Dorner 2200 series User manual

851−452 Rev. H
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Installation Sequence 5. . . . . . . . . . . . . . . . .
Conveyors Up to 12 ft (3658 mm) 5. . . . . . . . . . . . . . . . . . .
Conveyors Longer Than 12 ft (3658 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. . . . . . . . . . . . . . . . . . . . . . . . . .
V−Guided Belts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non V−Guided Belts 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley Removal 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A−Idler Pulley Removal 13. . . . . . . . . . . . . . . . . . . . . . .
B−Drive Pulley Removal 14. . . . . . . . . . . . . . . . . . . . . .
Bearing Removal & Replacement 14. . . . . . . . . . . . . . . . . . .
Removal 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pulley and Pulley Installation 15. . . . . . . . . . . . . . . . .
Drive Pulley Installation 15. . . . . . . . . . . . . . . . . . . . . . . .
Idler Pulley Installation 15. . . . . . . . . . . . . . . . . . . . . . . . .
Nose Bar Bearing Replacement 16. . . . . . . . . . . . . . . . . . . .
Service Parts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2” (51mm) Wide Conveyor 18. . . . . . . . . . . . . . . . . . . . . . . .
3” (76mm) to 6” (152mm) Wide Conveyor 20. . . . . . . . . . .
8” (203mm) to 12” (305mm) Wide Conveyor 22. . . . . . . . .
18” (457mm) to 24” (610mm) Wide Conveyor 25. . . . . . . .
Nosebar End Assembly 28. . . . . . . . . . . . . . . . . . . . . . . . . . .
−04 3” (76mm) Aluminum Side 29. . . . . . . . . . . . . . . . . . . .
−05 1.5” (38mm) Aluminum Side 30. . . . . . . . . . . . . . . . . .
−07 Low to Side Wiper 31. . . . . . . . . . . . . . . . . . . . . . . . . . .
−09 Low to High Side 32. . . . . . . . . . . . . . . . . . . . . . . . . . .
−10 .5” (13mm) Extruded Plastic 33. . . . . . . . . . . . . . . . . . .
−13 Adjustable Guiding 34. . . . . . . . . . . . . . . . . . . . . . . . . .
.5” (13mm) Cleated Belt Guiding 35. . . . . . . . . . . . . . . . . . .
1” (25mm) Cleated Belt Guiding 36. . . . . . . . . . . . . . . . . . .
2” (51mm) 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’ (610mm)
Conveyors 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleated Belt Stand Mount Assembly for 2’ (610mm)
Conveyors 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Assembly without Stand Mount 41. . . . . . . . . .
Flat Belt Connecting Assembly with Stand Mount 41. . . . . .
Cleated Belt Connecting Assembly with Stand Mount 42. . .
2” (51mm) to 6” (152mm) Flat Belt Return Roller 42. . . . . .
8” (203mm) to 24” (610mm) Flat Belt Return Roller 43. . . .
Cleated Belt Return Roller 43. . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Part Number Configuration 44. . . . . . . . . . .
Return Policy 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. H 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
Ç
Climbing, sitting, walking or
riding on conveyor will
cause severe injury.
KEEP OFF CONVEYORS.
DANGER
Ç
Ç
DANGER
DO NOT OPERATE
CONVEYORS IN AN
EXPLOSIVE ENVIRONMENT.
Ç
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 equip-
ment or as part of a multiple
conveyor system, CHECK
FOR POTENTIAL PINCH
POINTS and other mechani-
cal 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 without guards.
Upon receipt of shipment:
DCompare shipment with packing slip. Contact factory
regarding discrepancies.
DInspect packages for shipping damage. Contact carrier
regarding damage.
DAccessories may be shipped loose. See accessory in-
structions 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 installa-
tion, 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 corre-
sponding 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. H
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
1 = with belt tracking cams and mounting brackets
2 = with V-guide tracking and mounting brackets
3 = with nosebar transfer tail and mounting brackets
4 = with V−guide tracking and no mounting brackets
5 = with belt tracking cams and no mounting brackets
6 = with nosebar transfer tail 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.
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*
* 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 12 ft (3658 mm), install
support at joint.
L
KM
Figure 2
Product Description

