Dorner 3200 Series User manual

851-516 Rev. A
Installation, Maintenance
& Parts Manual
3200 Series Flat Belt LPZ 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 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 – 6¨ (51 – 152 mm) Wide Flat Belt Conveyors 6. . . . . .
8 – 48¨ (203 – 1219 mm) Wide Flat Belt Conveyors 6. . .
Preventative Maintenance & Adjustment 7. . . . . . . . . . . . . . . .
Required Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining Conveyor Belt 7. . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 10. . . . . . . . . . . . .
Belt Installation for Conveyor With
Stands and Gearmotor Mounting Package 10. . . . . . . . . . . .
Conveyor Belt Tensioning 11. . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Tracking 12. . . . . . . . . . . . . . . . . . . . . . . . . .
V – Guided Belts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non V–Guided Belts 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Angle Adjustment 13. . . . . . . . . . . . . . . . . . . . . . .
Pulley Removal 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A – Idler Pulley Removal 14. . . . . . . . . . . . . . . . . . . . . . .
B – Drive Pulley Removal 15. . . . . . . . . . . . . . . . . . . . . .
C – Transfer Tail Pulley Removal 17. . . . . . . . . . . . . . . .
D – Knuckle Idler Pulley Removal 18. . . . . . . . . . . . . . . .
E – Knuckle Return Roller Removal 19. . . . . . . . . . . . . .
Bearing Replacement 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
A – Idler Bearing Replacement 20. . . . . . . . . . . . . . . . . .
B – Drive Bearing Removal and Replacement 20. . . . . . .
C – Transfer Tail Pulley 20. . . . . . . . . . . . . . . . . . . . . . . .
D – Knuckle Idler Pulley 20. . . . . . . . . . . . . . . . . . . . . . .
E – Knuckle Return Roller 20. . . . . . . . . . . . . . . . . . . . . .
Pulley Replacement 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Pulley 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pulley 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Tail Pulley 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Parts 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive End Tail Assembly 22. . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Tail Assembly 23. . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler End Tail Assembly 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Knuckle Assembly 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame Assembly 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Configurations 28. . . . . . . . . . . . . . . . . . . . . . . . .
Guiding Options 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section and Length Determination 28. . . . . . . . . . . . . . . . . .
Walk Through Frame – Section L1 29. . . . . . . . . . . . . . . . .
Walk Through Frame – Section L2 30. . . . . . . . . . . . . . . . .
Walk Through Frame – Section L3 31. . . . . . . . . . . . . . . . .
Noseover Frame – Section L2 32. . . . . . . . . . . . . . . . . . . . . .
Noseover Frame – Section L3 33. . . . . . . . . . . . . . . . . . . . . .
–13 Adjustable Guiding 34. . . . . . . . . . . . . . . . . . . . . . . . . .
Flat Belt Mounting Bracket 35. . . . . . . . . . . . . . . . . . . . . . . .
Connecting Assembly without Stand Mount 36. . . . . . . . . .
Flat Belt Connecting Assembly without
Stand Mount 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4” (102mm) to 6” (152mm) Flat Belt Return Roller 36. . . . .
8” (203mm) to 48” (1219mm) Flat Belt Return Roller 37. . .
Conveyor Belt Part Number Configuration 38. . . . . . . . . . .
Return Policy 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
851-516 Rev. A 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
LPZ Series Conveyors are
not reversible. Reversing
creates pinch points which
can cause severe injury.
DO NOT REVERSE LPZ SE-
RIES CONVEYORS.
WARNING
Ç
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
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
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:
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 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 Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 3851-516 Rev. A
Refer to Figure 1 for typical conveyor components.
A Conveyor
B Gearmotor Mounting Package
C Gearmotor
D Guiding & Accessories
E Mounting Brackets
F Knuckle
G Support Stand
H Drive End
I Idler/Tension End
Typical Components
Figure 1
A
BC
D
EI
F
H
G
Specifications
Models:
Flat Belt LPZ Series End Drive Conveyor
Conveyor Width Reference
Conveyor Section 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 E 1 0 M WW LLLL–LLLL–LLLLA PP BB
0 = 3”tails
1 = 1”tails
Conveyor Section Length
Reference
Conveyor Section Length Reference
E = Elevating
D = Declining
* See Ordering and Specifications Catalog for details.
Conveyor Supports:
Maximum Distances:
J = 24¨(610 mm) (Drive End)
K = 12 ft (3658 mm)
L = 36¨(914 mm) (Idler End)
Maximum Angle:
M = 0 to 35 degrees
KJ
Figure 2
L
M
Product Description

