Dorner 2100 Series User manual

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DORNER MFG. CORP. INSIDE THE USA OUTSIDE THE USA
P.O. Box 20 • 975 Cottonwood Ave. TEL: [phone] TEL: [phone]
Hartland, WI 53029-0020 USA FAX: [phone] FAX: [phone]
851-257 Rev. L
2100, 2200, 2300, 4100, 6200,
MPB Series Top Mount Drive
Package for Standard Load
90° Industrial Gearmotors
Installation, Maintenance & Parts Manual
Featuring: Technology

Dorner Mfg. Corp. 2 851-257 Rev. L
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Table of Contents
Introduction ......................................................................... 2
Warnings -General Safety ................................................. 3
Product Description ............................................................. 4
Specifications ...................................................................... 5
Gearmotor Mounting Package Models: .......................... 5
Table 1: Gearmotor Specifications ................................. 5
U.S. Version ................................................................. 5
CE Version ................................................................... 5
Table 2: RPM/Torque for Standard Load
Fixed Speed 90° Gearmotors ........................................... 6
U.S. Version (60 Hz Gearmotors)................................ 6
CE Version (50 Hz Gearmotors) .................................. 6
Table 3: RPM/Torque for Standard Load
Variable Speed 90° DC Gearmotors................................ 7
U.S. Version (60 Hz Gearmotors)................................ 7
CE Version (50 Hz Gearmotors) .................................. 7
Table 4: Belt Speeds for Brushless 90° Gearmotors........ 7
Table 5: Pulley Ratio / Timing Belt Number................... 8
Table 6: Conveyor Belt Speed Factor.............................. 8
Belt Speed Calculation: ................................................... 8
How to Calculate Belt Speed ....................................... 8
Installation ........................................................................... 9
Required Tools................................................................. 9
Mounting ......................................................................... 9
Preventive Maintenance and Adjustment .......................... 13
Required Tools ............................................................... 13
Timing Belt Tensioning ................................................. 13
Timing Belt Replacement .............................................. 13
Drive or Driven Pulley Replacement ............................. 14
Gear Reducer Replacement ............................................ 14
For eDrive style gearmotor ......................................... 15
For old style gearmotor prior to June 2011................. 16
Motor Replacement ........................................................ 17
Single Phase Motor..................................................... 17
Three Phase Motor...................................................... 17
DC Variable Speed Motor .......................................... 17
Brushless Motor.......................................................... 17
All Models .................................................................. 18
Notes .................................................................................. 19
Service Parts....................................................................... 20
2100, 2200, 2300, 4100, 6200 Series and MPB Series
Flat Belt Conveyors Top Mount Drive Package
for Standard Load 90° Industrial Gearmotors ................ 20
Pulley Ratio / Timing Belt Combinations ...................... 22
MPB Series Cleated Belt Conveyor Top Mount
Drive Package for Standard Load 90° Industrial
Gearmotors (Old Style Gearmotor Only)....................... 23
4100 Mounting Package ................................................. 24
U.S. Version Gearmotors .............................................. 25
CE Version Gearmotors ................................................. 25
Return Policy...................................................................... 26
Introduction
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 instruc-
tions for installation.
Dorner 2100 Series conveyors are covered by the following
patent numbers: 5,131,529, 5,174,435, and corresponding
patents and patent applications in other countries.
Dorner 4100 Series conveyors are covered by patent number
3,923,148, 5,131,529 and corresponding patents and patent
applications in other countries.
Dorner 2200, 6200 & MPB Series conveyors are covered by
patent number 5,174,435, 6,109,427, 6,298,981, 6,422,382,
6,685,009 and corresponding patents and patent applications
in other countries.
Dorner’s Limited Warranty applies.
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 .
IMPORTANT
Some illustrations may show guards
removed. Do NOT operate equipment without
guards.

