Dorner 6200 Series User manual

851-565 Rev. B
Installation, Maintenance
& Parts Manual
6200 Series Industrial End Drive 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) 4. . . . . . . . . . . . . . . . .
Conveyors Longer Than 13 ft (3962 mm) 5. . . . . . . . . . . .
Mounting Brackets 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Rollers 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2¨ to 6¨ (51 mm to 152 mm) Wide Conveyors 6. . . . . .
8¨ (203 mm) to 18¨ (457 mm) Wide
Flat Belt Conveyors 7. . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance & Adjustment 8. . . . . . . . . . . . . .
Required Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyors with Standard 0.47¨ (12 mm) Diameter
Output Shaft 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor with Optional Gang Drive Pulley 8. . . . . . . .
Return Rollers 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining Conveyor Belt 9. . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement 9. . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement Sequence 9. . . . . . . . . . . .
Belt Removal for Conveyor Without
Gearmotor Mounting Package or Stands 9. . . . . . . . . . . .
Belt Removal for Conveyor With Stands
and/or Gearmotor Mounting Package 10. . . . . . . . . . . . .
Belt Removal for Conveyor With
Optional Gang Drive Pulley 11. . . . . . . . . . . . . . . . . .
Belt Installation for Conveyor Without
Gearmotor Mounting Package or Stands 11. . . . . . . . . . .
Belt Installation for Conveyor With Stands
and/or Gearmotor Mounting Package 12. . . . . . . . . . . . .
Belt Installation for Conveyor With
Optional Gang Drive Pulley 12. . . . . . . . . . . . . . . . . .
Conveyor Belt Tensioning 12. . . . . . . . . . . . . . . . . . . . . . .
Pulley Removal 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A −Removal of Drive Pulley with Standard
0.47¨ (12 mm) Diameter Outboard Shaft 13. . . . . . . . .
B −Idler Pulley Removal 14. . . . . . . . . . . . . . . . . . . . .
C −Gang Drive Pulley Removal 15. . . . . . . . . . . . . . . .
Bearing Replacement for Drive Pulley with Standard
0.47¨ (12 mm) Diameter Output Shaft or Idler Pulley 15.
Bearing Removal 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Installation 16. . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Replacement for a Gang Drive Pulley 17. . . . . . .
Bearing Removal 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Installation 18. . . . . . . . . . . . . . . . . . . . . . . . . .
Pulley Installation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Parts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive End Components 20. . . . . . . . . . . . . . . . . . . . . . . . .
Tension End Components 21. . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Frame and Extensions 22. . . . . . . . . . . . . . . . . .
Gang Drive Thru−Shaft Option 23. . . . . . . . . . . . . . . . . . .
−02 0 .5” (13 mm) Bolt−On High Side Guides 24. . . . . . .
−03 Bolt−On Side Wipers 25. . . . . . . . . . . . . . . . . . . . . . .
−04 3” (76 mm) Bolt−On High Side Guides 26. . . . . . . . .
−05 1.5” (38 mm) Bolt−On High Side Guides 27. . . . . . . .
−13 Fully Adjustable UHMW Guides 28. . . . . . . . . . . . . .
−20 Adjustable Width UHMW Guides 29. . . . . . . . . . . . .
1” (25 mm) Cleated Belt Conveyor Guides 30. . . . . . . . . .
2” (51 mm) Cleated Belt Conveyor Guides 31. . . . . . . . . .
2” (51 mm) Through 6” (152 mm) Flat Belt and
Cleated Belt Return Roller 32. . . . . . . . . . . . . . . . . . . . . . .
8” (203 mm) Through 18” (457 mm) Flat Belt
Return Roller 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Mounting Brackets 33. . . . . . . . . . . . . . . . . . . .
Configuring Conveyor Belt Part Number 33. . . . . . . . . . .
Return Policy 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-565 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
Ç
Climbing, sitting, walking or
riding on conveyor will
cause severe injury.
KEEP OFF CONVEYORS.
DANGER
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
Ç
Dorner cannot control the
physical installation and
application of conveyors.
Taking protective measures
is the responsibility of the
user.
When conveyors are used in
conjunction with other equip-
ment or as part of a multiple
conveyor system, CHECK
FOR POTENTIAL PINCH
POINTS and other mechani-
cal hazards before system
start-up.
Ç
Loosening stand height or
angle adjustment screws
may cause conveyor
sections to drop down,
causing severe injury.
SUPPORT CONVEYOR
SECTIONS PRIOR TO
LOOSENING STAND HEIGHT
OR ANGLE ADJUSTMENT
SCREWS.
Introduction
IMPORTANT: Some illustrations may show guards
removed. Do NOT operate equipment without guards.
Upon receipt of shipment:
DCompare shipment with packing slip. Contact factory
regarding discrepancies.
DInspect packages for shipping damage. Contact carrier
regarding damage.
DAccessories may be shipped loose. See accessory in-
structions for installation.
Dorner’s Limited Warranty applies.
Dorner 6200 Series conveyors are covered by Patent
Nos. 5174435, 6109427 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

