Locate anti rotation nub (CD) to align with slot (CE), and twist bearing into housing. Figure 6 Exposed moving parts can cause severe injury. LOCK OUT POWER before removing guards or performing maintenance. CE CC CB A Idler Bearing B Drive Bearing C Transfer Tail Bearing A Idler Bearing Replacement The bearings in a 00 Series Idler Pulley can not be removed. Replace the entire pulley assembly when worn. B Drive Bearing Removal and Replacement A WARNING CD Figure 6 C Transfer Tail Bearing Replacement The bearings in a 00 Series Transfer Tail Pulley can not be removed. Replace the entire pulley assembly when worn. Pulley Replacement Removal. Turn bearing (Figure 6, item CB) to align with slots (CC) in bearing housing. Then remove bearing. Figure 6 Drive shaft keyway may be sharp. HANDLE WITH CARE. CC CB Idler Pulley To replace the idler pulley, reverse the Idler Pulley Removal procedure on page 4. Drive Pulley To replace the drive pulley, reverse the Drive Pulley Removal procedure on page 5. Transfer Tail Pulley To replace the transfer tail pulley, reverse the Transfer Tail Pulley Removal procedure on page 8. Figure Rev. G 9 Dorner Mfg. Corp.

20 Notes Dorner Mfg. Corp Rev. G

21 Drive End Tail Assembly NOTE Service Parts For replacement parts other than those shown in this section, contact an authorized Dorner Service Center or the factory. Key Service Parts and Kits are identified by the Performance Parts Kits logo. Dorner recommends keeping these parts on hand Drive Spindle Bearing Kit Spindle Kit 7 Knurled Tail Assembly 8 Lagged Tail Assembly Shaft Cover Bearing Retainer 0048 Drive Tail Cover Plate Inner Tail Plate Tail Bar Clamp Hex Tension Tracking Shaft 7 0WW Tail Articulation Bar 8 86WW Knurled Drive Spindle Assy. 88WW Lagged Drive Spindle Assy D Lok Bearing Retaining Ring Hex Head Cap Screw M6 x 0mm 906M Socket Head Screw M6 x mm 9089M Low Head Socket Screw M8x6mm M Low Head Socket Screw M8x5mm 5 D Drive Spindle Bearing Kit (Includes Items, 9 and ) 6 KD WW Knurled Spindle Kit (Includes Items, 8, 9 and ) LD WW Lagged Spindle Kit (Includes Items, 8, 9 and ) 7 KDTA WW Knurled Tail Assy. Position A and B (Includes items through 5, 7 through 9 and through 4) KDTD WW Knurled Tail Assy. Position C and D (Includes items through 5, 7 through 9 and through 4) 8 LDTA WW Lagged Tail Assy. Position A and B (Includes items through 5, 7 through 9 and through 4) LDTD WW Lagged Tail Assy. Position C and D (Includes items through 5, 7 through 9 and through 4) WW = Conveyor width reference: in 0 increments 85-5 Rev. G Dorner Mfg. Corp.

22 Service Parts Transfer Tail Assembly 0 Tail Assembly Idler Spindle Kit Nosebar Cover Plate 0084 Inner Tail Plate 0088 Tail Bar Clamp Transfer Tail Support Plate Hex Tension Tracking Shaft 6 05 Nut, E ring, Brace Inner Transfer Tail Support Plate 8 0WW Tail Articulation Bar 9 7WW Idler Tail Axle Shaft 0 9WW Support Bar 7WW Transfer Tail Roller (Qty. = 4 for 04 4 Wide, 8 for 6 48 Wide) Washer Retaining Ring Hex Head Cap Screw M6 x 0mm /8 Hex Nut Retaining Ring M Hex Head Cap Screw M4 x 8mm M Low Head Socket Screw M8 x 6mm 9 T WW Idler Spindle Kit (includes items 6, 9,,, 5 and 6) 0 TT WW Tail Assembly (includes items through 4, 6 through, 5 through 8) WW = Conveyor width reference: in 0 increments Dorner Mfg. Corp Rev. G

23 Idler End Assembly Service Parts Idler Spindle Kit 4 Tail Assembly Idler Cover Plate 008 Inner Tail Plate 0088 Tail Bar Clamp 4 8WW Idler Spindle Wand Assembly (includes items 8 and ) Hex Tension Tracking Shaft 6 0WW Tail Articulation Bar 7 89WW Idler Pulley P Hard Washer Tracking Shaft Retaining Ring Hex Head Cap Screw M6 x 0mm 95 5 Stub Shaft Retaining Ring 9089M Low Head Socket Screw M8 x 6mm T WW Idler Spindle Kit (includes items 4 and 7) 4 TT WW Tail Assembly (including items through 4, 6, 7 and ) WW = Conveyor width reference: in 0 increments 85-5 Rev. G Dorner Mfg. Corp.

