Dorner 2100 Series User manual

851-179 Rev. E
Installation, Maintenance
& Parts Manual
2100 Series Center Drive Conveyors
Table of Contents
Warnings – General Safety 2. . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tools 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Installation Sequence 5. . . . . . . . . . . . . .
Conveyors Up to 3962 mm 5. . . . . . . . . . . . . . . . . . . . . .
Conveyors Longer Than 3962 mm 5. . . . . . . . . . . . . . . .
Mounting Brackets with Return Rollers 6. . . . . . . . . . . .
44 mm to 152 mm Wide
Flat Belt Conveyors 6. . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance & Adjustment 7. . . . . . . . . . . . . .
Required Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Pulley Bearings 7. . . . . . . . . . . . . . . . . . . . . . . . .
Drive Module Idler Pulley Bearings 7. . . . . . . . . . . . .
Drive Module Drive Pulley Bearings 7. . . . . . . . . . . .
Mounting Brackets with Return Rollers 7. . . . . . . . . .
Maintaining Conveyor Belt 8. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement 8. . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement Sequence 8. . . . . . . . . . .
Belt Removal for Conveyor Without
Gearmotor Mounting Package or Stands 8. . . . . . . . . . .
Belt Removal for Conveyor With Stands
and/or Gearmotor Mounting Package 9. . . . . . . . . . . . .
Center Drive Module Removal 11. . . . . . . . . . . . . . . . .
Belt Removal from Center Drive Module 11. . . . . . . . . .
Installing a New Conveyor Belt 12. . . . . . . . . . . . . . . . .
Conveyor Belt Tensioning 14. . . . . . . . . . . . . . . . . . . . . .
Pulley Removal 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A – End Pulley Removal 14. . . . . . . . . . . . . . . . . . . . .
B – Drive Pulley Removal 15. . . . . . . . . . . . . . . . . . . .
C – Idler Pulley Removal 15. . . . . . . . . . . . . . . . . . . .
Bearing Replacement End Pulleys 16. . . . . . . . . . . . . . . .
Bearing Removal 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Installation 17. . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Replacement for Drive Pulley 18. . . . . . . . . . . .
Bearing Removal 18. . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Installation 18. . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Replacement for Idler Pulleys 18. . . . . . . . . . . .
Pulley Replacement 18. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Parts 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51mm Wide Conveyor Assembly 21. . . . . . . . . . . . . . . .
76mm to 152mm Wide Conveyor Assembly 23. . . . . . . .
203mm to 605mm Wide Conveyor Assembly 24. . . . . . .
457mm to 610mm Wide Conveyor Assembly 26. . . . . . .
127mm to 610mm Wide Center Drive Module 28. . . . . .
51mm, 76mm, 102mm Wide
Center Drive Module 28. . . . . . . . . . . . . . . . . . . . . . . . .
–04 76mm Aluminum Side 30. . . . . . . . . . . . . . . . . . . . .
–05 38mm Aluminum Side 31. . . . . . . . . . . . . . . . . . . . .
–07 Low to Side Wiper 32. . . . . . . . . . . . . . . . . . . . . . . .
–09 Low to High Side 33. . . . . . . . . . . . . . . . . . . . . . . . .
–10 13mm Extruded Plastic 34. . . . . . . . . . . . . . . . . . . .
–13 Adjustable Guiding 35. . . . . . . . . . . . . . . . . . . . . . .
Flared Side Guiding 36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Assembly without Stand Mount 36. . . . . . . .
Configuring Conveyor Belt Part Number 37. . . . . . . . . .
Return Policy 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
851-179 Rev. E 2Dorner Mfg. Corp.
The safety alert symbol, black triangle with white
exclamation, is used to alert you to potential
personal injury hazards.
ÇÇ
Ç
WARNING
ÇÇ
ÇÇ
Climbing, sitting, walking or
riding on conveyor will
cause severe injury.
KEEP OFF CONVEYORS.
DANGER
ÇÇ
DANGER
DO NOT OPERATE
CONVEYORS IN AN
EXPLOSIVE ENVIRONMENT.
ÇÇ
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
ÇÇ
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
WARNING
ÇÇ
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.
WARNING
ÇÇ
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.
WARNING
Introduction
IMPORTANT: Some illustrations may show
guards removed. Do NOT operate equipment with-
out 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 in-
structions for installation.
Dorner’s Limited Warranty applies.
Dorner 2100 Series conveyors are covered by Patent
No. 5,174,435, 5,131,529 and corresponding patents
and patent applications in other countries.
Dorner reserves the right to make changes at any time
without notice or obligation.
Warnings – General Safety