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 3851-565 Rev. B
Refer to Figure 1 for typical conveyor components.
A Conveyor
B Gearmotor
C Belt (Cleated Belt Shown)
D Mounting Plates
E Stand Mounting Brackets
F Support Stands
G Variable Speed Controller
H Drive End
I Idler/Tension End
Typical Components
A
B
C
G
H
I
F
Figure 1
E
D
Specifications
Models:
Flat Belt 6200 Series Industrial Conveyor
Conveyor Width Reference
Conveyor Length Reference
Belt Type*
Output Shaft Position*
Conveyor Profile*
2 = End drive
3 = Gang drive
Document Language, M = English
6 D B M WW LLLL P GG BB
1= No wiper −with mounting bracket
2 = No wiper −no mounting bracket
3 = End wiper −with mounting bracket
4 = End wiper −no mounting bracket
5 = Dual wiper −with mounting bracket
6 = Dual wiper −no mounting Bracket
Cleated Belt 6200 Series Industrial Conveyor
Conveyor Width Reference
Conveyor Length Reference
Output Shaft Position*
Cleat Spacing*
Cleat type (A−J)*
Document Language, M = English
6 D B M WW LLLL P SSSS
7= Low Friction Cleated −with mounting bracket
8 = Low Friction Cleated −no mounting bracket
* See “Ordering and Specifications” Catalog for details.
Conveyor Supports:
Maximum Distances:
J = 18¨ (457 mm)**
K= 6 ft (1829 mm)***
L= 18¨ (457 mm)
** For Heavy Load Bottom Mount Package, mount
support under gear head.
*** For conveyors longer than 13 ft (3962 mm), install
support at joint.
Figure 2
KJ L
Product Description

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-565 Rev. B 4Dorner Mfg. Corp.
Specifications:
NOTE: Maximum conveyor loads based on:
DNon-accumulating product
DProduct moving towards gearmotor
DConveyor being mounted horizontal
Conveyor Width
Reference (WW) 02 03 04 05 06 08 10 12 18
Conveyor Belt Width 1.75¨
(44 mm)
2.75¨
(70 mm)
3.75¨
(95 mm)
5¨
(127 mm)
6¨
(152 mm)
8¨
(203 mm)
10¨
(254 mm)
12¨
(305 mm)
18¨
(457 mm)
Maximum Conveyor Load*
(See NOTE Below)
30 lb
(14 kg)
35 lb
(16 kg)
42 lb
(19 kg)
50 lb
(23 kg)
60 lb
(27 kg)
70 lb
(32 kg)
80 lb
(36 kg)
80 lb
(36 kg)
80 lb
(36 kg)
Conveyor Start-up Torque* 4 in-lb
(0.5 Nm)
5 in-lb
(0.6 Nm)
6 in-lb
(0.7 Nm)
7 in-lb
(0.8 Nm)
8 in-lb
(0.9 Nm)
10 in-lb
(1.1 Nm)
12 in-lb
(1.4 Nm)
14 in-lb
(1.5 Nm)
15 in-lb
(1.7 Nm)
Belt Travel 3.5¨(88 mm) per revolution of pulley
Maximum Belt Speed* 235 feet/minute (72 meters/minute)
Belt Take-up 0.38¨ (10 mm) of stroke = 0.75¨ (19 mm) of belt take-up
Conveyor Length
Reference (LL) 02 03 04 05 06 07 08 09 10 11 12 13** 14** 15** 16** 17** 18**
Conveyor Length
2-ft (610 mm) 3-ft (914 mm)
4-ft (1219 mm)
5-ft (1524 mm)
6-ft (1829 mm) 7-ft (2134 mm)
8-ft (2438 mm)
9-ft (2743 mm)
10-ft (3048 mm)
11-ft (3353 mm)
12-ft (3658 mm)
13-ft (3962 mm)**
14-ft (4267 mm)** 15-ft (4572 mm)**
16-ft (4877 mm)** 17-ft (5182 mm)** 18-ft (5486 mm)**
* See “Ordering and Specifications” Catalog for details. ** Lengths available only in 6¨ (152 mm) & wider conveyors.
Installation
NOTE: Conveyor MUST be mounted straight, flat and
level within confines of conveyor. Use a level (M of
Figure 3) for setup.
Figure 3
M
Required Tools
DHex key wrenches: 4 mm, 5 mm
D10 mm open−end wrench
DLevel
DTorque wrench
Recommended Installation Sequence
DAssemble conveyor (if required)
DAttach mounting brackets to conveyor (see page 5)
DInstall stands (see accessory instructions)
DAttach conveyor to stands
DMount gearmotor mounting package (see accessory
instructions)
DAttach guides/accessories (see “Service Parts” sec-
tion, pages 20 through 33)
Conveyors Up to 13 ft (3962 mm)
No assembly is required. Install mounting brackets and
return rollers. Refer to “Mounting Brackets” on page 5
and “Return Rollers” on page 6.
Specifications