851-257 Rev. L 3 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Warnings -General Safety
A
WARNING
The safety alert symbol, black triangle with
white exclamation, is used to alert you to
potential personal injury hazards.
DANGER
Climbing, sitting, walking or riding on
conveyor will cause severe injury. KEEP OFF
CONVEYORS.
DANGER
DO NOT OPERATE CONVEYORS IN AN
EXPLOSIVE ENVIRONMENT.
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
WARNING
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
WARNING
Exposed moving parts can cause severe
injury. REPLACE ALL GUARDS BEFORE
RUNNING CONVEYOR.
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.
WARNING
MPB Series Conveyors are not reversible.
Reversing creates pinch points which can
cause severe injury.
DO NOT REVERSE MPB SERIES
CONVEYORS.
A
A
A
A
A

Dorner Mfg. Corp. 4 851-257 Rev. L
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Product Description
Refer to Figure 1 for typical components.
Figure 1
Figure 1
Figure 2
Mount Packages with Old Style Gearmotors prior to
June 2011
Figure 2
Figure 3
Mount Package with e-Drive Gearmotors
Figure 3
1 Conveyor
2 Mounting Bracket
3 Gearmotor
4 Timing Belt Tensioner
5 Cover
6 Timing Belt
7 Drive Pulley
8DrivenPulley
5
4
8
7
6
1
2
3
NOTE
The 90° industrial gearhead changed
configuration in 2011. See below for
configuration details.

851-257 Rev. L 5 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Specifications
Gearmotor Mounting Package Models:
Example: * See Ordering and Specifications Catalog for details.
Table 1: Gearmotor Specifications
U.S. Version
* Controller Inputs
CE Version
Gearmotor Type:
Mount Style = Top Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
22 M T H S WW A 32 32
2 = 2100 Series Conveyor
22 = 2200 & 2300 Series Conveyor
4 = 4100 Series Conveyor
6 = 6200 Series Conveyor
2P = MPB Series Conveyor
Belt Type: = flat belt, A through J = cleated belt
Drive Pulley (see Table 2 & 3)
Driven Pulley (see Table 2 & 3)
Language Code
M = U.S. English
U = CE English
Output Shaft Type
°
E = 90 e-Drive
°
H = 90 Old-Style Gearmotors prior to June 2011
S = Standard Load
K = Indexing / VFD
B = Brushless DC
DC
B
A
Single Phase Three Phase DC Variable Speed Brushless DC
Output Power 0.25 hp (0.19 kw)
Input Voltage 115 Volts A.C. 208 to 230/460 Volts
A.C.
130 Volts D.C. *115/230 Volts D.C.
Input Frequency 60 Hz N/A 60 Hz
Input Current 5.0 Amperes 1.2 /0.6 Amperes 2.2 Amperes 8.8 / 3.4 Amperes
Motor RPM 1725 2500 3000
Gearmotor Ratios 5:1, 10:1, 20:1, 40:1, 60:1
Frame Size NEMA 42 CZ
Motor Type Totally Enclosed, Fan-cooled Totally Enclosed,
Non-ventilated
Single Phase Three Phase VFD Variable Speed
Output Power 0.18 kw
Input Voltage 230 Volts A.C. 230/400 Volts A.C. 230 Volts A.C.
Input Frequency 50 Hz 25 to 63 Hz
Input Current 1.6 Amperes 1.4 /0.8 Amperes 1.4 Amperes
Gearmotor Ratios 5:1, 10:1, 20:1, 40:1, 60:1
Protection Rating IP55
Frame Size IEC 63 B5