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 3851-179 Rev. E
Refer to Figure 1 for typical conveyor components.
A Conveyor
B Center Drive Module
C Gearmotor Mounting Package
D Guiding & Accessories
E Gearmotor
F Mounting Brackets with Return Rollers
G Support Stands
H Variable Speed Controller
I Fixed End
J Tension End
Typical Components
Figure 1
J
F
G
H
E
F
G
I
AD
CB
Specifications
Models:
2100 Series Center Drive Conveyor
2150 M WW LL
Conveyor Width Reference
Conveyor Length Reference
Belt Type*
A 01 / 02
Mount Position (A or D)*
Conveyor Profile*
* See “Ordering and Specifications”Catalog for details.
Conveyor Supports:
Maximum Distances:
K = 457 mm
L = 1829 mm**
** For conveyors longer than 3962 mm, install
support at joint.
Figure 2
K
KL
Product Description

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
851-179 Rev. E 4Dorner Mfg. Corp.
Specifications:
Conveyor Width
Reference (WW) 02 03 04 05 06 08 10 12
Conveyor Belt Width 44 mm 70 mm 95 mm 127 mm 152 mm 203 mm 254 mm 305 mm
Maximum Conveyor Load*
(See NOTE Below) 18 kg 23 kg 27 kg 34 kg 41 kg 47 kg 54 kg 54 kg
Conveyor Start-up Torque* 1.0 Nm 1.1 Nm 1.2 Nm 1.4 Nm 1.7 Nm 2.3 Nm 2.6 Nm 2.8 Nm
Belt Travel 88 mm per revolution of pulley
Maximum Belt Speed* 72 meters/minute
Belt Take-up 25 mm of stroke = 51 mm of belt take-up
Conveyor Length
Reference (LL) 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Conveyor Length
610 mm 914 mm
1219 mm 1524 mm 1829 mm 2134 mm 2438 mm 2743 mm 3048 mm 3353 mm 3658 mm 3962 mm 4267 mm 4572 mm 4877 mm 5182 mm 5486 mm 5791 mm 6096 mm 6401 mm 6706 mm 7010 mm 7315 mm
NOTE: Maximum conveyor loads based on:
Non-accumulating product
Product moving towards gearmotor
Conveyor being mounted horizontal
* See “Ordering and Specifications”Catalog for details.
Installation
NOTE: Conveyor MUST be mounted straight, flat
and level within confines of conveyor. Use a level (M
of Figure 3) for set-up.
Figure 3
M
N Conveyor frame without belt
O Conveyor frame with belt
P Connector Strips (2x) (Attached to conveyor sec-
tion)
Q Mounting bracket with return roller
Z Roller guards (2x)
AA Mounting bracket end block (2x)
Installation Component List
Specifications

