Dorner 2200 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]
851-686 Rev. A
2200 Series
iDrive Conveyors
Installation, Maintenance & Parts Manual

Dorner Mfg. Corp. 2 851-686 Rev. A
2200 Series iDrive Conveyors
Table of Contents
Introduction ......................................................................... 2
Warnings −General Safety ................................................. 3
Product Description............................................................. 4
Specifications ...................................................................... 4
Models ............................................................................. 4
Conveyor Supports: ......................................................... 4
Maximum Distances..................................................... 4
Specifications................................................................... 5
Motor Specifications........................................................ 5
iDrive Load Capacity....................................................... 5
Installation........................................................................... 7
Required Tools................................................................. 7
Recommended Installation Sequence.............................. 7
Mounting Brackets........................................................... 8
Return Rollers.................................................................. 9
Cleated Belt and 3 - 6¨ (70 - 152 mm)
Wide Flat Belt Conveyors............................................ 9
8 - 18¨ (203 - 457 mm) Wide Flat Belt Conveyors...... 9
Wiring.............................................................................. 9
Customer Wired Control........................................... 9
Preventive Maintenance and Adjustment.......................... 10
Required Tools............................................................... 10
Standard Tools............................................................ 10
Special Tools.............................................................. 10
Checklist ........................................................................ 10
Lubrication..................................................................... 10
Maintaining Conveyor Belt ........................................... 10
Troubleshooting ......................................................... 10
Cleaning ..................................................................... 10
Conveyor Belt Replacement.......................................... 10
Conveyor Belt Replacement Sequence ...................... 10
Belt Removal.............................................................. 10
Belt Installation .......................................................... 11
Conveyor Belt Tensioning............................................. 12
Conveyors with 1.25” (32 mm) Diameter Pulleys ..... 12
Conveyors with Nose Bar Idlers ................................ 12
Conveyor Belt Tracking................................................. 13
V-Guided Belts........................................................... 13
Non V-Guided Belts................................................... 13
Spindle Removal............................................................ 14
A −Idler Spindle Removal......................................... 14
B −Drive Spindle Removal........................................ 14
Bearing Removal & Replacement.................................. 16
Removal...................................................................... 16
Replacement................................................................ 16
Spindle Installation......................................................... 17
Idler Spindle Installation............................................. 17
Drive Spindle Installation........................................... 17
Nose Bar Roller Replacement........................................ 19
Motor Removal and Replacement.................................. 19
Circuit Board Removal and Replacement...................... 21
Service Parts....................................................................... 22
Drive End ....................................................................... 22
Idler End......................................................................... 24
Nose Bar Idler End......................................................... 25
3” (76 mm) to 6” (152 mm) Frame Assembly ............... 26
8” (203 mm) to 18” (457 mm) Wide Frame Assembly.. 27
−04 3” (76 mm) Aluminum Side.................................... 28
−05 1.5” (38 mm) Aluminum Side................................. 29
−07 Low to Side Wiper .................................................. 30
−09 Low to High Side .................................................... 31
−10.5” (13 mm) Extruded Plastic................................... 32
−13 Adjustable Guiding ................................................. 33
−14 Tool-Less Adjustable Guiding................................ 34
0.5” (13 mm) Cleated Belt Guiding ............................... 35
1” (25 mm) Cleated Belt Guiding .................................. 36
2” (51 mm) Cleated Belt Guiding .................................. 37
Flared Side Guiding........................................................ 38
Flat Belt Stand Mount Assembly ................................... 39
Cleated Belt Stand Mount Assembly ............................. 39
Flat Belt Stand Mount Assembly
for 2’ (610 mm) Conveyors............................................ 40
Cleated Belt Stand Mount Assembly
for 2’ (610 mm) Conveyors............................................ 40
3” (70 mm) to 6” (152 mm) Flat Belt Return Roller...... 41
8” (203 mm) to 18” (457 mm) Flat Belt Return Roller.. 41
Cleated Belt Return Roller ............................................. 42
Conveyor Belt Part Number Configuration.................... 42
Notes .................................................................................. 43
Return Policy...................................................................... 44
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’s Limited Warranty applies.
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 .
Dorner 2200 series conveyors are covered by Patent
Numbers 5,174,435, 6,298,981, 6,422,382 and
corresponding patents and patent applications in other
countries.
Dorner reserves the right to make changes at any time
without notice or obligation.
IMPORTANT
Some illustrations may show guards
removed. DO NOT operate equipment
without guards.