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 5851-565 Rev. B
Conveyors Longer Than 13 ft (3962 mm)
N Conveyor frame without belt
O M6 x 10 mm Low−Head Screws (6x) (shipped loose)
P Connector Strips (2x) (Attached to conveyor section)
Q Conveyor frame with belt
Illustration References
1.Typical components (Figure 4)
Figure 4
O
PQ
N
2.Compress tension end (Figure 5). Refer to steps 3
and 4 under the “Belt Removal for Conveyor
Without Gearmotor Mounting Package or Stands”
on page 9.
Figure 5
3.Roll out conveyor belt.
4.Place conveyor frame (N Figure 6) into belt loop.
Figure 6
NP
5.Join conveyor sections (N and Q of Figure 7). Install
screws (O) through frame and into connector bar (P)
on both sides. Tighten screws to 60 in-lb (7 Nm).
Figure 7
O
N
Q
6.Tension conveyor belt. Refer to “Conveyor Belt
Tensioning” on page 12.
Mounting Brackets
1.Typical mounting bracket components (Figure 8)
R M6 x 12 mm Socket Head Screws (4x)
S M6 x 20 mm Socket Head Screw (4x)
T Hard Washer (4x)
U M6 Square Nut (4x)
V Stand Mounting Bracket (2x)
W Mounting Plate, Flat Belt (2x)
or
X Mounting Plate, Cleated Belt (2x)
Mounting Bracket Components (One Pair)
Figure 8
S
X
U
RV
W
T
2.Attach clamp plate (W or X of Figure 8) to stand
mounting bracket (V) with two screws (R). Do not
tighten screws.
Installation

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-565 Rev. B 6Dorner Mfg. Corp.
3.Attach stand mounting bracket (V of Figure 9) to
bottom of conveyor (Y). Snug−up screws (R).
Figure 9
R
V
W
X
or
Y
4.Repeat steps 2 and 3 for other stand mounting
bracket(s).
5.Position conveyor (Y of Figure 10) on stands (Z) .
Figure 10
S
R
Y
Z
6.Attach stand mounting bracket (V of Figure 11) to
stand (Z) with two screws (S), hard washers (T) and
square nuts (U). Tighten screws (S) to 80 in-lb (9
Nm).
Figure 11
S
R
Z
U
V
T
7.Repeat step 6 for other stand mounting bracket(s).
8.Tighten all screws (R) to 80 in-lb (9 Nm).
Return Rollers
2¨ to 6¨ (44 mm to 152 mm) Wide Conveyor
NOTE: No return rollers are required on conveyor
lengths up to 7 ft (2134 mm). Use one pair of rollers
centered between the idler and drive spindles on 8−15
ft (2438−4572 mm) conveyors. Use two pairs of rollers
at one third distances between the idler and drive
spindles on 16−18 ft (4877−5486 mm) conveyors.
1.Typical return roller components (Figure 12)
AA Return Roller Guard
AB Return Roller Clip (Flat Belt)
AC Low−Head Cap Screw M6−1.00 x 20mm (2)
AD Return Roller Clip (Cleated Belt)
Typical Components
Figure 12
or
AC
AA
AD
AB
2.Loosely attach clip (AB or AD of Figure 13) on
guard (AA) with two screws (AC). Do not tighten
screws.
Figure 13
AC
AA
AD
AB
AC
AA
Installation

