Dorner 6200 Series User manual

851-571 Rev. B
Installation, Maintenance
& Parts Manual
6200 Series Industrial Center Drive Conveyors
Table of Contents
Warnings −General Safety 2. . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Installation Sequence 5. . . . . . . . . . . . . . .
Conveyors Up to 12 ft (3658 mm) 5. . . . . . . . . . . . . . . . .
Conveyors Longer Than 12 ft (3658 mm) 5. . . . . . . . . . . .
Mounting Brackets 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Rollers 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2¨ (51mm) Through 6” (152mm) Wide Conveyor 7. . .
8¨ (203mm) Through 18” (457mm) Wide Conveyor 7
Preventative Maintenance & Adjustment 8. . . . . . . . . . . . . .
Required Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyors 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Rollers 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining Conveyor Belt 8. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement 8. . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement Sequence 8. . . . . . . . . . .
Belt Removal for Conveyor Without
Gearmotor Mounting Package or Stands 9. . . . . . . . . . . .
Belt Removal for Conveyor With Stands
and/or Gearmotor Mounting Package 10. . . . . . . . . . . . .
Center Drive Module Removal 11. . . . . . . . . . . . . . . . .
Belt Removal from Center Drive Module 12. . . . . . . . . .
Installing a New Conveyor Belt 12. . . . . . . . . . . . . . . . . .
Conveyor Belt Tensioning 14. . . . . . . . . . . . . . . . . . . . . . .
Pulley Removal 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A −Tension End Pulley Removal 15. . . . . . . . . . . . . . .
B −Fixed End Pulley Removal 16. . . . . . . . . . . . . . . . .
C −Drive Pulley Removal 16. . . . . . . . . . . . . . . . . . . . .
D −Idler Pulley Removal 16. . . . . . . . . . . . . . . . . . . . .
Bearing Replacement for Tension End
and Fixed End Pulleys 17. . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Removal 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Installation 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Replacement for Drive Pulley 18. . . . . . . . . . . . .
Bearing Removal 18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Installation 18. . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Replacement for Idler Pulleys 19. . . . . . . . . . . . .
Pulley Installation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Parts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fixed End Components 20. . . . . . . . . . . . . . . . . . . . . . . . .
Tension End Components 21. . . . . . . . . . . . . . . . . . . . . . . .
Center Drive Module 5” (127mm) Through
18” (457mm) Wide Conveyors 22. . . . . . . . . . . . . . . . . .
Center Drive Module 2” (51mm) Through
4” (102mm) Wide Conveyors 22. . . . . . . . . . . . . . . . . . .
Conveyor Frame and Extension 24. . . . . . . . . . . . . . . . . .
−02 0.5” (13mm) Bolt on High Side Guides 25. . . . . . . .
−03 Bolt on Side Wipers 26. . . . . . . . . . . . . . . . . . . . . . . .
−04 3” (76mm) Bolt on High Side Guides 27. . . . . . . . . .
−05 1.5” (38mm) Bolt on High Side Guides 28. . . . . . . .
−13 Fully Adjustable UHMW Guides 29. . . . . . . . . . . . .
−20 Adjustable Width UHMW Guides 30. . . . . . . . . . . . .
2” (51mm) Through 6” (152mm) Wide Flat
Belt Return Roller 31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
8” (203mm) Through 18” (457mm) Wide Flat
Belt ReturnRoller 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Mounting Brackets 32. . . . . . . . . . . . . . . . . . . .
Configuring Conveyor Belt Part Number 32. . . . . . . . . . .
Return Policy 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
851-571 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 Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 3851-571 Rev. B
Refer to Figure 1 for typical conveyor components.
A Conveyor
B Center Drive Module
C Gearmotor Mounting Package
D Mounting Brackets
E Support Stands
F Speed Controller
G Fixed End
H Tension End
Typical Components
B
C
D
E
F
H
Figure 1
G
A
Specifications
Models:
6200 Series Industrial Center Drive Conveyor
Conveyor Width Reference
Conveyor Length Reference
Belt Type*
Output Shaft Position*
Conveyor Profile*
5 = Center 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
* See “Ordering and Specifications” Catalog for details.
