7400 Series Nose Bar Conveyors
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1 700 Series Nose Bar Conveyors Installation, Maintenance and Parts Manual DORNER MFG. CORP. INSIDE THE USA OUTSIDE THE USA P.O. Box Cottonwood Ave. TEL: TEL: Hartland, WI USA FAX: FAX: Rev. C For other service manuals visit our website at:
2 Table of Contents Table of Contents Introduction... Warnings General Safety... Product Description... Specifications... Flat Belt 700 Series Conveyor... Flat Belt 700 Series LPZ Conveyor... Conveyor Supports... 5 Specifications... 5 Installation... 6 Required Tools... 6 Recommended Installation Sequence... 6 Conveyors Longer than 0 ft (08 mm)... 6 LPZ Conveyors... 7 Knuckles... 7 Belt... 7 Guides... 8 All Conveyors... 8 Stand Installation... 8 Tail Assembly Installation... 9 Lifter Installation... Wear Strip Installation... Belt Installation... Belt Return Installation... Mounting Block Installation... Preventive Maintenance and Adjustment... 5 Required Tools... 5 Checklist... 5 Cleaning... 5 Routine Cleaning... 5 Periodic Cleaning... 6 Lubrication... 6 Conveyor Bearings... 6 Wearstrips and Belt Returns... 6 Maintaining the Conveyor Belt... 6 Troubleshooting... 6 Conveyor Belt Replacement... 7 Conveyors with Guides... 7 Standard Belts... 7 Replacing a Section of Belt... 7 Replacing the Entire Belt... 8 Specialty Intralox 00 Series Belts... 8 Replacing a Section of Belt... 8 Replacing the Entire Belt... 8 Conveyor Belt Tensioning... 9 Sprocket and Puck Removal... 9 A - Drive Sprocket Removal... 9 B - Idler Puck Removal... C - Nose Bar Puck Removal... Reassembling Tail Assemblies... Nose Bar Idler... Idler Tail... Drive Tail Assembly... Bearing Replacement... LPZ Knuckles... Wearstrips and Belt Returns... NOTES... 5 Service Parts... 6 Nose Bar Drive End Components... 6 Tension End Components... 8 Nose Bar Tension End... 9 Upper Knuckle for Upper Knuckle for 0... Lower Knuckle for Lower Knuckle for 0... Conveyor Frame and Extension... Lifters... 5 Mounting Block... 5 " (76 mm) High Sides... 6 Adjustable Guiding... 7 Tool-Less Adjustable Guiding... 8 Hinged Guides... 9 Adjustable Hinged Guides... 0 Tool-Less Adjustable Hinged Guides... Returns for Flat Belt Conveyors 6 (660 mm) and Wider... Returns for Flat Belt Conveyors up to (60 mm) Wide and Cleated Belt Conveyors Opposed (Thru Beam) Photo Eye Mount... Reflective Photo Eye Mount... Reflective Photo Eye Kit... Flat Belt Chain Repair Kit... 5 Belt Removal Tool... 5 Ordering a Replacement Chain... 5 Configuring a Conveyor Part Number... 6 Flat Belt Conveyor... 6 Notes... 7 Return Policy... 8 Introduction CAUTION CAUTION 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. The Dorner Limited Warranty applies. Dorner 700 series conveyors are covered by Patent Numbers 7,6,697, 7,07,5, 7,59,5 B, 7,68,79 B, 7,8,9, 8,0,68 B 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. Intralox is a registered trademark of Laitram L.L.C. in the United States and / or other countries. Dorner Mfg. Corp Rev. C
3 Warnings General Safety DANGER WARNING SEVERE HAZARD! KEEP OFF CONVEYORS. Climbing, sitting, walking or riding on conveyor will result in death or serious injury. DANGER SEVERE HAZARD! LOCK OUT POWER before removing guards or performing maintenance. Exposed moving parts can cause serious injury. WARNING EXPLOSION HAZARD! DO NOT OPERATE CONVEYORS IN AN EXPLOSIVE ENVIRONMENT. The electric gearmotor generates heat and could ignite combustible vapors. Failure to comply will result in death or serious injury. BURN HAZARD! DO NOT TOUCH the motor while operating, or shortly after being turned off. Motors may be HOT and can cause serious burn injuries. WARNING WARNING CRUSH HAZARD! DO NOT place hands or fingers inside the conveyor while it is running. DO NOT wear loose garments while operating the conveyor. Loose garments can become caught up in the conveyor. Failure to comply could result in serious injury. WARNING CRUSH HAZARD! SUPPORT CONVEYOR SECTIONS PRIOR TO LOOSENING STAND HEIGHT OR ANGLE ADJUSTMENT SCREWS. Loosening stand height or angle adjustment screws may cause conveyor sections to drop down, causing serious injury. PUNCTURE HAZARD! Handle drive shaft keyway with care. It may be sharp and could puncture the skin, causing serious injury. WARNING SEVERE HAZARD! 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. Failure to comply could result in serious injury Rev. C Dorner Mfg. Corp.