Dorner Mfg. Corp. 6 851-257 Rev. L
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Specifications
Table 2: RPM/Torque for Standard Load Fixed Speed 90° Gearmotors
U.S. Version (60 Hz Gearmotors)
(vp) = voltage and phase
11 = 115 V, 1-phase
23 = 208-230/460 V, 3-phase
(n) = Reversing Capability
N = No Reversing switch
R = With reversing switch
* = Nosebar transfers operate at maximum 77 Ft/min (23.5 M/min) belt speed
CE Version (50 Hz Gearmotors)
(vp) = voltage and phase
21 = 230 V, 1-phase
23 = 230 V, 3-phase
43 = 400 V, 3-phase
Gearmotors
Part Number RPM In-lb N-m
32M060EL4(vp)F(n) 29 226 25.5
32M040EL4(vp)F(n) 43 237 26.8
32M020EL4(vp)F(n) 86 142 16.0
32M010EL4(vp)F(n) 173 78 8.8
32M005EL4(vp)F(n) 345 41 4.6
Gearmotors
Part Number RPM N-m
62Z060ES4(vp)FN 23 26.4
62Z040ES4(vp)FN 35 28.9
62Z020ES4(vp)FN 70 19.4
62Z010ES4(vp)FN 140 10.7
62Z005ES4(vp)FN 280 5.6

851-257 Rev. L 7 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Specifications
Table 3: RPM/Torque for Standard Load Variable Speed 90° DC Gearmotors
U.S. Version (60 Hz Gearmotors)
* = Nosebar transfers operate at maximum 77 Ft/min (23.5 M/min) belt speed
CE Version (50 Hz Gearmotors)
Table 4: Belt Speeds for Brushless 90° Gearmotors
Gearmotors
Part Number RPM In-lb N-m
32M060ELD3DEN 5-42 198 22.4
32M040ELD3DEN 8-63 163 18.4
32M020ELD3DEN 15-125 98 11.1
32M010ELD3DEN 30-250 54 6.1
32M005ELD3DEN 60-500 28 3.2
Gearmotors
Part Number RPM N-m
62Z060ES423EN 9-23 26.4
62Z040ES423EN 14-35 28.9
62Z020ES423EN 28-70 19.4
62Z010ES423EN 56-140 10.7
62Z005ES423EN 111-280 5.6
Gearmotors
Part Number RPM In-lb N-m
62M060ESBDDEN 2-50 106 12.4
62M040ESBDDEN 3-75 123 14.3
62M020ESBDDEN 5-150 89 10.4
62M010ESBDDEN 10-300 49 5.7
62M005ESBDDEN 20-600 25 2.9
NOTE
For belt speed other than those listed, contact
factory for details.

Dorner Mfg. Corp. 8 851-257 Rev. L
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Specifications
Table 5: Pulley Ratio / Timing Belt Number
Figure 4
Figure 4
Table 6: Conveyor Belt Speed Factor
Belt Speed Calculation:
How to Calculate Belt Speed
1. Determine gearmotor RPM from tables 2-4.
2. Determine the pulley kit ratio. Count the number of teeth on the drive and driven pulleys following figure 2. Using table 5,
look up pulley ratio based on pulley combinations.
3. Determine conveyor speed factor using table 6. Based on your conveyor type, select the appropriate factor.
4. Calculate belt speed:
Example: Belt Speed = Gearmotor RPM (tables 2-4) x Pulley Kit Ratio (table 5) x Conveyor Speed Factor (table 6)
2200 Series standard load variable speed 60:1 gearmotor with 22 tooth sprocket on gearmotor (Drive) and 32 tooth sprocket on
the conveyor output shaft (Driven).
Motor
(Drive)
Pulley
Teeth
Conveyor
(Driven)
Pulley
Teeth
Pulley
Ratio
Timing Belt
2200/
MB/MPB 4100/6200
22 28 0.79 N/A 814-104
22 32 0.69 814-105 814-105
28 22 1.27 N/A N/A
28 28 1.00 814-105 N/A
28 32 0.88 814-065 N/A
32 19 1.68 N/A 814-104
32 22 1.45 814-105 814-105
32 28 1.14 814-065 N/A
32 32 1.00 N/A 814-112
44 19 2.32 N/A N/A
44 22 2.00 814-101 814-112
44 28 1.57 814-101 814-108
44 32 1.38 814-108 814-064
48 19 2.53 N/A 814-112
48 22 2.18 814-101 814-112
48 28 1.71 814-108 814-064
48 32 1.50 814-064 814-064
60 19 3.16 N/A 814-064
60 22 2.73 814-064 814-064
60 28 2.14 814-099 814-099
60 32 1.88 814-099 814-099
Drive Pulley
Driven Pulley
Series Ft/revolution M/revolution
2200 / 2300 0.350 0.107
2100 / 4100 / 6100 / 6200 0.278 0.085
2200 MPB 0.590 0.180
2200 Precision Move 0.394 0.120
2200 / 2300 Modular Belt 0.394 0.120
Gearmotor = 32M060ELD3DEN = 5 - 42 RPM
Pulley Kit = 22 t mtr. - 32 t conv. = 0.69
Speed Factor = 2200 Series = 0.350 ft/min per RPM
Minimum Belt Speed = 5 x 0.69 x 0.350 = 1.2 Ft/min
Maximum Belt Speed = 42 x 0.69 x 0.350 = 10.1 Ft/min