3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
851-516 Rev. A 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 Section
Length Reference
(LLLL)
0200 to 3800 in 0001 increments
(2 ft to 38 ft in 0.12”increments)
Total Conveyor
Length 4 ft (1219mm) 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:
DNon-accumulating product
DProduct moving towards gearmotor
DConveyor being mounted horizontal
Installation
Ç
LPZ Series Conveyors are
not reversible. Reversing
creates pinch points which
can cause severe injury.
DO NOT REVERSE LPZ SE-
RIES CONVEYORS.
WARNING
NOTE: Conveyor MUST be mounted straight, flat
and level within confines of conveyor. Use a level
(N of Figure 3) for setup.
N
Figure 3
Required Tools
DHex-key wrenches:
4 mm, 5 mm
DLevel
DTorque wrench
D8mm hex, open end wrench
Recommended Installation Sequence
DInstall support stands (see accessory instructions)
DAssemble conveyor (if required)
DAttach mounting brackets to conveyor (see page 6
for instructions)
DAdjust angle (see page 13 for instructions)
DAttach conveyor to stands
DInstall return rollers on conveyor (see page 6 for in-
structions)
DMount gearmotor mounting package (see accessory
instructions)
DAttach guides/accessories (see page NO TAG
through NO TAG of “Service Parts”section for
details)
Specifications

3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 5851-516 Rev. A
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 6.
Conveyors Longer Than 13 ft (3962 mm)
1.Locate components (see Figure 4).
O Conveyor frame with knuckle
P Conveyor frame with idler end
Q Belt
R Knuckle
S Intermediate Conveyor Frame (required for convey–
or sections over 13’(3962 mm) long)
Installation Component List
Figure 4
O
P
R
Q
S
2.On tension end of the conveyor, identified by the
pinion locking screw (T of Figure 5), push in head
plate assembly (V): Loosen the pinion locking screw
(T), adjust the pinion torque screw (W of Figure 6).
On both sides of conveyor, loosen the two tail clamp
bolts (U of Figure 5), and push head plate assembly
(V) inward.
Figure 5
UV
T
Figure 6
W
3.Roll out conveyor belt (Q of Figure 7). Loosen (4)
screws (X) on both sides of knuckle (R). Slide frame
(P) into knuckle (R). Tighten screws (X) to 60 in-lb
(7 N–m) on both sides of conveyor.
Figure 7
P
R
X
Q
4.Join additional conveyor sections if necessary and
install connector brackets (Y of Figure 8) or
connector/mount brackets (YA) and screws (Z) on
both sides as indicated. Tighten screws to 60 in-lb (7
Nm).
Figure 8
Y
ZYA
5.Slide belt (Q of Figure 9) over assembled conveyor
sections (AA).
Installation

3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
851-516 Rev. A 6Dorner Mfg. Corp.
Figure 9
Q
AA
6.Tension conveyor belt, refer to “Conveyor Belt
Tensioning”on page 11.
7.Install mounting brackets and return rollers. Refer to
“Mounting Brackets”on page 6 and “Return
Roller”on page 6.
8.Adjust conveyor angle. See “Conveyor Angle Ad-
justment”on page 13.
Mounting Brackets
1.Locate brackets. Exploded views shown in Figure 10.
Figure 10
AB
AF
AE
AD
AC
Mounting Brackets for Flat Belt Conveyor
2.Remove screws (AB & AC of Figure 10), washers
(AD), nuts (AE) and T-bars (AF) from brackets.
3.Insert T-bars (AF of Figure 10) into conveyor side
slots (AF of Figure 11). Fasten brackets (AG of
Figure 11) to conveyor with mounting screws (AB).
Figure 11
AD
AC
AF
AB
AG
AE
4.Fasten brackets to support stand with mounting
screws (AC of Figure 11), washers (AD) and nuts
(AE).
5.Tighten screws (AB & AC of Figure 11) to 60 in-lb
(7 Nm).
Return Rollers
4–6¨(51–152 mm) Wide Flat Belt Conveyors
1.Locate return rollers. Exploded view shown in
Figure 12.
Figure 12
AH AI
AH
AI
Return Rollers for Flat Belt Conveyor
2.Remove screws (AH of Figure 12) and clips (AI)
from roller assembly.
3.Install roller assemblies (AJ of Figure 13) as shown.
Tighten screws (AH) to 60 in-lb (7 Nm).
Figure 13
AH
AJ
AJ
InstallationInstallation