24 Service Parts Frame Assembly Rack Gear 009 Pinion Bearing 60579P Washer M Flange Torx Screw, M4 x 6mm M Socket Head Screw M6 x 6mm M Low Head Socket Screw M6 x 6mm 7 45WW Cross Support Rail LLLLL RH Side Rail LLLLL LH Side Rail 0 9WW Pinion See Bed Plate Rail chart Bed Plate Rail WW = Conveyor width reference: in 0 increments LLLLL = Frame Length (see Bed Plate & Frame Formulas) Item : Bed Plate Rail Width Part Number.75 (mm) LLLLL (54mm) LLLLL 4 (0mm) LLLLL 6 (5mm) LLLLL LLLLL = Bed Plate Length (see Bed Plate & Frame Formulas on the next page) Dorner Mfg. Corp Rev. G

25 Service Parts Bed Plate and Frame Formulas Bed Plate and Frame Formulas Bed Plate LLLLL = Frame LLLLL 000 Frame LLLLL = Conveyor Length LLLL X Tail Adder # of Sections of Conveyor Tail Adder = for each Tension End 0045 for each Non Tension End Width Bed Plate Configuration Rev. G 5 Dorner Mfg. Corp.

26 Service Parts 04 (76mm) Aluminum Side 4 00 Guide Retaining Clip LLLLL 00 Guide (76mm) HS (see Formulas) 6997M Single Drop in Tee Bar M Socket Head Screw M6 x 0mm Length Formulas LLLLL = (Conveyor Length XXXX) X Tail Factor # of Sections of Conveyor Tail Factor = for center drive with transfer tail both ends 0000 for end drive with one transfer tail 0000 for end drive and center drives with standard tails 005 for All Cleated Conveyors # of Conveyor Sections = XXXX = Conveyor Length (XX.XX ft) Example (Conveyor Length XXXX 000) End Drive Conveyor with Standard Tails Conveyor Length = 7 Tail Factor = 0000 (7 000) # of Sections (round up)= =.6 = Sections 00 (7 x ) 0000 LLLLL = = 098 Dorner Mfg. Corp Rev. G

27 05.5 (8mm) Aluminum Side Service Parts 4 00 Guide Retaining Clip LLLLL 00 Guide, 0.5 (mm) HS (see Formulas) 6997M Single Drop in Tee Bar M Socket Head Screw M6 x 0mm Length Formulas Length Formulas LLLLL = (Conveyor Length XXXX) X Tail Factor # of Sections of Conveyor Tail Factor = for center drive with transfer tail both ends 0000 for end drive with one transfer tail 0000 for end drive and center drives with standard tails 005 for All Cleated Conveyors # of Conveyor Sections = XXXX = Conveyor Length (XX.XX ft) Example (Conveyor Length XXXX 000) End Drive Conveyor with Standard Tails Conveyor Length = 7 Tail Factor = 0000 (7 000) # of Sections (round up)= =.6 = Sections 00 (7 x ) 0000 LLLLL = = Rev. G 7 Dorner Mfg. Corp.

28 Service Parts 07 Low to Side Wiper Guide Retaining Clip LLLLL (see Formulas) 00 Guide, 0.5 (mm) HS Side Wiper Nylatron (per foot) M Single Drop in Tee Bar M Socket Head Screw M6 x 0mm Length Formulas LLLLL = (Conveyor Length XXXX) X Tail Factor # of Sections of Conveyor Tail Factor = for center drive with transfer tail both ends 0000 for end drive with one transfer tail 0000 for end drive and center drives with standard tails 005 for All Cleated Conveyors (Conveyor Length XXXX 000) # of Conveyor Sections = 00 XXXX = Conveyor Length (XX.XX ft) Example 7 4 End Drive Conveyor with Standard Tails Conveyor Length = 7 Tail Factor = 0000 (7 000) # of Sections (round up)= =.6 = Sections 00 (7 x ) 0000 LLLLL = = 098 Dorner Mfg. Corp Rev. G