4 Product Description Refer to (Figure ) for typical conveyor components. Typical Components Conveyor 8 Gearmotor Belt Return 5 Support Stands 6 Motor Controller 7 Drive End Tension End 5 Figure Specifications Flat Belt 700 Series Conveyor Flat Belt 700 Series LPZ Conveyor Dorner Mfg. Corp Rev. C
5 Specifications Conveyor Supports Maximum Distances: = ft (9 mm) = 8 ft (8 mm)** = ft (9 mm) ** For conveyors longer than 0 ft (.05 m), install support at frame joint. Figure Specifications Conveyor Width Reference (WW) Conveyor Belt Width in 0 increments 6" (5 mm) 60" (5 mm) in " (5 mm) increments Maximum Conveyor Load 0 lb / ft (97 kg / m ) with a maximum of 000 lb / ft (88 kg / m ) Belt Travel Maximum Belt Speed Belt Take-up " (05 mm) per revolution of pulley ft / minute (7 m / minute) " (5 mm) Conveyor Length Reference (LLL) Conveyor Length LPZ Section Lengths (LLL) LPZ Section Length Total LPZ Conveyor Length in 00 increments 6" (9 mm) 999" (5. m) in " (5 mm) increments 0 5 in 00 increments " (60 mm) 5" (60 mm) in " (5 mm) increments (L +L + L) = Maximum 8' (.6 m) long conveyor IMPORTANT Maximum conveyor loads are based on: Non-accumulating product Product moving toward gearmotor Conveyor being mounted horizontally Conveyor being located in a dry environment Conveyor equipped with standard belt only Rev. C 5 Dorner Mfg. Corp.
6 Installation Installation CAUTION CAUTION Dorner recommends cleaning all the food zones prior to placing conveyor into service. Ensure adequate access is provided for cleaning and servicing equipment so that the required level of hygiene can be maintained. Conveyors Longer than 0 ft (08 mm) Typical Connection Components (Figure ). M0 x.5 mm hex head cap screws (x) Connector hex rods (x) Conveyor frames CAUTION CAUTION Conveyor MUST be mounted straight, flat, and level within confines of conveyor. Use a level (Figure, item ), during setup. Figure Required Tools Figure. Locate and arrange conveyor sections by section labels (Figure 5, item ). 7 mm wrench (for hexagonal head fasteners) mm hex wrench (for bearing shaft assembly fasteners) Level Torque wrench Recommended Installation Sequence. Attach the stands to the conveyor. Refer to Stand Installation on page 8.. Attach the tail assemblies to the frame. Refer to Tail Assembly Installation on page 9.. Attach the lifters, if applicable. Refer to Lifter Installation on page.. Install the gearmotor, if applicable. Refer to the 700 Series Drive Package Installation, Maintenance and Parts Manual. 5. Attach the wearstrips. Refer to Wear Strip Installation on page. 6. Install the belt. Refer to Belt Installation on page. 7. Attach the belt returns. Refer to Belt Return Installation on page. 8. Attach any guides / accessories. Refer to the "Service Parts" section starting on page 6. Figure 5. Position the frame sections in the correct order. Dorner Mfg. Corp Rev. C
7 Installation. Connect the frame sections by bolting the hex post connectors (Figure 6, item ) the sections of frame.. Attach lower knuckle (Figure 8, item ) to frame (Figure 8, item ) with hex rods (Figure 8, item ) and bolts (Figure 8, item ). 5 6 LPZ Conveyors Knuckles Figure 6. Attach upper knuckle (Figure 7, item ) to frame (Figure 7, item ) with hex rods (Figure 7, item ) and bolts (Figure 7, item ). Figure 8. Install wear strips (Figure 8, item 5). Belt Slide belt (Figure 9, item ) over knuckles on top of the wear strips. 5 Figure 7. Install wear strips (Figure 7, item 5). Figure Rev. C 7 Dorner Mfg. Corp.
8 Installation Guides. Slide guides (Figure 0, item ) on to the knuckle frame, and secure with pull pins (Figure 0, item ). All Conveyors Stand Installation Typical Stand Components (Figure ) Conveyor frame Stand M0 -.5 x mm hex head cap screws (x) Figure 0. Install return guides and secure with pull pin (Figure 0, item ).. Slide guides (Figure, item ) onto lower knuckle frame, and secure with pull pins (Figure, item ). Figure. Position the stands on a flat, level surface.. Attach the stands to the frame (Figure ). Figure Figure Dorner Mfg. Corp Rev. C
9 Installation Tail Assembly Installation Nose Bar Drive Tail Typical Nose Bar Drive Tail Components (Figure ) Nose bar drive tail assembly M0 x.5 x mm hex head cap screws (x) Conveyor frame Tip Up Assembly Typical Tip Up Assembly Components (Figure 6) Hex Bar Stop Key (x) Tip Up Sleeve (x) Figure. Bolt the nose bar drive tail assembly to the conveyor frame (Figure 5). Figure 6. Slide stop keys (Figure 7, item ) and tip up sleeves (Figure 7, item ) onto hex shaft (Figure 7, item ). The tabs on the tip up sleeves face outward and align with the slotted ends of the hex shaft as shown. Figure 7 Figure 5. Install the drive package, if applicable. Refer to the 700 Series Drive Package Installation, Maintenance and Parts Manual Rev. C 9 Dorner Mfg. Corp.