3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 7851-516 Rev. A
8–48¨(203–1219 mm) Wide Flat Belt Conveyors
1.Locate return rollers. Exploded view shown in
Figure 14.
Figure 14
AK AL
AK
AL
2.Remove screws (AK of Figure 14) and clips (AL)
from roller assembly.
3.Install roller assembly as shown (AM of Figure 15).
Tighten screws (AK) to 60 in-lb (7 Nm).
Figure 15
AK
AM
Preventive Maintenance and Adjustment
Required Tools
Standard Tools
DHex-key wrenches:
2.5 mm, 4 mm, 5 mm
D8mm hex, open end wrench
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 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.
Installation

3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
851-516 Rev. A 8Dorner Mfg. Corp.
Conveyor Belt Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
Conveyor Belt Replacement Sequence
DRelease Tension
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
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 (T of Figure 16), push in head
plate assembly (V): Loosen the pinion locking screw
(T), adjust the pinion torque screw (W of Figure 17).
On both sides of conveyor, loosen the two tail clamp
bolts (U of Figure 16), and push head plate assembly
(V) inward.
Figure 16
UV
T
Figure 17
W
3.Remove screws (AN of Figure 18) on both sides of
knuckle and remove guard (AO).
Figure 18
AO
AN
4.Push in hex posts (AP of Figure 19) and remove
roller (AQ).
Figure 19
AP
AQ
Preventive Maintenance and Adjustment

3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 9851-516 Rev. A
5.Remove belt (AR of Figure 20) from conveyor.
Figure 20
AR AR
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 (AS of Figure 21) at
both ends of the conveyor. Place an additional
support stand under the drive motor (AT), if
equipped. See WARNING.
Figure 21
AS
AT AS
AU
AU
2.Remove mounting brackets (AU of Figure 21) 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 (T of Figure 22), push in head
plate assembly (V): Loosen the pinion locking screw
(T), adjust the pinion torque screw (W of Figure 23).
On both sides of conveyor, loosen the two tail clamp
bolts (U of Figure 22), and push head plate assembly
(V) inward.
Figure 22
U
V
T
Figure 23
W
5.Remove screws (AN of Figure 24) on both sides of
knuckle and remove guard (AO).
Figure 24
AO
AN
Preventive Maintenance and Adjustment

3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
851-516 Rev. A 10 Dorner Mfg. Corp.
6.Push in hex posts (AP of Figure 25) and remove
pulley (AQ).
Figure 25
AP
AQ
7.Remove belt (AR of Figure 26) from conveyor.
Figure 26
AR AR
Belt Installation for Conveyor without Stands or
Gearmotor Mounting Package
1.Orient belt so splice leading fingers (AV of Fig-
ure 27) point in the direction of belt travel as identi-
fied by the conveyor directional label (AW).
Figure 27
AV
AW
2.Slide belt onto the conveyor frame assembly.
3.Install spring loaded return pulley (AQ of Figure 28)
into knuckle plate (AX).
Figure 28
AQ AX
4.Install knuckle guard (AO of Figure 29) with screws
(AN) on both sides of knuckle. Tighten screws to 25
in–lbs (3 N–m).
Figure 29
AO
AN
5.Tension belt. Refer to “Conveyor Belt Tensioning”on
page 11.
6.If equipped, install wipers, return rollers and guid-
ing.
Belt Installation 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.Ensure temporary support stands (AS of Figure 21)
are placed at both ends of the conveyor. Place an
additional support stand under the drive motor (AT),
if equipped. See WARNING.
Preventive Maintenance and Adjustment