29 09 Low to High Side Service Parts 4 00 Guide Retaining Clip LLLLL 00 Guide, 0.5 (mm) HS (see Formulas) 6997M Single Drop in Tee Bar M Socket Head Screw M6 x 0mm Length Formulas LLLLL = (Conveyor Length XXXX) X Tail Factor # of Sections of Conveyor Tail Factor = for center drive with transfer tail both ends 0000 for end drive with one transfer tail 0000 for end drive and center drives with standard tails 005 for All Cleated Conveyors (Conveyor Length XXXX 000) # of Conveyor Sections = 00 XXXX = Conveyor Length (XX.XX ft) Example 7 4 End Drive Conveyor with Standard Tails Conveyor Length = 7 Tail Factor = 0000 (7 000) # of Sections (round up)= =.6 = Sections 00 (7 x ) 0000 LLLLL = = Rev. G 9 Dorner Mfg. Corp.

30 Service Parts 0.5 (mm) Extruded Plastic Guide Retaining Clip 00054P Snap On Guide (per foot) LLLLL (see Formulas) 00 Guide M Single Drop in Tee Bar M Socket Head Screw M6 x 0mm Length Formulas LLLLL = (Conveyor Length XXXX) X Tail Factor # of Sections of Conveyor Tail Factor = for center drive with transfer tail both ends 0000 for end drive with one transfer tail 0000 for end drive and center drives with standard tails 005 for All Cleated Conveyors # of Conveyor Sections = XXXX = Conveyor Length (XX.XX ft) Example (Conveyor Length XXXX 000) End Drive Conveyor with Standard Tails Conveyor Length = 7 Tail Factor = 0000 (7 000) # of Sections (round up)= =.6 = Sections 00 (7 x ) 0000 LLLLL = = 098 Dorner Mfg. Corp Rev. G

31 Adjustable Guiding Service Parts Aluminum Profile Guide (60mm) 0984 Aluminum Profile Guide (94mm) 0985 Aluminum Profile Guide 4 (9mm) 0986 Aluminum Profile Guide 5 (54mm) 0987 Aluminum Profile Guide 6 (89mm) 0988 Aluminum Profile Guide 7 (4mm) 0989 Aluminum Profile Guide 8 (48mm) 0990 Aluminum Profile Guide 9 (74mm) 099 Aluminum Profile Guide 0 (048mm) 099 Aluminum Profile Guide (5mm) 099 Aluminum Profile Guide (658mm) 0994 Aluminum Profile Guide (96mm) 0080M Drop In Tee Bar 0004 Mounting Bracket 4 007M Guide Mounting Shaft Vertical 5 008M Guide Mounting Shaft Horizontal MP Square Nut Cross Block Vinyl Shaft Cap P Flat Extruded Guide (per foot) 0 906M Socket Head Screw M6 x mm 9066M Socket Head Screw M6 x 6mm 85-5 Rev. G Dorner Mfg. Corp.

32 Service Parts 4 Tool-Less Adjustable Guiding Shaft Cap Cross Block 0080M Drop-In Tee Bar M Mounting Bracket 5 007M Vertical Mounting Guide Shaft 6 008M Horizontal Mounting Guide Shaft MP Square Nut, M M Socket Head Screw, M6-.00 x mm M Socket Head Screw, M6-.00 x 6 mm LLLLL Aluminum Profile Guide 64068P-LLLLL Extruded Guide LLLLL = Length in inches with decimal places. Length Example: Length = 95.5" LLLLL = 0955 Dorner Mfg. Corp Rev. G

33 .5 (mm) Cleated Guiding Service Parts 4 00 Guide Retaining Clip 8600 LLLLL 00 Guide, 0.47 (mm) Cleated (see Formulas) 6997M Drop In Tee Bar M Socket Head Screw M6 x 0mm Length Formulas LLLLL = (Conveyor Length XXXX) X Tail Factor # of Sections of Conveyor Tail Factor = for center drive with transfer tail both ends 0000 for end drive with one transfer tail 0000 for end drive and center drives with standard tails 005 for All Cleated Conveyors (Conveyor Length XXXX 000) # of Conveyor Sections = 00 XXXX = Conveyor Length (XX.XX ft) Example 7 4 End Drive Conveyor with Standard Tails Conveyor Length = 7 Tail Factor = 0000 (7 000) # of Sections (round up)= =.6 = Sections 00 (7 x ) 0000 LLLLL = = Rev. G Dorner Mfg. Corp.