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 5851-179 Rev. E
Required Tools
Standard Tools
Hex key wrenches
–4 mm
–5 mm
Level
Torque wrench
Recommended Installation Sequence
NOTE: See Table of Contents for beginning page
numbers of following procedures.
Assemble conveyor (if required)
Attach mounting bracket(s) with return roller to
conveyor
Install stands (see accessory instructions)
Attach conveyor to stands
Mount gearmotor mounting package (see accessory
instructions)
Attach guides/accessories (see accessory instructions)
Conveyors Up to 3962 mm
No additional assembly is required.
Conveyors Longer Than 3962 mm
1.Typical components (Figure 4)
Figure 4
N
PO
Q
2.On tension end of the conveyor, identified with
label (R of Figure 5), loosen tracking cam
assemblies (S) and cover plate screws (T) on both
sides of the conveyor.
Figure 5
RS
UT
3.Slide the cam assemblies toward the center of the
conveyor and push the end (U of Figure 5) into the
conveyor frame.
4.Roll out conveyor belt.
5.Place conveyor frame (N of Figure 6) into belt loop.
Figure 6
N
V
W
6.Loosen connector strip screws (V) and mounting
bracket screws (W) on both sides of the conveyor.
7.Join conveyor sections (N and O of Figure 7).
Position mounting bracket (P and Q) across convey-
or sections.
Figure 7
O
N
V
QWP
8.Tighten connector strip screws (V) to 2 Nm. Tighten
bracket screws (W) to 9 Nm.
9.Insert a 5 mm hex key wrench into either end of the
pinion gear (X of Figure 8). Rotate the pinion gear to
extend the tensioning end gap (Y) to 30 mm.
Figure 8
Y
TX
10.While holding the pinion gear (X), tighten cover plate
screws (T) to 2 Nm.
Installation

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
851-179 Rev. E 6Dorner Mfg. Corp.
Mounting Brackets with Return Rollers
44 mm to 305 mm Wide Flat Belt Conveyors
1.Typical components (Figure 9). Roller guards (Z) are
shipped fastened to one end block (AA). Do NOT
fasten to other block.
Figure 9
AA
Z
2.Loosen screws (AC of Figure 10) and remove screws
and washers (AD).
Figure 10
AD
AD AC
AC
3.Attach clamp plates on each side of conveyor (Figure
11). Tighten the screws (AC) to 9 Nm.
Figure 11
AC
AC
AD
AD
4.Attach to support stand. Tighten screws (AD) to
9 Nm. Make sure belt is free to move.
Installation

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 7851-179 Rev. E
Required Tools
Standard Tools
Hex key wrenches
–2 mm
–4 mm
–2.5 mm
–5 mm
–3 mm
–6 mm
Small flat blade screwdriver
Adjustable wrench
Arbor press
Special Tools
2500M–ENG, 2100 Tool Kit
450282, Sealed Bearing Installation Tool
Checklist
Keep service parts on hand. (See “Service Parts”for
recommendations.)
Keep supply of belt cleaner (part number 625619)
Clean entire conveyor and knurled pulley while dis-
assembled
Replace worn or damaged parts
Lubrication
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Pulley Bearings
NOTE:
Optional permanent grease fittings (part number
200398M) may be installed.
NOTE:
44 mm wide conveyors use shielded ball bearings
and do not require lubrication.
1.With a small flat-blade screwdriver, remove plug
(AE of Figure 12) from retainer (AF).
Figure 12
AE
AF
2.Install Dorner greasing adapter (AG of Figure 13),
part number 200046M. Make sure the adapter
shoulder is seated against the conveyor tail plate.
Figure 13
AG
3.Use Dorner red grease, 397 gram cartridge (part #
829-002) or 397 gram can (part number 829-003).
Lubricate pulley bearing every 750 hours or more
frequently, depending on operating conditions.
NOTE: Lubricate pulley bearing every 750 hours or
more frequently, depending on operating condi-
tions. When lubricating pulley bearings, use a con-
ventional hand grease gun with a maximum of one
pump per application. Do not over-lubricate. Do not
use a power grease gun.
4.Grease bearing with one (1) pump from a manual
grease gun. Do not over-lubricate.
5.Remove grease adapter and install on opposite side
of pulley. Repeat steps 2 and 4.
Drive Module Idler Pulley Bearings
No lubrication is required. Replace pulley if worn.
Drive Module Drive Pulley Bearings
No lubrication is required. Replace bearings if worn.
Mounting Brackets with Return Rollers
No lubrication is required. Replace bearings if worn.
Preventive Maintenance and Adjustment