Conveyor Supports:
Maximum Distances:
I = 18¨ (457 mm)
J = 6 ft (1829 mm)**
** For conveyors longer than 12 ft (3658 mm), install
support at joint.
Figure 2
II J
Product Description

6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
851-571 Rev. B 4Dorner Mfg. Corp.
Specifications:
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”
(457mm)
Maximum Conveyor Load*
(See NOTE Below)
40 lb
(18 kg)
50 lb
(23 kg)
60 lb
(27 kg)
75 lb
(34 kg)
90 lb
(41 kg)
105 lb
(47 kg)
120 lb
(54 kg)
120 lb
(54 kg)
120 lb
(54kg)
Conveyor Start-up Torque* 9 in-lb
(1.0 Nm)
10 in-lb
(1.1 Nm)
11 in-lb
(1.2 Nm)
12 in-lb
(1.4 Nm)
15 in-lb
(1.7 Nm)
20 in-lb
(2.3 Nm)
23 in-lb
(2.6 Nm)
25 in-lb
(2.8 Nm)
30 in−lb
(8.4Nm)
Belt Travel 3.5¨(88 mm) per revolution of pulley
Maximum Belt Speed* 235 feet/minute (72 meters/minute)
Belt Take-up 1¨ (25 mm) of stroke = 2¨ (51 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
**
19
**
20
**
21
**
22
**
23
**
24
**
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) 19-ft (5791 mm) 20-ft (6096 mm) 21-ft (6401 mm) 22-ft (6706 mm) 23-ft (7010 mm) 24-ft (7315 mm)
* See “Ordering and Specifications” Catalog for details. ** Lengths available only in 6¨ (152 mm) & wider conveyors.
NOTE: Maximum conveyor loads are based on:
DNon-accumulating product
DProduct moving towards gearmotor
DConveyor being mounted horizontal
DConveyor being located in a dry environment
DConveyor with standard belt only
Specifications

6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 5851-571 Rev. B
NOTE: Conveyor MUST be mounted straight, flat and
level within confines of conveyor. Use a level (K of
Figure 3) for set-up.
Figure 3
K
Required Tools
DHex key wrenches: 4 mm, 5 mm
D10 mm open−end wrench
DLevel
DTorque wrench
Recommended Installation Sequence (see
Table of Contents for page number)
DAssemble conveyor (if required)
DAttach mounting brackets (see page 6)
DAttach return roller to conveyor (see page 6)
DAssemble stands (see accessory instructions)
DAttach conveyor to stands
DMount gearmotor mounting package (see accessory
instructions)
DAttach guides/accessories (see “Service Parts” section,
pages 20 through 32)
Conveyors Up to 12 ft (3658 mm)
No additional assembly is required.
Conveyors Longer Than 12 ft (3658 mm)
L Conveyor frame without belt
M M6 x 10 mm Low−Head Screws (6x) (shipped loose)
N Connector Strips (2x) (Attached to conveyor section)
O Conveyor frame with belt
Illustration References
1.Typical components (Figure 4)
Figure 4
M
NO
L
2.Compress tension end (Figure 5). Refer to steps 6
and 7 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 (L of Figure 6) into belt loop.
Figure 6
LN
5.Join conveyor sections (L and O of Figure 7). Install
screws (M) through frame and into connector bar
(N) on both sides. Tighten screws to 60 in-lb (7 Nm).
Figure 7
M
L
O
6.Tension conveyor belt. Refer to “Conveyor Belt
Tensioning” on page 14.
Installation

6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
851-571 Rev. B 6Dorner Mfg. Corp.
Mounting Brackets
1.Typical mounting bracket components (Figure 8)
P M6 x 12 mm Socket Head Screws (4x)
Q M6 x 20 mm Socket Head Screw (4x)
R Hard Washer (4x)
S M6 Square Nut (4x)
T Stand Mounting Bracket (2x)
U Mounting Plate, Flat Belt (2x)
Mounting Bracket Components (One Pair)
Figure 8
Q
S
PT
U
R
2.Attach clamp plate (U of Figure 8) to stand mounting
bracket (T) with two screws (P). Do not tighten
screws.