34 Service Parts (5mm) Cleated Guiding 4 00 Guide Retaining Clip See Chart Below 00 Guide (5mm) Cleated 6997M Drop In Tee Bar M Socket Head Screw M6 x 0mm # of Sections (see Formulas) Item : 00 Guide Each Side 875 LLLLL Left Hand 876 LLLLL Right Hand End Guide (for LLLLL See Formulas) 877 LLLLL or More Left Hand 876 LLLLL Middle Sections Right Hand 8700 LLLLL 877 LLLLL Length Formulas LLLLL = (Conveyor Length XXXX) X Tail Factor # of Sections of Conveyor Tail Factor = for center drive with transfer tail both ends 0000 for end drive with one transfer tail 0000 for end drive and center drives with standard tails 005 for All Cleated Conveyors # of Conveyor Sections = XXXX = Conveyor Length (XX.XX ft) Example (Conveyor Length XXXX 000) End Drive Conveyor with Standard Tails Conveyor Length = 7 Tail Factor = 0000 (7 000) # of Sections (round up)= =.6 = Sections 00 (7 x ) 0000 LLLLL = = 098 Dorner Mfg. Corp Rev. G

35 (5mm) Cleated Guiding Service Parts 4 00 Guide Retaining Clip See Chart 00 Guide. Cleated Below 6997M Drop In Tee Bar M Socket Head Screw M6 x 0mm # of Sections (see Formulas) Item : 00 Guide End Guide (for LLLLL See Formulas) Each Side 895 LLLLL Left Hand 896 LLLLL Right Hand 897 LLLLL or More Left Hand 896 LLLLL Middle Sections Right Hand 8900 LLLLL 897 LLLLL Length Formulas Example Figure 64 LLLLL = (Conveyor Length XXXX) X Tail Factor # of Sections of Conveyor Tail Factor = for center drive with transfer tail both ends 0000 for end drive with one transfer tail 0000 for end drive and center drives with standard tails 005 for All Cleated Conveyors # of Conveyor Sections = XXXX = Conveyor Length (XX.XX ft) (Conveyor Length XXXX 000) End Drive Conveyor with Standard Tails Conveyor Length = 7 Tail Factor = 0000 (7 000) # of Sections (round up)= =.6 = Sections 00 (7 x ) 0000 LLLLL = = 098 Figure Rev. G 5 Dorner Mfg. Corp.

36 Service Parts Flared Side Guiding Guide Retaining Clip 0 Side Flare Mounting Guide (60mm) 0 Side Flare Mounting Guide (94mm) 04 Side Flare Mounting Guide 4 (9mm) 05 Side Flare Mounting Guide 5 (54mm) 06 Side Flare Mounting Guide 6 (89mm) 05M Flared Guide 45 (60mm) 05M Flared Guide 45 (94mm) 054M Flared Guide 45 4 (9mm) 055M Flared Guide 45 5 (54mm) 056M Flared Guide 45 6 (89mm) Drop In Tee Bar M Button Head Screw M5 x 6mm Washer M Cap Low Head Screw M6 x 0mm Dorner Mfg. Corp Rev. G

37 Flat Belt Mounting Brackets Service Parts Stand Mount 0050M Drop In Tee Bar 60579P Washer Square Nut M6 5mm x 0mm M Socket Head Screw M6 x 0mm M Socket Head Screw M6 x mm Cleated Belt Mounting Brackets Cleated Mounting Assembly 0050M Drop In Tee Bar 60579P Washer Square Nut M6 5mm x 0mm M Socket Head Screw M6 x 0mm M Socket Head Screw M6 x mm 85-5 Rev. G 7 Dorner Mfg. Corp.

38 Service Parts Connecting Assembly without Stand Mount Frame Bar Connector Intermediate Clamp Plate 9069M Socket Head Screw M6 x mm Flat Belt Connecting Assembly with Stand Mount Frame Connector Bar 4087 Stand Mount Joint 60579P Washer Square Nut M6 5mm x 0mm M Socket Head Screw M6 x 0mm M Socket Head Screw M6 x mm Dorner Mfg. Corp Rev. G

39 Cleated Belt Connecting Assembly with Stand Mount Service Parts Frame Connector Bar Cleat Stand Bracket Assembly 60579P Washer Square Nut M6 5mm x 0mm M Socket Head Screw M6 x 0mm M Socket Head Screw M6 x mm 4 (0mm) to 6 (5mm) Flat Belt Return Roller Return Roller Guard Short 4087 Return Roller Clip Bearing Dowel Pin M Socket Low Head Screw M6 x 6mm Roller Assembly (Includes Items, and 4) (0mm) to 6 (5mm) Flat Belt Return Roller Assy 85-5 Rev. G 9 Dorner Mfg. Corp.

