Dorner 6200 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]
851-565 Rev. G
6200 Series Industrial End
Drive Conveyors
Installation, Maintenance & Parts Manual
Featuring: Technology

Dorner Mfg. Corp. 2 851-565 Rev. G
6200 Series Industrial End Drive Conveyors
Table of Contents
Introduction ......................................................................... 3
Warnings - General Safety .................................................. 4
Product Description............................................................. 5
Specifications ...................................................................... 5
Models: ............................................................................ 5
Flat Belt 6200 Series Industrial Conveyor................... 5
Cleated Belt 6200 Series Industrial Conveyor............. 5
Conveyor Supports: ......................................................... 6
Specifications: ................................................................. 6
Installation........................................................................... 7
Required Tools ................................................................ 7
Recommended Installation Sequence.............................. 7
Conveyors Up to 13 ft (3962 mm)................................... 7
Conveyors Longer Than 13 ft
(3962 mm) ....................................................................... 7
Mounting Brackets .......................................................... 8
Return Rollers.................................................................. 9
2¨ to 6¨ (44 mm to 152 mm) Wide Conveyor .............. 9
8¨ to 18¨ (203 mm to 457 mm)
Wide Flat Belt Conveyors........................................... 9
Preventive Maintenance and Adjustment.......................... 10
Required Tools .............................................................. 10
Standard Tools ........................................................... 10
Special Tools.............................................................. 10
Checklist ........................................................................ 10
Lubrication..................................................................... 10
Conveyor with Standard 0.47¨ (12 mm)
Diameter Output Shaft .............................................. 10
Conveyor with Optional Gang Drive Pulley.............. 10
Return Rollers ............................................................ 11
Maintaining Conveyor Belt ........................................... 11
Troubleshooting ......................................................... 11
Cleaning ..................................................................... 12
Conveyor Belt Replacement.......................................... 12
Conveyor Belt Replacement Sequence
(see Table of Contents for page number).................. 12
Belt Removal for Conveyor Without
Gearmotor Mounting Package or Stands .................. 12
Belt Removal for Conveyor With
Stands and/or Gearmotor Mounting Package ........... 12
Belt Removal for Conveyor With
Optional Gang Drive Pulley...................................... 14
Belt Installation for Conveyor without
Gearmotor Mounting Package or Stands .................. 14
Belt Installation for Conveyor with
Gearmotor Mounting Package and/or Stands............ 14
Belt Installation for Conveyor With
Optional Gang Drive Pulley ...................................... 14
Conveyor Belt Tensioning ............................................. 15
Pulley Removal .............................................................. 15
A −Removal of Drive Pulley with
Standard 0.47¨ (12 mm) Diameter Output Shaft ....... 15
B −Idler Pulley Removal ........................................... 16
C −Gang Drive Pulley Removal................................ 17
Bearing Replacement for Drive Pulley with Standard
0.47¨ (12 mm) Diameter Output Shaft or Idler Pulley.. 18
Bearing Removal ........................................................ 18
Bearing Installation .................................................... 18
Bearing Replacement for Gang Drive Pulley ................ 19
Bearing Removal ........................................................ 19
Bearing Installation .................................................... 20
Pulley Replacement........................................................ 21
Drive Pulley with Standard 0.47¨ (12 mm)
Diameter Output Shaft Replacement......................... 21
Idler Pulley Replacement........................................ 21
Gang Drive Pulley Replacement............................. 21
Service Parts ...................................................................... 22
Drive End Components.................................................. 22
Tension End Components .............................................. 23
Conveyor Frame and Extensions ................................... 24
Gang Drive Thru−Shaft Option ..................................... 25
−02 0.5” (13mm) Bolt−On High Side Guides ............... 26
−03 Bolt−On Side Wipers.............................................. 27
−04 3” (76 mm) Bolt −On High Side Guides ............... 28
−05 1.5” (38mm) Bolt−On High Side Guides ............... 29
−13 Fully Adjustable UHMW Guides ........................... 30
−20 Adjustable Width UHMW Guides.......................... 31
1” (25mm) Cleated Belt Conveyor Guides .................... 32
2” (51mm) Cleated Belt Conveyor Guides .................... 33
2” (51mm) Through 6” (152mm) Flat Belt and
Cleated Belt Return Roller............................................ 34
8” (203mm) Through 18” (457mm)
Flat Belt Return Roller.................................................. 34
Conveyor Mounting Brackets ........................................ 35
Configuring Conveyor Belt Part Number ...................... 35
Flat Belt ...................................................................... 35
Cleated Belt ................................................................ 35
Return Policy ..................................................................... 36

851-565 Rev. G 3 Dorner Mfg. Corp.
6200 Series Industrial End Drive 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 6200 Series conveyors are covered by Patent Nos.
5174435, 6109427, 6298981, 6685009 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 .
IMPORTANT
Some illustrations may show guards
removed. DO NOT operate equipment
without guards.