10 Installation. Place hex shaft assembly (Figure 8, item ) through the conveyor frame tip up holes (Figure 8, item ) and center with conveyor.. Slide the tip up sleeves (Figure 0, item ) and stop keys (Figure 0, item ) outward on hex shaft assembly (Figure 0, item ) until the sleeves seat in the holes of the frame and stop keys are seated against frame stops (Figure 0, item ). Figure 0 Figure 8. Hex shaft assembly will need to be rotated (Figure 9) for stop keys (Figure 9, item ) to pass by the frame stops (Figure 9, item ). Nose Bar Idler Tail Typical Nose Bar Idler Tail Components (Figure ) Nose bar idler tail assembly Bolt (x) Conveyor frame Figure 9 Figure Dorner Mfg. Corp Rev. C
11 Installation. Place the nose bar idler shafts (Figure, item ) against the holes in the hex shaft assembly (Figure, item ) and secure each with a bolt (Figure, item ). Idler Tail Typical Idler Tail Components (Figure ) Conveyor Frame Bolt (x) Idler tail assembly Figure. Attach the nose bar transfer post (Figure, item ) to the nose bar idler shafts.. Ensure that the nose bar pucks (Figure, item ) are in line with the conveyor frame (Figure, item ). 80 Figure CAUTION CAUTION To avoid injury and damage to parts, have an assistant hold opposite end of idler tail when removing or installing it.. Place the idler tail assembly (Figure 5, item ) against the holes in the tip up hex shaft assembly (Figure 5, item ) and secure with a bolt (Figure 5, item ) on each side. Figure Figure Rev. C Dorner Mfg. Corp.
12 Installation Lifter Installation Typical Lifter Components (Figure 6) Wear Strip Installation Typical Wear Strip Components (Figure 8) Belt lift pivot bar Lifter bars Belt lift handle M8 -.5 x 6 mm hex head cap screw Wear strip Figure 6. Slide the belt lift pivot bar (Figure 7, item ) through the designated holes in the frame. Figure 8. Position the wear strips (Figure 9, item ) on the frame. Figure 7. Attach the lifter bars (Figure 7, item ) to the belt lift pivot bar (Figure 7, item ). Make sure the hooked ends of the lifter bars are facing down when resting against the frame.. Attach the lifter handle (Figure 7, item ) to the belt lift pivot rod. Figure 9. Make sure the wear strips are situated securely in the frame slots (Figure 9, item ). Dorner Mfg. Corp Rev. C
13 Installation Belt Installation Typical Belt Components (Figure 0). Insert the belt rod (Figure, item ). Chain belt Belt rod Figure 0. Position the belt on the conveyor frame (Figure ). Figure 5. Push the belt rod in as far as possible. 6. Lightly tap the head of the rod with a hammer until it snaps into position. 7. Check belt sag by measuring from the top of the return (Figure ). Figure Up to " (0 mm) CAUTION CAUTION Belt sag should not exceed " (0 mm) from the top of the returns. Figure. Wrap the belt around the conveyor, making sure the sprocket teeth have engaged the belt.. Bring the ends of the belt together (Figure ). Figure Rev. C Dorner Mfg. Corp.
14 Installation Belt Return Installation Typical Belt Return Components (Figure 5) Return shaft Chain return shoe Figure 5. Attach the chain return shoes (Figure 6, item ) to the return shaft (Figure 6, item ). Figure 7. Push up on the return shaft (Figure 7, item ) and slide the notched end of the shaft through the small slot on the opposite side of the frame.. See step 7 of Belt Installation to check for proper belt sag. Mounting Block Installation. Clamp mounting block (Figure 8, item ) to frame (Figure 8, item ).. Tighten bolt to 0 in-lb ( Nm) to secure (Figure 8, item ). Figure 6. Slide the return shaft (Figure 7, item ) up and through the large slot (Figure 7, item ) in the frame (picture shown without the belt or wear strips). Figure 8 CAUTION CAUTION Do not over tighten bolt. Over tightening may cause the mounting block to deform. Dorner Mfg. Corp Rev. C
15 Preventive Maintenance and Adjustment Preventive Mainten ance an d Adjustment Required Tools 7 mm wrench (or adjustable wrench) /8 hex wrench (for bearing shaft assembly fasteners) mm hex wrench Punch and hammer (to remove belt rod) Checklist. Remove the guides, if applicable, by removing the pull pins (Figure 9, item ) that connect the guide (Figure 9, item ) to the frame. Keep service parts on hand. Refer to the "Service Parts" section starting on page 6 for recommendations. Replace any worn or damaged parts. Cleaning NOTE Proper conveyor application, cleaning, and sanitation are the responsibility of the end user. Figure 9. Use the lifter handle (Figure 0, item ) to raise the lifters (Figure 0, item ) and raise the tip up tail (Figure 0, item ). CAUTION CAUTION Dorner recommends cleaning all the food zones prior to placing conveyor into service. Ensure adequate access is provided for cleaning and servicing equipment so that the required level of hygiene can be maintained. Routine Cleaning WARNING Figure 0. Lift up on the belt (Figure ). SEVERE HAZARD! LOCK OUT POWER before removing guards or performing maintenance. Exposed moving parts can cause serious injury. Dorner recommends cleaning the inside and the outside of the conveyor on a daily basis. Refer to the following steps to access the inside of the conveyor. Figure CAUTION CAUTION DO NOT submerge or soak bearing assemblies. This will reduce the life of the bearing Rev. C 5 Dorner Mfg. Corp.