40 Service Parts 8 (0mm) to 48 (9mm) Flat Belt Return Roller Return Roller Bearing Quantity Chart (Item ) Width Bearing Quantity 8 (0mm) (05mm) 4 4 (56mm) 8 (457mm) (508mm) 4 (60mm) 6 (660mm) 8 (7mm) 0 (76mm) 4 (864mm) (94mm) 40 (06mm) 8 4 (067mm) 46 (68mm) 9 48 (9mm) Return Roller Bearing 4087 Return Roller Clip 409WW Return Roller Guard 4 40WW Return Roller Rod M Socket Head Screw M6 x 6mm 6 49WW 8 (0mm) 48 (9mm) Flat Belt Return Roller Assembly WW = Conveyor width reference: in 0 increments Cleated Belt Return Roller Return Roller Guard Short 4088 Cleated Return Roller Clip Bearing Dowel Pin M Socket Low Head Screw M6 x 6mm Roller Assembly (Includes Items, and 4) Cleated Belt Return Roller Assembly Dorner Mfg. Corp Rev. G

41 Conveyor Belt Part Number Configuration Figure 65 Service Parts Flat Belt Conveyor Model Number Cleated Belt Conveyor Model Number T WW LLLL / SBV* T WW LLLL C SSSSV* SERIAL # MODEL # DORNER MFG CORP HARTLAND, WI USA Figure 65 Flat Belt Part Number Configuration Refer to Dorner patent plate (Figure 65). From the model number, determine tail type ( T ), width ( WW ), length ( LLLL ), splice type ( S ) and belt type ( B ). Use data to configure belt part number as indicated below. *Add V for V-guided belts. T - WW LLLL / SBV * (Fill In) _ / V* Cleated Belt Part Number Configuration Refer to Dorner patent plate (Figure 65). From the model number determine, cleated belt ( T ), width ( WW ), length ( LLLL ), cleat type ( C ), and cleat spacing ( SSSS ). Use data to configure belt part number as indicated below. *Add V for V-guided belt. T WW LLLL C SSSS V* (Fill In) _ C V* 85-5 Rev. G 4 Dorner Mfg. Corp.

42 Return Policy Returns must have prior written factory authorization or they will not be accepted. Items that are returned to Dorner without authorization will not be credited nor returned to the original sender. When calling for authorization, please have the following information ready for the Dorner factory representative or your local distributor:. Name and address of customer.. Dorner part number(s) of item(s) being returned.. Reason for return. 4. Customer's original order number used when ordering the item(s). 5. Dorner or distributor invoice number (if available, part serial number). A representative will discuss action to be taken on the returned items and provide a Returned Goods Authorization (RMA) number for reference. RMA will automatically close 0 days after being issued. To get credit, items must be new and undamaged. There will be a return charge on all items returned for credit, where Dorner was not at fault. It is the customer s responsibility to prevent damage during return shipping. Damaged or modified items will not be accepted. The customer is responsible for return freight. Conveyors and conveyor accessories Standard catalog conveyors 0% MPB, 700, 700 Series, cleated and specialty belt 50% AquaGard & AquaPruf Series conveyors non-returnable items Engineered to order products case by case Drives and accessories 0% Sanitary stand supports non-returnable items Parts Standard stock parts 0% Plastic chain, cleated and specialty belts non-returnable items Returns will not be accepted after 60 days from original invoice date. The return charge covers inspection, cleaning, disassembly, disposal and reissuing of components to inventory. If a replacement is needed prior to evaluation of returned item, a purchase order must be issued. Credit (if any) is issued only after return and evaluation is complete. Dorner has representatives throughout the world. Contact Dorner for the name of your local representative. Our Customer Service Team will gladly help with your questions on Dorner products. For a copy of Dorner's Warranty, contact factory, distributor, service center or visit our website at For replacement parts, contact an authorized Dorner Service Center or the factory. Dorner Mfg. Corp. reserves the right to change or discontinue products without notice. All products and services are covered in accordance with our standard warranty. All rights reserved. Dorner Mfg. Corp. 00 DORNER MFG. CORP. 975 Cottonwood Ave., PO Box 0 Hartland, WI USA TEL (USA) FAX (USA) Internet: Outside the USA: TEL FAX Rev. G Printed in U.S.A.