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
851-179 Rev. E 8Dorner Mfg. Corp.
Maintaining Conveyor Belt
Troubleshooting
Inspect conveyor belt for:
Surface cuts or wear
Stalling or slipping
Surface cuts and wear indicate:
Sharp or heavy parts impacting belt
Jammed parts
Improperly installed bottom wiper
Accumulated dirt in wiper
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
NOTE: Visit www.dorner.com for complete list of
troubleshooting solutions.
Cleaning
IMPORTANT: Do not use belt cleaners that con-
tain alcohol, acetone, Methyl Ethyl Ketone (MEK) or
other harsh chemicals.
Use Dorner Belt Cleaner (part number 625619). 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
ÇÇ
ÇÇ
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Conveyor Belt Replacement Sequence
NOTE: See Table of Contents for beginning page
numbers of following procedures.
Remove old conveyor belt
- Conveyor without Gearmotor Mounting Package
or Stands
- Conveyor with Stands and/or Gearmotor
Mounting Package
Center Drive Module Removal
Conveyor Belt Removal from Center Drive Module
Install New Conveyor Belt
Tension Conveyor Belt
Belt Removal for Conveyor Without
Gearmotor Mounting Package or Stands
1.From the discharge end, remove tail cover plate
screws (AJ of Figure 14) from one side of the
conveyor.
Figure 14
AJ
AK
AI
AL
2.Remove tail cover plate (AK).
3.Slide bottom wiper (AI) through side slot of tail plate
(AL).
4.If the conveyor is equipped with guiding and
accessories, remove them from one side.
Preventive Maintenance and Adjustment

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 9851-179 Rev. E
5.Loosen corner screws (AN of Figure 15), on each
side of the center drive module (AO).
Figure 15
AP
AO
AN
AR AQ
6.Remove tension door screws (AP) on each side of the
center drive module.
7.Using finger grip holes (AQ), open the tension door
(AR) to release conveyor belt tension.
8.On tension end of the conveyor, identified with
label (AS of Figure 16), loosen tracking cam
assemblies (AT) and cover plate screws (AU) on both
sides of the conveyor.
Figure 16
AS AT
AV AU
9.Slide the cam assemblies toward the center of the
conveyor and push the end (AV) into the conveyor
frame.
NOTE: On 1219 mm and shorter by 203 mm and
wider conveyors, it will be necessary to remove the
center drive module at the same time the conveyor
belt is removed. See “Center Drive Module Removal”
on page 11.
10.Remove conveyor belt.
11.Proceed to “Center Drive Module Removal”on page
11.
Belt Removal for Conveyor With Stands
and/or Gearmotor Mounting Package
1.From the discharge end, remove tail cover plate
screws (AJ of Figure 14) from one side of the
conveyor.
2.Remove tail cover plate (AK).
3.Slide bottom wiper (AI) through side slot of tail plate
(AL).
4.If the conveyor is equipped with guiding and
accessories, remove them from one side.
NOTE:Figures 17 & 18 show a vertical mount in the
A position with a parallel shaft gearmotor. Horizontal
mount, D position and/or 905gearmotor are similar.
5.Remove cover screws (AV of Figure 17) and remove
cover (AW).
Figure 17
AV
AW
AV
Preventive Maintenance and Adjustment

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
851-179 Rev. E 10 Dorner Mfg. Corp.
6.Loosen belt tensioner (AX of Figure 18) then
remove the belt (AY).
Figure 18
AX
AY
NOTE: If the timing belt does not slide over the
pulley flange, loosen the driven pulley set screws
(AZ of Figure 19) and remove the pulley (BA) with the
belt (BB).
Figure 19
AZ
BA
BB
7.Remove three mounting screws (BE of Figure 20)
and remove gearmotor package.
Figure 20
BE
8.Loosen corner screws (AN of Figure 15), on each
side of the center drive module (AO).
9.Remove tension door screws (AP) on each side of the
center drive module.
NOTE:With vertical mounts, two cover screws (BE
of Figure 20) were removed in step 7.
10.Using finger grip holes (AQ), open the tension door
(AR) to release conveyor belt tension.
11.On tension end of the conveyor, identified with
label (AS of Figure 16), loosen tracking cam
assemblies (AT) and cover plate screws (AU) on both
sides of the conveyor.
12.Slide the cam assemblies toward the center of the
conveyor and push the end (AV) into the conveyor
frame.
ÇÇ
Ç
To prevent injury from the support stand
tipping-over when conveyor is uncoupled, anchor
stand to floor or otherwise stabilize the stand.
WARNING
Preventive Maintenance and Adjustment

