Dorner 2200 series User manual

851-452 Rev. D
Installation, Maintenance
& Parts Manual
2200 Series End Drive Conveyors
Table of Contents
Warnings – General Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RequiredTools 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Installation Sequence 5. . . . . . . . . . . . . . . . .
Conveyors Up to 13 ft (3962 mm) 5. . . . . . . . . . . . . . . . . . .
Conveyors Longer Than 13 ft (3962 mm) 5. . . . . . . . . . . . .
Mounting Brackets 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Rollers 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleated Belt and 2 – 6¨ (51 – 152 mm) Wide
Flat Belt Conveyors 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 – 24¨ (203 – 610 mm) Wide
Flat Belt Conveyors 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance & Adjustment 8. . . . . . . . . . . . . . . .
Required Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining Conveyor Belt 8. . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement 8. . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement Sequence 8. . . . . . . . . . . . . .
Belt Removal for Conveyor Without
Stands or Gearmotor Mounting Package 9. . . . . . . . . . . . . .
Belt Removal for Conveyor With
Stands and Gearmotor Mounting Package 9. . . . . . . . . . . . .
Belt Installation for Conveyor Without
Stands or Gearmotor Mounting Package 10. . . . . . . . . . . . .
Belt Installation for Conveyor With
Stands and Gearmotor Mounting Package 10. . . . . . . . . . . .
Conveyor Belt Tensioning 11. . . . . . . . . . . . . . . . . . . . . . . . .
Conveyors with 1.25¨ (32 mm) Diameter Pulleys 11. . . .
Conveyors with Nose Bar Idlers 12. . . . . . . . . . . . . . . . . .
Conveyor Belt Tracking 12. . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley Removal 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A – Idler Pulley Removal 13. . . . . . . . . . . . . . . . . . . . . . .
A – Idler Pulley Removal 13. . . . . . . . . . . . . . . . . . . . . . .
B – Drive Pulley Removal 13. . . . . . . . . . . . . . . . . . . . . .
Bearing Removal & Replacement 14. . . . . . . . . . . . . . . . . . .
Pulley Replacement 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pulley 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Pulley 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nose Bar Bearing Replacement 17. . . . . . . . . . . . . . . . . . . .
Service Parts 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2” (51mm) Wide Conveyor Assembly 19. . . . . . . . . . . . . . .
3” (76mm) to 6” (152mm) Wide Conveyor Assembly 21. . .
8” (203mm) to 12” (305mm) Wide Conveyor Assembly 22.
18” (457mm) to 24” (610mm) Wide Conveyor Assembly 24
Nosebar End Assembly 2” (51mm) to 24” (610mm) 26. . . .
–04 3” (76mm) Aluminum Side 27. . . . . . . . . . . . . . . . . . . .
–05 1.5” (38mm) Aluminum Side 28. . . . . . . . . . . . . . . . . .
–07 Low to Side Wiper 29. . . . . . . . . . . . . . . . . . . . . . . . . . .
–09 Low to High Side 30. . . . . . . . . . . . . . . . . . . . . . . . . . .
–10 .5” (13mm) Extruded Plastic 31. . . . . . . . . . . . . . . . . . .
–13 Adjustable Guiding 32. . . . . . . . . . . . . . . . . . . . . . . . . .
.5” (13mm) Cleated Guiding 33. . . . . . . . . . . . . . . . . . . . . . .
1” (25mm) Cleated Guiding 34. . . . . . . . . . . . . . . . . . . . . . .
2” (51mm) Cleated Guiding 35. . . . . . . . . . . . . . . . . . . . . . .
Flared Side Guiding 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flat Belt Mounting Bracket 37. . . . . . . . . . . . . . . . . . . . . . . .
Cleated Belt Mounting Bracket 37. . . . . . . . . . . . . . . . . . . . .
Flat Belt Mounting Brackets for 2’ (610mm)
Conveyors 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleated Belt Mounting Brackets for 2’ (610mm)
Conveyors 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Assembly without Stand Mount 39. . . . . . . . . .
Flat Belt Connecting Assembly without
Stand Mount 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleated Belt Connecting Assembly without
Stand Mount 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2” (51mm) to 6” (152mm) Flat Belt Return Roller 40. . . . . .
8” (203mm) to 24” (610mm) Flat Belt Return Roller 41. . . .
Cleated Belt Return Roller 41. . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Part Number Configuration 42. . . . . . . . . . .
Return Policy 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. D 2Dorner Mfg. Corp.
The safety alert symbol, black triangle with white
exclamation, is used to alert you to potential
personal injury hazards.
Ç
Ç
Ç
Climbing, sitting, walking or
riding on conveyor will
cause severe injury.
KEEP OFF CONVEYORS.
DANGER
Ç
DANGER
DO NOT OPERATE
CONVEYORS IN AN
EXPLOSIVE ENVIRONMENT.
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
Ç
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
Ç
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.
Ç
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.
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 2200 series conveyors are covered by Patent
Numbers 5,174,435, 6,298,981 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

