Dorner 3200 Series User manual

851-512 Rev. B
Installation, Maintenance
& Parts Manua
l
3200 Series End Drive Flat and Cleated Belt
Conveyors
Table of Contents
Warnings − General Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RequiredTools 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Installation Sequence 4. . . . . . . . . . . . . . . . .
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 – 48¨ (203 – 1219 mm) Wide
Flat Belt Conveyors 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance & Adjustment 7. . . . . . . . . . . . . . . . .
Required Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 8. . . . . . . . . . . . . . .
Belt Removal for Conveyor With
Stands and Gearmotor Mounting Package 9. . . . . . . . . . . . .
Belt Installation for Conveyor Without
Stands or Gearmotor Mounting Package 9. . . . . . . . . . . . . . .
Belt Installation for Conveyor With
Stands and Gearmotor Mounting Package 10. . . . . . . . . . . .
Conveyor Belt Tensioning 10. . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Tracking 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
V − Guided Belts 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non V−Guided Belts 11. . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley Removal 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A − Idler Pulley Removal 12. . . . . . . . . . . . . . . . . . . . . . .
B − Drive Pulley Removal 13. . . . . . . . . . . . . . . . . . . . . .
C − Transfer Tail Pulley Removal 16. . . . . . . . . . . . . . . . .
Bearing Replacement 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Bearing Replacement 17. . . . . . . . . . . . . . . . . . . . . .
Drive Bearing Removal and Replacement 17. . . . . . . . . .
Transfer Tail Pulley 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley Replacement 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Pulley 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pulley 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Tail Pulley 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Parts 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive End Tail Assembly 19. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Tail Assembly 20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler End Tail Assembly 21. . . . . . . . . . . . . . . . . . . . . . . . . .
Frame Assembly 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−04 3” (76mm) Aluminum Side 24. . . . . . . . . . . . . . . . . . . .
−05 1.5” (38mm) Aluminum Side 25. . . . . . . . . . . . . . . . . .
−07 Low to Side Wiper 26. . . . . . . . . . . . . . . . . . . . . . . . . . .
−09 Low to High Side 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
−10 .5” (13mm) Extruded Plastic 28. . . . . . . . . . . . . . . . . . .
−13 Adjustable Guiding 29. . . . . . . . . . . . . . . . . . . . . . . . . .
.5” (13mm) Cleated Guiding 30. . . . . . . . . . . . . . . . . . . . . . .
1” (25mm) Cleated Guiding 31. . . . . . . . . . . . . . . . . . . . . . .
2” (51mm) Cleated Guiding 32. . . . . . . . . . . . . . . . . . . . . . .
Flared Side Guiding 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flat Belt Mounting Bracket 34. . . . . . . . . . . . . . . . . . . . . . . .
Cleated Belt Mounting Bracket 34. . . . . . . . . . . . . . . . . . . . .
Connecting Assembly without Stand Mount 35. . . . . . . . . . .
Flat Belt Connecting Assembly without
Stand Mount 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleated Belt Connecting Assembly without
Stand Mount 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2” (51mm) to 6” (152mm) Flat Belt Return Roller 36. . . . . .
8” (203mm) to 48” (1219mm) Flat Belt Return Roller 37. . .
Cleated Belt Return Roller 37. . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Part Number Configuration 38. . . . . . . . . . . .
Return Policy 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-512 Rev. B 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
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
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:
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 3200 series conveyors are covered by Patent
Numbers 5,156,260, 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

3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 3851-512 Rev. B
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 3200 Series Conveyor
Conveyor Width Reference
Conveyor Length Reference
Belt Type*
Output Shaft Position*
Conveyor Profile*
1 = Flat belt with tracking cams and supports
2 = Flat belt with V-guide tracking and supports
3 = Flat belt with tracking cams
4 = Flat belt with V−guide tracking
Document Language, M = English
3 1 0 M WW LLLL A PP BB
0 = 3” tails
1 = 1” tails
Cleated Belt 3200 Series Conveyor
Conveyor Width Reference
Conveyor Length Reference
3 1 C M WW LLLL A SSSS
Output Shaft Position*
Cleat Spacing*
Document Language, M = English
Cleat Type*
1 = Flat belt with tracking cams and supports
2 = Flat belt with V-guide tracking and supports
3 = Flat belt with tracking cams
4 = Flat belt with V−guide tracking
* See Ordering and Specifications Catalog for details.
Conveyor Supports:
Maximum Distances:
K = 24¨ (610 mm) (Drive End)
L = 12 ft (3658 mm)
M = 36¨ (914 mm) (Idler End)
LK M
Figure 2
Product Description

3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-512 Rev. B 4Dorner Mfg. Corp.
Specifications:
Conveyor Width
Reference (WW) 04 06 08 10 12 18 24 30 36 48
Conveyor Belt Width 3.75¨
(95mm) 6¨ (152mm) 8¨ (203mm) 10¨ (254mm) 12¨ (305mm) 18¨ (457mm) 24¨ (609mm) 30¨ (762mm) 36¨ (915mm) 48¨
(1220mm)
Maximum Conveyor
Load*
(See NOTE Below)
200 lb
(91kg) 250 lb (113kg) 300 lb (136kg) 350 lb (159kg) 400 lb (181kg) 400 lb (181kg) 400 lb (181kg) 400 lb (181kg) 400 lb (181kg) 400 lb
(181kg)
Conveyor Startup
Torque* 7 in-lb
(0.8Nm) 8 in-lb (0.9Nm) 10 in-lb (1.1Nm) 13 in-lb (1.5Nm) 15 in-lb (1.7Nm) 25 in-lb (2.8Nm) 30 in-lb (3.9Nm) 35 in-lb (3.9Nm) 38 in-lb (4.2Nm) 40 in-lb
(4.4Nm)
Conveyor Length Ref-
erence (LLLL) 0300 to 4000 in 0001 increments
Conveyor Length 3 ft (914mm) to 40 ft (12192mm) in 0.12” (0.31mm) increments
Belt Travel 9.7¨(246 mm) per revolution of pulley
Maximum Belt Speed* 421 ft/minute (128 m/minute)
Belt Takeup 1.62” (41 mm) of Belt Takeup on Conveyors Under 20’ Length
3.24” (82 mm) of Belt Takeup on Conveyors Over 20’ Length
NOTE: Maximum conveyor loads based on:
Non-accumulating product
Product moving towards gearmotor
Conveyor being mounted horizontal
* See Ordering and Specifications Catalog for details.
Installation
NOTE:Conveyor MUST be mounted straight, flat and
level within confines of conveyor. Use a level (N of
Figure 3) for setup.
Figure 3
N
Required Tools
Hex-key wrenches:
4 mm, 5 mm
Level
Torque wrench
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 24 through 32 of
“Service Parts” section for details)
Specifications

3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 5851-512 Rev. B
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)
O Conveyor frame with drive end
P Conveyor frame with idler end
Q Belt
R Connector bracket
Installation Component List
Figure 4
O
P
R
Q
2.On tension end of the conveyor, identified by the
pinion locking screw (S of Figure 5), push in head
plate assembly (U): Loosen the pinion locking screw
(S), adjust the pinion torque screw (V of Figure 6).
On both sides of conveyor, loosen the two tail clamp
bolts (T of Figure 5), and push head plate assembly
(U) inward.
Figure 5
TU
S
Figure 6
V
3.Roll out conveyor belt and place conveyor frame
sections (O of Figure 7) into belt loop.
Figure 7
OO
4.Join conveyor sections and install connector brack-
ets (W of Figure 8) or connector/mount brackets
(WA) and screws (X) on both sides as indicated.
Tighten screws to 60 in-lb (7 Nm).
Figure 8
W
XWA
Installation

3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-512 Rev. B 6Dorner Mfg. Corp.
NOTE: For Conveyors longer than 20 ft (6096 mm)
use the process outlined in the “Conveyor Belt Ten-
sioning” section on page 10. Extend the Drive End Tail
Assembly to the zero mark of the tension indicator (AR
of Figure9) before proceeding to step 5. The zero mark
for the tension indicator is when the indicator begins
to turn black.
Figure 9
AR
5.Tighten conveyor belt, refer to “Conveyor Belt
Tensioning” on page 10.
6.Install mounting brackets and return rollers. Refer to
“Mounting Brackets” on page 6 and “Return
Roller” on page 7.
Mounting Brackets
1.Locate brackets. Exploded views shown in Fig-
ures 10 & 11.
Figure 10
Y
AC
AB
AA
Z
Mounting Brackets for Flat Belt Conveyor
Figure 11
YAC
AB
AA
Z
Mounting Brackets for Cleated Belt Conveyor
2.Remove screws (Y &Z of Figures 10 &11), washers
(AA), nuts (AB) and T-bars (AC) from brackets.
3.Insert T-bars (AC of Figures 10 &11) into conveyor
side slots (AC of Figure 12). Fasten brackets (AD of
Figure 12) to conveyor with mounting screws (Y).
Figure 12
AA
Z
AC
Y
AD
AB
NOTE: Mounting brackets for flat belt conveyors
shown.
4.Fasten brackets to support stand with mounting
screws (Z of Figure 12), washers (AA) and nuts
(AB).
5.Tighten screws (Y & Z of Figure 12) to 60 in-lb
(7 Nm).
Installation

3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 7851-512 Rev. B
Return Rollers
Cleated Belt and 4–6¨ (51–152 mm) Wide Flat Belt
Conveyors
1.Locate return rollers. Exploded views shown in
Figures 13 & 14.
Figure 13
AE AF
AE
AF
Return Rollers for Flat Belt Conveyor
Figure 14
Return Rollers for Cleated Belt Conveyor
AF
AE
AF
AE
2.Remove screws (AE of Figures 13 & 14) and clips
(AF) from roller assembly.
3.Install roller assemblies (AG of Figure 15) as shown.
Tighten screws (AE) to 60 in-lb (7 Nm).
Figure 15
AE
AG
AG
8–48¨ (203–1219 mm) Wide Flat Belt Conveyors
1.Locate return rollers. Exploded view shown in
Figure 16.
Figure 16
AH AI
AH
AI
2.Remove screws (AH of Figure 16) and clips (AI)
from roller assembly.
3.Install roller assembly as shown (AJ of Figure 17).
Tighten screws (AH) to 60 in-lb (7 Nm).
Figure 17
AH
AJ
Preventive Maintenance and Adjustment
Required Tools
Standard Tools
Hex-key wrenches:
2.5 mm, 4 mm, 5 mm
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.
InstallationInstallation

3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-512 Rev. B 8Dorner Mfg. Corp.
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 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
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
Belt Removal for Conveyor Without Stands or
Gearmotor Mounting Package
1.If equipped, remove return rollers and guiding and
accessories from one side of conveyor.
2.On tension end of the conveyor, identified by the
pinion locking screw (S of Figure 18), push in head
plate assembly (U): Loosen the pinion locking screw
(S), adjust the pinion torque screw (V of Figure 19).
On both sides of conveyor, loosen the two tail clamp
bolts (T of Figure18), and push head plate assembly
(U) inward.
Figure 18
TU
S
Preventive Maintenance and Adjustment

3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 9851-512 Rev. B
Figure 19
V
3.Remove conveyor belt.
Belt Removal 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.Place temporary support stands (AK of Figure 20) at
both ends of the conveyor. Place an additional
support stand under the drive motor (AL), if
equipped. See WARNING.
Figure 20
AK
AL AK
AM
AM
2.Remove mounting brackets (AM of Figure 20) from
one side of conveyor. (Reverse steps 3 & 4 of
“Mounting Brackets” section on page 6).
3.If equipped, remove return rollers, guiding and
accessories from side opposite drive cover.
4.On tension end of the conveyor, identified by the
pinion locking screw (S of Figure 21), push in head
plate assembly (U): Loosen the pinion locking screw
(S), adjust the pinion torque screw (V of Figure 22).
On both sides of conveyor, loosen the two tail clamp
bolts (T of Figure21), and push head plate assembly
(U) inward.
Figure 21
T
U
S
Figure 22
V
5.Remove belt (AN of Figure 23) from conveyor.
Figure 23
AN AN
Belt Installation for Conveyor without Stands or
Gearmotor Mounting Package
1.Orient belt so splice leading fingers (AO of Fig-
ure 24) point in the direction of belt travel as identi-
fied by the conveyor directional label (AP).
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-512 Rev. B 10 Dorner Mfg. Corp.
Figure 24
AO
AP
2.Slide belt onto the conveyor frame assembly.
3.Tension belt. Refer to “Conveyor Belt Tensioning” on
page 10.
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 20)
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 (AO of Fig-
ure 24) point in the direction of belt travel as identi-
fied by the conveyor directional label (AP).
3.Install belt (AN of Figure 25) on conveyor. Lift
conveyor slightly to avoid pinching belt on tempo-
rary support stands.
Figure 25
AN AN
4.Re-install conveyor mounting brackets. Refer
“Mounting Brackets” on page 6, steps 3 through 5.
5.Tension belt. Refer to “Conveyor Belt Tensioning” on
page 10.
6.If equipped, re-install return rollers and guiding.
Conveyor Belt Tensioning
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
NOTE: For conveyors longer than 20 ft (6096 mm)
thebelttensioning proceedureoutlinedbelowmay
be preformed on both the Drive and Idler Ends of
the conveyor.
1.On tension end of the conveyor, identified by the
pinion locking screw (S of Figure 26), loosen the
two tail clamp bolts(T), on both sides of conveyor.
Figure 26
TU
S
2.With 5mm hex wrench, hold pinion torque screw (V
of Figure 27). Loosen the pinion locking screw (S of
Figure 26) and turn the pinion torque screw(V) to
extend head plate assembly.
Figure 27
V
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 11 851-512 Rev. B
NOTE: On pinion gear, do not exceed a torque of
100 in-lb (11.3 N−m). Over tensioning the conveyor
belt could cause excessive pulley bearing load and
early failure.
3.Extend head plate assembly until proper tension in
the belt is achived. If proper tensioning can not be
obtained before the belt life indicator is all black (AR
of Figure 28) the belt must be replaced.
Figure 28
AR
4.After adjusting proper tensioning, tighten the pinion
locking screw (S of Figure 26) to 69 in−lbs (7.8
N−m), and tighten tail clamp bolts (T of Figure 26)
on both sides of conveyor to 146 in-lb (16.5 N−m).
5.If belt tracking is neccesary, refer to “Conveyor Belt
Tracking” on page 11.
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 assemblies.
When adjusting belt tracking, always adjust the dis-
charge end of the conveyor first. To adjust belt tracking:
1.Ensure tensioning racks are extended and touching
the idler pulley headplates: loosen the pinion locking
screw (S of Figure 26) and rotate the pinion torque
screw (V of Figure 27) clockwise until contact with
the head plate is made, then tighten the pinion
locking screw (S) to 69 in−lbs (7.8 N−m)
2.On the side of conveyor to be adjusted, loosen two
(2) tail clamp screws(T of Figure 29).
Figure 29
T
S
3.With the conveyor running, use wrench (AS of
Figure30) to rotate the tracking screw (AT of Figure
31) in small increments until the belt tracks in the
center of the conveyor.
Figure 30
AS
Figure 31
AT
4.Re-tighten the head plate fastening screws (T) with
a 5 mm hex-key wrench to 146 in-lb (16.5 Nm).
Preventive Maintenance and Adjustment

3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-512 Rev. B 12 Dorner Mfg. Corp.
Figure 32
T
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
C− Transfer Tail Pulley Removal
A− Idler Pulley Removal
1.Temporarily support the idler pulley.
Figure 33
2.On one side of conveyor, loosen the two (2) back
fastening screws (T of Figure 34) and remove two
(2) front fastening screws (AU).
Figure 34
T
AU
3.Pull back the outer headplate (U of Figure 35) and
remove the inner spacer (AV).
Figure 35
AV
U
AV
4.Slide the idler pulley assembly (AW of Figure 36)
out of the headplate on the opposite side.
Figure 36
AW
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3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 13 851-512 Rev. B
5.Remove the pulley shaft assembly: remove the clip
ring (AX of Figure 37) and washer (AY) from one
side of the pulley assembly.
Figure 37
AX
AY
6.Slide the shaft assembly (AZ of Figure 38) out of the
pulley (AW).
Figure 38
AZ
AW
B− Drive Pulley Removal
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
1.Remove the gearmotor mounting package:
a− Top and Bottom Mount Packages
b− Side Mount Packages
NOTE: Bottom Mount Package shown, Top Mount
Package similar.
a. Top and Bottom Mount Packages
1) Use a temporary support (BA of Figure 39)to
support Gearmotor.
Figure 39
BA
2) Remove four (4) screws (BB of Figure 40) and
remove cover (BC).
Figure 40
BC
BB
BB
3) Loosen tensioner (BD of Figure 41).
Figure 41
BD
BE
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3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
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4) Remove taper-lock screws (BF of Figure 42) on the
driven pulley (BE of Figure 41). Insert one (1) of
taper lock screws (BF of Figure42) in remaing hole
(BG). Tighten screw (BF) until pulley is loose.
Remove pulley, taper hub assembly and timing belt.
Figure 42
BF
BG
5) Remove four (4) M5 mounting screws (BH of
Figure 43) and two (2) M8 mounting screws (BI).
Figure 43
BI
BH
BJ
6) Remove gearmotor and mounting plate assembly
(BJ of Figure 43).
b. Side Mount Package
1) Temporarily support Gearmotor
2) Loosen the four (4) lock screws (BK of Figure
44).
Figure 44
BK
3) Rotate and remove the gear motor and guard
assembly (BL of Figure 45).
Figure 45
BL
4) Remove the four (4) lock screws (BK of Figure
46) and the short side drive guard (BM).
Figure 46
BM
BK
BN
BO
2.Loosen set screw (BN of Figure 46) and remove
3−jaw coupling (BO).
3.Temporarily support the drive pulley.
Figure 47
4.Remove four shaft cover screws (BP of Figure 48).
Remove the shaft cover (BQ).
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3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 15 851-512 Rev. B
Figure 48
BP
BQ
5.Loosen the bearing collar set screw (BR of Figure
49) and remove bearing collar (BS). Repeat on drive
shaft side of pulley (BR and BS of Figure 50)../mn
Figure 49
BR
BS
Figure 50
BR
BS
6.On the drive headplate, remove two (2) screws (T of
Figure 51).
Figure 51
T
7.Remove the outer headplate assembly (BT of Figure
52), and inner spacer (AV).
Figure 52
BT
AV
8.Slide the drive pulley (BU of Figure 53) out of the
headplate on the opposite side.
Figure 53
BU
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C− Transfer Tail Pulley Removal
1.Temporarily support the transfer tail assembly.
Figure 54
2.On one side of conveyor, remove the two (2) back
fastening screws (T of Figure 55), and the two (2)
front fastening screws (AU).
Figure 55
T
AU
3.Remove the inner spacer (AV of Figure 56).
Figure 56
U
AV
4.Slide the transfer tail pulley assembly (BV of Figure
57) out of the headplate on the opposite side.
Figure 57
BV
5.Remove hex nuts (BW of Figure 58).
Figure 58
BW
6.Remove support plates (BX of Figure 59) and
washers (BY).
Figure 59
BX
BY
7.Remove pulleys (BZ of Figure 60) and additional
washers (CA).
Figure 60
BZ
CA
8.To remove additonal pulleys, repeat steps 6 through
7.
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Dorner Mfg. Corp. 17 851-512 Rev. B
Bearing Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
A− Idler Bearing
B− Drive Bearing
C− Transfer Tail Bearing
A− Idler Bearing Replacement
The bearings in a 3200 Series Idler Pulley can not be
removed. Replace the entire pulley assembly when
worn.
B− Drive Bearing Removal and Replacement
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
Removal
1.Turn bearing (CB of Figure 61) to align with slots
(CC) in bearing housing. Then remove bearing.
Figure 61
CB
CC
Replacement
1.Inspect bearing housing bearing surface. If worn or
damaged, replace. See “Service Parts” on page 19.
2.Insert bearing (CB of Figure 62) into housing slot
(CC). Locate anti−rotation nub (CD) to align with
slot (CE), and twist bearing into housing.
Figure 62
CB
CE
CD
CC
C− Transfer Tail Bearing Replacement
The bearings in a 3200 Series Transfer Tail Pulley
can not be removed. Replace the entire pulley
assembly when worn.
Pulley Replacement
Idler Pulley
To replace the idler pulley, reverse the “Idler Pulley
Removal” proceedure on page 12.
Drive Pulley
To replace the drive pulley, reverse the “Drive Pulley
Removal” proceedure on page 13.
Transfer Tail Pulley
To replace the transfer tail pulley, reverse the “Transfer
Tail Pulley Removal” proceedure on page 16.
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Notes

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Dorner Mfg. Corp. 19 851-512 Rev. B
NOTE: For replacement parts other than those shown in this section, contact an authorized Dorner Service
Center or the factory.
Drive End Tail Assembly
3
7
5
8
13
10
9
12
4
14
15
6
12
11
Item Part Number Description
1 300139 Shaft Cover
2 300885 Bearing Retainer
3 301048 Drive Tail Cover Plate
4 301083 3” Inner Tail Plate
5 301088 Tail Bar Clamp
6 301196 Hex Tension Tracking Shaft
7 3202WW Tail Articulation Bar
8 3216WW Drive Spindle Assy
9 802−135 D−Lok Bearing
10 807−1125 Groove Pin
11 807−1151 Retaining Ring
12 807−1152 Hex Head Cap Screw M6 x 20mm
13 920612M Socket Head Screw M6 x 12mm
14 920893M Low Head Socket Screw M8x16mm
15 920895M Low Head Socket Screw M8x25mm
WW = Conveyor width reference: 04 − 48 in 02 increments
Service Parts

3200 Series End Drive Conveyor Installation, Maintenance & Parts Manual
851-512 Rev. B 20 Dorner Mfg. Corp.
Transfer Tail Assembly
7
8
2
3
12
9
4
14
13
18
19
1
10
17
6
11
16
515
Item Part Number Description
1 301082 Nosebar Cover Plate
2 301084 1” Inner Tail Plate
3 301088 Tail Bar Clamp
4 301090 Transfer Tail Support Plate
5 301196 Hex Tension Tracking Shaft
6 301352 Nut, E−ring, Brace
7 301354 Inner Transfer Tail Support Plate
8 3202WW Tail Articulation Bar
9 3217WW 1” Idler Tail Axel Shaft
10 3235WW Support Bar
11 3237WW Transfer Tail Roller − (Qty. = 4 for
04−24 Wide, 8 for 26−48 Wide)
12 807−1125 Groove Pin
13 807−1136 Washer
14 807−1151 Retaining Ring
15 807−1152 Hex Head Cap Screw M6 x 20mm
16 910−203 3/8” Hex Nut
17 915−319 Retaining Ring
18 920408M Hex Head Cap Screw M4 x 8mm
19 920893M Low Head Socket Screw M8 x 16mm
WW = Conveyor width reference: 04 − 48 in 02 increments
Service PartsService Parts