16 Preventive Maintenance and Adjustment Periodic Cleaning Dorner recommends complete disassembly of the conveyor periodically for thorough cleaning. For conveyor disassembly and reassembly instructions: Refer to Conveyor Belt Replacement on page 7. Refer to Sprocket and Puck Removal on page 9. Refer to Slide the nose bar pucks (Figure 6, item ) off the nose bar shaft (Figure 6, item ). on page. Lubrication Conveyor Bearings Conveyor bearing lubrication is required. Dorner recommends using an H- food grade grease. NOTE Although bearings are sealed, re-greasing is recommended to increase bearing life. An H- food grade grease is recommended. The frequency of bearing re-greasing is dependent upon the application in which the conveyor is being used. Frequency of re-greasing will increase with the frequency of conveyor washing. Maintaining the Conveyor Belt Troubleshooting Inspect conveyor belt for: Surface cuts or wear Skipping Damage to belt links or rods, surface cuts and / or wear indicate: Sharp or heavy parts impacting belt Jammed parts Accumulated dirt Foreign material inside the conveyor Improperly positioned accessories Skipping indicates: Excessive load on belt Worn sprockets or impacted dirt on drive pulley Damage to belt links or rods indicate: Excessive load on belt Dirt impacted on sprockets Excessive or improper side loading Improperly positioned accessories. Add grease to the bearing using the zerk fitting (Figure, item ) on the exterior of the bearing shaft assembly. Figure. Replace the bearings if they become worn. Wearstrips and Belt Returns Replace the wearstrips and belt returns if they become worn. For wearstrip and belt return installation instructions: Refer to Wear Strip Installation on page. Refer to Belt Return Installation on page. Dorner Mfg. Corp Rev. C
17 Preventive Maintenance and Adjustment Conveyor Belt Replacement Conveyors with Guides WARNING SEVERE HAZARD! LOCK OUT POWER before removing guards or performing maintenance. Exposed moving parts can cause serious injury.. Remove the pull pins (Figure, item ) that connect the guide (Figure, item ) to the frame. Standard Belts Replacing a Section of Belt CAUTION CAUTION Secure the retaining head side of the belt prior to removing a belt rod in order to prevent damaging the belt.. Secure the retaining head side of the belt. Use the belt removal tool (Figure 5, item ) for " pitch belts. For all other belts, position the section of belt so that it is braced by the flanged puck (Figure 5, item ). Figure. Remove the guide (Figure, item ). Figure 5. Use a punch and hammer to push the belt rod out by striking the rod end opposite the retaining head (Figure 6). Figure. Follow the belt replacement procedures described in Standard Belts on page 7, Specialty Intralox 00 Series Belts on page 8, or Specialty Intralox 600 Series Belts on page 8. Figure 6. Remove the belt rods on both sides of the section of belt being replaced.. Replace the old section with a new section of belt Rev. C 7 Dorner Mfg. Corp.
18 Preventive Maintenance and Adjustment CAUTION CAUTION DO NOT reuse belt rods that are damaged or show signs of wear.. Use a second belt rod of the same size to push on the opposite end of the belt rod. (Figure 9). Replacing the Entire Belt. Remove the belt returns by pushing up on the return shaft (Figure 7, item ) and sliding it through the large hole (Figure 7, item ) in the frame. Figure 7. Lower the opposite end of the return shaft (Figure 7, item ) and slide it out of the frame.. Follow steps in "Standard Belts: Replacing a Section of Belt" on page 7.. Remove the belt. 5. Replace the damaged or worn belt. Refer to Belt Installation on page and Belt Return Installation on page. Specialty Intralox 00 Series Belts Figure 9. Remove the belt rods on both sides of the section of belt being replaced.. Replace the old section with a new section of belt. CAUTION CAUTION DO NOT reuse belt rods that are damaged or show signs of wear. Replacing the Entire Belt. Remove the belt returns.. Follow steps in "Specialty Intralox 00 Series Belts: Replacing a Section of Belt" on page 8.. Remove the belt.. Replace the damaged or worn belt. Refer to Belt Installation on page and Belt Return Installation page. Replacing a Section of Belt. Place the edge of a flat head screwdriver between the the two belt links and turn clockwise (Figure 8). Figure 8 Dorner Mfg. Corp Rev. C
19 Preventive Maintenance and Adjustment Conveyor Belt Tensioning WARNING A - Drive Sprocket Removal WARNING SEVERE HAZARD! LOCK OUT POWER before removing guards or performing maintenance. Exposed moving parts can cause serious injury. CAUTION CAUTION Belt sag should not exceed " (0 mm) from the top of the returns. PUNCTURE HAZARD! Handle drive shaft keyway with care. It may be sharp and could puncture the skin, causing serious injury.. Loosen the fasteners (Figure 50, item ) that connect the gearmotor to the drive spindle using a hex wrench (Figure 50, item ).. Check belt for proper sag. Refer to step 7 of Belt Installation on page.. If belt has excessive sag, remove one or more belt links to take up the tension. Refer to Replacing a Section of Belt on page 7. Sprocket and Puck Removal WARNING SEVERE HAZARD! LOCK OUT POWER before removing guards or performing maintenance. Exposed moving parts can cause serious injury. Figure 50. Remove the bolts that connect the motor to the drive assembly (Figure 5).. Remove the motor (Figure 5, item ) from the drive assembly (Figure 5, item ).. Remove the conveyor belt to access the sprockets / pucks. Refer to Conveyor Belt Replacement starting on page 7.. Remove the desired sprocket / puck by following these instructions: A - Drive Sprocket Removal B - Nose Bar Puck Removal C - Idler Puck Removal Figure Rev. C 9 Dorner Mfg. Corp.