3.Attach stand mounting bracket (T of Figure 9) to
bottom of conveyor (V). Snug−up screws (P).
Figure 9
P
T
U
V
4.Repeat steps 2 and 3 for other stand mounting
bracket(s).
5.Position conveyor (V of Figure 10) on stands (W) .
Figure 10
V
W
6.Attach stand mounting bracket (T of Figure 11) to
stand (W) with two screws (Q), hard washers (R) and
square nuts (S). Tighten screws (Q) to 80 in-lb (9
Nm).
Figure 11
S
P
W
S
T
R
7.Repeat step 6 for other stand mounting bracket(s).
8.Tighten all screws (P) to 80 in-lb (9 Nm).
Installation

6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 7851-571 Rev. B
Return Rollers
2¨ (51mm) Through 6¨ (152mm) Wide
Conveyor
1.Typical return roller components (Figure 12)
X Return Roller Guard
Y Return Roller Clip
Z Low−Head Cap Screw M6−1.00 x 20mm (2)
Typical Components
Figure 12
Z
X
Y
2.Loosely attach clip (Y of Figure 13) on guard (X)
with two screws (Z). Do not tighten screws.
Figure 13
Z
Y
X
3.Attach return roller assembly (AA of Figure 14) on
each side of conveyor (V). Tighten screws (Z) to 80
in-lb (9 Nm).
V
AA
Figure 14
Z
8¨ (203mm) Through 18¨ (457mm) Wide
Conveyor
1.Typical return roller components (Figure 15)
AB Return Roller and Guard Assembly
AC Return Roller Clip (2x)
AD Low−Head Cap Screw M6−1.00 x 20mm (4x)
Typical Components
Figure 15
AD
AB
AC
2.Loosely attach two clips (AC of Figure 16) on roller
and guard assembly (AB) with four screws (AD). Do
not tighten screws.
Figure 16
AB
AD
AC
3.Attach return roller assembly (AE of Figure 17) on
conveyor (V). Tighten screws (AD of Figure 16) to
80 in-lb (9 Nm).
Figure 17
AE
V
4.On 16−18 ft (4877−5486 mm) conveyor, repeat step 3
for other return roller.
Installation

6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
851-571 Rev. B 8Dorner Mfg. Corp.
Required Tools
Standard Tools
DHex key wrenches:
3 mm, 4 mm, 5 mm, 6 mm and 3/16”
D3/8” Open−end wrench or an adjustable wrench
DArbor press
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)
DKeep supply of belt cleaner (part # 625619)
DClean entire conveyor and knurled pulley while dis-
assembled
DReplace worn or damaged parts
Lubrication
Conveyor
No lubrication is required. Replace bearings if worn.
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
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
DCenter Drive Module Removal
DConveyor Belt Removal from Center Drive Module
DInstall New Conveyor Belt
DTension Conveyor Belt
Preventive Maintenance and Adjustment

6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 9851-571 Rev. B
Belt Removal for Conveyor Without Gearmotor
Mounting Package or Stands
1.If installed, loosen two set screws (AF of Figure 18)
to remove and retain bottom wiper(s) (AG).
Figure 18
AG
AF
AF
2.If conveyor is equipped with guiding and accesso-
ries and/or return rollers, remove them from one
side.
3.Loosen screw (AI of Figures 19 & 20) on each side
of center drive module (AJ).
Figure 19
AK
AI
AJ
4.Remove screws (AK of Figures 19 & 20) on each
side of center drive module (AJ).
5.Using finger grip holes (AL of Figure 20), open tension
door (AM) to release conveyor belt tension.
Figure 20
AI
AK
AL
AJ
AM
6.On tension end of the conveyor identified with a
label (AN of Figures 21 and 22), loosen two
M6 socket head cap screws (AO) on each side of
conveyor.
Figure 21
AN
AO
7.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
NOTE: On 4-foot (1219 mm) and shorter by 8¨ (203
mm) and wider conveyors, the center drive module and
the conveyor belt must be removed at the same time.
See “Center Drive Module Removal” on page 11.
