Dorner 6100 Series User manual

851-488 Rev.A
Maintenance &
Parts Manual
701049 and 701549
6100 Series Quad Pack Conveyor Assembly
Table of Contents
Warnings – General Safety 2. . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance & Adjustment 3. . . . . . . . . . . . . .
Required Tools 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tools 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining Conveyor Belt 3. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement 4. . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement Sequence 4. . . . . . . . . . .
Belt Removal 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Tensioning 6. . . . . . . . . . . . . . . . . . . . . . . .
Pulley Removal 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A – Idler Pulley Removal 6. . . . . . . . . . . . . . . . . . . . . .
B – Drive Pulley Removal 7. . . . . . . . . . . . . . . . . . . . . . .
Drive Bearing Replacement 9. . . . . . . . . . . . . . . . . . . . . .
Drive Bearing Removal 9. . . . . . . . . . . . . . . . . . . . . .
Drive Bearing Installation 9. . . . . . . . . . . . . . . . . . . .
Idler Bearing Replacement 9. . . . . . . . . . . . . . . . . . . . . .
Idler Bearing Removal 9. . . . . . . . . . . . . . . . . . . . . .
Idler Bearing Installation 9. . . . . . . . . . . . . . . . . . . . .
Pulley Replacement 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Pulley 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pulley 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Parts 11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overall Assembly 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Ladder Assembly 11. . . . . . . . . . . . . . . . . . . . . . .
Kickplate Assembly 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Assembly 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive End Assembly 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Policy 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

701049 and 701549 6100 Series Quad Pack Conveyor Assembly Maintenance & Parts Manual
851-488 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
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
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
Ç
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
Ç
Dorner cannot control the
physical installation and
application of conveyors.
Taking protective measures
is the responsibility of the
user.
When conveyors are used in
conjunction with other
equipment or as part of a
multiple conveyor system,
CHECK FOR POTENTIAL
PINCH POINTS and other
mechanical hazards before
system start-up.
Ç
Loosening stand height or
angle adjustment screws
may cause conveyor
sections to drop down,
causing severe injury.
SUPPORT CONVEYOR
SECTIONS PRIOR TO
LOOSENING STAND
HEIGHT OR ANGLE
ADJUSTMENT SCREWS.
Introduction
IMPORTANT: Some illustrations may show
guards removed. Do NOT operate equipment with-
out guards.
Upon receipt of shipment:
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 6100 Series conveyors are covered by Patent
Nos. 5174435,6109472 andcorresponding patentsand
patent applications in other countries.
Dorner reserves the right to make changes at any time
without notice or obligation.
Warnings – General Safety

701049 and 701549 6100 Series Quad Pack Conveyor Assembly Maintenance & Parts Manual
Dorner Mfg. Corp. 3851-488 Rev. A
Refer to Figure 1 for typical conveyor components.
A Conveyor
B Tie Bar
C Outer Support Bar
D Kick Plate
E Motion Sensor
F Spur Gear
G Conveyor Sprocket
H Drive Sprocket
I Idler End
J Drive End
Typical Components
A
B
C
D
E
F
G
I
J
H
Figure 1
Preventative Maintenance & Adjustment
Required Tools
Standard Tools
DBox wrenches
–8 mm
–10 mm
–13 mm
–16 mm
–1/2 in
DHex key wrenches
–3 mm
–5 mm
DNarrow blade screwdriver
DSmall, 2 jaw bearing puller
DArbor press
DTorque Wrench (to 30 in–lb)
Special Tools
D450281 Sealed Bearing Removal Tool
D450282 Sealed Bearing Installation Tool
Checklist
DKeep service parts on hand (see “Service Parts”sec-
tion for recommendations)
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
DForeign material inside the conveyor
DImproperly positioned accessories
DBolt-on guiding is pinching belt
Stalling or slipping indicates:
DExcessive load on belt
DConveyor belt is 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.
Product Description