20 Preventive Maintenance and Adjustment. Unbolt the drive assembly and slide it off the bearing spindle (Figure 5). 7. Disconnect the hole flange bearing (Figure 5, item ) from the nose bar drive weldment (Figure 5, item ). Figure 5 5. Remove the bearing cover. 6. Loosen the hole flange (Figure 5, item ) with bearing fasteners using a hex wrench (Figure 5, item ). Figure 5 8. Lower the entire drive assembly. 9. Slide the hole flange with bearing (Figure 55, item ) and flanged puck (Figure 55, item ) off the drive spindle. Figure 5 Figure Slide the sprockets (Figure 56, item ) and the sprocket alignment bar (Figure 56, item ) off the drive spindle (Figure 56, item ). Figure 56 Dorner Mfg. Corp Rev. C
21 Preventive Maintenance and Adjustment B - Idler Puck Removal. Remove bolt (Figure 57, item ) from each side, and remove idler tail assembly (Figure 57, item ) from take up blocks (Figure 57, item ). C - Nose Bar Puck Removal. Slide the nose bar drive or transfer post (Figure 60, item ) out of the nose bar drive weldment or idler hands (Figure 60, item ). Figure 57. Remove the bearing end rod (Figure 58, item ) from idler shaft (Figure 58, item ) and pinch guard shaft (Figure 58, item ). Figure 60. Remove the nose bar tracking pucks (Figure 60, item ), if applicable.. Remove the nose bar wear strip (Figure 6, item ). Figure 58. Remove pinch guard (Figure 59, item ) from idler shaft (Figure 59, item ) and pinch guard shaft (Figure 59, item ). Figure 6. Slide the nose bar pucks (Figure 6, item ) off the nose bar shaft (Figure 6, item ). 5 Figure 59. Slide the pucks (Figure 59, item ) and alignment bar (Figure 59, item 5) off the idler shaft (Figure 59, item ) Rev. C Dorner Mfg. Corp.
22 Preventive Maintenance and Adjustment Reassembling Tail Assemblies Refer to the "Service Parts" section starting on page 6 for complete diagrams and lists of all tail assembly components. Nose Bar Idler. Slide the nose bar pucks (Figure 6, item ) onto the nose bar drive post (Figure 6, item ).. After all tracking pucks (Figure 6, item ) are installed, slide the nose bar drive or transfer post (Figure 6, item ) into of the nose bar drive weldment or idler hands (Figure 6, item ). Figure 6 Figure 6. Attach the nose bar wear strip (Figure 6, item ).. Attach the nose bar tracking pucks (Figure 6, item ) to the nose bar drive post (Figure 6, item ). Idler Tail. Place the pucks (Figure 65, item ) into the slots (Figure 65, item ) of alignment bar (Figure 65, item ), and install onto the idler shaft (Figure 65, item ). Figure 6 Figure 65 Dorner Mfg. Corp Rev. C
23 Preventive Maintenance and Adjustment. Slide all the idler pucks (Figure 66, item ) along with alignment bar onto idler shaft (Figure 66, item ). Drive Tail Assembly. Slide the first sprocket (Figure 68, item ) onto the drive spindle (Figure 68, item ). Figure 66. Install the pinch guard (Figure 67, item ) to each side onto idler shaft (Figure 67, item ) and pinch guard shaft (Figure 67, item ). Figure 68. Insert the sprocket alignment bar (Figure 68, item ) into the first sprocket and align the sprocket with the notch (Figure 68, item ) in the sprocket alignment bar.. Slide the remaining sprockets (Figure 68, item 5) onto drive spindle and align each sprocket with the notches (Figure 68, item ) in the sprocket alignment bar. Be sure that at least three sprockets (Figure 69, item ) are positioned such that they are on alternate opposing locations on the alignment bar. Figure 67. Install the bearing end rod (Figure 67, item ) onto idler shaft (Figure 67, item ) and rod (Figure 67, item ). Figure 69. Attach the flanged pucks (Figure 70, item ) and the hole flange with bearing (Figure 70, item ) to the drive spindle. Figure Rev. C Dorner Mfg. Corp.
24 Preventive Maintenance and Adjustment 5. Tighten the hole flange with bearing fasteners (Figure 7, item ) using a hex wrench (Figure 7, item ) to 6 N m (5 in lbs). Check after hours of conveyor use.. Remove the worn or damaged bearing (Figure 7). Figure 7 Bearing Replacement. Secure the bearing shaft in the take up blocks.. Insert the rod end of a second bearing shaft through the bearing (Figure 7). 5. Replace the bearing. Figure 7 NOTE When inserting the new bearing, make sure the anti-rotation notch (Figure 7, item ) on the bearing lines up with the groove inside the housing (Figure 7, item ). LPZ Knuckles Wearstrips and Belt Returns Replace the wearstrips and belt returns if they become worn. For wearstrip and belt return installation instructions: For wearstrips, replace as needed, making sure wear strips are situated securely in the frame slots. For belt returns, Refer to Belt Return Installation on page. Figure 7. Apply lateral pressure to the rod until the bearing comes loose. Dorner Mfg. Corp Rev. C