8.Remove conveyor belt (AR of Figure 23) from both
ends of conveyor.
Figure 23
AQ
AR
9.Proceed to “Center Drive Module Removal” on page
11.
Preventive Maintenance and Adjustment

6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
851-571 Rev. B 10 Dorner Mfg. Corp.
Belt Removal for Conveyor With Stands and/or
Gearmotor Mounting Package
1.If installed, loosen two set screws (AF of Figure 18)
to remove and retain bottom wiper(s) (AG).
2.If conveyor is equipped with guiding and accesso-
ries and/or return rollers, remove them from one
side.
NOTE: Figures 24 & 25 show a vertical mount in the
A1 position with a parallel shaft gearmotor. Horizontal
mount, D1 position and/or 905gearmotor mounting is
similar.
3.Remove four (4) screws (AS of Figure 24) and
remove cover (AT).
Figure 24
AS
AT
AS
4.Loosen tensioner (AU of Figure 25) to release
tension on timing belt (AV).
Figure 25
AU
AV
NOTE: If timing belt (AV) does not slide over pulley
flange, loosen driven pulley set screws (AW of
Figure 26) and remove pulley (AX) with belt.
Figure 26
AV
AW
AX
5.Remove timing belt (AV of Figure 25).
6.Remove three (3) screws (AY of Figure 27) and
remove gearmotor mounting package.
Figure 27
AY
7.Loosen screw (AI of Figures 19 & 20) on each side
of center drive module (AJ).
NOTE: With a vertical mount, two (2) screws (AY of
Figure 27) were removed in step 6.
8.Remove screws (AK of Figures 19 & 20) on each
side of center drive module (AJ).
9.Using finger grip holes (AL of Figure 20), open tension
door (AM) to release conveyor belt tension.
Preventive Maintenance and Adjustment

6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 11 851-571 Rev. B
10.On tension end of the conveyor identified with a
label (AN of Figures 21 and 22), loosen two
M6 socket head cap screws (AO) on each side of
conveyor.
11.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.
Ç
Ç
To prevent injury from the support stand
tipping-over when conveyor is uncoupled, anchor
stand to floor or otherwise stabilize the stand.
NOTE: On 4-foot (1219 mm) and shorter by 8¨ (203
mm) and wider conveyors, the center drive module and
the conveyor belt must be removed at the same time.
See “Center Drive Module Removal” on page 11.
12.Loosen two mounting plate screws (P of Figure 28).
Remove two screws, hard washers and square nuts
(AZ). Slide stand mounting bracket (T) off stand (W)
and remove from conveyor (V).
Figure 28
V
T
AZ
P
W
13.Repeat step 12 for remaining stand mounting
brackets on same side of conveyor between convey-
or tail and center drive module.
14.Remove conveyor belt (AR of Figure 29) from
conveyor end.
Figure 29
AR
15.After belt is removed, secure conveyor with moun-
ting plate(s) and stand mounting bracket(s) (T of
Figure 28) and mounting hardware (AZ).
16.Repeat steps 12 through 15 for other end of
conveyor.
17.Proceed to “Center Drive Module Removal”.
Center Drive Module Removal
Ç
Ç
Before loosening clamps (BA of Figure 30), provide
a support (BB) under center drive module.
NOTE: If desired, mark center drive module location
on conveyor.
1.Loosen clamp screw (BA of Figure 30) in each cor-
ner of module.
BA
BB
Figure 30
2.Remove module.
Preventive Maintenance and Adjustment

6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
851-571 Rev. B 12 Dorner Mfg. Corp.
Belt Removal from Center Drive Module
1.Remove two (2) screws (BC of Figure 31). Remove
tension drive plate (BD).
Figure 31
BD
BC
2.Remove drive pulley [BE of Figure 32, for 2¨ (44
mm), 3¨ (70 mm) or 4¨ (95 mm) wide conveyor] or
[BE of Figure 33, for 5¨ (127 mm) or wider
conveyor].
BF
BG
BH
Figure 32
BE
BI
Figure 33
BE
3.Remove grooved idler pulley:
DFor 2¨ (44 mm), 3¨ (70 mm) or 4¨ (95 mm) wide con-
veyor, remove E-ring clip (BF of Figure 32). Remove
pulley shaft (BG) and remove pulley (BH).