Dorner Mfg. Corp. 4 851-565 Rev. G
6200 Series Industrial End Drive Conveyors
Warnings - General Safety
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.

851-565 Rev. G 5 Dorner Mfg. Corp.
6200 Series Industrial End Drive Conveyors
Product Description
Refer to Figure 1 for typical conveyor components. Figure 1
Figure 1
Specifications
Models:
Flat Belt 6200 Series Industrial Conveyor
Cleated Belt 6200 Series Industrial
Conveyor
* See “Ordering and Specifications” Catalog for details.
AConveyor
B Gearmotor
C Belt (Cleated Belt Shown)
D Mounting Plates
E Stand Mounting Brackets
F Support Stands
G Variable Speed Controller
HDriveEnd
I Idler/Tension End
A
B
C
G
H
I
F
E
D
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

Dorner Mfg. Corp. 6 851-565 Rev. G
6200 Series Industrial End Drive Conveyors
Specifications
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
Figure 2
Specifications:
* See “Ordering and Specifications” Catalog for details. ** Lengths available only in 6¨ (152 mm) & wider
conveyors.
KJ L
NOTE
Maximum conveyor loads based on:
• Non-accumulating product
• Product moving towards gearmotor
• Conveyor 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¨ (95mm) 5¨ (127 mm) 6¨ (152mm) 8¨ (203mm) 10¨ (254mm) 12¨ (305mm) 18¨ (457mm)
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)**

851-565 Rev. G 7 Dorner Mfg. Corp.
6200 Series Industrial End Drive Conveyors
Installation
Figure 3
Figure 3
Required Tools
• Hex key wrenches: 4 mm, 5 mm
• 10 mm open−end wrench
• Level
• Torque wrench
Recommended Installation
Sequence
• Assemble conveyor (if required)
• Attach mounting brackets to conveyor (see page 8)
• Install stands (see accessory instructions)
• Attach conveyor to stands
• Mount gearmotor mounting package (see accessory
instructions)
• Attach guides/accessories (see “Service Parts” section,
page 23)
Conveyors Up to 13 ft (3962 mm)
No assembly is required. Install mounting brackets and
return rollers. Refer to “Mounting Brackets” on page 8 and
“Return Rollers” on page 9.
Conveyors Longer Than 13 ft
(3962 mm)
1. Typical components (Figure 4)
Figure 4
Figure 4
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 13.
Figure 5
Figure 5
3. Roll out conveyor belt.
4. Place conveyor frame (Figure 6, item N) into belt loop.
Figure 6
Figure 6
NOTE
Conveyor MUST be mounted straight, flat and
level within confines of conveyor. Use a level
(Figure 3, item M) for setup.
M
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
O
PQ
N
NP

Dorner Mfg. Corp. 8 851-565 Rev. G
6200 Series Industrial End Drive Conveyors
Installation
5. Join conveyor sections (Figure 7, item N and Q). Install
screws (O) through frame and into connector bar (P) on
both sides. Tighten screws to 60 in-lb (7 Nm).
Figure 7
Figure 7
6. Tension conveyor belt. Refer to “Conveyor Belt
Tensioning” on page 15.
Mounting Brackets
1. Typical mounting bracket components (Figure 8)
Figure 8
Figure 8
2. Attach clamp plate (Figure 8, item W or X) to stand
mounting bracket (V) with two screws (R). Do not
tighten screws.
3. Attach stand mounting bracket (Figure 9, item V) to
bottom of conveyor (Y). Snug−up screws (R).
Figure 9
Figure 9
4. Repeat steps 2 and 3 for other stand mounting
bracket(s).
5. Position conveyor (Figure 10, item Y) on stands (Z).
Figure 10
Figure 10
6. Attach stand mounting bracket (Figure 11, item V) 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
Figure 11
7. Repeat step 6 for other stand mounting bracket(s).
8. Tighten all screws (R) to 80 in-lb (9 Nm).
R M6 x 12 mm Socket Head Screws (4x)
S M6 x 20 mm Socket Head Screws (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)
O
N
Q
S
X
U
RV
W
T
R
V
W
X
or
Y
S
R
Y
Z
S
R
Z
U
V
T