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. H 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)
14 in-lb
(1.5Nm)
15 in-lb
(1.7Nm)
18 in-lb
(2.0Nm)
20 in-lb
(2.3Nm)
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:
DNon-accumulating product
DProduct moving towards gearmotor
DConveyor 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
DHex-key wrenches:
4 mm, 5 mm
DLevel
DTorque wrench
Specifications

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 5851-452 Rev. H
Recommended Installation Sequence
DInstall support stands (see accessory instructions)
DAssemble conveyor (if required)
DAttach mounting brackets to conveyor
DAttach conveyor to stands
DInstall return rollers on conveyor (optional)
DMount gearmotor mounting package (see accessory
instructions)
DAttach guides/accessories (see page 29 through 37 of
“Service Parts” section for details)
Conveyors Up to 12 ft (3658 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 12ft (3658 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 frame connector
plates (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
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. H 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
Y
AC
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. H
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. H 8Dorner Mfg. Corp.
Required Tools
Standard Tools
DHex-key wrenches:
2.5 mm, 4 mm, 5 mm
DArbor press
Special Tools
D807−1078 Bearing Puller Tool (or equivalent)
D450292 Bearing Installation Tool
D456070 Bearing Removal Tool
Checklist
DKeep service parts on hand (see “Service Parts” sec-
tion for recommendations)
DKeep supply of belt cleaner (part # 625619)
DClean entire conveyor and knurled pulley while dis-
assembled
DReplace worn or damaged parts
Lubrication
No lubrication is required. Replace bearings if worn.
Maintaining Conveyor Belt
Troubleshooting
Inspect conveyor belt for:
DSurface cuts or wear
DStalling or slipping
DDamage to V-guide
Surface cuts and wear indicate:
DSharp or heavy parts impacting belt
DJammed parts
DImproperly installed bottom wipers (if installed)
DAccumulated dirt in wipers (if installed)
DForeign material inside the conveyor
DImproperly positioned accessories
DBolt-on guiding is pinching belt
Stalling or slipping indicates:
DExcessive load on belt
DConveyor belt or drive timing belt are not properly
tensioned
DWorn knurl or impacted dirt on drive pulley
DIntermittent jamming or drive train problems
Damage to V-guide indicates:
DTwisted or damaged conveyor frame
DDirt impacted on pulleys
DExcessive or improper side loading
NOTE: Visit www.dorner.com for complete list of
troubleshooting solutions.
Cleaning
IMPORTANT: Do not use belt cleaners that contain
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
DRemove old conveyor belt:
-Conveyor without Stands or Gearmotor Mounting
Package
-Conveyor with Stands and Gearmotor Mounting
Package
DInstall new conveyor belt
DTension conveyor belt
Preventive Maintenance and Adjustment

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 9851-452 Rev. H
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. H 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. H
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. H 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 or 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. H
Pulley Removal
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
Leaving the conveyor belt in place, remove the desired
pulley following the corresponding instructions below:
DA−Idler Pulley Removal
DB−Drive Pulley Removal
A−Idler Pulley Removal
1.On one side of the conveyor, loosen two (2) head
plate fastening screws (U of Figure 30) and remove
them.
NOTE: To prevent damage to the head plates and
pulley, be sure to remove them slowly because they
are not attached to pulley.
Figure 30
U
2.Remove the head plate (BA of Figure 31) from the
conveyor frame.
Figure 31
BA
3.Pulley will slide out of opposite head plate and drop
into slack of belt (Figure 32).
Figure 32
4.Slide spindle out of the belt loop.
Preventive Maintenance and Adjustment

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. H 14 Dorner Mfg. Corp.
B−Drive Pulley Removal
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
1.On one side of the conveyor, loosen two (2) head
plate fastening screws (U of Figure 33) and remove.
NOTE: To prevent damage to the head plates, be
sure to remove them slowly because they are not at-
tached to pulley.
Figure 33
U
2.Remove the head plate (BA of Figure 34) from the
conveyor frame.
Figure 34
BA
3.Drive pulley will slide out of opposite head and drop
into slack of belt.
4.Slide the drive pulley out of the belt loop.
Bearing Removal & Replacement
Removal
IMPORTANT: Do not use any removed bearings.
Replace them.
1.Use a bearing removal tool, (BD of Figure 35, 36),
part number 807−1078, or equivalent and remove
both bearings from the pulley and the drive pulley.
Figure 35 −Conveyor Pulley
BD
Figure 36 −Drive Pulley
BD