DFor 5¨ (127 mm) or wider conveyor, depress both
sides of spring-loaded shaft and remove pulley (BI of
Figure 33).
4.Remove conveyor belt.
Installing a New Conveyor Belt
IMPORTANT: Belt travel direction is identified by an
arrow decal on the side of the conveyor (BJ of Figures
34 & 35).
BJ
Figure 34
Preventive Maintenance and Adjustment

6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 13 851-571 Rev. B
Figure 35
BK BJ
1.Orient the conveyor belt so that the splice leading
fingers (BL of Figure 36) point in the direction of
belt travel (BK) as identified by the label (BJ of
Figures 34 and 35).
Figure 36
BL
BK
2.Place loop of belt into module (Figure 37).
Figure 37
3.Place grooved idler pulley (BH of Figure 32 or BI of
Figure 33) into belt loop and replace in center drive
module. Refer to step 3 under “Belt Removal from
Center Drive Module” on page 12.
4.Place drive pulley (BE of Figure 32 or 33) into belt
loop and install in center drive module. Refer to
“Belt Removal from Center Drive Module” section
and reverse steps 1 and 2 on page 12. Tighten screws
(BC of Figure 31) to 80 in-lb (9 Nm).
NOTE: On 4-foot (1219 mm) and shorter by 8¨ (203
mm) and wider conveyors, the center drive module and
the conveyor belt must be installed at the same time.
5.Install center drive module onto conveyor and
secure with clamp and clamp screw (BA of Figure
30) in each corner. Tighten screws to 80 in-lb (9
Nm).
6.Loosen two mounting plate screws (P of Figure 28).
Remove two screws, hard washers and square nuts
(AZ). Slide stand mounting bracket (T) off stand (W)
and remove from conveyor (V).
7.Repeat step 6 for remaining stand mounting brackets
on same side of conveyor between conveyor tail and
center drive module.
8.Install conveyor belt (AR of Figure 29) on conveyor
end.
9.Tighten all mounting bracket screws to 80 in-lb (9
Nm).
10.Repeat steps 6 through 9 for other end of conveyor.
11.On tension end of the conveyor identified with a
label (AN of Figures 21 and 22), loosen four
M6 low head screws (AO).
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6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
851-571 Rev. B 14 Dorner Mfg. Corp.
NOTE: The M6 low head screw (BM of Figure 38),
which is used for extending the idler spindle assembly
to tension the belt, has a yellow colored head.
12.Turn M6 low head screw (BM of Figure 38)
clockwise to extend idler spindle assembly (AP) 1¨
(25 mm) (BN).
Figure 38
BN
AP
BM
AO
13.Tighten four M6 low head screws (AO of Figures 21
and 38) to 40 in-lb (4.5 Nm) to secure idler spindle
assembly (AP).
Ç
Tension door closes quickly
and may cause injury.
KEEP FINGERS CLEAR OF
TENSION DOOR.
14.Close tension door (AM of Figure 39).
Figure 39
AM
15.Tighten screw (AI of Figures 40) on each side of
center drive module (AJ) to 80 in-lb (9 Nm).
Figure 40
AK
AI
AJ
BO
NOTE: If equipped with gearmotor mounting package,
install by completing in reverse order steps 3 through
6 of “Belt Removal for Conveyor With Stands and/or
Gearmotor Mounting Package” section on page 10.
16.Install screws (AK of Figure 40) on each side of
center drive module (AJ). Tighten screws to 80 in-lb
(9 Nm).
17.If removed, install bottom wiper(s) (AH of Figure 18).
Center set screws in frame and tighten to 33 in-lb (3.7
Nm).
18.Where applicable, install return rollers, guiding and
accessories.
Conveyor Belt Tensioning
NOTE: For a new belt, the tension plate will be in
position (BO of Figure 40). When tension plate ex-
tends to position (BP of Figure 41), the conveyor belt
must be replaced.
Figure 41
BP
Conveyor is equipped with automatic tensioning cylin-
der. No tensioning adjustment is required.