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 11 851-179 Rev. E
NOTE: On 1219 mm and shorter by 203 mm and
wider conveyors, it will be necessary to remove the
center drive module at the same time the conveyor
belt is removed. See “Center Drive Module Removal”
(next section).
NOTE:To remove the belt, complete steps 13 & 14,
at each stand location.
13.Loosen the mounting clamp plates (BF of Figure 21)
on both sides of the conveyor. Raise the conveyor
and remove the belt.
Figure 21
BF
14.With the belt removed, secure the conveyor with
clamp plates (BF).
15.Proceed to “Center Drive Module Removal”, (next
section).
Center Drive Module Removal
Ç
Ç
Before loosening clamps (BG of Figure 22), provide
a support (BH) under center drive module.
WARNING
NOTE: If desired, mark center drive module
location on conveyor.
1.Loosen clamp screws (BG of Figure 22) in each cor-
ner of the module.
Figure 22
BH
BG
2.Remove the module.
Belt Removal from Center Drive Module
1.Remove drive plate screws (BI of Figure 23). Re-
move the tension drive plate (BJ).
Figure 23
BI
BJ
2.Remove drive pulley (BK of Figure 24).
BL
BM
Figure 24
BN
BK
Preventive Maintenance and Adjustment

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
851-179 Rev. E 12 Dorner Mfg. Corp.
Figure 25
BO BK
3.Remove grooved idler pulley:
For 44 mm, 70 mm or 95 mm wide conveyor, detach
E-ring clip (BL of Figure 24). Remove pulley shaft
(BM) and remove pulley (BN).
For 127 mm or wider conveyor, depress both sides of
spring-loaded shaft and remove pulley (BO of Figure
25).
4.Remove the conveyor belt.
Installing a New Conveyor Belt
IMPORTANT: On a center drive conveyors, belt
travel direction is identified by an arrow decal on the
side of the conveyor (BP of Figures 26 & 27).
Figure 26
BP
Figure 27
BP
1.Orient the conveyor belt so that the splice leading
fingers (BQ of Figure 28) point in the direction of
belt travel as identified by the label (BP of Figure
26).
Figure 28
BQ
2.Place loop of belt into the drive module (Figure 29).
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 13 851-179 Rev. E
Figure 29
3.Place grooved idler pulley (BN of Figure 24 or BO
of Figure 25) into the belt loop and install it in the
drive module. Refer to “Belt Removal from Center
Drive Module”on page 12 and reverse step 3.
4.Place drive pulley (BK of Figure 24 or 25) into the
belt loop and install it in the drive module. Refer to
“Belt Removal from Center Drive Module”on page
11 and reverse steps 1 and 2. Tighten screws (BI of
Figure 23) to 9 Nm.
NOTE: On 1219 mm and shorter by 203 mm and
wider conveyors, it will be necessary to replace the
center drive module at the same time the conveyor
belt is replaced.
5.Replace the center drive module onto the conveyor
and attach clamps (BG of Figure 22) in each corner.
Tighten screws to 9 Nm.
NOTE:On conveyor with stands, complete steps 6,
7 & 8 at each stand location.
6.Loosen the mounting clamp plates (BF of Figure 21),
on both sides of the conveyor. Raise the conveyor
and replace the belt.
7.Lower the conveyor onto the mounting blocks. Use
care not to pinch belt.
8.Tighten clamp plate screws to 9 Nm.
9.Insert a 5 mm hex key wrench into either end of the
pinion gear (BR of Figure 30). Rotate the pinion gear
to extend the tensioning end gap (BU) to 30 mm.
Figure 30
BT
BS BR
10.While holding the pinion gear (BR), tighten cover plate
screws (BS) to 2 Nm.
Ç
Ç
Tension door closes
quickly, may cause injury.
KEEP FINGERS CLEAR OF
TENSION DOOR.
WARNING
11.Carefully close the tension door (BU of Figure 31).
Figure 31
BU
Preventive Maintenance and Adjustment

