Dorner 3200 Series User manual

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DORNER MFG. CORP. INSIDE THE USA OUTSIDE THE USA
P.O. Box 20 • 975 Cottonwood Ave. TEL: [phone] TEL: [phone]
Hartland, WI 53029-0020 USA FAX: [phone] FAX: [phone]
851-512 Rev. H
3200 Series End Drive Flat and
Cleated Belt Conveyors
Installation, Maintenance & Parts Manual

851-512 Rev. H 2 Dorner Mfg. Corp.
3200 Series End Drive Flat and Cleated Belt Conveyors
Table of Contents
Introduction.......................................................................... 3
Warnings −General Safety .................................................. 3
Product Description.............................................................. 4
Specifications ....................................................................... 4
Installation............................................................................ 6
Required Tools ................................................................. 6
Recommended Installation Sequence............................... 6
Conveyors Up to 13 ft (3962 mm) ................................... 6
Conveyors Longer Than 13 ft (3962 mm)........................ 6
Mounting Brackets ........................................................... 7
Return Rollers................................................................... 8
Cleated Belt and 4–6” (51–152 mm) Wide Flat Belt
Conveyors ..................................................................... 8
8–48” (203–1219 mm) Wide Flat Belt Conveyors....... 8
Preventive Maintenance and Adjustment ............................ 9
Required Tools ................................................................. 9
Standard Tools .............................................................. 9
Checklist ........................................................................... 9
Lubrication ....................................................................... 9
Maintaining Conveyor Belt .............................................. 9
Troubleshooting ............................................................ 9
Cleaning ........................................................................ 9
Conveyor Belt Replacement ......................................... 9
Conveyor Belt Replacement Sequence......................... 9
Belt Removal for Conveyor Without Stands or
Gearmotor Mounting Package ...................................... 9
Belt Removal for Conveyor With Stands and Gearmotor
Mounting Package ...................................................... 10
Belt Installation for Conveyor without Stands or
Gearmotor Mounting Package .................................... 11
Belt Installation for Conveyor with Stands and
Gearmotor Mounting Package .................................... 11
Conveyor Belt Tensioning.............................................. 12
Conveyor Belt Tracking ................................................. 12
V-Guided Belts ........................................................... 12
Non V-Guided Belts ................................................... 13
Pulley Removal .............................................................. 13
A −Idler Pulley Removal ........................................... 14
B −Drive Pulley Removal.......................................... 15
C −Transfer Tail Pulley Removal.............................. 18
Bearing Replacement...................................................... 19
A −Idler Bearing Replacement .................................. 19
B −Drive Bearing Removal and Replacement........... 19
Removal .................................................................. 19
Replacement ............................................................ 19
C −Transfer Tail Bearing Replacement ..................... 19
Pulley Replacement ........................................................ 19
Idler Pulley.................................................................. 19
Drive Pulley ................................................................ 19
Transfer Tail Pulley .................................................... 19
Notes .................................................................................. 20
Service Parts ...................................................................... 21
Drive End Tail Assembly............................................... 21
Transfer Tail Assembly.................................................. 22
Idler End Assembly........................................................ 23
Frame Assembly ............................................................ 24
Bed Plate and Frame Formulas .................................. 25
−04 3” (76mm) Aluminum Side .................................... 26
Length Formulas......................................................... 26
Example...................................................................... 26
−05 1.5” (38mm) Aluminum Side ................................. 27
Length Formulas......................................................... 27
Example...................................................................... 27
−07 Low to Side Wiper.................................................. 28
Length Formulas......................................................... 28
Example...................................................................... 28
−09 Low to High Side.................................................... 29
Length Formulas......................................................... 29
Example...................................................................... 29
−10.5” (13mm) Extruded Plastic ................................... 30
Length Formulas......................................................... 30
Example...................................................................... 30
−13 Adjustable Guiding ................................................. 31
−14 Tool-Less Adjustable Guiding................................ 32
.5” (13mm) Cleated Guiding.......................................... 33
Length Formulas......................................................... 33
Example...................................................................... 33
1” (25mm) Cleated Guiding........................................... 34
Length Formulas......................................................... 34
Example...................................................................... 34
2” (51mm) Cleated Guiding........................................... 35
Length Formulas......................................................... 35
Example...................................................................... 35
Flared Side Guiding ....................................................... 36
Flat Belt Mounting Brackets.......................................... 37
Cleated Belt Mounting Brackets .................................... 37
Connecting Assembly without Stand Mount ................. 38
Flat Belt Connecting Assembly with Stand Mount ....... 38
Cleated Belt Connecting Assembly with Stand Mount . 39
4” (102mm) to 6” (152mm) Flat Belt Return Roller ..... 39
8” (203mm) to 48” (1219mm) Flat Belt Return Roller . 40
Cleated Belt Return Roller............................................. 40
Conveyor Belt Part Number Configuration ................... 41
Flat Belt Part Number Configuration ......................... 41
Cleated Belt Part Number Configuration ................... 41
Return Policy ..................................................................... 42