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 7851-565 Rev. B
3.Attach return roller assembly (AE of Figure 14) on
each side of conveyor (Y). Tighten screws (AC) to 80
in-lb (9 Nm).
Y
AE
Figure 14
AC
4.On 8−18 ft (2338−5486 mm) conveyor, repeat step 3
as necessary for other return rollers.
8¨ to 18¨ (203 mm to 457 mm) Wide Flat Belt
Conveyors
NOTE: No return rollers are required on conveyor
lengths up to 7 ft (2134 mm). Use one roller centered
between the idler and drive spindles on 8−15 ft
(2438−4572 mm) conveyors. Use two rollers at one
third distances between the idler and drive spindles on
16−18 ft (4877−5486 mm) conveyors.
1.Typical return roller components (Figure 15)
AF Return Roller and Guard Assembly
AG Return Roller Clip (2x)
AH Low−Head Cap Screw M6−1.00 x 20mm (4x)
Typical Components
Figure 15
AH
AF
AG
2.Loosely attach two clips (AG of Figure 16) on roller
and guard assembly (AF) with four screws (AH). Do
not tighten screws.
Figure 16
AF
AH
AG
3.Attach return roller assembly (AI of Figure 17) on
conveyor (Y). Tighten screws (AH of Figure 16) to
80 in-lb (9 Nm).
Figure 17
AI
Y
4.On 16−18 ft (4877−5486 mm) conveyor, repeat step 3
for other return roller.
Installation

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-565 Rev. B 8Dorner Mfg. Corp.
Required Tools
Standard Tools
DHex key wrenches:
2 mm, 2.5 mm, 3 mm, 4 mm, 5 mm and 6 mm
DManual grease gun
DAdjustable wrench
DArbor press
Special Tools
D450281 Sealed Bearing Removal Tool
D450282 Sealed Bearing Installation Tool
D2500M Tool Kit for Gang Drive Bearings
Checklist
DKeep service parts on hand (see “Service Parts” sec-
tion for recommendations)
DKeep supply of belt cleaner (part # 625619)
DFor optional gang-driven conveyors, keep supply of
bearing grease [for 14 oz (397 gram) cartridge (part #
829-002)or for 14 oz (397 gram) can(part # 829-003)]
DClean entire conveyor and knurled pulley while dis-
assembled
DReplace worn or damaged parts
Lubrication
Conveyor with Standard 0.47¨ (12 mm)
Diameter Output Shaft
No lubrication is required. Replace bearings if worn.
Conveyor with Optional Gang Drive Pulley
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
NOTE: Only drive pulley bearings require lubrication
(refer to the following steps). For all other bearings, re-
place if worn.
1.Disassemble support (AJ of Figure 18) and remove
hex shaft and shaft guard sections (AK).
Figure 18
AJ
AK
NOTE: Optional permanent grease fittings (part #
200398M) may be installed.
2.Install Dorner greasing adapter (part # 200046M)
(AL of Figure 19). Make sure the adapter shoulder
is seated against the conveyor tail plate.
Figure 19
AL
3.Use Dorner red grease, 14 oz (397 gram) cartridge
(part #829-002) or 14 oz (397 gram) can (part #
829-003). Lubricate pulley bearing every 750 hours
or more frequently, depending on operating condi-
tions.
NOTE: Lubricate pulley bearing every 750 hours or
more frequently, depending on operating conditions.
When lubricating pulley bearings, use a conventional
hand grease gun with a maximum of one pump per
application. Do not over-lubricate. Do not use a power
grease gun.
4.Grease bearing with one (1) pump from a manual
grease gun. Do not over-lubricate.
Preventive Maintenance and Adjustment