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
851-179 Rev. E 14 Dorner Mfg. Corp.
12.Tighten corner screws (BU of Figure 32) on each
side of the drive module to 9 Nm.
Figure 32
BV
BW
BU
NOTE: If equipped with gearmotor mounting
package, replace by completing in reverse order
steps 3 through 5 of “Belt Removal for Conveyor
With Stands and/or Gearmotor Mounting Package”
on page 9.
13.Re-install tension door screws (BV of Figure 32) on
each side of the module. Tighten screws to 9 Nm.
14.Re–install discharge bottom wiper (AI of Figure 14):
Reverse steps 1 through 3 of “Belt Removal for
Conveyor Without Gearmotor Mounting Package or
Stands”, page 8.
15.Replace guiding, if applicable.
Conveyor Belt Tensioning
NOTE: For a new belt, the tension plate will be in
position indicated in Figure 32 (BW). When the ten-
sion plate extends to position indicated in Figure 33
(BW), the conveyor belt must be replaced.
Figure 33
BW
The conveyor is equipped with an automatic tensioning
cylinder. No tensioning adjustment is required.
Pulley Removal
ÇÇ
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
WARNING
Remove the conveyor belt to access the pulley(s).
Perform the indicated steps of one of the following
procedures:
“Belt Removal for Conveyor Without Gearmotor
Mounting Package or Stands”, page 8, steps 1
through 10.
“Belt Removal for Conveyor With Stands and/or
Gearmotor Mounting Package”, page 9, steps 1
through 14.
Remove the desired pulley following procedures A, B or
C:
A–End Pulley Removal
B–Drive Pulley Removal
C–Idler Pulley Removal
A–End Pulley Removal
NOTE: Bearing removal tools (part numbers 25–09
and 906–278 included in Tool Kit 2500M–ENG) are
required to remove end pulleys.
1.With a small flat blade screwdriver, remove plug
(BX of Figure 34) from retainer (BY).
Figure 34
BX
BY
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2.Remove the tail cover plate screws (BZ of Figure 35)
and tail cover plates (CA) on both sides of the
conveyor.
Figure 35
BZ
CA
BZ
CB
CC
CA
CB CD
3.Position bearing anvil/sleeve removal tool (CJ of
Figure 36), part number 25-09, over the retaining
sleeve (CB of Figure 35 or Figure 36).
Figure 36
CJ
CC
CF CB
CK
CA
4.Insert threaded bolt (CK of Figure 36), part number
906-278, through the bearing anvil/sleeve removal
tool (CJ) and into the retaining sleeve (CB).
5.Tighten the bolt (CK) until the retaining sleeve (CB)
is free of the tail pulley plate (CA).
6.Remove the retaining sleeve (CB) from the bolt
(CK) and repeat for the other side.
7.Remove the pulley (CC).
B–Drive Pulley Removal
1.Remove the gearmotor drive package. Refer to “Belt
Removal for Conveyor With Stands and/or Gearmo-
tor Mounting Package”, page 9, steps 5 through 7.
2.Remove the drive pulley. Refer to “Belt Removal
from Center Drive Module”, page 11, steps 1 and 2.
C–Idler Pulley Removal
1.Remove the gearmotor drive package. Refer to “Belt
Removal for Conveyor With Stands and/or Gearmo-
tor Mounting Package”, page 9, steps 5 through 7.
2.Detach the center drive module. Refer to ”Center
Drive Module Removal”, page 11.
3.Remove the grooved idler pulley. Refer to “Belt
Removal from Center Drive Module”, step 3, page 12.
4.Remove smooth idler pulleys:
For 44 mm, 70 mm or 95 mm wide conveyor, detach
E-ring clips and remove washers (CL of Figure 37).
Remove pulley shafts (CM) and pulleys (CN).
Figure 37
CL CM
CM
CN
For 127 mm or wider conveyor, depress both sides of
each spring-loaded shaft (CO of Figure 38). Remove
pulleys (CP).
Figure 38
CO
CP