851-565 Rev. G 9 Dorner Mfg. Corp.
6200 Series Industrial End Drive Conveyors
Installation
Return Rollers
2¨ to 6¨ (44 mm to 152 mm) Wide Conveyor
1. Typical return roller components (Figure 12)
Figure 12
Figure 12
2. Loosely attach clip (Figure 13, item AB or AD) on
guard (AA) with two screws (AC). Do not tighten
screws.
Figure 13
Figure 13
3. Attach return roller assembly (Figure 14, item AE) on
each side of conveyor (Y). Tighten screws (AC) to 80
in-lb (9 Nm).
Figure 14
Figure 14
4. On 8−18 ft (2338−5486 mm) conveyor, repeat step 3 as
necessary for other return rollers.
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.
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)
or
AC
AA
AD
AB
AC
AA
AD
AB
AC
AA
Y
AE
AC

Dorner Mfg. Corp. 10 851-565 Rev. G
6200 Series Industrial End Drive Conveyors
Installation
8¨ to 18¨ (203 mm to 457 mm) Wide Flat
Belt Conveyors
1. Typical return roller components (Figure 15)
Figure 15
Figure 15
2. Loosely attach two clips (Figure 16, item AG) on roller
and guard assembly (AF) with four screws (AH). Do not
tighten screws.
Figure 16
Figure 16
3. Attach return roller assembly (Figure 17, item AI) on
conveyor (Y). Tighten screws (Figure 16, item AH) to
80 in-lb (9 Nm).
Figure 17
Figure 17
4. On 16−18 ft (4877−5486 mm) conveyor, repeat step 3
for other return roller.
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.
AF Return Roller and Guard Assembly
AG Return Roller Clip (2x)
AH Low−Head Cap Screw M6−1.00 x 20mm (4x)
AH
AF
AG
AF
AH
AG
AI
Y

851-565 Rev. G 11 Dorner Mfg. Corp.
6200 Series Industrial End Drive Conveyors
Preventive Maintenance and Adjustment
Required Tools
Standard Tools
• Hex key wrenches:
2 mm, 2.5 mm, 3 mm, 4 mm, 5 mm and 6 mm
• Manual grease gun
• Adjustable wrench
• Arbor press
Special Tools
• 450281 Sealed Bearing Removal Tool
• 450282 Sealed Bearing Installation Tool
• 2500M Tool Kit for Gang Drive Bearings
Checklist
• Keep service parts on hand (see “Service Parts” section for
recommendations)
• Keep supply of belt cleaner
• For optional gang-driven conveyors, keep supply of bear-
ing grease [for 14 oz (397 gram) cartridge (part # 829-
002)or for 14 oz (397 gram) can(part # 829-003)]
• Clean entire conveyor and knurled pulley while disassem-
bled
• Replace 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
1. Disassemble support (Figure 18, item AJ) and remove
hex shaft and shaft guard sections (AK).
Figure 18
Figure 18
2. Install Dorner greasing adapter (part # 200046M)
(Figure 19, item AL). Make sure the adapter shoulder is
seated against the conveyor tail plate.
Figure 19
Figure 19
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 conditions.
A
WARNING
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, replace if worn.
NOTE
Optional permanent grease fittings (part #
200398M) may be installed.
AJ
AK
AL

Dorner Mfg. Corp. 12 851-565 Rev. G
6200 Series Industrial End Drive Conveyors
Preventive Maintenance and Adjustment
4. Grease bearing with one (1) pump from a manual grease
gun. Do not over-lubricate.
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 (Figure
18, item T).
Return Rollers
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 wiper(s)
• Accumulated dirt in wiper(s)
• 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
(see Table of Contents for page number)
• Remove old conveyor belt
- Conveyor without Gearmotor Mounting Package or
Stands
- Conveyor with Stands and/or Gearmotor Mounting
Package
- Conveyor with Optional Gang Drive Pulley
• Install new conveyor belt
• Tension conveyor belt
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.
A
WARNING
Exposed moving parts can cause severe
injury.
LOCK OUT POWER before removing guards
or performing maintenance.