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6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 15 851-571 Rev. B
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).
DRefer to “Belt Removal for Conveyor Without Gear-
motor Mounting Package or Stands” section, steps 1
through 8 on page 9.
DRefer to “Belt Removal for Conveyor With Stands
and/or Gearmotor Mounting Package” section, steps
1 through 16 on pages 10 and 11.
Remove the desired pulley following instructions:
DA−Tension End Pulley
DB−Fixed End Pulley
DC−Drive Pulley
DD−Idler Pulleys
A−Tension End Pulley Removal
1.Remove two screws (AO of Figure 42) on each side
of conveyor (V).
Figure 42
AQ
BQ
AO
V
2.While holding hex pinion (BQ) with a 3/8” open−end
wrench, loosen screw (AQ).
3.Remove screw (AQ of Figure 43) and sleeve (BR)
from conveyor (V) and hex pinion (BQ).
Figure 43
AQ BR V
BM BR
BQ
4.Repeat steps 2 and 3 for screw (BM of Figues 38 and
43) on opposide of conveyor (V).
5.Remove two pinion ends (BT of Figure 44), clamp
blocks (BU), hex pinion (BQ) and tail assembly (BS)
from conveyor (V).
Figure 44
BS
BU
BT BQ
V
NOTE: Note on which side of conveyor magnet (BV
of Figure 45) is located.
6.Locate magnet (BV of Figure 45) on spindle and
bearing assembly (BW).
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6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
851-571 Rev. B 16 Dorner Mfg. Corp.
Figure 45
BX
BW
BY
BV
7.Remove screw (BX), headplate (BY), and spindle
and bearing assembly (BW).
B−Fixed End Pulley Removal
1.Remove three (3) screws (BZ of Figure 46) on both
sides of conveyor.
Figure 46
BZ
CA
2.Remove fixed end tail assembly (CA).
NOTE: Note on which side of conveyor magnet (CB
of Figure 47) is located.
3.Locate magnet (CB of Figure 47) on spindle and
bearing assembly (CC).
4.Remove screw (CD) to separate head plate (CE) from
spindle and bearing assembly.
Figure 47
CD
CC
CE
CB
C−Drive Pulley Removal
1.Remove gearmotor drive package. Refer to “Belt
Removal for Conveyor With Stands and/or Gearmo-
tor Mounting Package” section, steps 3 through 9 on
page 10.
2.Remove drive pulley. Refer to “Belt Removal from
Center Drive Module” section, steps 1 and 2 on
page 12.
D−Idler Pulley Removal
1.Remove gearmotor drive package. Refer to “Belt
Removal for Conveyor With Stands and/or Gearmo-
tor Mounting Package” section, steps 3 through 9 on
page 10.
2.Detach center drive module. Refer to ”Center Drive
Module Removal” section on page 11.
3.Remove grooved idler pulley. Refer to “Belt Removal
from Center Drive Module” section, step 3 on page 12.
4.Remove smooth idler pulleys:
DFor 2¨ (44 mm), 3¨ (70 mm) or 4¨ (95 mm) wide con-
veyor, detach E-ring clips (CF of Figure 48). Remove
washers (CG). Remove pulley shafts (CH) and two
pulleys (CI).
Figure 48
CF
CH
CI
CG
CH
DFor 5¨ (127 mm) or wider conveyor, depress both
sides of each spring-loaded shaft (CJ of Figure 49).
Remove pulleys (CK).
Figure 49
CK
CJ
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6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 17 851-571 Rev. B
Bearing Replacement for Tension End and
Fixed End Pulleys
IMPORTANT: Once removed, do not re-use
bearings.
Bearing Removal
1.Place bearing removal tool (part # 450281) (CL of
Figure 50) over bearing (CM) with lip (CN) located
in gap (CO) between bearing and spindle (CP) as
shown.
CN
CO
Figure 50
CL
CM
CP
2.Using a 3/16¨ hex key wrench (CQ of Figure 51),
tighten bearing removal tool.
Figure 51
CQ
3.Using a puller (CR of Figure 52), remove and
discard bearing(s).