25 NOTES NOTES Rev. C 5 Dorner Mfg. Corp.
26 Service Parts Service Parts NOTE 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. Nose Bar Drive End Components 7 Nose Bar Drive Spindle Kit Dorner Mfg. Corp Rev. C
27 Service Parts Nose Bar Puck 5055WW 0.5" Pitch Nose Bar Wear Strip 5057WW " Pitch Nose Bar Wear Strip 508WW Nose Bar Drive Post Cover MSS Hex Head Cap Screw M0-.5x6mm Hole Flange with Bearing 7 505WW Flange Puck for Standard Belt 507WW Flange Puck for Specialty Intralox Belt 8 505WW Drive Spindle for Standard Belt 5070WW Drive Spindle for Specialty Intralox Belt 595WW CE Drive Spindle for Standard Belt 59WW CE Drive Spindle for Specialty Intralox Belt WW Sprocket Alignment Bar for Standard 0.50" Pitch Belt 5087WW Sprocket Alignment Bar for Specialty Intralox 0.60" Pitch Belt 0 9-SS Square Key 0.05" x.50" 807- Sprocket for Standard 0.50" Pitch Belt Sprocket for Specialty Intralox 0.60" Pitch Belt Nose Bar Drive Plate Chain Return 509WW Return Shaft 5 960MSS Hex Head Cap Screw M0-.5xmm Bearing 7 7NBDD-WW Nose Bar Drive Spindle Kit with a Dorner Gearmotor Mounting Package for Standard.50" Pitch Belt (Includes Items,,, 7,, and 6) 7NBDD-WW Nose Bar Drive Spindle Kit with a Dorner Gearmotor Mounting Package for Specialty Intralox.60" Pitch Belt (Includes Items,,, 7,, and 6) 7NBDC-WW Nose Bar Drive Spindle Kit without a Dorner Gearmotor Mounting Package for Standard.50" Pitch Belt (Includes Items,,, 7,, and 6) 7NBDC-WW Nose Bar Drive Spindle Kit without a Dorner Gearmotor Mounting Package for Specialty Intralox.60" Pitch Belt (Includes Items,,, 7,, and 6) WW = Conveyor width ref: in 0 increments Sprocket Quantity (Item ) Width Sprocket Quantity 6" (5mm) 8" (0mm) 0" (5mm) " (05mm) " (56mm) 6" (06mm) 8" (57mm) 5 0" (508mm) 5 " (559mm) 6 " (60mm) 6 6" (660mm) 7 8" (7mm) 7 0" (76mm) 8 " (8mm) 8 " (86mm) 9 6" (9mm) 9 8" (965mm) 0 0" (06mm) 0 " (067mm) " (8mm) 6" (68mm) 8" (9mm) 50" (70mm) 5" (mm) 5" (7mm) 56" (mm) 58" (7mm) 5 60" (5mm) Rev. C 7 Dorner Mfg. Corp.
28 Service Parts Tension End Components Idler Spindle Kit Idler Tail Kit Shaft Assembly WW Idler Shaft WW Pinch Guard Shaft 5067-WW Tracking Plate for Standard Belt 506-WW Tracking Plate for Specialty Intralox Belt Idler Puck WW Alignment Bar for Standard Belt 506-WW Alignment Bar for Specialty Intralox Belt Tip Up Sleeve Stop Key WW Hex Bar 0 965MSS Hex Head Cap Screw M-.75 x 5mm 7IX-WW Idler Spindle Tail Kit for Standard Belt (Includes Items and 5) 7ISX-WW Idler Spindle Tail Kit for Specialty Intralox Belt (Includes Items and 5) 7ITX-WW Idler Tail Kit for Standard Belt (Includes Items through 6) 7ITSX-WW Idler Tail Kit for Specialty Intralox Belt (Includes Items through 6) WW = Conveyor width ref: in 0 increments Dorner Mfg. Corp Rev. C
29 Service Parts Nose Bar Tension End 0 Nose Bar Kit Nose Bar Tail Kit Nose Bar Tracking Puck Nose Bar Puck 5056WW.5" Pitch Nose Bar Wear Strip 5058WW " Pitch Nose Bar Wear Strip 507WW Nose Bar Transfer Post for Standard Belt 5076WW Nose Bar Transfer Post for Specialty Intralox Belt Nose Bar Idler Shaft Tip Up Sleeve Stop Key WW Hex Bar 9 965MSS Hex Head Cap Screw M-.75 x 5mm 0 7NB5X-WW.5" Nose Bar Kit (Includes Items through ) 7NBX-WW " Nose Bar Kit (Includes Items through ) 7NBT5X-WW.5" Nose Bar Tail Kit, for Standard Belt (Includes Items through 5) 7NBTX-WW " Nose Bar Tail Kit, for Standard Belt (Includes Items through 5) 7NBT5SX-WW.5" Nose Bar Tail Kit, for Specialty Intralox Belt (Includes Items through 5) 7NBTSX-WW " Nose Bar Tail Kit, for Specialty Intralox Belt (Includes Items through 5) WW = Conveyor width ref: in 0 increments Rev. C 9 Dorner Mfg. Corp.