851-565 Rev. G 13 Dorner Mfg. Corp.
6200 Series Industrial End Drive Conveyors
Preventive Maintenance and Adjustment
Belt Removal for Conveyor Without
Gearmotor Mounting Package or Stands
1. If installed, remove and retain bottom wiper(s) (Figure
20, item AM).
Figure 20
Figure 20
2. If conveyor is equipped with guiding and accessories or
return rollers, remove them as necessary.
3. On tension end of the conveyor identified with a
label (Figure 21, item AN) and (Figure 22, item AN),
loosen four M6 socket head cap screws (AO).
Figure 21
Figure 21
4. Retract idler spindle assembly (Figure 22, item AP) by
pushing in on it or by turning M6 pinion screw (Figure
22, item AQ) and (Figure 23, item AQ) clockwise.
Figure 22
Figure 22
5. Remove conveyor belt (Figure 23, item AR).
Figure 23
Figure 23
Belt Removal for Conveyor With Stands
and/or Gearmotor Mounting Package
Figure 24
Figure 24
1. If installed, remove and retain bottom wiper(s) (Figure
20, item AM).
2. If conveyor is equipped with guiding and accessories or
return rollers, remove them as necessary.
3. On tension end of the conveyor identified with a
label (Figure 21, item AN) and (Figure 22, item AN),
loosen four M6 socket head cap screws (AO).
4. Retract idler spindle assembly (Figure 22, item AP) by
pushing it in or by turning M6 pinion screw (Figure
22, item AQ) and (Figure 23, item AQ) clockwise.
AM
AN
AO
AN AO AQ
AP
AQ
AR
NOTE
For conveyor with a Heavy Load Bottom or
Top Mount Package, bracket (Figure
24, item AT) must be removed.
• Remove two M6x16 mm socket head screws
(AS).
• Remove two M6x12 mm socket head screws
(AU).
• Remove bracket (AT).
AS
AT
AU

Dorner Mfg. Corp. 14 851-565 Rev. G
6200 Series Industrial End Drive Conveyors
Preventive Maintenance and Adjustment
5. Place a temporary support (Figure 25, item AV) under
gearmotor mounting package.
Figure 25
Figure 25
6. Loosen two mounting plate screws (Figure 25, item R).
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 (Figure 26, item AR).
Figure 26
Figure 26
9. If a new belt will not be installed immediately, secure
conveyor with mounting plate(s) and stand mounting
bracket(s) (Figure 25, item V).
Belt Removal for Conveyor With Optional
Gang Drive Pulley
1. Disassemble support (Figure 18, item AJ) and remove
the hex shaft and shaft guard sections (AK).
2. If installed, remove and retain bottom wiper(s) (Figure
20, item AM).
3. If conveyor is equipped with guiding and accessories or
return rollers, remove them as necessary.
4. On tension end of the conveyor identified with a
label (Figure 21, item AN) and (Figure 22, item AN),
loosen four M6 socket head cap screws (AO).
5. Retract idler spindle assembly (Figure 22, item AP) by
pushing it in or by turning M6 pinion screw (Figure
22, item AQ) and (Figure 23, item AQ) clockwise.
6. Remove conveyor belt (Figure 23, item AR).
Belt Installation for Conveyor without
Gearmotor Mounting Package or Stands
Figure 27
Figure 27
A
WARNING
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
(Figure 25, item AV) underneath the
gearmotor while changing the belt.
AV
S
R
Z
U
V
T
Y
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
conveyor (Figure 27, item AW). With a
reversing gearmotor, a second bottom wiper
must be installed on opposite end.
AR
AW