851-257 Rev. L 9 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Installation
Required Tools
• Hex key wrenches:
2 mm, 2.5 mm, 3 mm, 5 mm
• Straight edge
• Torque wrench
Mounting
Figure 5
Flat Belt Conveyor
Figure 5
Figure 6
Cleated Belt Conveyor
Figure 6
Figure 7
MPB Series Conveyor
Figure 7
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
WARNING
MPB Series Conveyors are not reversible.
Reversing creates pinch points which can
cause severe injury.
DO NOT REVERSE MPB SERIES
CONVEYORS.
WARNING
Gearmotors must be mounted as shown in
Figure 5, Figure 6 and Figure 7.
Failure to do so creates pinch points which
can cause severe injury.
NOTE
Gearmotor position on Flat Belt conveyors
shown in Figure 5. Gearmotor position on
Cleated Belt Figure 6 and MPB Series
conveyors shown in Figure 7.
A
A
A

Dorner Mfg. Corp. 10 851-257 Rev. L
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Installation
Installation Component List:
1. Typical gearmotor components (Figure 8)
Figure 8
Figure 8
2. For your reference, the following figures show
gearmotor mounting configurations for various
conveyor series.
• For 2100, 2200, and MPB models, gearmotor and drive
plate are mounted to head plate (Figure 9, item 1), (Fig-
ure 10, item 1), and (Figure 11, item 1).
Figure 9
2100 Series
Figure 9
Figure 10
MPB Series
Figure 10
Figure 11
2200 Series
Figure 11
• For 6200 series models, gearmotor is mounted to drive
spacer (Figure 12, item 1).
Figure 12
6200 Series
Figure 12
• For 4100 series models, gearmotor is mounted to drive
adapter plate (Figure 13, item 1).
Figure 13
4100 Series
Figure 13
1 Top Mount Assembly
2DrivePulley
3Cover
4 M4 Socket Head Screws (4x)
5 Driven Pulley
6Key
7 M6 Socket Head Screws (2x)
8 Timing Belt
NOTE
Flat belt mounting package shown above
(Figure 8), cleated belt mounting package
similar.
4
1
1
3
8
7
2
5
6

851-257 Rev. L 11 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Installation
Figure 14
Figure 14
3. If required, change gearmotor position by removing four
(4) screws (Figure 15, item 1). Rotate gearmotor to
other position and replace screws (Figure 15, item 1).
Tighten to 103 in-lb (12 N-m).
Figure 15
Figure 15
4. Locate drive output shaft (Figure 16, item 1) and
remove two (2) screws (Figure 16, item 2).
Figure 16
Figure 16
5. Install M6x8 socket head screw (Figure 17, item 1) and
washer.
Figure 17
Figure 17
6. Attach mount assembly (Figure 18, item 1) with screws
(Figure 18, item 2). Tighten to 80 in-lb (9 N-m).
Figure 18
Figure 18
NOTE
Gearmotor may be operated in positions 1, 2
or 3 (Figure 14). Dependent on conveyor belt
speed and gearmotor type, position 2 may
require a vibration dampening bracket. Order
7018WW for 2200 and MPB conveyors or
7019WW for 2100 and 6200 conveyors. (WW
= conveyor width). 4100 conveyors do not
require brackets.
NOTE
6200 conveyor shown, 2100, 2200, 4100 &
MPB similar.
1
2
3
1
1
2
1
1
31
2