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 9851-565 Rev. B
5.Remove grease adapter and install on opposite side
of pulley. Repeat steps 2 and 4.
6.Re-assemble hex shaft with guards and support (T of
Figure 18).
Return Rollers
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 wiper(s)
DAccumulated dirt in wiper(s)
DForeign material inside the conveyor
DImproperly positioned accessories
DBolt-on guiding is pinching belt
Stalling or slipping indicates:
DExcessive load on belt
DConveyor belt or drive timing belt are not properly
tensioned
DWorn knurl or impacted dirt on drive pulley
DIntermittent jamming or drive train problems
Damage to V-guide indicates:
DTwisted or damaged conveyor frame
DDirt impacted on pulleys
DExcessive or improper side loading
NOTE: Visit www.dorner.com for complete list of
troubleshooting solutions.
Cleaning
IMPORTANT: Do not use belt cleaners that contain
alcohol, acetone, Methyl Ethyl Ketone (MEK) or other
harsh chemicals.
Use Dorner Belt Cleaner (part # 625619). Mild soap and
water may also be used. Do not soak the belt.
For /05 woven polyester and /06 black anti-static belts,
use a bristled brush to improve cleaning.
Conveyor Belt Replacement
Ç
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
- Conveyor without Gearmotor Mounting Package
or Stands
- Conveyor with Stands and/or Gearmotor
Mounting Package
- Conveyor with Optional Gang Drive Pulley
DInstall new conveyor belt
DTension conveyor belt
Belt Removal for Conveyor Without Gearmotor
Mounting Package or Stands
1.If installed, remove and retain bottom wiper(s) (AM
of Figure 20).
Figure 20
AM
2.If conveyor is equipped with guiding and accesso-
ries or return rollers, remove them as necessary.
Preventive Maintenance and Adjustment

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-565 Rev. B 10 Dorner Mfg. Corp.
3.On tension end of the conveyor identified with a
label (AN of Figures 21 and 22), loosen four
M6 socket head cap screws (AO).
Figure 21
AN
AO
4.Retract idler spindle assembly (AP of Figure 22) by
pushing in on it or by turning M6 pinion screw (AQ
of Figures 22 and 23) clockwise.
Figure 22
AN AO AQ
AP
5.Remove conveyor belt (AR of Figure 23).
Figure 23
AQ
AR
Belt Removal for Conveyor With Stands and/or
Gearmotor Mounting Package
NOTE: For conveyor with a Heavy Load Bottom or
Top Mount Package, bracket (AT of Figure 24) must
be removed.
DRemove two M6x16 mm socket head screws (AS).
DRemove two M6x12 mm socket head screws(AU).
DRemove bracket (AT).
Figure 24
AS
AT
AU
1.If installed, remove and retain bottom wiper(s) (AM
of Figure 20).
2.If conveyor is equipped with guiding and accesso-
ries or return rollers, remove them as necessary.
3.On tension end of the conveyor identified with a
label (AN of Figures 21 and 22), loosen four
M6 socket head cap screws (AO).
4.Retract idler spindle assembly (AP of Figure 22) by
pushing it in or by turning M6 pinion screw (AQ of
Figures 22 and 23) clockwise.
Ç
ÇÇ
The weight of the gearmotor is all on one end of the
conveyor which could cause it to tip off the stands
when the mounting clamp plates are loosened. Be
sure to provide support (AV of Figure 25)
underneath the gearmotor while changing the belt.

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 11 851-565 Rev. B
5.Place a temporary support (AV of Figure 25) under
gearmotor mounting package.
Figure 25
AV
S
R
Z
U
V
T
Y
6.Loosen two mounting plate screws (R of Figure 25).
Remove two screws (S), hard washers (T) and square
nuts (U). Slide stand mounting bracket (V) off stand
(Z) and remove from conveyor (Y).
7.Repeat step 6 for remaining stand mounting brackets
on same side of conveyor.
8.Remove conveyor belt (AR of Figure 26).
Figure 26
AR
9.If a new belt will not be installed immediately,
secure conveyor with mounting plate(s) and stand
mounting bracket(s) (V of Figure 25).
Belt Removal for Conveyor With Optional Gang
Drive Pulley
1.Disassemble support (AJ of Figure 18) and remove
the hex shaft and shaft guard sections (AK).
2.If installed, remove and retain bottom wiper(s) (AM
of Figure 20).
3.If conveyor is equipped with guiding and accesso-
ries or return rollers, remove them as necessary.
4.On tension end of the conveyor identified with a
label (AN of Figures 21 and 22), loosen four
M6 socket head cap screws (AO).
5.Retract idler spindle assembly (AP of Figure 22) by
pushing it in or by turning M6 pinion screw (AQ of
Figures 22 and 23) clockwise.
6.Remove conveyor belt (AR of Figure 23).
Belt Installation for Conveyor without Gearmotor
Mounting Package or Stands
IMPORTANT: On a flat belt conveyor, the wiper is
installed on discharge end. Belt travel direction is
identified by an arrow decal on the side of the convey-
or (AW of Figure 27). With a reversing gearmotor, a
second bottom wiper must be installed on opposite
end.
Preventive Maintenance and Adjustment