851-686 Rev. A 3 Dorner Mfg. Corp.
2200 Series iDrive Conveyors
Warnings −General Safety
A
DANGER
SEVERE HAZARD!
KEEP OFF CONVEYORS. Climbing, sitting,
walking or riding on conveyor will result in
death or serious injury.
A
DANGER
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.
A
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.
A
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.
A
WARNING
SEVERE HAZARD!
LOCK OUT POWER before removing guards or
performing maintenance. Exposed moving
parts can cause serious injury.
A
WARNING
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.
A
WARNING
PUNCTURE HAZARD!
Handle drive shaft keyway with care. It may be
sharp and could puncture the skin, causing
serious injury.
A
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.

Dorner Mfg. Corp. 4 851-686 Rev. A
2200 Series iDrive Conveyors
Product Description
Refer to Figure 1 for typical components. Figure 1
Figure 1
Specifications
Models
* See Ordering and Specifications Catalog for details.
Conveyor Supports:
Maximum Distances
1 = 18” (457 mm)
2 = 18” (457 mm)
Figure 2
Figure 2
1Conveyor
2 Support Stand
3DriveEnd
4 Idler/Tension End
4
2
3
1
Flat Belt 2200 Series Conveyor
1 = with belt tracking cams and mounting brackets
2 = with V-guide tracking and mounting brackets
4 = with V guide tracking and no mounting brackets
5 = with belt tracking cams and no mounting brackets
Conveyor Width Reference
Conveyor Length Reference
Belt Type*
Output Shaft Position*
Conveyor Profile*
Document Language, M = English
2 1 0 M WW LLLL A PP BB
Pulley Type:
0 = Standard 1.25” (32mm) Dia .
1 = Gang Drive 1” (25mm) Dia.
FDMPH
In frame
iDrive Type
-
Cleated Belt 2200 Series Conveyor
Conveyor Width Reference
Conveyor Length Reference
2 4 C M WW LLLL A SSSS
Output Shaft Position*
Cleat Spacing*
0 = with V-guide tracking and no mounting brackets
4 = with V-guide tracking and mounting brackets
5 = with belt tracking cams and mounting brackets
9 = with belt tracking cams and no mounting brackets
Document Language, M = English
Cleat Type*
FDMPH
In frame
iDrive Type
-
12

851-686 Rev. A 5 Dorner Mfg. Corp.
2200 Series iDrive Conveyors
Specifications
Specifications
* See Ordering and Specifications Catalog for details.
Motor Specifications
iDrive Load Capacity
Conveyor Width
Reference (WW)
03 04 05 06 08 10 12 18
Conveyor Belt Width 2.75¨
(70mm)
3.75¨
(95mm)
5¨
(127mm)
6¨
(152mm)
8¨
(203mm)
10¨
(254mm)
12¨
(305mm)
18¨
(457mm)
Maximum Conveyor
Load
See Load Capacity Chart
Belt Travel 4.0¨ (88 mm) per revolution of spindle
Maximum Belt Speed* 100 ft/minute (30.5 m/minute)
Belt Takeup 0.38¨ (10 mm) of stroke = 0.75¨ (19 mm) of belt take-up
Conveyor Length
Reference (LLLL)
0200 - 1200 in 0001 increments
Conveyor Length 2 ft (610 mm) to 12 ft (3658 mm) in 0.12” (0.31 mm) increments
NOTE
Maximum conveyor loads based on:
• Non-accumulating product
• Product moving towards gearmotor
• Conveyor being mounted horizontal
Output Power 50 watt
Motor Voltage 24 volt DC, 5 amp
Transformer Voltage 100-240 VAC, 50/60 Hz
Gearmotor Ratio 23:1
Motor Type Brushless DC
Belt Speeds 7-70 Ft./Min., Low Speed, 10-100 Ft./Min. High Speed
WIDTH
LOW SPEED (07 - 70 FPM) FOR 09 BELT TYPE
LENGTH
23456789101112
33 30303030303030292929
44 28282828282828272727
55 28282828282828272727
66 27272727272727262626
88 26262626252525252424
10 10 23 23 23 22 22 22 21 21 21 20
12 12 21 21 20 20 20 19 19 18 18 18
18 18 16 15 15 14 13 13 12 12 11 11
WIDTH
HIGH SPEED (10 - 100 FPM) FOR 09 BELT TYPE
LENGTH
23456789101112
317 17 17 17 17 17 17 16 16 16 16
415 15 15 15 15 15 15 15 14 14 14
515 15 15 15 14 14 14 14 14 14 13
614 14 14 14 14 14 13 13 13 13 13
813 13 13 13 12 12 12 12 11 11 11
10 10101099988877