30 Service Parts Upper Knuckle for Knuckle Kit WW Frame Assembly for 5 Knuckle 55WW Frame Assembly for 0 Knuckle 56WW Frame Assembly for 5 Knuckle AA Wear Strips for 5-5 Knuckle 5089-AA.5" Hold Down Guide for 5-5 Knuckle Right Hand 6"-6" wide AA.5" Hold Down Guide for 5-5 Knuckle Right Hand 8"-" wide 5088-AA " Hold Down Guide for 5-5 Knuckle Right Hand 6"-6" wide 5068-AA " Hold Down Guide for 5-5 Knuckle Right Hand 8"-" wide AA.5" Hold Down Guide for 5-5 Knuckle Left Hand 6"-6" wide AA.5" Hold Down Guide for 5-5 Knuckle Left Hand 8"-" wide AA " Hold Down Guide for 5-5 Knuckle Left Hand 6"-6" wide AA " Hold Down Guide for 5-5 Knuckle Left Hand 8"-" wide Pull Pin Return Shaft Return Shoe 8 7UKL-WW-AA Upper Knuckle Kit (Includes items and 7) WW = Conveyor width ref: 06 - in 0 increments AA = Angle 05, 0 or 5 Dorner Mfg. Corp Rev. C
31 Service Parts Upper Knuckle for 0 6 Knuckle Kit 5 57WW Frame Assembly for 0 Knuckle Wear Strips for 0 Knuckle " Hold Down Guide for 0 Knuckle " Hold Down Guide for 0 Knuckle Pull Pin Return Guide 6 7UKH-WW-0 Upper Knuckle Kit (Includes items and 5) WW = Conveyor width ref: 06 - in 0 increments Rev. C Dorner Mfg. Corp.
32 Service Parts Lower Knuckle for Knuckle Kit 58WW Frame Assembly for 5 Knuckle 59WW Frame Assembly for 0 Knuckle 50WW Frame Assembly for 5 Knuckle 5069-AA Wear Strips for 5-5 Knuckle 5069-AA.5" Hold Down Guide for 5-5 Knuckle 6"-6" wide 5097-AA.5" Hold Down Guide for 5-5 Knuckle 8"-" wide AA " Hold Down Guide for 5-5 Knuckle 6"-6" wide 5097-AA " Hold Down Guide for 5-5 Knuckle 8"-" wide Pull Pin 5 7LKL-WW-AA Lower Knuckle Kit (Includes item ) WW = Conveyor width ref: 06 - in 0 increments AA = Angle 05, 0 or 5 Dorner Mfg. Corp Rev. C
33 Service Parts Lower Knuckle for 0 5 Knuckle Kit 6 5WW Frame Assembly for 0 Knuckle Wear Strips for 0 Knuckle " Hold Down Guide, for 0 Knuckle " Hold Down Guide, for 0 Knuckle Pull Pin 5 7LKH-WW-0 Lower Knuckle Kit (Includes item ) WW Wearstrip Retention Bar WW = Conveyor width ref: 06 - in 0 increments Rev. C Dorner Mfg. Corp.
34 Service Parts Conveyor Frame and Extension Consult Factory for Frame Part Number LLL Straight Wear Strip 5009 Hex Post Connector 9606MSS Hex Head Cap Screw M0-.5x6mm LLL = Conveyor length ref: in 00 increments WW = Conveyor width ref: in 0 increments Conveyor Width (WW) 06- Wear Strip Quantity (Item ) Conveyor Length (LLL) Conveyor Width (WW) 06- Wear Strip Quantity (Item ) Conveyor Length (LLL) Dorner Mfg. Corp Rev. C
35 Service Parts Lifters Mounting Block 5 505WW Belt Lifter Shaft 5076 Belt Lifter 5009 Belt Lifter Handle 9608MSS Hex Head Cap Screw, M8-.5 x mm WW = Conveyor width ref: in 0 increments Mounting Block Washer Eyebolt, M0 x.50 mm 9606MSS Hex Head Cap Screw, M x 6 mm MSS Hex Nut, M mm Rev. C 5 Dorner Mfg. Corp.
36 Service Parts " (76 mm) High Sides LLLLL Right Hand High Side Guide 5060-LLLLL Left Hand High Side Guide Pull Pin 500-LLLLL Square End High Side Guide LLLLL = Guide Length in inches with decimal places. Example: Guide Length = 95.5" LLLLL = 0955 Dorner Mfg. Corp Rev. C
37 Service Parts Adjustable Guiding Rail Clamp Washer Eye Bolt M0 x.50 mm Mounting Bracket Vertical Post Assembly LLLLL Round Guide Rail Guide Post MSS Hex Head Cap Screw, M8 -.5 x mm MSS Hex Nut, M mm LLLLL = Length in inches with decimal places. Length Example: Length = 95.5" LLLLL = Rev. C 7 Dorner Mfg. Corp.
38 Service Parts Tool-Less Adjustable Guiding Rail Clamp Handle Washer Eye Bolt M0 x.50 mm Mounting Bracket Vertical Post Assembly LLLLL Round Guide Rail Guide Post MSS Hex Head Cap Screw, M8 -.5 x mm LLLLL = Length in inches with decimal places. Length Example: Length = 95.5" LLLLL = 0955 Dorner Mfg. Corp Rev. C
39 Service Parts Hinged Guides Mounting Block Pivot Guide Mounting Bracket Guide Clamp Bracket PH-0800 Mounting Guide Shaft for " Guides PH-00 Mounting Guide Shaft for 6" Guides 5 57-LLLLL Guiding for " Guides LLLLL Guiding for 6" Guides Washer Eyebolt M0 x.50 mm Cotter Pin SS Weld Nut, M8 x.5 mm MSS Hex Head Cap Screw, M8 -.5 x 5 mm 9606MSS Hex Head Cap Screw, M x 6 mm 99008MSS Hex Nut, M mm LLLLL = Length in inches with decimal places. Length Example: Length = 95.5" LLLLL = Rev. C 9 Dorner Mfg. Corp.