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-565 Rev. B 12 Dorner Mfg. Corp.
AW
Figure 27
1.Orient the conveyor belt so that the splice leading
fingers (AX of Figure 28) point in the direction of
belt travel (AY) as identified by the label (AW of
Figure 27).
Figure 28
AX
AY
2.Slide belt (AR of Figure 23) onto the conveyor frame
assembly.
3.On a flat belt conveyor, install bottom wiper(s) (AM
of Figure 20). Center set screws in frame and tighten
to 33 in-lb (3.7 Nm).
4.Tension belt. Refer to “Conveyor Belt Tensioning” on
page 12.
5.Where applicable, install return rollers, guiding and
accessories.
Belt Installation for Conveyor with Gearmotor
Mounting Package and/or Stands
1.Orient conveyor belt so that the splice leading fin-
gers (AX of Figure 28) point in the direction of belt
travel (AY) as identified by the label (AW of Figure
27).
2.Slide belt (AR of Figure 23) onto conveyor frame
assembly.
3.Install stand mounting bracket (V of Figure 25) onto
stand (Z) and conveyor (Y). Refer to “Mounting
Brackets” on page 5.
4.Repeat step 3 for remaining stand mounting brackets
on same side of conveyor.
5.If removed, install bottom wiper(s) (W of Figure 20).
Center set screws in frame and tighten to 33 in-lb (3.7
Nm).
6.For a conveyor with a Heavy Load Bottom or Top
Mounting package, re-install bracket (AT of Figure
24).
7.Tension belt. Refer to “Conveyor Belt Tensioning” on
page 12.
8.Where applicable, install return rollers, guiding and
accessories.
Belt Installation for Conveyor With Optional
Gang Drive Pulley
1.Orient the conveyor belt so that the splice leading
fingers (AX of Figure 28) point in the direction of
belt travel (AY) as identified by the label (AW of
Figure 27).
2.Slide belt (AR of Figure 23) onto the conveyor frame
assembly.
3.If removed, install bottom wiper(s) (W of Figure 20).
Center set screws in frame and tighten to 33 in-lb (3.7
Nm).
4.Tension belt. Refer to “Conveyor Belt Tensioning” on
page 12.
5.Where applicable, install return rollers, guiding and
accessories.
6.Re-assemble hex shaft with guards sections (AK of
Figure 18). Re-assemble support (AJ).
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 with a
label (AN of Figures 21 and 22), loosen four
M6 low head screws (AO).
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 13 851-565 Rev. B
NOTE: The M6 low head screw (AZ of Figure 29),
which is used for extending the idler spindle assembly
to tension the belt, has a yellow colored head.
Do not exceed a torque of 25 in-lb (2.8 Nm) for 2¨ to
12¨ (44 mm to 305 mm) wide conveyors or 40 in-lb (4.5
Nm) for an 18¨ (457 mm) wide conveyor on this screw.
Over-tensioning the conveyor belt could cause
excessive pulley bearing load and early failure.
2a.For an existing belt, extend idler spindle assembly
(AP of Figure 29) by turning M6 low head screw
(AZ) clockwise to sufficiently tension belt to handle
conveyor load.
2b.For a new belt, extend idler spindle assembly (AP of
Figure 29) 1¨ (25 mm) (BA) by turning M6 low head
screw (AZ) clockwise.
Figure 29
BA
AP
AZ AO
3. Tighten four M6 low head screws (AO of Figures 21,
22 and 29) to 40 in-lb (4.5 Nm) to secure idler spindle
assembly (AP).
NOTE: If the maximum take-up stroke is achieved,
replace the conveyor belt.
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 9. Remove the desired
pulley following instructions:
DA−Drive Pulley with Standard 0.47¨ (12 mm) Diam-
eter Output Shaft
DB−Idler Pulley
DC−Gang Drive Pulley
A−Removal of Drive Pulley with Standard
0.47¨ (12 mm) Diameter Output Shaft
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
1.Remove the gearmotor mounting package. See
accessory instructions.
2.For 10¨ (254 mm), 12¨ (305 mm) or 18¨ (457 mm)
wide conveyors, remove key (BB of Figure 30) and
two M5 low head screws (BC) to remove outboard
bearing (BD).
Figure 30
BD
BB
BC
BEBE
BF
NOTE: Two screws (BF of Figure 30) were removed
in step 1.
3.Remove screw (BE) on drive shaft side of conveyor.
4.Remove three (3) screws (BG of Figure 31) on side
opposite of drive shaft.
5.Remove drive spindle assembly (BH).
Figure 31
BG
BH
Preventive Maintenance and Adjustment