3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 11 851-516 Rev. A
2.Orient belt so splice leading fingers (AV of Fig-
ure 27) point in the direction of belt travel as identi-
fied by the conveyor directional label (AW).
3.Install belt (AR of Figure 30) on conveyor. Lift
conveyor slightly to avoid pinching belt on tempo-
rary support stands.
Figure 30
AR AR
4.Re-install conveyor mounting brackets. Refer
“Mounting Brackets”on page 6, steps 3 through 5.
5.Install spring loaded return pulley (AQ of Figure 31)
into knuckle plate (AX).
Figure 31
AQ AX
6.Install knuckle guard (AO of Figure 32) with screws
(AN) on both sides of knuckle. Tighten screws to 25
in–lbs (3 N–m).
Figure 32
AO
AN
7.Tension belt. Refer to “Conveyor Belt Tensioning”on
page 11.
8.If equipped, re-install return rollers and guiding.
Conveyor Belt Tensioning
Ç
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
1.On tension end of the conveyor, identified by the
pinion locking screw (T of Figure 33), loosen the
two tail clamp bolts(U), on both sides of conveyor.
Figure 33
U
V
T
2.With 5mm hex wrench, hold pinion torque screw (W
of Figure 34). Loosen the pinion locking screw (T of
Figure 33) and turn the pinion torque screw(W) to
extend head plate assembly.
Figure 34
W
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
851-516 Rev. A 12 Dorner Mfg. Corp.
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 achieved. If proper tensioning can not be
obtained before the belt life indicator is all black (BA
of Figure 35) the belt must be replaced.
Figure 35
BA
4.After adjusting proper tensioning, tighten the pinion
locking screw (T of Figure 33) to 69 in–lbs (7.8
N–m), and tighten tail clamp bolts (U of Figure 33)
on both sides of conveyor to 146 in-lb (16.5 N–m).
5.If belt tracking is necessary, refer to “Conveyor Belt
Tracking”on page 12.
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 (T of Figure 33) and rotate the pinion torque
screw (W of Figure 34) clockwise until contact with
the head plate is made, then tighten the pinion
locking screw (T) to 69 in–lbs (7.8 N–m)
2.On the side of conveyor to be adjusted, loosen two
(2) tail clamp screws(U of Figure 36).
Figure 36
U
T
3.With the conveyor running, use wrench (BB of
Figure 37) to rotate the tracking screw (BC of Figure
38) in small increments until the belt tracks in the
center of the conveyor.
Figure 37
BB
Figure 38
BC
4.Re-tighten the head plate fastening screws (U) with
a 5 mm hex-key wrench to 100 in-lb (12 Nm).
Preventive Maintenance and Adjustment