40 Service Parts Adjustable Hinged Guides Mounting Block Pivot Guide Bracket 500 Guide Post DH-00 Adjustable Guide Shaft LLLLL Guiding Clamp Rail Lanyard Pin Washer Eyebolt M0 x Cotter Pin 9608MSS Hex Head Cap Screw, M8 -.5 x mm 9606MSS Hex Head Cap Screw, M x 6 mm 9900MSS Hex Nut, M MSS Hex Nut, M LLLLL = Length in inches with decimal places. Length Example: Length = 95.5" LLLLL = 0955 Dorner Mfg. Corp Rev. C
41 Service Parts Tool-Less Adjustable Hinged Guides Mounting Block Pivot Guide Bracket 500 Guide Post DH-00 Adjustable Guide Shaft LLLLL Guiding Clamp Rail Handle Lanyard Pin Washer Eyebolt M0 x.50/ Cotter Pin 9608MSS Hex Head Cap Screw, M8 -.5 x mm 9606MSS Hex Head Cap Screw, M x 6 mm LLLLL = Length in inches with decimal places. Length Example: Length = 95.5" LLLLL = Rev. C Dorner Mfg. Corp.
42 Service Parts Returns for Flat Belt Conveyors 6 (660 mm) and Wider Chain Support Kit 50WW Return Shaft Chain Return Shoe 7R-WW Chain Support Kit ( Includes Item ) WW = Conveyor width ref: in 0 increments Returns for Flat Belt Conveyors up to (60 mm) Wide and Cleated Belt Conveyors 5 Cleated Return Shoe Dorner Mfg. Corp Rev. C
43 Service Parts Opposed (Thru Beam) Photo Eye Mount Mount Clamp Washer Eyebolt, M0 x Mounting Block NH-00 Mounting Shaft MSS Hex Head Cap Screw, M x 6 mm MSS Hex Nut, M Reflective Photo Eye Mount Reflector Mount Clamp Photo Eye Mount Clamp Washer Eyebolt, M0 x Reflector Mounting Block NH-00 Mounting Shaft MSS Hex Head Cap Screw, M x 6 mm MSS Hex Nut, M Rev. C Dorner Mfg. Corp.
44 Service Parts Reflective Photo Eye Kit Reflector Mount Clamp Photo Eye Mount Clamp Washer Eyebolt, M0 x Reflector Photo Eye Sensor Mounting Block NH-00 Mounting Shaft MSS Hex Head Cap Screw, M x 6 mm MSS Hex Nut, M Dorner Mfg. Corp Rev. C
45 Service Parts Flat Belt Chain Repair Kit Flat Belt Chain Kit Ordering a Replacement Chain Determine the length of chain required for the conveyor and round up to the nearest foot length. Order the proper number of chain repair kits (' long each) for your conveyor. Dorner will ship chain kits that are of a reasonable length fully assembled. Example: Overall chain length = ' 5" (rounded up = ') Order: Qty () of 7BB-WW 7BB-WW Flat Belt Chain Repair Kit (Includes ft (05 mm) of flat belt chain and assembly pins) BB = Chain Reference Number WW = Conveyor width ref: in 0 increments BB = Chain reference number WW = Conveyor width ref: in 0 increments Belt Removal Tool Tool Rod Removal for " Pitch Flush Grid Belt 5009 Tool Rod Removal for /" Pitch Flush Grid Belt Rev. C 5 Dorner Mfg. Corp.
46 Service Parts Configuring a Conveyor Part Number Figure 7 Flat Belt Conveyor Refer to the model number on the conveyor frame (Figure 7). From the model number, determine conveyor width (WW), length (LLL), drive stand location (S), idler stand location (S), cleaning options (C), drive/pulley type (D), profile (G) and belt material (BB). Example: 7M-07CCNA0 700 Series end drive, cleated belt conveyor, " (05 mm) wide x 7" (89 mm) long, stands located 8" (57 mm) from each end, frame cutout cleaning option, NA cleated belt material, side drive with standard pulleys on each end, and 0 link spacing for cleats. Dorner Mfg. Corp Rev. C
47 Notes Rev. C 7 Dorner Mfg. Corp.
48 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.. 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. Product Line 00 Conveyors Gearmotors & Mounting Packages Support Stands Product Type Standard Products Accessories Spare Parts (non-belt) Spare Belts - Standard Flat Fabric Spare Belts - Cleated & Specialty Fabric Spare Belts - Plastic Chain Engineered to order parts All equipment and parts Modular Belt 00 Precision Move Modular Belt 00 0% return fee for all products except: 50% return fee for conveyors with modular belt, 00 LPZ cleated belt or specialty belts non-returnable case-by-case 00 Precision Move Controls 700 / % return fee for all products non-returnable 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. 0 DORNER MFG. CORP. 975 Cottonwood Ave., PO Box 0 Hartland, WI USA TEL (USA) FAX (USA) Internet: Outside the USA: TEL FAX Rev. C Printed in U.S.A.
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