Dorner Mfg. Corp. 6 851-686 Rev. A
2200 Series iDrive Conveyors
Specifications
*Load capacity reduced by 50% when used with Nose Bar tail.
WIDTH
LOW SPEED (07 - 70 FPM) FOR DOUBLE CARCASS (TYPE 05) BELTS
LENGTH
23456789101112
326 26 26 26 26 26 26 25 25 25 25
424 24 24 24 24 24 24 24 23 23 23
524 24 24 23 23 23 23 23 23 23 23
623 23 23 23 23 23 22 22 22 22 22
822 22 22 22 21 21 21 21 21 21 20
10 19 19 19 18 18 18 18 18 17 17 17
12 17 17 16 16 16 16 15 15 15 15 14
18 11111110101099888
WIDTH
HIGH SPEED (10 - 100 FPM) FOR DOUBLE CARCASS (TYPE 05) BELTS
LENGTH
23456789101112
313 13 13 13 13 13 13 12 12 12 12
411 11 11 11 11 11 11 11 10 10 10
511 11 11 10 10 10 10 10 10 10 10
6101010101010109999
899999888888
10 66655555444
WIDTH
*LOW SPEED (07 - 70 FPM) FOR SINGLE PLY (TYPE 19 AND 53) BELTS
LENGTH
23456789101112
336 36 36 36 36 36 36 36 36 36 36
434 34 34 34 34 34 34 34 34 34 34
534 34 34 34 34 34 34 34 34 34 34
634 33 33 33 33 33 33 33 33 33 33
832 32 32 32 32 32 32 32 32 32 32
10 29 29 29 29 29 29 29 28 28 28 28
12 27 27 27 27 27 26 26 26 26 26 26
18 22 22 21 21 21 21 21 20 20 20 20
WIDTH
HIGH SPEED (10 - 100 FPM) FOR SINGLE PLY (TYPE 19 AND 53) BELTS
LENGTH
23456789101112
323 23 23 23 23 23 23 23 23 23 23
421 21 21 21 21 21 21 21 21 21 21
521 21 21 21 21 21 21 21 21 21 21
620 20 20 20 20 20 20 20 20 20 20
819 19 19 19 19 19 19 19 19 19 19
10 16 16 16 16 16 16 16 16 15 15 15
WIDTH
LOW SPEED (07 - 70 FPM) FOR ALL OTHER BELTS
LENGTH
23456789101112
323 23 23 23 23 22 22 22 22 22 22
421 21 21 21 21 21 20 20 20 20 20
521 21 20 20 20 20 20 20 20 19 19
620 20 20 20 19 19 19 19 19 19 18
819 19 19 18 18 18 18 18 17 17 17
10 16 16 15 15 15 14 14 14 14 13 13
12 14 13 13 13 12 12 12 11 11 11 10
18 88776655443

851-686 Rev. A 7 Dorner Mfg. Corp.
2200 Series iDrive Conveyors
Installation
Figure 3
Figure 3
Installation Component List
Required Tools
• Hex-key wrenches:
4 mm, 5 mm
• Level
• Torque wrench
Recommended Installation
Sequence
• Attach mounting brackets to conveyor
• Attach conveyor to stands
• Install return rollers on conveyor (optional)
• Attach guides/accessories (see page 22 through page 42 of
“Service Parts” section for details)
• Remove and discard shipping brackets (Figure 4, item 1).
Figure 4
Figure 4
NOTE
Conveyor MUST be mounted straight, flat and
level within confines of conveyor. Use a level
(Figure 3, item 1) for setup.
Conveyor frame (two sections if longer than 12ft)
Conveyor brackets (4x)
Return rollers (for longer conveyors)
1
1