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 3851-452 Rev. D
Refer to Figure 1 for typical conveyor components.
A Conveyor
B Gearmotor Mounting Package
C Gearmotor
D Guiding & Accessories
E Mounting Brackets
F Return Rollers
G Support Stand
H Variable Speed Controller
I Drive End
J Idler/Tension End
Typical Components
Figure 1
A
BCD
E
E
J
F
G
H
I
Specifications
Models:
Flat Belt 2200 Series Conveyor
Conveyor Width Reference
Conveyor Length Reference
Belt Type*
Output Shaft Position*
Conveyor Profile*
1 = Flat belt with tracking cams (non V-guided belt)
2 = Flat belt with V-guide tracking
3 = Nose bar transfer at tension end
(non V-guided belt)
Document Language, M = English
2 1 0 M WW LLLL A PP BB Cleated Belt 2200 Series Conveyor
Conveyor Width Reference
Conveyor Length Reference
2 4 C M WW LLLL A SSSS
Output Shaft Position*
Cleat Spacing*
4 = Cleated belt with V-guide tracking
5 = Cleated belt with tracking cams
(non V-guided belt)
Document Language, M = English
Cleat Type*
* See Ordering and Specifications Catalog for details.
Conveyor Supports:
Maximum Distances:
K = 18¨(457 mm)**
L = 6 ft (1829 mm)***
M = 18¨(457 mm)
** For Heavy Load Bottom Mount Package, mount
support under gear head.
*** For conveyors longer than 13 ft (3962 mm), install
support at joint.
LK M
Figure 2
Product Description

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. D 4Dorner Mfg. Corp.
Specifications:
Conveyor Width
Reference (WW) 02 03 04 05 06 08 10 12 18 21 24
Conveyor Belt Width 1.75¨
(44mm) 2.75¨ (70mm) 3.75¨ (95mm) 5¨ (127mm) 6¨ (152mm) 8¨ (203mm) 10¨ (254mm) 12¨ (305mm) 18¨ (457mm) 21¨
(533mm) 24¨ (609mm)
Maximum Conveyor
Load*
(See NOTE Below)
30 lb
(14kg) 35 lb (16kg) 42 lb (19kg) 50 lb (23kg) 60 lb (27kg) 70 lb (32kg) 80 lb (36kg) 80 lb (36kg) 80 lb (36kg) 80 lb
(36kg) 80 lb (36kg)
Conveyor Startup
Torque* 2 in-lb
(0.5Nm) 3 in-lb (0.6Nm) 4 in-lb (0.7Nm) 6 in-lb (0.8Nm) 8 in-lb (0.9Nm) 10 in-lb (1.1Nm) 12 in-lb (1.4Nm) 12 in-lb (1.4Nm) 12 in-lb (1.4Nm) 12 in-lb
(1.4Nm) 12 in-lb (1.4Nm)
Belt Travel 4.0¨(88 mm) per revolution of pulley
Maximum Belt Speed* 264 ft/minute (80.5 m/minute)
Belt Takeup 0.38¨ (10 mm) of stroke = 0.75¨(19 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**
Conveyor Length
Up to 18 ft in any length
to nearest 0.12”(3mm)
2-ft (610 mm)
3-ft (914 mm)
4-ft (1219 mm) 5-ft (1524 mm) 6-ft (1829 mm) 7-ft (2134 mm) 8-ft (2438 mm) 9-ft (2743 mm)
10-ft (3048 mm) 11-ft (3353 mm) 12-ft (3658 mm)
13-ft (3962 mm)** 14-ft (4267 mm)** 15-ft (4572 mm)** 16-ft (4877 mm)** 17-ft (5182 mm)** 18-ft (5486 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.
** Lengths available only in 6¨(152 mm) & wider
conveyors.
Installation
NOTE: Conveyor MUST be mounted straight, flat
and level within confines of conveyor. Use a level
(N of Figure 3) for setup.
Figure 3
N
O Conveyor frame (two sections if longer than 12ft)
P Conveyor brackets (4x)
Q Return rollers (for longer conveyors)
Installation Component List
Required Tools
Hex-key wrenches:
4 mm, 5 mm
Level
Torque wrench
Specifications