851-512 Rev. H 3 Dorner Mfg. Corp.
3200 Series End Drive Flat and Cleated Belt Conveyors
Introduction
Upon receipt of shipment:
• Compare shipment with packing slip. Contact factory
regarding discrepancies.
• Inspect packages for shipping damage. Contact carrier
regarding damage.
• Accessories may be shipped loose. See accessory instruc-
tions for installation.
Dorner’s Limited Warranty applies.
Dorner 3200 series conveyors are covered by Patent
Numbers 5,156,260, 6,871,737B2, 6,910,571B1,
6,971,509B2, and corresponding patents and patent
applications in other countries.
Dorner reserves the right to make changes at any time
without notice or obligation.
Dorner has convenient, pre−configured kits of Key Service
Parts for all conveyor products. These time saving kits are
easy to order, designed for fast installation, and guarantee
you will have what you need when you need it. Key Parts
and Kits are marked in the Service Parts section of this
manual with the Performance Parts Kits logo .
Warnings −General Safety
IMPORTANT
Some illustrations may show guards removed.
DO NOT operate equipment without guards.
A
WARNING
The safety alert symbol, black triangle with
white exclamation, is used to alert you to
potential personal injury hazards.
A
DANGER
Climbing, sitting, walking or riding on
conveyor will cause severe injury. KEEP OFF
CONVEYORS.
A
DANGER
DO NOT OPERATE CONVEYORS IN AN
EXPLOSIVE ENVIRONMENT.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
A
WARNING
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
A
WARNING
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.
A
WARNING
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.

Dorner Mfg. Corp. 4 851-512 Rev. H
3200 Series End Drive Flat and Cleated Belt Conveyors
Product Description
Refer to Figure 1 for typical components.
Typical Components:
Figure 1
Figure 1
Specifications
Models:
Flat Belt 3200 Series Conveyor
Cleated Belt 3200 Series Conveyor
* See Ordering and Specifications Catalog for details.
A Conveyor
B Gearmotor Mounting Package
C Gearmotor
D Guiding & Accessories
E Mounting Brackets
F Return Rollers
G Support Stand
H Variable Speed Controller
IDriveEnd
J Idler/Tension End
A
BCD
E
E
J
F
G
H
I
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

851-512 Rev. H 5 Dorner Mfg. Corp.
3200 Series End Drive Flat and Cleated Belt Conveyors
Specifications
Conveyor Supports:
Maximum Distances:
K = 24” (610 mm) (Drive End)
L = 12 ft (3658 mm)
M = 36” (914 mm) (Idler End)
Figure 2
Figure 2
Specifications:
* See Ordering and Specifications Catalog for details.
LK M
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
Reference (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

Dorner Mfg. Corp. 6 851-512 Rev. H
3200 Series End Drive Flat and Cleated Belt Conveyors
Installation
Figure 3
Figure 3
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 21 through 35 of
“Service Parts” section for details)
Conveyors Up to 13 ft (3962 mm)
No assembly is required. Install mounting brackets and
return rollers. Refer to “Mounting Brackets” on page 7 and
“Return Rollers” on page 8.
Conveyors Longer Than 13 ft
(3962 mm)
Installation Component List:
1. Locate and arrange conveyor sections by section labels
(Figure 4, item P).
Figure 4
Figure 4
2. On tension end of the conveyor, identified by the pinion
locking screw (Figure 5, item S), push in head plate
assembly (U): Loosen the pinion locking screw (S),
adjust the pinion torque screw (Figure 6, item V). On
both sides of conveyor, loosen the two tail clamp bolts
(Figure 5, item T), and push head plate assembly (U)
inward.
Figure 5
Figure 5
NOTE
Conveyor MUST be mounted straight, flat and
level within confines of conveyor. Use a level
(Figure 3, item N) for setup.
N
O Conveyor frame
P Section Label
P
P
O
TU
S