851-565 Rev. G 15 Dorner Mfg. Corp.
6200 Series Industrial End Drive Conveyors
Preventive Maintenance and Adjustment
1. Orient the conveyor belt so that the splice leading
fingers (Figure 28, item AX) point in the direction of
belt travel (AY) as identified by the label (Figure
27, item AW).
Figure 28
Figure 28
2. Slide belt (Figure 23, item AR) onto the conveyor frame
assembly.
3. On a flat belt conveyor, install bottom wiper(s) (Figure
20, item AM). Center set screws in frame and tighten to
33 in-lb (3.7 Nm).
4. Tension belt. Refer to “Conveyor Belt Tensioning” on
page 15.
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 fingers
(Figure 28, item AX) point in the direction of belt travel
(AY) as identified by the label (Figure 27, item AW).
2. Slide belt (Figure 23, item AR) onto conveyor frame
assembly.
3. Install stand mounting bracket (Figure 25, item V) onto
stand (Z) and conveyor (Y). Refer to “Mounting
Brackets” on page 8.
4. Repeat step 3 for remaining stand mounting brackets on
same side of conveyor.
5. If removed, install bottom wiper(s) (Figure 20, item W).
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 (Figure
24, item AT).
7. Tension belt. Refer to “Conveyor Belt Tensioning” on
page 15.
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 (Figure 28, item AX) point in the direction of
belt travel (AY) as identified by the label (Figure
27, item AW).
2. Slide belt (Figure 23, item AR) onto the conveyor frame
assembly.
3. If removed, install bottom wiper(s) (Figure 20, item W).
Center set screws in frame and tighten to 33 in-lb (3.7
Nm).
4. Tension belt. Refer to “Conveyor Belt Tensioning” on
page 15.
5. Where applicable, install return rollers, guiding and
accessories.
6. Re-assemble hex shaft with guards sections (Figure
18, item AK). Re-assemble support (AJ).
Conveyor Belt Tensioning
1. On tension end of the conveyor identified with a
label (Figure 21, item AN) and (Figure 22, item AN),
loosen four M6 low head screws (AO).
2. Idler spindle assembly
a. For an existing belt, extend idler spindle assembly
(Figure 29, item AP) by turning M6 low head screw
(AZ) clockwise to sufficiently tension belt to
handle conveyor load.
b. For a new belt, extend idler spindle assembly
AX
AY
A
WARNING
Exposed moving parts can cause severe
injury.
LOCK OUT POWER before removing guards
or performing maintenance.
NOTE
The M6 low head screw (Figure 29, item AZ),
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.

Dorner Mfg. Corp. 16 851-565 Rev. G
6200 Series Industrial End Drive Conveyors
Preventive Maintenance and Adjustment
(Figure 29, item AP) 1¨ (25 mm) (BA) by turning
M6 low head screw (AZ) clockwise.
Figure 29
Figure 29
3. Tighten four M6 low head screws (Figure 21, item AO),
(Figure 22, item AO) and (Figure 29, item AO) to 40 in-
lb (4.5 Nm) to secure idler spindle assembly (AP).
Pulley Removal
Remove conveyor belt to access pulley(s). See “Conveyor
Belt Replacement” on page 12. Remove the desired pulley
following instructions:
•A−Drive Pulley with Standard 0.47¨ (12 mm) Diameter
Output Shaft
•B−Idler Pulley
•C−Gang Drive Pulley
A −Removal of Drive Pulley with Standard
0.47¨ (12 mm) Diameter Output Shaft
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 (Figure 30, item BB) and two
M5 low head screws (BC) to remove outboard bearing
(BD).
Figure 30
Figure 30
3. Remove screw (BE) on drive shaft side of conveyor.
4. Remove three (3) screws (Figure 31, item BG) on side
opposite of drive shaft.
5. Remove drive spindle assembly (BH).
Figure 31
Figure 31
NOTE
If the maximum take-up stroke is achieved,
replace the conveyor belt.
A
WARNING
Exposed moving parts can cause severe
injury.
LOCK OUT POWER before removing guards
or performing maintenance.
BA
AP
AZ AO
A
WARNING
Drive shaft keyway may be sharp.
HANDLE WITH CARE.
NOTE
Two screws (Figure 30, item BF) were
removed in step 1.
BD BB BC
BEBE
BF
BG
BH

851-565 Rev. G 17 Dorner Mfg. Corp.
6200 Series Industrial End Drive Conveyors
Preventive Maintenance and Adjustment
6. Remove screw (Figure 32, item BI).
7. Remove headplate (BJ).
8. Remove pulley (BK).
Figure 32
Figure 32
B −Idler Pulley Removal
1. Remove two screws (Figure 33, item AO) on each side
of conveyor.
Figure 33
Figure 33
2. Loosen two screws (Figure 34, item AQ and AZ).
Figure 34
Figure 34
3. Remove two screws (Figure 35, item AQ and AZ) and
sleeves (BL) from conveyor (Y) and hex pinion (BM).
Figure 35
Figure 35
4. Remove two pinion ends (Figure 36, item BN), Wedge-
Lok® clamp blocks (BO), hex pinion (BM) and tail
assembly (BP) from conveyor (Y).
Figure 36
Figure 36
5. Locate magnet (Figure 37, item BQ) on spindle and
bearing assembly (BR).
Figure 37
Figure 37
6. Remove screw (BS), headplate (BT), and spindle and
bearing assembly (BR).
BI
BK
BJ
AO
Y
AQ
AZ
NOTE
Note which side of conveyor magnet (Figure
37, item BQ) is located.
AQ BL Y
AZ BL
BM
BP
BO
BN BM
Y
BS
BR
BT
BQ