Dorner Mfg. Corp. 12 851-257 Rev. L
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Installation
7. Install key (Figure 19, item 1).
Figure 19
Figure 19
8. Wrap timing belt (Figure 19, item 2) around driven
pulley (Figure 19, item 3) and drive pulley (Figure
19, item 4). Install driven pulley (Figure 19, item 3)
onto conveyor shaft.
9. Remove cam bearing and spacer (Figure 18, item 3).
Place the cam bearing and spacer (Figure 18, item 3)
next to the driven pulley (Figure 20, item 1). Ensure the
flanges of the driven pulley are aligned with the cam
bearing. Tighten driven pulley set screws (Figure
20, item 2). This will allow for proper belt alignment
while conveyor is in use. Replace cam bearing and
spacer (Figure 20, item 3).
Figure 20
Figure 20
10. Depending on conveyor belt travel (direction 1 or 2 on
Figure 21), locate timing belt tensioner (Figure
21, item 3) as shown. Tension timing belt to obtain
0.125¨ (3 mm) deflection for 1.0 lb (456 grams) of force
at timing belt mid-point (Figure 21, item 4). Tighten
tensioner screw to 103 in-lb (12 N-m).
Figure 21
Figure 21
11. Install cover (Figure 22, item 1) with four (4) screws
(Figure 22, item 2). Tighten to 35 in-lb (4 N-m).
Figure 22
Figure 22
WARNING
Drive shaft keyway may be sharp.
HANDLE WITH CARE.
3
2
4
1
1
3
2
1
2
3
44
22
1
A

851-257 Rev. L 13 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Preventive Maintenance and Adjustment
Required Tools
• Hex key wrenches:
2 mm, 2.5 mm, 3 mm & 5 mm
• Adjustable wrench (for hexagon head screws)
• Straight edge
• Torque wrench
Timing Belt Tensioning
1. Remove four (4) screws (Figure 22, item 2) and
remove cover (Figure 22, item 1).
2. Loosen tensioner (Figure 23, item 1).
Figure 23
Figure 23
3. Depending on conveyor belt travel (direction 1 or 2 on
Figure 21), locate timing belt tensioner (Figure
21, item 3) as shown. Tension timing belt to obtain
0.125¨ (3 mm) deflection for 1.0 lb (456 grams) of force
at timing belt mid-point (Figure 21, item 4). Tighten
tensioner screw to 103 in-lb (12 Nm).
4. Install cover (Figure 22, item 1) with four (4) screws
(Figure 22, item 2). Tighten to 35 in-lb (4 Nm).
Timing Belt Replacement
1. Remove four (4) screws (Figure 22, item 2) and
remove cover (Figure 22, item 1).
2. Loosen tensioner (Figure 23, item 1).
3. Remove timing belt (Figure 24, item 1).
Figure 24
Figure 24
4. Install new timing belt.
5. Depending on conveyor belt travel (direction 1 or 2 on
Figure 21), locate timing belt tensioner (Figure
21, item 3) as shown. Tension timing belt to obtain
0.125¨ (3 mm) deflection for 1.0 lb (456 grams) of force
at timing belt mid-point (Figure 21, item 4). Tighten
tensioner screw to 103 in-lb (12 N-m).
6. Install cover (Figure 22, item 1) with four (4) screws
(Figure 22, item 1). Tighten to 35 in-lb (4 Nm).
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
1
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
NOTE
If timing belt does not slide over pulley flange,
loosen driven pulley set screws (Figure
24, item 2) and remove pulley with belt
((Figure 24, item 1). For re-installation, see
steps 7 and 8 on page 12.
1
2
A
A

Dorner Mfg. Corp. 14 851-257 Rev. L
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Preventive Maintenance and Adjustment
Drive or Driven Pulley Replacement
1. Complete steps 1 through 3 of “Timing Belt
Replacement” section on page 13.
2. Loosen set screws and remove drive or driven pulley.
3. Complete steps 7 through 10 of “Installation” section on
page 12.
Gear Reducer Replacement
Figure 25
Old Style Gearmotor prior to June 2011
Figure 25
Figure 26
e-Drive Gearmotor
Figure 26
1. Remove four (4) screws (Figure 22, item 2) and
remove cover (Figure 22, item 1).
2. Loosen tensioner (Figure 23, item 1).
3. Loosen drive pulley set screws on drive pulley (Figure
27, item 1). Remove drive pulley and timing belt
(Figure 27, item 2).
Figure 27
Figure 27
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
NOTE
If drive pulley (Figure 27, item 1) is replaced,
wrap timing belt around drive pulley and
complete step 3.
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
NOTE
The 90° industrial gearhead changed
configuration in 2011. See below for
configuration details. See Service Parts
section to ensure proper replacement parts
are installed.
1
2
A
A

851-257 Rev. L 15 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Preventive Maintenance and Adjustment
4. Remove four (4) gear reducer mounting screws (Figure
28, item 1). Remove gearmotor.
Figure 28
Figure 28
5. Remove four screws (Figure 29, item 1). Detach motor
(Figure 29, item 2) from gear reducer (Figure
29, item 3). Retain motor output shaft key (Figure
29, item 4).
Figure 29
Figure 29
6. Remove two (2) screws (Figure 29, item 5) and detach
output shaft cover (Figure 29, item 6).
For eDrive style gearmotor
1. Hold the driveshaft with a wrench (Figure 30, item 1)
as shown to keep shaft from turning, while removing
screw (Figure 30, item 2) with hex wrench (Figure
30, item 3).
Figure 30
Figure 30
2. Remove driveshaft (Figure 31, item 1) and key (Figure
31, item 2).
Figure 31
Figure 31
3. Replace gear reducer (Figure 31, item 3).
4. Apply anti-seize (Figure 32, item 1) to shaft.
1
1
4
23
65
1
32
1
2
3

Dorner Mfg. Corp. 16 851-257 Rev. L
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Preventive Maintenance and Adjustment
Figure 32
Figure 32
5. Replace the original shaft components into new gear
reducer (Figure 31).
6. Hold the driveshaft with a wrench (Figure 30, item 1)
as shown to keep shaft from turning, while installing
screw with hex wrench (Figure 30, item 3). Tighten
screw to 100 in-lb (11.5 Nm) for 42CZ or 350 in-lb
(39.5 Nm) for 56C, 63B5 and 71B5.
7. Apply anti-seize to motor shaft before assembling to
gearbox. With key (Figure 29, item 4) in keyway, slide
motor (Figure 29, item 2) and gear reducer (Figure
29, item 3) together. Install screws (Figure 29, item 1)
and tighten.
8. Install output shaft cover (Figure 29, item 6) and secure
with two (2) screws (Figure 29, item 5).
9. Reverse steps 1 through 4 beginning on page 16.
10. Install gearmotor to mounting bracket and tighten
screws (Figure 28, item 1) to 103 in-lb (12 Nm).
11. Complete installation steps 7 through 10 of
“Installation” section on pages 14.
For old style gearmotor prior to June 2011
1. Loosen six (6) set screws (Figure 33, item 1). Remove
drive shaft (Figure 33, item 2) and key (Figure
33, item 3).
Figure 33
Figure 33
2. Apply anti-seize (Figure 34, item 1) to shaft.
Figure 34
Figure 34
3. Replace the original shaft components into new gear
reducer (Figure 33).
4. Apply anti-seize to motor shaft before assembling to
gearbox. With key (Figure 29, item 4) in keyway, slide
motor (Figure 29, item 2) and gear reducer (Figure
29, item 3) together. Install screws (Figure 29, item 1)
and tighten.
5. Install output shaft cover (Figure 29, item 6) and secure
with two (2) screws (Figure 29, item 5).
6. Reverse steps 1 through 4 beginning on page 16.
7. Complete installation steps 7 through 10 of
“Installation” section on pages 14.
IMPORTANT
Be extremely careful when coupling motor to
gear reducer. Avoid misalignment and forcing
the connection causing possible permanent
gear reducer seal damage.
NOTE
Gearmotor position on Flat Belt conveyors
shown in Figure 5. Gearmotor position on
Cleated Belt and MPB Series conveyors
shown in Figure 6 and Figure 7
on page 11
1
IMPORTANT
Be extremely careful when coupling motor to
gear reducer. Avoid misalignment and forcing
the connection causing possible permanent
gear reducer seal damage.
2
3
1
1

851-257 Rev. L 17 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Preventive Maintenance and Adjustment
Motor Replacement
Single Phase Motor
1. For single phase motor, unplug power cord from outlet.
Three Phase Motor
1. Loosen terminal box screws (Figure 35, item 1) and
remove cover (Figure 35, item 2).
Figure 35
Figure 35
2. Record wire colors connecting to wires 1, 2 and 3.
Loosen wire nuts and remove wires 1, 2 and 3.
3. Loosen cord grip and remove cord.
DC Variable Speed Motor
1. For DC variable speed motor, unplug motor cord at
disconnect (Figure 36, item 1).
Figure 36
Figure 36
Brushless Motor
1. Twist covers (Figure 37, item 1) apart.
Figure 37
Figure 37
2. Remove outer cord cover (Figure 38, item 1) from
inner cord cover (Figure 38, item 2).
Figure 38
Figure 38
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
DANGER
Hazardous voltage will cause severe injury or
death. LOCKOUT POWER BEFORE before
wiring.
1
2
1
1
2
1
A

Dorner Mfg. Corp. 18 851-257 Rev. L
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Preventive Maintenance and Adjustment
3. Open inner cord cover (Figure 39, item 1).
Figure 39
Figure 39
4. Unplug motor cord connectors (Figure 40, item 1) and
signal cable connectors (Figure 40, item 2).
Figure 40
Figure 40
All Models
1. Remove four screws (Figure 41, item 1). Detach motor
(Figure 41, item 2) from gear reducer (Figure
41, item 3). Retain motor output shaft key (Figure
41, item 4).
Figure 41
Figure 41
2. Apply anti-seize to motor shaft before assembling to
gearbox. With key (Figure 42, item 1) in keyway, slide
motor and gear reducer together. Install screws (Figure
42, item 2) and tighten.
Figure 42
Figure 42
3. Replace wiring:
• For a single phase motor, reverse step 1 in “Single Phase
Motor” on page 17.
• For a three phase motor, reverse steps 1-3, in “Three Phase
Motor” on page 17.
• For a DC variable speed motor, reverse step 1 on “DC
Variable Speed Motor” on page 17.
• For a brushless motor, reverse steps 1-2 on “Brushless
Motor” on page 17.
1
2
1
IMPORTANT
Be extremely careful when coupling motor to
gear reducer. Avoid misalignment and forcing
the connection causing possible permanent
gear reducer seal damage.
21
43
1
2

851-257 Rev. L 19 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Notes

Dorner Mfg. Corp. 20 851-257 Rev. L
2100, 2200, 2300, 4100, 6200, MPB Series Top Mount Drive Package for Standard Load 90° Industrial Gearmotors
Service Parts
2100, 2200, 2300, 4100, 6200 Series and MPB Series Flat Belt Conveyors Top
Mount Drive Package for Standard Load 90° Industrial Gearmotors
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.
19
17
18
21 25
27
11
12
30
28
23
2
20 6
10
7
16
13
1
15
14
22
8
4
24
23
24
26
29
5
22
39
Standard Load (42CZ) Shown
31
32