701049 and 701549 6100 Series Quad Pack Conveyor Assembly Maintenance & Parts Manual
851-488 Rev. A 4Dorner 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 (see
Table of Contents for page number)
DRemove old conveyor belt
DInstall new conveyor belt
DTension conveyor belt
Belt Removal
1.On idler end of the conveyor, insert a 5 mm hex key
wrench to engage pinion gear (Kof Figure 2).
Figure 2
K
2.With pinion gear engaged, place a 10 mm wrench on
lock screw (L of Figure 3).
Figure 3
L
3.While maintaining tension on pinion gear (K of
Figure 4) loosen lock screw (L). Rotate pinion gear
(K) clockwise to release conveyor belt tension.
Figure 4
KL
4.On the eight (8) outer support bars (M of figure 5),
use a 13mm wrench to loosen pivot screws (N).
Loosen slot screws (O).
Figure 5
O
N
M
5.Pivot outer support bars (M of figure 6) along
conveyor frame. Hand tighten screws (N).
Figure 6
N
M
6.Remove conveyor belt, starting from idler end.
Preventive Maintenance and Adjustment

701049 and 701549 6100 Series Quad Pack Conveyor Assembly Maintenance & Parts Manual
Dorner Mfg. Corp. 5851-488 Rev. A
Belt Installation
1.Orient the conveyor belt so that the splice leading
fingers (P of Figure 7) point in the direction of belt
travel (Q of Figures 7 and 8).
Figure 7
P
Q
Figure 8
Q
Q
2.Loop belt (R of Figure 9) over drive pulley (S).
Figure 9
R
S
3.Loop belt (R of Figure 10) on idler end pulley(T).
Figure 10
R
T
4.Tension belt. Refer to “Conveyor Belt Tensioning”on
page 6.
5.On the eight (8) outer support bars. Loosen pivot screw
(N of figure 6).
6.Rotate outer support bar (M of figure 5).
7.Ensure frames are located against the steps of the
support bars (U of figure 11). Tighten screws (N) and
(O) to 140 in–lbs (9.6 N–m).
Figure 11
U
O
N

701049 and 701549 6100 Series Quad Pack Conveyor Assembly Maintenance & Parts Manual
851-488 Rev. A 6Dorner Mfg. Corp.
Conveyor Belt Tensioning
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
1.On tension end of the conveyor insert a 5 mm hex
key wrench to engage pinion gear (Kof Figure 12).
Figure 12
K
2.With pinion gear engaged, place a 10 mm wrench on
lock screw (L of Figure 13).
Figure 13
L
3.Loosen lock screw (L of Figure 14).
Figure 14
KL
NOTE: On pinion gear (K of Figure 12), do not
exceed of 25 in-lb (2.8 Nm). Over-tensioning the
conveyor belt could cause excessive pulley bearing
load and early failure.
4.With V-guide seated in pulley, rotate the pinion gear
(K) counter-clockwise to tension the belt to 25 in–lb
(2.8 N–m).
NOTE: If the maximum take-up stroke is achieved,
replace the conveyor belt.
5.Secure lock screw (L of Figure 14) to 40 in–lb (4.5
N–m)
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 4. Remove the desired
pulley following instructions:
DA–Idler Pulley
DB–Drive Pulley
A–Idler Pulley Removal
1.Loosen connector nut (Y of Figure 15). Remove wire
disconnect (X).
Y
Figure 15
X
2.Remove reed switch (W of Figure 16).
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