851-512 Rev. H 7 Dorner Mfg. Corp.
3200 Series End Drive Flat and Cleated Belt Conveyors
Installation
Figure 6
Figure 6
3. Roll out conveyor belt and place conveyor frame
sections (Figure 7, item O) into belt loop.
Figure 7
Figure 7
4. Join conveyor sections and install connector brackets
(Figure 8, item W) or connector/mount brackets (WA)
and screws (X) on both sides as indicated. Tighten
screws to 60 in-lb (7 Nm).
Figure 8
Figure 8
Figure 9
Figure 9
5. Tighten conveyor belt, refer to “Conveyor Belt
Tensioning” on page 12.
6. Install mounting brackets and return rollers. Refer to
“Mounting Brackets” on page 7 and “Return Roller” on
page 8.
Mounting Brackets
1. Locate brackets. Exploded views shown in Figure 10 &
Figure 11.
Figure 10
Figure 10
Figure 11
Figure 11
NOTE
For Conveyors longer than 20 ft (6096 mm)
use the process outlined in the “Conveyor
Belt Tensioning” section on page 12. Extend
the Drive End Tail Assembly to the zero mark
of the tension indicator (Figure 9, item AR)
before proceeding to step 5. The zero mark
for the tension indicator is when the indicator
begins to turn black.
V
OO
W
XWA
AR
Y
AC
AB
AA
Z
Mounting Brackets for Flat Belt Conveyor
YAC
AB
AA
Z
Mounting Brackets for Cleated Belt Conveyor

Dorner Mfg. Corp. 8 851-512 Rev. H
3200 Series End Drive Flat and Cleated Belt Conveyors
Installation
2. Remove screws (Figure 10, item Y & Z) & (Figure
11, item Y & Z), washers (AA), nuts (AB) and T-bars
(AC) from brackets.
3. Insert T-bars (Figure 10, item AC) & (Figure
11, item AC) into conveyor side slots (Figure
12, item AC). Fasten brackets (Figure 12, item AD) to
conveyor with mounting screws (Y).
Figure 12
Figure 12
4. Fasten brackets to support stand with mounting screws
(Figure 12, item Z), washers (AA) and nuts (AB).
5. Tighten screws (Figure 12, item Y & Z) to 60 in-lb (7
Nm).
Return Rollers
Cleated Belt and 4–6” (51–152 mm) Wide
Flat Belt Conveyors
1. Locate return rollers. Exploded views shown in Figure
13 & Figure 14.
Figure 13
Figure 13
Figure 14
Figure 14
2. Remove screws (Figure 13, item AE) & (Figure
14, item AE) and clips (AF) from roller assembly.
3. Install roller assemblies (Figure 15, item AG) as shown.
Tighten screws (AE) to 60 in-lb (7 Nm).
Figure 15
Figure 15
8–48” (203–1219 mm) Wide Flat Belt
Conveyors
1. Locate return rollers. Exploded view shown in Figure
16.
Figure 16
Figure 16
2. Remove screws (Figure 16, item AH) and clips (AI)
from roller assembly.
3. Install roller assembly as shown (Figure 17, item AJ).
Tighten screws (AH) to 60 in-lb (7 Nm).
Figure 17
Figure 17
NOTE
Mounting brackets for flat belt conveyors
shown.
AA
Z
AC
Y
AD
AB
AE AF
AE
AF
Return Rollers for Flat Belt Conveyor
AF
AE
AF
AE
AE
AG
AG
AH AI
AH
AI
AH
AJ

851-512 Rev. H 9 Dorner Mfg. Corp.
3200 Series End Drive Flat and Cleated Belt Conveyors
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” section for
recommendations)
• Keep supply of belt cleaner
• Clean entire conveyor and knurled pulley while disassem-
bled
• Replace worn or damaged parts
Lubrication
No lubrication is required. Replace bearings if worn.
Maintaining Conveyor Belt
Troubleshooting
Inspect conveyor belt for:
• Surface cuts or wear
• Stalling or slipping
• Damage to V-guide
Surface cuts and wear indicate:
• Sharp or heavy parts impacting belt
• Jammed parts
• Improperly installed bottom wipers (if installed)
• Accumulated dirt in wipers (if installed)
• Foreign material inside the conveyor
• Improperly positioned accessories
• Bolt-on guiding is pinching belt
Stalling or slipping indicates:
• Excessive load on belt
• Conveyor belt or drive timing belt are not properly ten-
sioned
• Worn knurl or impacted dirt on drive 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
Cleaning
Use Dorner Belt Cleaner. Mild soap and water may also be
used. Do not soak the belt.
For /05 woven polyester and /06 black anti-static belts, use a
bristled brush to improve cleaning.
Conveyor Belt Replacement
Conveyor Belt Replacement Sequence
• Remove old conveyor belt:
-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.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.