Figure 52
CR
Bearing Installation
IMPORTANT: Install bearings one at a time.
1.Inspect seating surface(s) on spindle shaft for damage.
Replace spindle if damaged.
2.Slide bearing (part # 802-121) (CS of Figure 53) onto
spindle shaft.
Figure 53
CS
3.Slide the sleeve of tool (part # 450282) (CT of Figure
54) over bearing.
Figure 54
CT
4.Place open end of shaft (CU of Figure 55) into
sleeve.
Figure 55
CU
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6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
851-571 Rev. B 18 Dorner Mfg. Corp.
5.Using arbor press or similar device, press bearing onto
pulley shaft (see Figure 56).
Figure 56
6.Repeat steps 2 through 5 for each bearing.
Bearing Replacement for Drive Pulley
IMPORTANT: Once removed, do not re-use
bearings.
Bearing Removal
1.Position drive pulley (BE of Figure 57) in a standard
bearing separator (CV) as shown.
Figure 57
CV
BE
CW
2.Using an arbor press or similar device, press drive
pulley (BE) through bearing (CW).
3.Repeat steps 1 through 2 for other bearing.
Bearing Installation
1.Inspect seating surface(s) on drive pulley for damage.
Replace drive pulley if damaged.
2.Slide bearing (CW) (part # 802-124) over drive pulley
(BE). Place two 5/8 flat washers (CX of Figure 58), or
equivalent, over the drive pulley (BE) and against the
bearing.
Figure 58
CX BE
CW
3.Place the shaft of tool (part # 450282) (CZ of Figure
59) over drive pulley (BE).
Figure 59
BE
CZ
CW
4.Using an arbor press or similar device, press bearing
(CW) onto pulley shaft as shown.
5.Repeat steps 1 through 4 for other bearing.
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6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 19 851-571 Rev. B
Bearing Replacement for Idler Pulleys
NOTE: Bearings can not be removed from idler pul-
leys. Replace entire pulley, when worn. See Service
Parts section on page 18.
Pulley Installation
A −Tension Pulley
IMPORTANT: On a tension tail assembly, orient
both pinion ends (BT of Figure 60) so they engage the
same tooth positions on their respective racks.
Figure 60
BT
NOTE: Install magnet (BV of Figure 45) end of
spindle and bearing assembly (BW) at same location
as noted during removal.
1.Reverse the removal procedure “A” (see page 15).
B −Fixed End Pulley
NOTE: Install magnet (CB of Figure 47) end of
spindle and bearing assembly (CC) at same location
as noted during removal.
2.Reverse the removal procedure “B” (see page 16).
C −Drive Pulley
3.Reverse the removal procedure “C” (see page 16).
D −Idler Pulley
4.Reverse the removal procedure “D” (see page 16).
Preventive Maintenance and Adjustment

Service Parts
6200 Series Industrial Center Drive Conveyors Installation, Maintenance & Parts Manual
851-571 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.
Fixed End Components
8
11
9
4
13
1
3
7
12
10
14
10
2
15 Fixed End Tail Kit 16 Fixed End Spindle Kit
5
6
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
3 807−963 Plastic Snap−Out Plug
4 802−121 Ball Bearing 12mm Bore x 21mm OD
5 4530WWM Fixed End Spindle
6 808−202 Magnet .25 x .25
7 450226SSP SS Sleeve .25 Magnet
8 456025 Head Plate RH 2−3” (51−76mm) Wide
456026 Head Plate RH 4−18” (102−457mm) Wide
9 4536WWM Support Tension/Fixed
10 920692M Low−Head Cap Screw M6−1.0x12mm
11 4527WWM Bottom Wiper
12 970508M Cup−Point Set Screw M5−.80 x 8mm
13 807−1022 Low−Head Pilot Screw M5−.8x12mm
14 4525WWM Frame Support Post
15 62FT−WW Fixed End Tail Kit (Includes Items 1
through 10)
16 62T−WW Fixed End Spindle Kit (Includes Items 3
through 7)
WW = Conveyor width ref.: 02, 03, 04, 05, 06, 08, 10, 12, 18
Service Parts