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-565 Rev. B 14 Dorner Mfg. Corp.
6.Remove screw (BI of Figure 32).
7.Remove headplate (BJ).
8.Remove pulley (BK).
Figure 32
BI
BK
BJ
B−Idler Pulley Removal
1.Remove two screws (AO of Figure 33) on each side
of conveyor.
Figure 33
AO
Y
2.Loosen two screws (AQ and AZ of Figure 34).
Figure 34
AQ
AZ
3.Remove two screws (AQ and AZ of Figure 35) and
sleeves (BL) from conveyor (Y) and hex pinion
(BM).
Figure 35
AQ BL Y
AZ BL
BM
4.Remove two pinion ends (BN of Figure 36), clamp
blocks (BO), hex pinion (BM) and tail assembly (BP)
from conveyor (Y).
Figure 36
BP
BO
BN BM
Y
BP
NOTE: Note which side of conveyor magnet (BQ of
Figure 37) is located.
5.Locate magnet (BQ of Figure 37) on spindle and
bearing assembly (BR).
Figure 37
BS
BR
BT
BQ

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 15 851-565 Rev. B
6.Remove screw (BS), headplate (BT), and spindle
and bearing assembly (BR).
C−Gang Drive Pulley Removal
k- Parts required from Tool Kit, part number 2500M.
1.Remove two M5 low head screws (BU of Figure 38)
and clip (BV) from head plate (BW).
Figure 38
BW
BU
BV
BX
2.Repeat step 1 for opposite side.
3.Install bolt (part # 906-278k) (BY of Figure 39) into
retaining sleeve (BX). Pull out on bolt to remove
retaining sleeve.
Figure 39
BY
BX
BY
BX
4.Repeat step 3 for opposite side.
NOTE: If retaining sleeve(s) (BX of Figure 38 and
39) does not slide out::
DRemove tail assembly following steps 3, 4 and 5
of Removal of Drive Pulley with Standard 0.47¨
(12 mm) Diameter Output Shaft on page 13
DAssemble removal tool (part # 25-09k) (BZ of Fig-
ure 40) and bolt (part # 906-278k) (BY) on spindle
(CA), as shown
DTighten bolt (BY) to remove bearing sleeve (BX
of Figure 38 and 39) from spindle (CA of Figure
40).
Figure 40
CA
BY
BZ
Bearing Replacement for Drive Pulley with
Standard 0.47¨ (12 mm) Diameter Output Shaft
or Idler Pulley
IMPORTANT: Once removed, do not re-use
bearings.
Bearing Removal
1.Place bearing removal tool (part # 450281) (CC of
Figure 41) over bearing (CD) with lip (CE) located in
gap (CF) between bearing and spindle (CB) as
shown.
CE
CF
Figure 41
CC
CD
CB
Preventive Maintenance and Adjustment

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-565 Rev. B 16 Dorner Mfg. Corp.
2.Using 3/16¨ hex key wrench (CG of Figure 42),
tighten bearing removal tool.
Figure 42
CG
3.Using a puller (CH of Figure 43), remove and
discard bearing(s).
Figure 43
CH
Bearing Installation
IMPORTANT: Install bearings one at a time.
1.Inspect seating surface(s) for damage. Replace if
damaged.
2.Slide bearing (part # 802-121) (CI of Figure 44) onto
pulley shaft.
Figure 44
CI
3.Slide the sleeve of tool (part # 450282) (CK of Figure
45) over bearing.
Figure 45
CK
4.Place open end of shaft (CL of Figure 46) into sleeve.
Figure 46
CL
5.Using arbor press or similar device, press bearing onto
pulley shaft (see Figure 47).
Figure 47
6.Repeat steps 1 through 5 for each bearing.
Preventive Maintenance and Adjustment