Dorner Mfg. Corp. 10 851-512 Rev. H
3200 Series End Drive Flat and Cleated Belt Conveyors
Preventive Maintenance and Adjustment
2. On tension end of the conveyor, identified by the pinion
locking screw (Figure 18, item S), push in head plate
assembly (U): Loosen the pinion locking screw (S),
adjust the pinion torque screw (Figure 19, item V). On
both sides of conveyor, loosen the two tail clamp bolts
(Figure 18, item T), and push head plate assembly (U)
inward.
Figure 18
Figure 18
Figure 19
Figure 19
3. Remove conveyor belt.
Belt Removal for Conveyor With Stands
and Gearmotor Mounting Package
1. Place temporary support stands (Figure 20, item AK) at
both ends of the conveyor. Place an additional support
stand under the drive motor (AL), if equipped. See
WAR N I NG.
Figure 20
Figure 20
2. Remove mounting brackets (Figure 20, item AM) from
one side of conveyor. (Reverse steps 3 & 4 of
“Mounting Brackets” section on page 7).
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 (Figure 21, item S), push in head plate
assembly (U): Loosen the pinion locking screw (S),
adjust the pinion torque screw (Figure 22, item V). On
both sides of conveyor, loosen the two tail clamp bolts
(Figure 21, item T), and push head plate assembly (U)
inward.
Figure 21
Figure 21
Figure 22
Figure 22
5. Remove belt (Figure 23, item AN) from conveyor.
Figure 23
Figure 23
A
WARNING
Removing mounting brackets without
support under gearmotor will cause
conveyor to tip, causing severe injury.
PROVIDE SUPPORT UNDERNEATH THE
GEARMOTOR WHEN CHANGING THE BELT
TU
S
V
AK
AL AK
AM
AM
T
U
S
V
AN AN

851-512 Rev. H 11 Dorner Mfg. Corp.
3200 Series End Drive Flat and Cleated Belt Conveyors
Preventive Maintenance and Adjustment
Belt Installation for Conveyor without
Stands or Gearmotor Mounting Package
1. Orient belt so splice leading fingers (Figure
24, item AO) point in the direction of belt travel as
identified by the conveyor directional label (AP).
Figure 24
Figure 24
2. Slide belt onto the conveyor frame assembly.
3. Tension belt. Refer to “Conveyor Belt Tensioning” on
page 12.
4. If equipped, install wipers, return rollers and guiding
Belt Installation for Conveyor with Stands
and Gearmotor Mounting Package
1. Ensure temporary support stands (Figure 20, item AK)
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 (Figure
24, item AO) point in the direction of belt travel as
identified by the conveyor directional label (AP).
3. Install belt (Figure 25, item AN) on conveyor. Lift
conveyor slightly to avoid pinching belt on temporary
support stands.
Figure 25
Figure 25
4. Re-install conveyor mounting brackets. Refer
“Mounting Brackets” on page 7, steps 3 through 5.
5. Tension belt. Refer to “Conveyor Belt Tensioning” on
page 12.
6. If equipped, re-install return rollers and guiding.
AO
AP
A
WARNING
Removing mounting brackets without
support under gearmotor will cause
conveyor to tip, causing severe injury.
PROVIDE SUPPORT UNDERNEATH THE
GEARMOTOR WHEN CHANGING THE BELT
AN AN

Dorner Mfg. Corp. 12 851-512 Rev. H
3200 Series End Drive Flat and Cleated Belt Conveyors
Preventive Maintenance and Adjustment
Conveyor Belt Tensioning
1. On tension end of the conveyor, identified by the pinion
locking screw (Figure 26, item S), loosen the two tail
clamp bolts (T), on both sides of conveyor.
Figure 26
Figure 26
2. With 5mm hex wrench, hold pinion torque screw
(Figure 27, item V). Loosen the pinion locking screw
(Figure 26, item S) and turn the pinion torque screw (V)
to extend head plate assembly.
Figure 27
Figure 27
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 (Figure
28, item AR) the belt must be replaced.
Figure 28
Figure 28
4. After adjusting proper tensioning, tighten the pinion
locking screw (Figure 26, item S) to 69 in−lbs (7.8 N−
m), and tighten tail clamp bolts (Figure 26, item T) 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-guides on belts help maintain proper belt tracking. Track
as needed to reduce belt bulge from center of belt (Figure
29). See steps below in “Non V-guided Belts” procedure for
adjusting for any belt bulging. Belt bulge will be minimal
when belt is properly tracked.
Figure 29
Figure 29
A
WARNING
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)
the belt tensioning procedure outlined below
may be preformed on both the Drive and Idler
Ends of the conveyor.
TU
S
V
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.
AR

851-512 Rev. H 13 Dorner Mfg. Corp.
3200 Series End Drive Flat and Cleated Belt Conveyors
Preventive Maintenance and Adjustment
Non V-Guided Belts
Non V-guided belt conveyors are equipped with belt tracking
assemblies.
When adjusting belt tracking, always adjust the discharge
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
(Figure 26, item S) and rotate the pinion torque screw
(Figure 27, item V) 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 (Figure 30, item T).
Figure 30
Figure 30
3. With the conveyor running, use wrench (Figure
31, item AS) to rotate the tracking screw (Figure
32, item AT) in small increments until the belt tracks in
the center of the conveyor.
Figure 31
Figure 31
Figure 32
Figure 32
4. Re-tighten the head plate fastening screws (Figure
33, item T) with a 5 mm hex-key wrench to 146 in-lb
(16.5 Nm).
Figure 33
Figure 33
Pulley Removal
Remove conveyor belt to access pulley(s). See “Conveyor
Belt Replacement” on page 9. Remove the desired pulley
following the corresponding instructions below:
•A−Idler Pulley Removal
•B−Drive Pulley Removal
•C−Transfer Tail Pulley Removal
T
S
AS
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
AT
T

Dorner Mfg. Corp. 14 851-512 Rev. H
3200 Series End Drive Flat and Cleated Belt Conveyors
Preventive Maintenance and Adjustment
A −Idler Pulley Removal
1. Temporarily support the idler pulley.
Figure 34
Figure 34
2. On one side of conveyor, loosen the two (2) back
fastening screws (Figure 35, item T) and remove two (2)
front fastening screws (AU).
Figure 35
Figure 35
3. Pull back the outer headplate (Figure 36, item U) and
remove the inner spacer (AV).
Figure 36
Figure 36
4. Slide the idler pulley assembly (Figure 37, item AW)
out of the headplate on the opposite side.
Figure 37
Figure 37
5. Remove the pulley shaft assembly: remove the clip ring
(Figure 38, item AX) and washer (AY) from one side of
the pulley assembly.
Figure 38
Figure 38
6. Slide the shaft assembly (Figure 39, item AZ) out of the
pulley (AW).
Figure 39
Figure 39
T
AU
AV
U
AW
AX
AY
AZ
AW

851-512 Rev. H 15 Dorner Mfg. Corp.
3200 Series End Drive Flat and Cleated Belt Conveyors
Preventive Maintenance and Adjustment
B −Drive Pulley Removal
1. Remove the gearmotor mounting package:
• Top and Bottom Mount Packages
• Side Mount Packages
Top and Bottom Mount Packages
a. Use a temporary support (Figure 40, item BA) to
support Gearmotor.
Figure 40
Figure 40
b. Remove four (4) screws (Figure 41, item BB) and
remove cover (BC).
Figure 41
Figure 41
c. Loosen tensioner (Figure 42, item BD).
Figure 42
Figure 42
d. Remove taper-lock screws (Figure 43, item BF) on
the driven pulley (Figure 42, item BE). Insert one
(1) of taper lock screws (Figure 43, item BF) in
remaining hole (BG). Tighten screw (BF) until
pulley is loose. Remove pulley, taper hub assembly
and timing belt.
Figure 43
Figure 43
A
WARNING
Drive shaft keyway may be sharp. HANDLE
WITH CARE.
NOTE
Bottom Mount Package shown, Top Mount
Package similar.
BA
BC
BB
BB
BD
BE
BF
BG