701049 and 701549 6100 Series Quad Pack Conveyor Assembly Maintenance & Parts Manual
Dorner Mfg. Corp. 7851-488 Rev. A
W
Figure 16
X
3.Remove pinion lock screw (L of Figure 17).
4.Remove four (4) tail plate mounting screws (Z of
Figures 17 & 18).
Figure 17
Z
L
Figure 18
Z
5.Remove tail assembly.
6.Remove fixed tension support screw (AA of Figure
19).
Figure 19
AB
AC
AA
7.Remove headplate (AB).
8.Remove pulley (AC).
B–Drive Pulley Removal
1.Remove belt from both conveyors attached to the
drive pulley. See “Conveyor Belt Replacement”
section on page 4.
2.Remove chain on drive sprocket (AG of Figure 20).
3.Loosen bearing set screws (AD of Figure 20).
4.Remove the three (3) bolts from bearing flanges (AE
of Figure 20). Remove bearing (AF). Repeat steps 3
and 4 on opposite side.
Figure 20
AE
AE
AD
AD
AG AF
AF
Preventive Maintenance and Adjustment

701049 and 701549 6100 Series Quad Pack Conveyor Assembly Maintenance & Parts Manual
851-488 Rev. A 8Dorner Mfg. Corp.
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
WARNING
5.Remove drive spindle (AH of Figure 21) with spur
gear (AI) and sprocket (AJ) from conveyor.
AH
AI
AJ
Figure 21
6.Remove upper set screws (AK of Figure 22) from
spur gear (AI). Loosen lower set screws (AL).
Remove spur gear (AI) from drive shaft.
Figure 22
AK AL
AK
AL
AI
7.If equipped, loosen set screw (AM of Figure 23) on
sprocket (AJ). Remove sprocket from drive shaft.
AJ
Figure 23
AM
Drive Bearing Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
Drive Bearing Removal
1.Loosen conveyor belt tension. See steps 1 through 3
of “Conveyor Belt Removal”section on page 4.
2.Loosen bearing set screw (AD of Figure 24).
Figure 24
AE
AD
AF
3.Remove the three (3) bolts from bearing flanges (AE
of Figure 24). Remove bearing (AF).
Preventive Maintenance and Adjustment

701049 and 701549 6100 Series Quad Pack Conveyor Assembly Maintenance & Parts Manual
Dorner Mfg. Corp. 9851-488 Rev. A
Drive Bearing Installation
1.Reverse the removal procedure. See steps 2 through
4 above.
2.Tension conveyor belt. See “Conveyor Belt Tension-
ing”on page 6.
Idler Bearing Replacement
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
IMPORTANT: Once removed, do not re-use
bearings.
Idler Bearing Removal
1.Place bearing removal tool (part # 450281) over
bearing(s) with lip (AN of Figure 25) located in
Bearing gap (AO) as shown.
Figure 25
AN
AO
2.Using 3/16¨hex key wrench (AP of Figure 26),
tighten tool.
Figure 26
AP
3.Using a puller (AQ of Figure 27), remove and
discard bearing(s).
Figure 27
AQ
Idler Bearing Installation
IMPORTANT: Install bearings one at a time.
1.Inspect seating surface(s) for damage. Replace if
damaged.
2.Slide bearing (part # 802-120) (AR of Figure 28) onto
pulley shaft.
Figure 28
AR
3.Slide the sleeve of tool (part # 450282) (AS of Figure
29) over bearing.
Figure 29
AS
4.Place open end of shaft (AT of Figure 30) into sleeve.
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

701049 and 701549 6100 Series Quad Pack Conveyor Assembly Maintenance & Parts Manual
851-488 Rev. A 10 Dorner Mfg. Corp.
Figure 30
AT
5.Using arbor press or similar device, press bearing
onto pulley shaft (see Figure 31).
Figure 31
6.Repeat steps 1 through 5 for each bearing.
Pulley Replacement
Idler Pulley
IMPORTANT: On tension tail, be sure to correctly
orient components to match the factory orientation.
1. Orient threaded hole side of pinion (AW of Figure
32) so it is toward detached tail plate as shown.
2. Be sure both pinion housings (AX) engage the
same tooth positions of racks as shown.
3. Orient sensor magnet (AY) as required for motion
sensor.
1.Reverse the removal procedure “A”(see page 6).
Figure 32
AX
AW
AY
Drive Pulley
1.Reverse the removal procedure “B”(see page 7).
Preventive Maintenance and Adjustment