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 15 851-452 Rev. H
Replacement
1.Inspect the head plates bearing seating surface (BC
of Figure 37). If they are worn or damaged, replace
the head. See ”Service Parts” on Page 20.
Figure 37
BC
NOTE: Two washers may be required when instal-
ling the bearing over the drive shaft on the drive
pulley, if the bearing installation tool is not long
enough to fit the length of the drive shaft.
2.Use a bearing installation tool, (BE of Figure 38),
part number 450292 or equivalent and press bear-
ings onto the pulley and drive pulley.
Figure 38
BE
Drive Pulley and Pulley Installation
Drive Pulley Installation
1.With opposite head plate installed, position the drive
pulley through the loop of the belt, into the opposite
head plate.
Figure 39
BA
2.Place the head plate (BA of Figure 39) and attach the
head plate to the conveyor frame with the two (2)
screws removed. Tighten screws 60 in-lb (7Nm).
Idler Pulley Installation
1.With opposite head plate installed, position the idler
pulley through the loop of the belt, into the opposite
head plate.
Figure 40
BA
2.Place the head plate (BA of Figure 40) and attach the
head plate to the conveyor frame with the two (2)
screws removed and hand tighten.

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. H 16 Dorner Mfg. Corp.
Nose Bar Bearing Replacement
1.On both sides of conveyor, use a 4 mm hex-key
wrench to loosen cam fastening screws (BI of Figure
41) and slide cam assemblies toward the center of the
conveyor.
Figure 41
U
BJ BI
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 (BJ & U) and remove head plate (S).
4.Slide bearing rods (BL of Figure 42) out side of
conveyor and replace bearings (BK) as necessary.
Figure 42
BK
BL
BK
5.After replacing bearings, re-install head plate (S of
Figure 41). Use a 3 mm hex-key wrench to tighten
one (1) fastening screw (BL) 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.
Preventive Maintenance and Adjustment

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 17 851-452 Rev. H
Notes

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-452 Rev. H 18 Dorner Mfg. Corp.
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.
2” (51mm) Wide Conveyor
18 Drive Spindle Kit 20 Idler Spindle Kit
19 Nosebar Drive
Spindle Kit
17
C & D Position
A & B Position
9
15
16 3
OR
14
13
12
11 10
9
7
8
6
5
2
2
4
1
Service Parts

2200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 19 851-452 Rev. H
Item Part Number Description
1 920692M Socket Head Screw M6 x 12mm
2 240425 Head Plate LH
3 240427 Head Plate LH Drive Side, Position
A and B
4 240428 Head Plate RH Drive Side, Posi-
tion C and D
5 240328 Bearing
6 247302 Idler Spindle 2” (51mm)
7 808−020 Magnet .25” Dia. x .25” long
8 450226SSP Sleeve, .25” Magnet Stainless
Steel
9 240426 Head Plate RH
10 920691M Socket Head Screw M6 x 10mm
11 240329 Tension Slide Bar
12 240420 Rack Gear 14.5 Degree PA x 24 P
13 240423 Pinion 2” (51mm)
14 240422 Pinion Pin
15 456402 Drive Spindle 2” (51mm)
247602 Nosebar Drive Spindle Lagged 2”
(51mm)
16 980422M Square Key 4mm x 22mm
17 See Frame
Chart
2” (51mm) Frame
18 22A−02 Drive Spindle Kit, Position A and B
−Grooved (Includes Items 1, 2, 3,
5, 9 and 15)
22D−02 Drive Spindle Kit, Position C and D
−Grooved (Includes Items 1, 2, 4,
5, 9 and 15)
19 22NA−02 Nosebar Drive Spindle Kit, Position
A and B −Lagged, Smooth (In-
cludes Items 1, 2, 3, 5, 9 and 15)
22ND−02 Nosebar Drive Spindle Kit, Position
C and D −Lagged, Smooth (In-
cludes Items 1,2, 4, 5, 9 and 15)
20 22T−02 Idler Spindle Kit (Includes Items 1,
2 and 5 through 10)
Item 17: 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. H 20 Dorner Mfg. Corp.
3” (76mm) to 6” (152mm) Wide Conveyor
20 Drive Spindle Kit
22 Idler Spindle Kit
21 Nosebar Drive
Spindle Kit
C & D Position
A & B Position
2
18
19
1
2
5
6
9
7
12
17
11 10
8
13
14
3
16
9
4
15
OR
Service Parts