Dorner Mfg. Corp. 16 851-512 Rev. H
3200 Series End Drive Flat and Cleated Belt Conveyors
Preventive Maintenance and Adjustment
e. Remove four (4) M5 mounting screws (Figure
44, item BH) and two (2) M8 mounting screws
(BI).
Figure 44
Figure 44
f. Remove gearmotor and mounting plate assembly
(Figure 44, item BJ).
Side Mount Package
a. Temporarily support Gearmotor.
b. Loosen the four (4) lock screws (Figure
45, item BK).
Figure 45
Figure 45
c. Rotate and remove the gear motor and guard
assembly (Figure 46, item BL).
Figure 46
Figure 46
d. Remove the four (4) lock screws (Figure
47, item BK) and the short side drive guard (BM).
Figure 47
Figure 47
2. Loosen set screw (Figure 47, item BN) and remove 3−
jaw coupling (BO).
3. Temporarily support the drive pulley.
Figure 48
Figure 48
4. Remove four shaft cover screws (Figure 49, item BP).
Remove the shaft cover (BQ).
Figure 49
Figure 49
BI
BH
BJ
BL
BM
BK
BN
BO
BP
BQ

851-512 Rev. H 17 Dorner Mfg. Corp.
3200 Series End Drive Flat and Cleated Belt Conveyors
Preventive Maintenance and Adjustment
5. Loosen the bearing collar set screw (Figure
50, item BR) and remove bearing collar (BS). Repeat on
drive shaft side of pulley (Figure 51, item BR and BS).
Figure 50
Figure 50
Figure 51
Figure 51
6. On the drive headplate, remove two (2) screws (Figure
52, item T). 60 in-lb (7 Nm)
Figure 52
Figure 52
7. Remove the outer headplate assembly (Figure
53, item BT), and inner spacer (AV).
Figure 53
Figure 53
8. Slide the drive pulley (Figure 54, item BU) out of the
headplate on the opposite side.
Figure 54
Figure 54
NOTE
When reassembling, tighten the bearing
collar set screws to 52 in-lbs (6 Nm). Check
after 24 hours of conveyor use.
BR
BS
BR
BS
T
BT
AV
BU

Dorner Mfg. Corp. 18 851-512 Rev. H
3200 Series End Drive Flat and Cleated Belt Conveyors
Preventive Maintenance and Adjustment
C −Transfer Tail Pulley Removal
1. Temporarily support the transfer tail assembly.
Figure 55
Figure 55
2. On one side of conveyor, remove the two (2) back
fastening screws (Figure 56, item T), and the two (2)
front fastening screws (AU)
Figure 56
Figure 56
3. Remove the inner spacer (Figure 57, item AV).
Figure 57
Figure 57
4. Slide the transfer tail pulley assembly (Figure
58, item BV) out of the headplate on the opposite side.
Figure 58
Figure 58
5. Remove hex nuts (Figure 59, item BW).
Figure 59
Figure 59
6. Remove support plates (Figure 60, item BX) and
washers (BY).
Figure 60
Figure 60
7. Remove pulleys (Figure 61, item BZ) and additional
washers (CA).
Figure 61
Figure 61
8. To remove additional pulleys, repeat steps 6 through 7.
T
AU
U
AV
BV
BW
BX
BY
BZ
CA

851-512 Rev. H 19 Dorner Mfg. Corp.
3200 Series End Drive Flat and Cleated Belt Conveyors
Preventive Maintenance and Adjustment
Bearing Replacement
•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
Removal
1. Turn bearing (Figure 62, item CB) to align with slots
(CC) in bearing housing. Then remove bearing.
Figure 62
Figure 62
Replacement
1. Inspect bearing housing bearing surface. If worn or
damaged, replace. See “Service Parts” on page 21.
2. Insert bearing (Figure 63, item CB) into housing slot
(CC). Locate anti−rotation nub (CD) to align with slot
(CE), and twist bearing into housing.
Figure 63
Figure 63
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” 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 18.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
A
WARNING
Drive shaft keyway may be sharp. HANDLE
WITH CARE.
CB
CC
CB
CE
CD
CC

Dorner Mfg. Corp. 20 851-512 Rev. H
3200 Series End Drive Flat and Cleated Belt Conveyors
Notes