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 17 851-565 Rev. B
Bearing Replacement for Gang Drive Pulley
k- Parts required from Tool Kit, part number 2500M.
IMPORTANT: Once removed, do not re-use
bearings.
Bearing Removal
NOTE: The bearings of a 2¨ (51 mm) wide gang drive
pulley cannot be replaced. Order pulley assembly
(part # 454702).
1.Insert bearing removal tool (part # 25-05k) (CN of
Figure 48) into the pulley (CQ) until shoulder (CM)
seats against bottom of bearing (CR).
Figure 48
CM
CO
CP
CQ
CR
CN
2.While holding bearing removal tool (CN) in posi-
tion, insert extension tool (part # 25-08k) (CO) into
opposite end of pulley (CQ). Rotate bearing removal
tool (CN) to engage hex tip of extension tool (CO)
into screw (CP).
3.While maintaining extension tool (CO) position, use
a wrench to rotate bearing removal tool (CN) to
expand flare.
Figure 49
CO
CN
4.Orient bearing anvil/sleeve removal tool (part #
25-09k) (CS of Figure 50) with cavity facing up and
place pulley onto tool.
Figure 50
CS
NOTE: If a severely worn bearing breaks apart during
removal, pulley must be replaced.
5.Press bearing out of pulley.
Figure 51
CO
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-565 Rev. B 18 Dorner Mfg. Corp.
Bearing Installation
1.Orient bearing anvil/sleeve removal tool (part #
25-09k) (CS of Figure 52) with cavity facing up and
place pulley (CQ) onto tool.
Figure 52
CS
CQ
2.Install bearing insertion tool (part # 25-10k) (CT of
Figure 53) into arbor press or similar device.
CT
Figure 53
3.Place and hold bearing (part # 21-33) (CR) onto tool
(CT).
Figure 54
CR
IMPORTANT: Bearing and pulley alignment is
critical.
4.Press bearing (CR of Figure 55) into pulley (CQ)
until seated.
Figure 55
CR
CQ
Pulley Replacement
Drive Pulley with Standard 0.47¨ (12 mm)
Diameter Output Shaft Replacement
1.Reverse the removal procedure “A” (see page 13).
Idler Pulley Replacement
IMPORTANT: On a tension tail assembly, orient
both pinion ends (BN of Figure 56) so they engage the
same tooth positions on their respective racks.
Figure 56
BN
1.Reverse the removal procedure “B” (see page 13).
Preventive Maintenance and Adjustment

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 19 851-565 Rev. B
Gang Drive Pulley Replacement
IMPORTANT: When installing clips (BV of Figure
57), ensure step (CU) is toward head plate (BW).
Figure 57
BW
CU
BV
1.Reverse the removal procedure “C” (see page 15).
Preventive Maintenance and Adjustment

6200 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-565 Rev. B 20 Dorner Mfg. Corp.
NOTE: For replacement parts other than those shown in this section, contact an authorized Dorner Service
Center or the factory.
Drive End Components
12*
7
15
8
5
18
1
3
6
16
9
4
17
9
10*
11* Note: Items with an * are
used on 10” (254mm), 12”
(305mm) and 18” (457mm)
conveyors only.
2
13 Drive Tail Kit
14 Drive Spindle Kit
*
19
Item Part Number Description
1 456021 Head Plate LH 2−3” (51−76mm) Wide
456022 Head Plate LH 4−18” (102−457mm) Wide
2 807−1022 Low−Head Pilot Screw M5−.8x12mm
3 802−121 Ball Bearing 12mm Bore x 21mm OD
4 980422M Square Key 4mm x 22mm
5 4531WWM Drive Spindle
6 456025 Head Plate RH 2−3” (51−76mm) Wide
456026 Head Plate RH 4−18” (102−457mm) Wide
7 807−963 Plastic Snap−Out Plug
8 4536WWM Support Tension/Fixed
9 920692M Low−Head Cap Screw M6−1.0x12mm
10 802−148 Ball Bearing 12mm Bore x 24mm OD
(used on 10” (254mm), 12” (305mm) and
18” (457mm) conveyors, only)
11 456032 Outboard Bearing Plate (used on 10”
(254mm), 12” (305mm) and 18” (457mm)
conveyors, only)
12 807−1022 Low−Head Pilot Screw M5−.8x12mm
13 62DTA−WW Drive Tail Kit −A & B Positions (Includes
Items 1 through 11)
62DTD−WW Drive Tail Kit −C & D Positions (Includes
Items 1 through 11)
14 62D−WW Drive Spindle Kit (Includes Items 2
through 5, and if applicable, 10, 11 and
12)
15 4527WWM Bottom Wiper
16 970508M Cup−Point Set Screw M5−.80 x 8mm
17 4525WWM Frame Support Post
18 807−1022 Low−Head Pilot Screw M5−.8x12mm
19 456033 Outboard Bearing Assembly
(includes items 10 & 11)
WW = Conveyor width ref.: 02, 03, 04, 05, 06, 08, 10, 12, 18
Service Parts