Dorner Mfg. Corp. 8 851-686 Rev. A
2200 Series iDrive Conveyors
Installation
Mounting Brackets
1. Locate brackets. Exploded views shown in Figure 5 and
Figure 6.
Figure 5
Figure 5
Figure 6
Figure 6
2. Remove screws (Figure 5, item 1 and 2) and (Figure
6, item 1 and 2) washers (Item 3), nuts (Item 4) and T-
bars (Item 5) from brackets.
3. Insert T-bars (Figure 5, item 5) and (Figure 6, item 5)
into conveyor side slots (Figure 7, item 1). Fasten
brackets (Figure 7, item 2) to conveyor with mounting
screws (Figure 7, item 3).
Figure 7
Figure 7
4. Fasten brackets to support stand with mounting screws,
washers, and nuts (Figure 7, item 4).
5. Tighten screws (Figure 7, item 3), and mounting
screws on nuts (Figure 7, item 4) to 60 in-lb (7 Nm).
1
5
4
3
2
1
5
4
3
2
NOTE
Mounting brackets for flat belt conveyors
shown.
13
2
4

851-686 Rev. A 9 Dorner Mfg. Corp.
2200 Series iDrive Conveyors
Installation
Return Rollers
Cleated Belt and 3 - 6¨ (70 - 152 mm) Wide
Flat Belt Conveyors
1. Locate return rollers. Exploded views shown in Figure 8
and Figure 9.
Figure 8
Figure 8
Figure 9
Figure 9
2. Remove screws (Figure 8, item 1) and (Figure
9, item 1) and clips (Item 2) from roller assembly.
3. Install roller assemblies (Figure 10, item 1) as shown.
Tighten screws (Figure 10, item 2) to 60 in-lb (7 Nm).
Figure 10
Figure 10
8 - 18¨ (203 - 457 mm) Wide Flat Belt
Conveyors
1. Locate return rollers. Exploded view shown in Figure
11.
Figure 11
Figure 11
2. Remove screws (Figure 11, item 1) and clips (Figure
11, item 2) from roller assembly.
3. Install roller assembly as shown (Figure 12, item 1).
Tighten screws (Figure 12, item 1) to 60 in-lb (7 Nm).
Figure 12
Figure 12
Wiring
Customer Wired Control
Wiring Designations (Figure 13)
Figure 13
Figure 13
Refer to Maxon Motor Operating Instructions manual
343253 for wiring details.
12
21
12
2
1
2
1
1
12
2
1
2
1
-
+
1
2
3
4
5
6
7
8
BLACK
CK
WHITE
WHITE
BLUE
BLUE
GREEN
GREEN
YELLO
YELLO
W
ORANGE
ORANGE
BR
BR
OWN
WN
RED
RED
FWD
FWD
REV
+5VDC
GND
BRAKE
24VDC, FILTERED
REGULATED PWR
TED PWR
24VDC
24VDC
POT
ENA
DIR
REF
SPEED
PRE-WIRED
PRE-WIRED
J1
PRE-WIRED
PRE-WIRED
CUSTOMER-WIRED CONTROL
CONTROLLER BOARD
BY CUST.
BY CUST.