Dorner Mfg. Corp. 18 851-565 Rev. G
6200 Series Industrial End Drive Conveyors
Preventive Maintenance and Adjustment
C −Gang Drive Pulley Removal
* - Parts required from Tool Kit, part number 2500M.
1. Remove two M5 low head screws (Figure 38, item BU)
and clip (BV) from head plate (BW).
Figure 38
Figure 38
2. Repeat step 1 for opposite side.
3. Install bolt (part # 906-278*) (Figure 39, item BY) into
retaining sleeve (BX). Pull out on bolt to remove
retaining sleeve.
Figure 39
Figure 39
4. Repeat step 3 for opposite side.
Figure 40
Figure 40
Bearing Replacement for Drive
Pulley with Standard 0.47¨ (12 mm)
Diameter Output Shaft or Idler Pulley
Bearing Removal
1. Place bearing removal tool (part # 450281) (Figure
41, item CC) over bearing (CD) with lip (CE) located in
gap (CF) between bearing and spindle (CB) as shown.
Figure 41
Figure 41
2. Using 3/16¨ hex key wrench (Figure 42, item CG),
tighten bearing removal tool.
Figure 42
Figure 42
NOTE
If retaining sleeve(s) (Figure 38, item BX) and
(Figure 39, item BX) does not slide out::
• Remove tail assembly following steps 3, 4 and
5 of Removal of Drive Pulley with Standard
0.47¨ (12 mm) Diameter Output Shaft on
page 16
• Assemble removal tool (part # 25-09*) (Figure
40, item BZ) and bolt (part # 906-278*) (BY)
on spindle (CA), as shown
• Tighten bolt (BY) to remove bearing sleeve
(Figure 38, item BX) and (Figure 39, item BX)
from spindle (Figure 40, item CA).
BW
BU
BV
BX
BY
BX
BY
BX
IMPORTANT
Once removed, do not re-use bearings.
CA
BY
BZ
CE
CF
CC
CD
CB
CG

851-565 Rev. G 19 Dorner Mfg. Corp.
6200 Series Industrial End Drive Conveyors
Preventive Maintenance and Adjustment
3. Using a puller (Figure 43, item CH), remove and
discard bearing(s).
Figure 43
Figure 43
Bearing Installation
1. Inspect seating surface(s) for damage. Replace if
damaged.
2. Slide bearing (part # 802-121) (Figure 44, item CI) onto
pulley shaft.
Figure 44
Figure 44
3. Slide the sleeve of tool (part # 450282) (Figure
45, item CK) over bearing.
Figure 45
Figure 45
4. Place open end of shaft (Figure 46, item CL) into
sleeve.
Figure 46
Figure 46
5. Using arbor press or similar device, press bearing onto
pulley shaft (Figure 47).
Figure 47
Figure 47
6. Repeat steps 1 through 5 for each bearing.
IMPORTANT
Install bearings one at a time.
CH
CI
CK
CL

Dorner Mfg. Corp. 20 851-565 Rev. G
6200 Series Industrial End Drive Conveyors
Preventive Maintenance and Adjustment
Bearing Replacement for Gang Drive
Pulley
* - Parts required from Tool Kit, part number 2500M.
Bearing Removal
1. Insert bearing removal tool (part # 25-05*) (Figure
48, item CN) into the pulley (CQ) until shoulder (CM)
seats against bottom of bearing (CR).
Figure 48
Figure 48
2. While holding bearing removal tool (CN) in position,
insert extension tool (part # 25-08*) (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
Figure 49
4. Orient bearing anvil/sleeve removal tool (part # 25-09*)
(Figure 50, item CS) with cavity facing up and place
pulley onto tool.
Figure 50
Figure 50
5. Press bearing out of pulley.
Figure 51
Figure 51
IMPORTANT
Once removed, do not re-use bearings.
NOTE
The bearings of a 2¨ (51 mm) wide gang drive
pulley cannot be replaced. Order pulley
assembly (part # 454702).
CM
CO
CP
CQ
CR
CN
CO
CN
NOTE
If a severely worn bearing breaks apart
during removal, pulley must be replaced.
CS
CO