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 5851-452 Rev. D
Recommended Installation Sequence
Install support stands (see accessory instructions)
Assemble conveyor (if required)
Attach mounting brackets to conveyor
Attach conveyor to stands
Install return rollers on conveyor (optional)
Mount gearmotor mounting package (see accessory
instructions)
Attach guides/accessories (see page 27 through 35 of
“Service Parts”section for details)
Conveyors Up to 13 ft (3962 mm)
No assembly is required. Install mounting brackets and
return rollers. Refer to “Mounting Brackets”on page 6
and “Return Rollers”on page 7.
Conveyors Longer Than 13 ft (3962 mm)
1.Locate conveyor sections (O Figure 4)
Figure 4
O
O
2.On tension end of the conveyor, identified with a
label (R of Figure 5), push in head plate
assembly (S): On both sides of conveyor, loosen and
move cam tracking assemblies (T) (if equipped)
away from head plates, then loosen fastening screws
(U) and push head plate assembly inward.
Figure 5
R
U
S
T
3.Roll out conveyor belt and place conveyor frame
sections (O of Figure 6) into belt loop.
Figure 6
OO
4.Join conveyor sections and install connector brack-
ets (V of Figure 7) or connector/mount brackets
(VA) and screws (W) on both sides as indicated.
Tighten screws to 60 in-lb (7 Nm).
Figure 7
V
W
VA
W
5.With a 5 mm hex-key wrench, rotate pinion gear (X
of Figure 8) to tension the conveyor belt. Tighten
fastening screws (U) on both sides of conveyor to
80 in-lb (9 Nm). For proper tensioning, refer to
“Conveyor Belt Tensioning”on page 11.
Figure 8
X
U
6.Install mounting brackets and return rollers. Refer to
“Mounting Brackets”on page 6 and “Return
Roller”on page 7.
7.If equipped with cam tracking assemblies (T of
Figure 5), reposition and adjust belt tracking. Refer
to “Conveyor Belt Tracking”on page 12.
Installation

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. D 6Dorner Mfg. Corp.
Mounting Brackets
1.Locate brackets. Exploded views shown in Fig-
ures 9 & 10.
Figure 9
Y
AC
AB
AA
Z
Mounting Brackets for Flat Belt Conveyor
Figure 10
YAC
AB
AA
Z
Mounting Brackets for Cleated Belt Conveyor
2.Remove screws (Y & Z of Figures 9 & 10), washers
(AA), nuts (AB) and T-bars (AC) from brackets.
3.Insert T-bars (AC of Figures 9 & 10) into conveyor
side slots (AD of Figure 11). Fasten brackets (P of
Figure 11) to conveyor with mounting screws (Y).
Figure 11
AA
Z
AD
Y
P
AB
NOTE: Mounting brackets for flat belt conveyors
shown.
4.Fasten brackets to support stand with mounting
screws (Z of Figure 11), washers (AA) and nuts
(AB).
5.Tighten screws (Y & Z of Figure 11) to 60 in-lb
(7 Nm).
Installation

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 7851-452 Rev. D
Return Rollers
Cleated Belt and 2–6¨(51–152 mm) Wide Flat Belt
Conveyors
1.Locate return rollers. Exploded views shown in
Figures 12 & 13.
Figure 12
AE AF
AE
AF
Return Rollers for Flat Belt Conveyor
Figure 13
Return Rollers for Cleated Belt Conveyor
AF
AE
AF
AE
2.Remove screws (AE of Figures 12 & 13) and clips
(AF) from roller assembly.
3.Install roller assemblies (Q of Figure 14) as shown.
Tighten screws (AE) to 60 in-lb (7 Nm).
Figure 14
AE
Q
Q
8–24¨(203–610 mm) Wide Flat Belt Conveyors
1.Locate return rollers. Exploded view shown in
Figure 15.
Figure 15
AG AH
AG
AH
2.Remove screws (AG of Figure 15) and clips (AH)
from roller assembly.
3.Install roller assembly as shown (Q of Figure 16).
Tighten screws (AG) to 60 in-lb (7 Nm).
Figure 16
AG
Q
Installation

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. D 8Dorner Mfg. Corp.
Required Tools
Standard Tools
Hex-key wrenches:
2.5 mm, 4 mm, 5 mm
Arbor press
Special Tools
807–1078 Sealed Bearing Removal Tool
450292 Sealed Bearing Installation Tool
Checklist
Keep service parts on hand (see “Service Parts”sec-
tion for recommendations)
Keep supply of belt cleaner (part # 625619)
Clean entire conveyor and knurled pulley while dis-
assembled
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
tensioned
Worn knurl or impacted dirt on drive pulley
Intermittent jamming or drive train problems
Damage to V-guide indicates:
Twisted or damaged conveyor frame
Dirt impacted on pulleys
Excessive or improper side loading
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 # 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
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
Conveyor Belt Replacement Sequence
Remove old conveyor belt:
-Conveyor without Stands or Gearmotor Mounting
Package
-Conveyor with Stands and Gearmotor Mounting
Package
Install new conveyor belt
Tension conveyor belt
Preventive Maintenance and Adjustment

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 9851-452 Rev. D
Belt Removal for Conveyor Without Stands or
Gearmotor Mounting Package
1.If equipped, remove bottom wipers (AJ of Figure
17): Remove fastening screws (AI) then remove
wiper (AJ).
Figure 17
AJ
AI
AI
2.If equipped, remove return rollers and guiding and
accessories from one side of conveyor.
3.On tension end of the conveyor, identified with a
label (R of Figure 18), push in head plate
assembly (S): On both sides of conveyor, loosen and
move cam tracking assemblies (T) (if equipped)
away from head plates, then loosen fastening screws
(U) and push head plate assembly inward.
Figure 18
R
U
S
T
4.Remove conveyor belt.
Belt Removal for Conveyor With Stands and
Gearmotor Mounting Package
Ç
Ç
Removing mounting brackets
without support under gear-
motor will cause conveyor to
tip, causing severe injury.
PROVIDE SUPPORT UNDER-
NEATH THE GEARMOTOR
WHEN CHANGING THE BELT
1.Place temporary support stands (AK of Figure 19) at
both ends of the conveyor. Place an additional
support stand under the drive motor (AL), if
equipped. See WARNING.
Figure 19
AK
AL
AK
AM
AM
2.Remove mounting brackets (AM of Figure 19) from
one side of conveyor. (Reverse steps 3 & 4 of
“Mounting Brackets”section on page 6.) If
equipped with heavy load drive package, remove
brackets from side opposite drive cover (AN of
Figure 20).
3.If equipped, remove bottom wipers (AJ of Figure
17): Remove fastening screws (AI) then remove
wiper (AJ).
4.If equipped, remove return rollers, guiding and
accessories from side opposite drive cover (AN of
Figure 20).
Figure 20
AP
AN
AO
AO
5.If equipped with heavy load drive package, remove
drive support bracket (AP of Figure 20): Remove
bracket screws (AO) then remove bracket (AP).
Preventive Maintenance and Adjustment

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. D 10 Dorner Mfg. Corp.
6.On tension end of the conveyor, identified with a
label (R of Figure 21), push in head plate
assembly (S): On both sides of conveyor, loosen and
move cam tracking assemblies (T) (if equipped)
away from head plates, then loosen fastening screws
(U) and push head plate assembly inward.
Figure 21
R
U
S
T
7.Remove belt (AQ of Figure 22) from conveyor.
Figure 22
AQ
AQ
Belt Installation for Conveyor without Stands or
Gearmotor Mounting Package
1.Orient belt so splice leading fingers (AR of Fig-
ure 23) point in the direction of belt travel as identi-
fied by the conveyor directional label (AS).
Figure 23
AR
AS
2.Slide belt onto the conveyor frame assembly.
3.Tension belt. Refer to “Conveyor Belt Tensioning”on
page 11.
4.If equipped, install wipers, return rollers and guid-
ing.
Belt Installation for Conveyor with Stands and
Gearmotor Mounting Package
Ç
Removing mounting brackets
without support under gear-
motor will cause conveyor to
tip, causing severe injury.
PROVIDE SUPPORT UNDER-
NEATH THE GEARMOTOR
WHEN CHANGING THE BELT
1.Ensure temporary support stands (AK of Figure 19)
are placed at both ends of the conveyor. Place an
additional support stand under the drive motor (AL),
if equipped. See WARNING.
2.Orient belt so splice leading fingers (AR of Fig-
ure 23) point in the direction of belt travel as identi-
fied by the conveyor directional label (AS).
3.Install belt (AQ of Figure 24) on conveyor. Lift
conveyor slightly to avoid pinching belt on tempo-
rary support stands.
Figure 24
AQ
AQ
4.Re-install conveyor mounting brackets. Refer
“Mounting Brackets”on page 6, steps 3 through 5.
5.If equipped with a heavy load drive package,
re-install drive support bracket (AP of Figure 20).
6.Tension belt. Refer to “Conveyor Belt Tensioning”on
page 11.
7.If equipped, re-install wipers, return rollers and
guiding.
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 11 851-452 Rev. D
Conveyor Belt Tensioning
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
Conveyors with 1.25¨(32 mm) Diameter Pulleys
1.On tension end of the conveyor, identified with a
label (R of Figure 25), adjust head plate
assembly (S): On both sides of conveyor, loosen
fastening screws (U) and rotate pinion gear (X) to
adjust head plate assembly.
Figure 25
R
U
SX
T
2.Adjust head plate assembly so end of conveyor
frame aligns with or between the head plate tension-
ing marks (AT & AU of Figure 26). 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 26
AU
AT
NOTE: On pinion gear, do not exceed a torque of
25 in-lb (2.8 Nm) for 2 –12¨(44 –305mm) wide con-
veyors and 50 in-lb (4.5 Nm) for an 18 –24¨
(457 –610mm) wide conveyor. Over tensioning the
conveyor belt could cause excessive pulley bearing
load and early failure.
3.After adjusting proper tensioning, tighten fastening
screws (U of Figure 25) on both sides of conveyor to
60 in-lb (7 Nm).
4.If equipped with cam tracking assemblies (T of
Figure 25), position against head plates and adjust
belt tracking. Refer to “Conveyor Belt Tracking”on
page 12.
Preventive Maintenance and Adjustment

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. D 12 Dorner Mfg. Corp.
Conveyors with Nose Bar Idlers
1.On tension end of the conveyor, identified with a
label (R of Figure 27), adjust head plate
assembly (S): On both sides of conveyor, loosen
fastening screws (U) and rotate pinion gear (X) to
adjust head plate assembly.
Figure 27
X
U
R
S
T
2.Adjust head plate assembly so the edge of the axle
support plate (AV of Figure 28) is separated from the
end of the conveyor (AW) by 1.125¨ (29 mm).
Replace belt if proper tensioning can not be obtained
within a distance of 1.50¨(38 mm). See NOTE.
Figure 28
AV AW 1.125¨(29 mm)
NOTE: On pinion gear, do not exceed a torque of
25 in-lb (2.8 Nm) for 2 –12¨(44 –305mm) wide con-
veyors and 50 in-lb (4.5 Nm) for an 18 –24¨
(457 –610mm) wide conveyor. Over tensioning the
conveyor belt could cause excessive pulley bearing
load and early failure.
3.After adjusting proper tensioning, tighten fastening
screws (U of Figure 27) on both sides of conveyor to
60 in-lb (7 Nm).
4.If equipped with cam tracking assemblies (T of
Figure 27) 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 (T of Figure 29) for belt
tracking adjustment.
Figure 29
AX
T
AZ
AY
U
BELT TRAVEL
S
When adjusting belt tracking, always adjust the dis-
charge end of the conveyor first. To adjust belt tracking:
1.Ensure head plate fastening screws (U of Figure 29)
on both sides of conveyor are tightened.
2.On both sides of conveyor, loosen two (2) cam
fastening screws (AX). Adjust cams (AY) until
indicator slots (AZ) are horizontal and facing end of
conveyor. Then slide cam assemblies against head
plates (S) and re-tighten cam fastening screws (AX)
to 60 in-lb (7 Nm).
3.On the side toward which the belt is tracking, loosen
head plate fastening screws (U).
4.With the conveyor running, use a 5 mm hex-key
wrench to rotate the tracking cam (AY) 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 (U) with
a 4 mm hex-key wrench to 60 in-lb (7 Nm).
Preventive Maintenance and Adjustment

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 13 851-452 Rev. D
Pulley Removal
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
Remove conveyor belt to access pulley(s). See “Convey-
or Belt Replacement”on page 8. Remove the desired
pulley following the corresponding instructions below:
A–Idler Pulley Removal
B–Drive Pulley Removal
A–Idler Pulley Removal
1.On both sides of conveyor, loosen two (2) fastening
screws (U of Figure 30). Then slide idler pulley
assembly out from the conveyor frame.
Figure 30
U
2.Remove bearing covers (BA of Figure 31).
Figure 31
BA
3.With 4mm hex-key wrench, loosen pulley taper
screw (BB of Figure 32). Steady pulley with second
hex-key wrench (BC) inserted into pulley hole.
Repeat procedure for opposite side of pulley.
Figure 32
BB
BC
4.Pull head plates with bearings off from the pulley.
B–Drive Pulley Removal
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
1.On both sides of conveyor, loosen two (2) fastening
screws (U of Figure 33). Then slide drive pulley
assembly out from the conveyor frame.
Figure 33
U
Preventive Maintenance and Adjustment

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. D 14 Dorner Mfg. Corp.
2.Remove bearing cover (BA of Figure 34) from side
opposite of drive shaft.
Figure 34
BA
3.On side opposite of drive shaft, loosen pulley taper
screw (BB of Figure 35) with 4mm hex-key wrench.
Steady pulley with second hex-key wrench (BC)
inserted into pulley hole.
Figure 35
BB
BC
4.On side opposite of drive shaft, pull head plate with
bearings off from the pulley.
5.With bearing removal tool, (BD of Figure 36), part
number 807–1078, remove head plate from drive
shaft side of pulley. Connect tool jaws at indicated
points (BE).
Figure 36
BD
BE
BE
Bearing Removal & Replacement
Removal
1.Turn bearing (BF of Figure 37) to align with slots
(BG) in head plate. Then remove bearing.
Figure 37
BF
BG
Replacement
1.Inspect head plate bearing surface. If worn or
damaged, replace head plate. See “Service Parts”on
page 19.
2.Insert bearing (BF of Figure 38) into head plate slot
and twist bearing to fit into bearing enclosure.
Figure 38
BF
Preventive Maintenance and Adjustment

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 15 851-452 Rev. D
Pulley Replacement
Drive Pulley
1.With bearing installed in head plate, use a bearing
installation tool, (BH of Figure 39), part number
450292, to press the bearing onto the drive shaft.
Figure 39
BH
2.With bearing installed in head plate, press bearing on
to non-drive shaft (BI of Figure 40) of pulley.
Figure 40
BI
NOTE: DO NOT tighten non-drive shaft bearing ta-
per screws at this time.
3.Install pulley assembly on conveyor. On both sides
of conveyor tighten fastening screws (U of Figure
41) to 60 in-lb (7 Nm).
Figure 41
U
4.With 4mm hex-key wrench, tighten pulley taper
screw (BB of Figure 42) to 75 in-lb (8.5 Nm). Steady
pulley with second hex-key wrench (BC) inserted
into pulley hole.
Figure 42
BB
BC
5.Install bearing covers (BA of Figure 43).
Figure 43
BA
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2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. D 16 Dorner Mfg. Corp.
Idler Pulley
1.With bearing installed in head plate, press bearing on
to shaft (BI of Figure 44) of pulley. Repeat for both
sides of pulley.
Figure 44
BI
NOTE: DO NOT tighten shaft bearing taper screws
at this time.
2.Install pulley assembly on conveyor. On both sides
of conveyor, hand tighten fastening screws (U of
Figure 45).
Figure 45
U
3.On both sides of pulley, use a 4mm hex-key wrench
to tighten pulley taper screw (BB of Figure 46) to 75
in-lb (8.5 Nm). Steady pulley with second hex-key
wrench (BC) inserted into pulley hole.
Figure 46
BB
BC
4.Install bearing covers (BA of Figure 47).
Figure 47
BA
Preventive Maintenance and Adjustment

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 17 851-452 Rev. D
Nose Bar Bearing Replacement
1.On both sides of conveyor, use a 4 mm hex-key
wrench to loosen cam fastening screws (BJ of Figure
48) and slide cam assemblies toward the center of the
conveyor.
Figure 48
U
BK BJ
S
2.On both sides of conveyor, use a 4 mm hex-key
wrench to loosen head plate fastening screws (U) 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 (BK & U) and remove head plate (S).
4.Slide bearing rods (BL of Figure 49) out side of
conveyor and replace bearings (BM) as necessary.
Figure 49
BL
BM
5.After replacing bearings, re-install head plate (S of
Figure 48). Use a 3 mm hex-key wrench to tighten
one (1) fastening screw (BK) to 30 in-lb (3.4 Nm).
Leave two (2) fastening screws (U) loose for belt
tensioning.
6.Re-install belt on end of conveyor, then tension the
belt. See “Conveyor Belt Tensioning”on page 11.
7.Re-position the cam assemblies against the head
plates and adjust belt tracking. See “Conveyor Belt
Tracking”on page 12.
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2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. D 18 Dorner Mfg. Corp.
NOTE: For replacement parts other than those shown on this page, contact an authorized Dorner Service
Center or the factory.
2”(51mm) Wide Conveyor
Assembly 142
3
6
5
7
10
9
8
11
12
13
14 15
16
16
16
16
1
2
4
Service Parts

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 19 851-452 Rev. D
Item Part Number Description
1 240325 Head Plate LH
2 240326 Head Plate RH
3 240327 Bearing Cover Disk
4 240328 Bearing
5 240329 Tension Slide Bar
6 240330 Taper Screw
7 240420 Rack Gear 14.5 PA x 24 P
8 240422 Pinion Pin
9 240423 Pinion 2”(51mm)
10 240602 Drive Spindle 2”(51mm)
11 240702 Idler Spindle 2”(51mm)
12 See Chart
Below 2”(51mm) Frame
13 450226SSP Sleeve, .25”Magnet Stainless Steel
14 808–020 Magnet .25”Dia x .25”Long
15 920691M Socket Head Screw M6 x 10mm
16 920692M Socket Head Screw M6 x 12mm
Item 12: 2”(51mm) Conveyor Frame
Length Part Number
2’(610mm) 240402–01908
3’(914mm) 240402–03108
4’(1219mm) 240402–04308
5’(1524mm) 240402–05508
6’(1829mm) 240402–06708
7’(2134mm) 240402–07908
8’(2438mm) 240402–09108
9’(2743mm) 240402–10308
10’(3048mm) 240402–11508
11’(3353mm) 240402–12708
12’(3658mm) 240402–13908
Service Parts

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. D 20 Dorner Mfg. Corp.
1
3”(76mm) to 6”(152mm) Wide Conveyor
Assembly
5
6
2
3
10
7
49
8
11
12
18
13
16
17
14
15
2
1
18 18
5
18
4
Service Parts