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Bearing Replacement for End Pulleys
IMPORTANT: Once removed, do not re-use
bearings.
NOTE:Bearing removal and installation tools (part
numbers 25–05, 25–08, 25–09 and 25–10 included in
Tool Kit 2500M–ENG) are required to remove and
install bearings.
Bearing Removal
NOTE: The bearings of a 44 mm wide gang drive
pulley cannot be replaced. Order pulley assembly
(part number 204002).
1.Insert bearing removal tool (CQ of Figure 39), part
number 25–05, into the pulley (CR) until shoulder (CS)
seats against bottom of bearing (CT).
Figure 39
CU CR
CQ
CS
CT
CV
2.While holding bearing removal tool (CQ) in posi-
tion, insert extension tool (CU), part number 25–08,
into opposite end of pulley (CR). Rotate bearing
removal tool (CQ) to engage hex tip of extension tool
(CU) into screw (CV) of bearing removal tool.
3.While maintaining extension tool (CU) position, use
a wrench (CW of Figure 40) to rotate the bearing
removal tool (CQ) to expand the flare end of the tool.
Figure 40
CU
CW
CQ
4.Orient bearing anvil/sleeve removal tool (CX of
Figure 41), part number 25–09, with cavity facing up
and place pulley (CR) onto tool.
Figure 41
CX
CR
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5.With arbor press (CY of Figure 42) or similar device,
press bearing out of pulley (CR).
Figure 42
CY
CR
NOTE:If a severely worn bearing breaks apart dur-
ing removal, pulley must be replaced.
Bearing Installation
1.Orient bearing anvil/sleeve removal tool (CX of
Figure 43), part number 25–09, with cavity facing up
and place pulley (CR) onto tool.
Figure 43
CX
CR
2.Install bearing insertion tool (CZ of Figure 44), part
number 25–10, into arbor press (CY) or similar
device.
Figure 44
CY
CZ
3.Place and hold bearing (CT of Figure 45), part
number 21–33, onto insertion tool (CZ) in position
over pulley (CR).
Figure 45
CT
CZ
CR
IMPORTANT: Bearing and pulley alignment is
critical.
4.Press bearing (CT of Figure 46) into pulley (CR)
until seated.
Figure 46
CT
CR
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Bearing Replacement for Drive Pulley
IMPORTANT: Once removed, do not re-use
bearings.
Bearing Removal
1.Position the drive pulley (DA of Figure 47) in a
standard bearing separator (DB) as shown.
Figure 47
DB
DC
DA
2.Using an arbor press or similar device, press-off the
bearing (DC).
Bearing Installation
Figure 48
DF
DE
DD
3.Place the shaft of the tool (part number 450282) (DG
of Figure 49) over pulley shaft (DH).
Figure 49
DG
DI
DH
4.Using an arbor press or similar device, press the
bearing (DI) onto pulley shaft as shown.
Bearing Replacement for Idler Pulleys
NOTE: Bearings can not be removed from idler pul-
leys. Replace entire pulley, when worn. See “Service
Parts”, page 20.
Pulley Replacement
End Pulleys
Reverse removal procedure “A”(see page 14).
Drive Pulley
Reverse removal procedure “B”(see page 15).
Idler Pulley
Reverse removal procedure “C”(see page 15).
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Notes

2100 Series Center Drive Conveyors Installation, Maintenance & Parts Manual
851-179 Rev. E 20 Dorner Mfg. Corp.
NOTE: For replacement parts other than those shown on this page, contact an authorized Dorner Service
Center or the factory.
51mm Wide Conveyor Assembly
1
2
3
4
5
9
8
10
11
12
13
14
16 18
19
17
32
17
18
19
19
19
15
15
14
6
7
Service Parts