Dorner Mfg. Corp. 10 851-686 Rev. A
2200 Series iDrive Conveyors
Preventive Maintenance and Adjustment
Required Tools
Standard Tools
• Hex-key wrenches:
2.5 mm, 4 mm, 5 mm, 5/64 in.
• Arbor press
• T20 Torque Wrench
Special Tools
• 807−1078 Bearing Puller Tool (or equivalent)
• 450292 Bearing Installation Tool
• 456070 Bearing Removal Tool
Checklist
• Keep service parts on hand (see “Service Parts” section for
recommendations)
• Keep supply of belt cleaner (part # 625619)
• Clean entire conveyor and knurled spindle while disas-
sembled
• Replace worn or damaged parts
Lubrication
No lubrication is required. Replace bearings if worn.
Maintaining Conveyor Belt
Troubleshooting
Inspect conveyor belt for:
• Surface cuts or wear
• Stalling or slipping
• Damage to V-guide
Surface cuts and wear indicate:
• Sharp or heavy parts impacting belt
• Jammed parts
• Improperly installed bottom wipers (if installed)
• Accumulated dirt in wipers (if installed)
• Foreign material inside the conveyor
• Improperly positioned accessories
• Bolt-on guiding is pinching belt
Stalling or slipping indicates:
• Excessive load on belt
• Conveyor belt or drive timing belt are not properly ten-
sioned
• Worn knurl or impacted dirt on drive spindle
• Intermittent jamming or drive train problems
Damage to V-guide indicates:
• Twisted or damaged conveyor frame
• Dirt impacted on spindles
• Excessive or improper side loading
Cleaning
Use Dorner Belt Cleaner (part # 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
Conveyor Belt Replacement Sequence
• Remove old conveyor belt
• Install new conveyor belt
• Tension conveyor belt
Belt Removal
1. Place temporary support stands (Figure 14, item 1) at
both ends of the conveyor.
Figure 14
Figure 14
2. Remove mounting brackets (Figure 14, item 2) from
one side of conveyor. (Reverse steps 3 & 4 of
“Mounting Brackets” section beginning on page 8.).
NOTE
Visit www.dorner.com for complete list of
troubleshooting solutions.
IMPORTANT
Do not use belt cleaners that contain alcohol,
acetone, Methyl Ethyl Ketone (MEK) or other
harsh chemicals.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
12

851-686 Rev. A 11 Dorner Mfg. Corp.
2200 Series iDrive Conveyors
Preventive Maintenance and Adjustment
3. If equipped, remove bottom wipers (Figure 15, item 1):
Remove fastening screws (Figure 15, item 2) then
remove wiper (Figure 15, item 1).
Figure 15
Figure 15
4. On tension end of the conveyor, identified with
a label (Figure 16, item 1), push in head plate
assembly (Figure 16, item 2): On both sides of
conveyor, loosen and move cam tracking assemblies
(Figure 16, item 3) (if equipped) away from head
plates, then loosen fastening screws (Figure 16, item 4)
and push head plate assembly inward.
Figure 16
Figure 16
5. Remove belt (Figure 17, item 1) from conveyor.
Figure 17
Figure 17
Belt Installation
1. Ensure temporary support stands (Figure 14, item 1)
are placed at both ends of the conveyor.
2. Orient belt so splice leading fingers (Figure 18, item 1)
point in the direction of belt travel as identified by the
conveyor directional label (Figure 18, item 2).
Figure 18
Figure 18
3. Install belt (Figure 19, item 1) on conveyor. Lift
conveyor slightly to avoid pinching belt on temporary
support stands.
Figure 19
Figure 19
4. Re-install conveyor mounting brackets. Refer
“Mounting Brackets” beginning on page 8, steps 3
through 5.
5. Tension belt. Refer to “Conveyor Belt Tensioning” on
page 12
6. If equipped, re-install wipers, return rollers and guiding.
1
22
2
4
1
3
1
2
1
1

Dorner Mfg. Corp. 12 851-686 Rev. A
2200 Series iDrive Conveyors
Preventive Maintenance and Adjustment
Conveyor Belt Tensioning
Conveyors with 1.25” (32 mm) Diameter
Pulleys
1. On tension end of the conveyor, identified with a
label (Figure 20, item 1), adjust head plate
assembly (Figure 20, item 2): On both sides of
conveyor, loosen fastening screws (Figure 20, item 3)
and rotate pinion gear (Figure 20, item 4) to adjust head
plate assembly.
Figure 20
Figure 20
2. Adjust head plate assembly so end of conveyor frame
aligns with or between the head plate tensioning marks
(Figure 21, item 1 and 2). Replace belt if proper
tensioning can not be obtained while aligning the end of
the conveyor frame with or between the tensioning
marks. See NOTE.
Figure 21
Figure 21
3. After adjusting proper tensioning, tighten fastening
screws (Figure 22, item 1) on both sides of conveyor to
60 in-lb (7 Nm).
Figure 22
Figure 22
4. If equipped with cam tracking assemblies (Figure
22, item 2), position against head plates and adjust belt
tracking. Refer to “Conveyor Belt Tracking” on
page 13.
Conveyors with Nose Bar Idlers
1. On tension end of the conveyor, identified with a
label (Figure 23, item 1), adjust head plate
assembly (Figure 23, item 2): On both sides of
conveyor, loosen fastening screws (Figure 23, item 3)
and rotate pinion gear (Figure 23, item 4) to adjust head
plate assembly.
Figure 23
Figure 23
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
3
24
1
12
NOTE
Tension belt with minimum tension to keep
belt from slipping. On pinion gear, do not
exceed a torque of 15 in-lb (1.6 Nm). Over
tensioning the conveyor belt could cause
reduced load capacity, excessive pulley
bearing load, and early failure.
12
12
3
4
5

851-686 Rev. A 13 Dorner Mfg. Corp.
2200 Series iDrive Conveyors
Preventive Maintenance and Adjustment
2. Adjust head plate assembly so the edge of the axle
support plate (Figure 24, item 1) is separated from the
end of the conveyor (Figure 24, item 2) by 1.125¨ (29
mm) (Figure 24, item 3). Replace belt if proper
tensioning can not be obtained within a distance of 1.50¨
(38 mm). See NOTE.
Figure 24
Figure 24
3. After adjusting proper tensioning, tighten fastening
screws (Figure 23, item 3) on both sides of conveyor to
60 in-lb (7 Nm).
4. If equipped with cam tracking assemblies (Figure
23, item 5) position against head plates and adjust belt
tracking. Refer to “Conveyor Belt Tracking”, next
section.
Conveyor Belt Tracking
V-Guided Belts
V-guided belts do not require tracking adjustment.
Non V-Guided Belts
Non V-guided belt conveyors are equipped with belt tracking
cam assemblies (Figure 25, item 1) for belt tracking
adjustment.
Figure 25
Figure 25
When adjusting belt tracking, always adjust the discharge
end of the conveyor first. To adjust belt tracking:
1. Ensure head plate fastening screws (Figure 25, item 2)
on both sides of conveyor are tightened.
2. On both sides of conveyor, loosen two (2) cam fastening
screws (Figure 25, item 3). Adjust cams (Figure
25, item 4) until indicator slots (Figure 25, item 5) are
horizontal and facing end of conveyor. Then slide cam
assemblies against head plates (Figure 25, item 6) and
re-tighten cam fastening screws (Figure 25, item 3) to
60 in-lb (7 Nm).
3. On the side toward which the belt is tracking, loosen
head plate fastening screws (Figure 25, item 2).
4. With the conveyor running, use a 5 mm hex-key wrench
to rotate the tracking cam (Figure 25, item 4) in small
increments until the belt tracks in the center of the
conveyor. Then while holding the cam in position, re-
tighten the head plate fastening screws (Figure
25, item 2) with a 4 mm hex-key wrench to 60 in-lb (7
Nm).
NOTE
Tension belt with minimum tension to keep
belt from slipping. On pinion gear, do not
exceed a torque of 15 in-lb (1.6 Nm). Over
tensioning the conveyor belt could cause
reduced load capacity, excessive pulley
bearing load, and early failure.
12
3
2
6
5
4
3
1

Dorner Mfg. Corp. 14 851-686 Rev. A
2200 Series iDrive Conveyors
Preventive Maintenance and Adjustment
Spindle Removal
•A−Idler Spindle Removal
•B−Drive Spindle Removal
A −Idler Spindle Removal
1. On one side of the conveyor, loosen two (2) head plate
fastening screws (Figure 26, item 1) and remove them.
Figure 26
Figure 26
2. Remove the head plate (Figure 27, item 1) from the
conveyor frame.
Figure 27
Figure 27
3. Spindle will slide out of opposite head plate and drop
into slack of belt (Figure 28).
Figure 28
Figure 28
4. Slide spindle out of the belt loop.
B −Drive Spindle Removal
1. Remove belt. (See “Belt Removal” on page 10.)
2. Remove inframe drive side cover (Figure 29, item 1)
by removing two head plate fastening screws (Figure
29, item 2).
Figure 29
Figure 29
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
NOTE
To prevent damage to the head plates and
spindle, be sure to remove them slowly
because they are not attached to spindle.
1
1
NOTE
To prevent damage to the head plates and
spindle, be sure to remove them slowly
because they are not attached to spindle.
12

851-686 Rev. A 15 Dorner Mfg. Corp.
2200 Series iDrive Conveyors
Preventive Maintenance and Adjustment
3. Loosen four clamp plate screws (Figure 30, item 1).
Figure 30
Figure 30
4. Loosen timing belt tension cam (Figure 31, item 1).
Figure 31
Figure 31
5. Loosen two set screws (Figure 32, item 1) on drive
pulley (Figure 32, item 2). Slide drive pulley outward
off of the gearmotor shaft, and remove timing belt
(Figure 32, item 3).
Figure 32
Figure 32
6. Loosen two set screws (Figure 33, item 1) on driven
pulley (Figure 33, item 2), and slide off of shaft to
remove.
Figure 33
Figure 33
7. Remove driven pulley (Figure 33, item 2).
8. Remove two head plate fastening screws (Figure
34, item 1) from opposite side of conveyor.
Figure 34
Figure 34
1
11
1
2
1
3
A
WARNING
Drive shaft keyway may be sharp. HANDLE
WITH CARE.
1
2
1

Dorner Mfg. Corp. 16 851-686 Rev. A
2200 Series iDrive Conveyors
Preventive Maintenance and Adjustment
9. Remove head plate (Figure 35, item 1) from frame.
Figure 35
Figure 35
10. Replace spindle (Figure 35, item 2).
Bearing Removal & Replacement
Removal
1. Use a bearing removal tool, (Figure 36, item 1),
(Figure 37, item 1), part number 807−1078, or
equivalent and remove both bearings from the idler
spindle and the drive spindle.
Figure 36
Figure 36
Figure 37
Figure 37
Replacement
1. Inspect the head plates bearing seating surface (Figure
38, item 1). If they are worn or damaged, replace the
head. See “Service Parts” beginning on page 22.
Figure 38
Figure 38
A
CAUTION
Spindle can slide out.
IMPORTANT
Do not use any removed bearings. Replace
them.
1
2
1
NOTE
Two washers may be required when installing
the bearing over the drive shaft on the drive
spindle, if the bearing installation tool is not
long enough to fit the length of the drive shaft.
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1

851-686 Rev. A 17 Dorner Mfg. Corp.
2200 Series iDrive Conveyors
Preventive Maintenance and Adjustment
2. Use a bearing installation tool, (Figure 39, item 1), part
number 450292 or equivalent and press bearings onto
the spindle and drive spindle.
Figure 39
Figure 39
Spindle Installation
Idler Spindle Installation
1. With opposite head plate installed, position the idler
spindle (Figure 40, item 1) through the loop of the belt,
into the opposite head plate.
Figure 40
Figure 40
2. Place the head plate (Figure 40, item 2) and attach the
head plate to the conveyor frame with the two (2)
screws removed and hand tighten.
Drive Spindle Installation
1. Install drive spindle (Figure 41, item 1) into head plate
(Figure 41, item 2). Install head plate (Figure
41, item 3) and install screws (Figure 41, item 4).
Figure 41
Figure 41
2. Install driven pulley (Figure 42, item 1) onto conveyor
shaft until flush with spindle end. Line up longer set
screw (Figure 42, item 2) on pulley over keyway
(Figure 42, item 3) of shaft. Tighten set screw (Figure
42, item 2) and set screw (Figure 42, item 4) to 18 in-lb
(7 Nm).
Figure 42
Figure 42
1
2
1
A
WARNING
Drive shaft keyway may be sharp. HANDLE
WITH CARE.
4
1
2
3
2
1
4
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Dorner Mfg. Corp. 18 851-686 Rev. A
2200 Series iDrive Conveyors
Preventive Maintenance and Adjustment
3. Slip timing belt (Figure 43, item 1) over driven pulley
(Figure 43, item 2) and slide drive pulley (Figure
43, item 3) through timing belt onto gearmotor shaft.
Figure 43
Figure 43
4. Tighten drive pulley set screws (Figure 43, item 4) on
gearhead shaft, making sure one set screw is over flat on
shaft, and drive pulley is aligned with driven pulley.
5. Tighten timing belt tension cam (Figure 44, item 1),
making certain that pointer (Figure 44, item 2) on cam
is pointing towards the motor drive spindle (Figure
44, item 2).
Figure 44
Figure 44
6. Rotate tension cam (Figure 44, item 1) to obtain 1/8 - 1/
4” belt deflection at center of belt (Figure 45, item 1)
with approximately 3-5 in-lb of pressure. Tighten four
clamp plate screws (Figure 45, item 2) to 15 in-lb (1.6
Nm) to secure position.
Figure 45
Figure 45
7. Install inframe drive side cover (Figure 46, item 1) with
two head plate fastening screws (Figure 46, item 2).
Figure 46
Figure 46
A
CAUTION
Over tightening of timing belt will result in
reduced gearmotor and timing belt life.
3
4
1
2
3
12
2
22
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12

851-686 Rev. A 19 Dorner Mfg. Corp.
2200 Series iDrive Conveyors
Preventive Maintenance and Adjustment
Nose Bar Roller Replacement
1. On both sides of conveyor, use a 4 mm hex-key wrench
to loosen cam fastening screws (Figure 47, item 1) and
slide cam assemblies toward the center of the conveyor.
Figure 47
Figure 47
2. On both sides of conveyor, use a 4 mm hex-key wrench
to loosen head plate fastening screws (Figure
47, item 2) to remove belt tension. Then remove belt
from end of conveyor.
3. On one side of conveyor, use a 3 mm and 4 mm hex-key
wrench to remove head plate fastening screws (Figure
47, item 3) and (Figure 47, item 2) and remove head
plate (Figure 47, item 4).
4. Slide nose bar rods (Figure 48, item 1) out side of
conveyor and replace rollers (Figure 48, item 2) as
necessary.
Figure 48
Figure 48
5. After replacing rollers, re-install head plate (Figure
47, item 4). Use a 3 mm hex-key wrench to tighten one
(1) fastening screw (Figure 47, item 3) to 30 in-lb (3.4
Nm). Leave two (2) fastening screws (Figure
47, item 2) loose for belt tensioning.
6. Re-install belt on end of conveyor, then tension the belt.
See “Conveyor Belt Tensioning” on page 12.
7. Re-position the cam assemblies against the head plates
and adjust belt tracking. See “Conveyor Belt Tracking”
on page 13.
Motor Removal and Replacement
1. Remove belt. (See “Belt Installation” on page 11.)
2. To unwire motor, remove four bedplate fastening screws
(Figure 49, item 1) with torx wrench.
Figure 49
Figure 49
3. Remove bedplate (Figure 49, item 2) and rotate upside
down on conveyor.
4. Unscrew the three terminal clamps (Figure 50, item 1)
from three motor wires.
Figure 50
Figure 50
14
2
4
1
3
1
2
NOTE
Be certain to make note of wire color and
location before removing wire from each wire
clamp.
1
2
1

Dorner Mfg. Corp. 20 851-686 Rev. A
2200 Series iDrive Conveyors
Preventive Maintenance and Adjustment
5. Remove inframe drive side cover (Figure 51, item 1)
by removing two head plate fastening screws
(Figure 51, item 2).
Figure 51
Figure 51
6. Loosen four clamp plate screws (Figure 52, item 1).
Figure 52
Figure 52
7. Loosen timing belt tension cam (Figure 52, item 2).
8. Loosen two set screws (Figure 53, item 1) on drive
pulley (Figure 53, item 2). Slide drive pulley outward
off of gearmotor shaft and remove timing belt (Figure
53, item 3).
Figure 53
Figure 53
9. Remove four clamp plate screws (Figure 54, item 1)
and clamp plate (Figure 54, item 2).
Figure 54
Figure 54
10. Remove motor (Figure 55, item 1).
Figure 55
Figure 55
11. Remove cap (Figure 55, item 2) from motor.
12. Replace motor.
13. Reinstall in reverse order of removal. (Refer to “Drive
Spindle Installation” on page 17 for timing belt
tensioning.)
1
2
21
2
1
3
NOTE
When reassembling, make sure the pointer
on the timing belt tension cam is pointing
towards the motor.
2
1
1
2