3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 13 851-516 Rev. A
Figure 39
U
Conveyor Angle Adjustment
Ç
Removing mounting brackets
or adjustment screws without
support under gearmotor and
conveyor will cause conveyor
to tip or drop, causing severe
injury.
PROVIDE SUPPORT UNDER-
NEATH THE GEARMOTOR
WHEN ADJUSTING THE CON-
VEYOR ANGLE
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
1.Place temporary support (BD of Figure 40) under
conveyor sections.
Figure 40
BD
2.Loosen screws (BE of Figure 41) on both sides of
knuckle.
Figure 41
BE
3.Move conveyor to desired angle as indicated by
angle label (BF of Figure 42).
Figure 42
BF
4.Tighten screws (BE of Figure 41) on both sides of
knuckle to 100 in–lbs (12 N–m).
Pulley Removal
Ç
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:
DA–Idler Pulley Removal
DB–Drive Pulley Removal
DC–Transfer Tail Pulley Removal
DD–Knuckle Idler Pulley Removal
DE–Knuckle Return Roller Removal
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3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
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A–Idler Pulley Removal
1.Temporarily support the idler pulley.
Figure 43
2.On one side of conveyor, loosen the two (2) back
fastening screws (U of Figure 44) and remove two
(2) front fastening screws (BG).
Figure 44
U
BG
3.Pull back the outer headplate (V of Figure 45) and
remove the inner spacer (BH).
Figure 45
BH
V
BH
4.Slide the idler pulley assembly (BI of Figure 46) out
of the headplate on the opposite side.
Figure 46
BI
5.Remove the pulley shaft assembly: remove the clip
ring (BJ of Figure 47) and washer (BK) from one
side of the pulley assembly.
Figure 47
BJ
BK
6.Slide the shaft assembly (BL of Figure 48) out of the
pulley (BI).
Figure 48
BL
BI
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3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 15 851-516 Rev. A
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 Drives
b–Side Mount Drives
a. Top and Bottom Mount Drives
1) Use a temporary support (BM of Figure 49)to
support Gearmotor.
Figure 49
BM
2) Remove four (4) screws (BN of Figure 50) and
remove cover (BO).
Figure 50
BO
BN
BN
3) Loosen tensioner (BP of Figure 51).
Figure 51
BP
BQ
4) Remove taper-lock screws (BR of Figure 52) on the
driven pulley (BQ of Figure 51). Insert one (1) of
taper lock screws (BR of Figure 52) in remaining
hole (BS). Tighten screw (BR) until pulley is loose.
Remove pulley, taper hub assembly and timing belt.
Figure 52
BR
BS
5) Remove four (4) M5 mounting screws (BT of
Figure 53) and two (2) M8 mounting screws (BU).
Figure 53
BU
BT
BV
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3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
851-516 Rev. A 16 Dorner Mfg. Corp.
6) Remove gearmotor and mounting plate assembly
(BV of Figure 53).
b. Side Mount Drives
1) Temporarily support Gearmotor
2) Loosen the four (4) lock screw (BW of Figure 54).
Figure 54
BW
3) Rotate and remove the gear motor and guard
assembly (BX of Figure 55).
Figure 55
BX
4) Remove the four (4) lock screws (BW of Figure
56)and the short side drive guard (BY).
Figure 56
BY
BW
2.Temporarily support the drive pulley.
Figure 57
3.Remove four shaft cover screws (BZ of Figure 58).
Remove the shaft cover (CA).
Figure 58
BZ
CA
4.Loosen the bearing collar set screw (CB of Figure
59) and remove bearing collar (CC). Repeat on drive
shaft side of pulley (CB and CC of Figure 60).
Figure 59
CB
CC
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3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 17 851-516 Rev. A
Figure 60
CB
CC
5.On the drive headplate, remove two (2) screws (U of
Figure 61).
Figure 61
U
6.Remove the outer headplate assembly (CD of Figure
62), and inner spacer (BH).
Figure 62
CD
BH
7.Slide the drive pulley (CE of Figure 63) out of the
headplate on the opposite side.
Figure 63
CE
C–Transfer Tail Pulley Removal
1.Temporarily support the transfer tail assembly.
Figure 64
2.On one side of conveyor, loosen the two (2) back
fastening screws (U of Figure 65), and remove the
two (2) front fastening screws (BG).
Figure 65
U
BG
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3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
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3.Pull back the outer headplate (V of Figure 66) and
remove the inner spacer (BH).
Figure 66
V
BH
4.Slide the transfer tail pulley assembly (CF of Figure
67) out of the headplate on the opposite side.
NOTE: Transfer tail assembly must be removed as
on piece. Removal may require removing screws U
of Figure 65 and headplate V of Figure 66 as shown
in Figure 67
Figure 67
CF
5.Remove hex nuts (CG of Figure 68).
Figure 68
CG
6.Remove support plates (CH of Figure 69) and
washers (CI).
Figure 69
CH
CI
7.Remove pulleys (CJ of Figure 70) and additional
washers (CK).
Figure 70
CJ
CK
8.To remove additional pulleys, repeat steps 6 through
7.
D–Knuckle Idler Pulley Removal
1.Remove knuckle return roller and guard see
“Knuckle Return Roller Removal”on page 19.
2.Temporarily support the knuckle idler pulley.
Figure 71
3.On one side of knuckle, remove screws (CL of
Figure 72) and knuckle plate assembly (CM).
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3200 Series Flat Belt LPZ Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 19 851-516 Rev. A
Figure 72
CL
CM
CL
4.Slide the idler pulley assembly (CN of Figure 73) out
of the knuckle plate on the opposite side.
Figure 73
CN
5.Remove the pulley shaft assembly: remove the clip
ring (BJ of Figure 74) and washer (BK) from one
side of the pulley assembly.
Figure 74
BJ
BK
6.Slide the shaft assembly (BL of Figure 48) out of the
pulley (CN).
Figure 75
BL
CN
E–Knuckle Return Roller Removal
1.Remove screws (AN of Figure 76) on both sides of
knuckle and remove guard (AO).
Figure 76
AO
AN
2.Push in hex posts (AP of Figure 77) and remove
pulley (AQ).
Figure 77
AP
AQ
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Bearing Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
DA–Idler Bearing
DB–Drive Bearing
DC–Transfer Tail Bearing
DD–Knuckle Idler Bearing
DE–Knuckle Return Roller 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
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
Removal
1.Turn bearing (CO of Figure 78) to align with slots
(CP) in bearing housing. Then remove bearing.
Figure 78
CO
CP
Replacement
1.Inspect bearing housing bearing surface. If worn or
damaged, replace. See “Service Parts”on page 22.
2.Insert bearing (CO of Figure 79) into housing slot
(CP). Locate anti–rotation nub (CQ) to align with
slot (CR), and twist bearing into housing.
Figure 79
CO
CR
CQ
CP
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.
D–Knuckle Idler Bearing Replacement
The bearings in a 3200 Series Knuckle Idler Pulley
can not be removed. Replace the entire pulley
assembly when worn.
E–Knuckle Return Roller Bearing Replacement
The bearings in a 3200 Series Knuckle Return Roller
can not be removed. Replace the entire roller
assembly when worn.
Pulley Replacement
Idler Pulley
To replace the idler pulley, reverse the “Idler Pulley
Removal”procedure on page 14.
Drive Pulley
To replace the drive pulley, reverse the “Drive Pulley
Removal”procedure on page 15.
Transfer Tail Pulley
To replace the transfer tail pulley, reverse the “Transfer
Tail Pulley Removal”procedure on page 17.
Knuckle Pulley
To replace the knuckle pulley, reverse the “Knuckle
Pulley Removal”procedure on page 15.
Knuckle Return Roller
To replace the knuckle return roller, reverse the
“Knuckle Return Roller Removal”procedure on page
19.
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment