Dorner Allegro 18" 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]
851-824 Rev. A
Allegro 18"Integral Conveyor
Maintenance & Parts Manual

Dorner Mfg. Corp. 2 851-824 Rev. A
Allegro 18" Integral Conveyor
Table of Contents
Table of Contents ................................................................ 2
Introduction ......................................................................... 2
Warnings −General Safety ................................................. 3
Product Description ............................................................. 4
Preventive Maintenance and Adjustment............................ 5
Conveyor Belt Replacement ............................................ 5
Conveyor Belt Tensioning/Tracking ............................... 5
Idler Pulley Removal ....................................................... 6
Drive Pulley Removal...................................................... 7
Bearing Removal & Replacement ................................... 8
Removal ....................................................................... 8
Replacement.................................................................. 8
Gearmotor Mounting Package Removal .......................... 9
Timing Belt Tensioning.................................................. 11
Timing Belt Replacement............................................... 11
Drive or Driven Timing Pulley Replacement................. 11
Gearmotor Replacement................................................. 12
Notes .................................................................................. 13
Service Parts....................................................................... 14
Drive Package and Gearmotor ....................................... 14
Frame Assembly............................................................. 16
Return Policy...................................................................... 18
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.
IMPORTANT
Some illustrations may show guards
removed. DO NOT operate equipment
without guards.

851-824 Rev. A 3 Dorner Mfg. Corp.
Allegro 18" Integral Conveyor
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.

Dorner Mfg. Corp. 4 851-824 Rev. A
Allegro 18" Integral Conveyor
Product Description
Refer to Figure 1 for typical components.
Figure 1
Figure 1
1DriveEnd
2 Gearmotor Mounting Package
3 Idler/Tension End
4Conveyor
5 Mounting Brackets
1
4
5
2
3

851-824 Rev. A 5 Dorner Mfg. Corp.
Allegro 18" Integral Conveyor
Preventive Maintenance and Adjustment
Conveyor Belt Replacement
1. Unlock spring plunger (Figure 2, item 1) by rotating
90 degrees. Pull spring plunger out and tip up the idler
tail (Figure 2, item 2).
Figure 2
Figure 2
2. Remove the belt (Figure 2, item 3) from the idler tail
and drive tail.
3. Install new belt.
4. Tip down idler tail (Figure 2, item 2) to the run
position. Pull spring plunger (Figure 2, item 1) out to
lock the idler tail into final position. Rotate the spring
plunger 90 degrees to lock.
Conveyor Belt Tensioning/Tracking
1. Confirm that the belt is on, the idler tail is in the down
position, and that the spring plunger has locked down
the idler tail.
2. Using an M10 wrench, loosen the M6 screw (Figure
3, item 1) on both sides of the conveyor to allow for
tensioning and tracking of the belt.
Figure 3
Figure 3
3. Using an M8 wrench, loosen (back out) the M5 screw
(Figure 4, item 1) on both sides of the conveyor to
tension the belt.
Figure 4
Figure 4
4. Tighten the M6 screws (Figure 4, item 2) on both sides
of the conveyor.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
1
2
3
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
NOTE
During first installation, make sure that the M5
screws are backed out equally on each side.
1
12

Dorner Mfg. Corp. 6 851-824 Rev. A
Allegro 18" Integral Conveyor
Preventive Maintenance and Adjustment
5. Turn on the conveyor, set at a slow speed, and check belt
tracking.
6. If necessary, loosen the M6 screw (Figure 4, item 2)
and back out the M5 screw (Figure 4, item 1) as needed
to track the belt.
Idler Pulley Removal
1. Remove conveyor belt. See “Conveyor Belt
Replacement” on page 5.
2. On one side of the conveyor, using a wrench to hold the
hex bar (Figure 5, item 1) underneath, remove the
shoulder screw (Figure 5, item 2) and spacer (Figure
5, item 3).
Figure 5
Figure 5
3. On the same side of the conveyor, using a wrench to
hold the hex bar (Figure 6, item 1) underneath, remove
the M6 screw (Figure 6, item 2).
Figure 6
Figure 6
4. Remove the head plate (Figure 7, item 1) from the
conveyor frame, holding spindle in place.
Figure 7
Figure 7
5. Slide the spindle out.
6. To replace the idler tail pulley, reverse the removal
procedure.
7. Install belt on the conveyor, then tension the belt. See
“Conveyor Belt Tensioning/Tracking” on page 5.
NOTE
Tracking adjustment should be minimal as the
belt is v-guided on the edge of the frame.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
1
2
3
NOTE
To prevent damage to the head plates, be
sure to remove them slowly because they are
not attached to pulley.
1
2
1

851-824 Rev. A 7 Dorner Mfg. Corp.
Allegro 18" Integral Conveyor
Preventive Maintenance and Adjustment
Drive Pulley Removal
1. Remove conveyor belt. See “Conveyor Belt
Replacement” on page 5.
2. On drive side of the conveyor, loosen four screws
(Figure 8, item 1) and remove timing belt covers
(Figure 8, item 2).
Figure 8
Figure 8
3. Remove tension on timing belt (Figure 9, item 1) by
loosening tensioner screw (Figure 9, item 2).
Figure 9
Figure 9
4. Loosen set screw (Figure 9, item 3) on driven pulley
(Figure 9, item 4). Remove driven pulley and timing
belt.
5. On the opposite drive side of the conveyor, using a
wrench to hold the hex bars (Figure 10, item 1)
underneath, remove the two M6 screws (Figure
10, item 2).
Figure 10
Figure 10
6. Remove the head plate (Figure 11, item 1) from the
conveyor frame, holding spindle in place.
Figure 11
Figure 11
7. Slide the spindle out.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
1
1
2
1
2
34
A
WARNING
Drive shaft keyway may be sharp. HANDLE
WITH CARE.
NOTE
To prevent damage to the head plates, be
sure to remove them slowly because they are
not attached to pulley.
1
2
1

Dorner Mfg. Corp. 8 851-824 Rev. A
Allegro 18" Integral Conveyor
Preventive Maintenance and Adjustment
8. To replace the drive tail pulley, reverse the removal
procedure.
9. Install belt on the conveyor, then tension the belt. See
“Conveyor Belt Tensioning/Tracking” on page 5.
Bearing Removal & Replacement
Removal
1. Place bearing removal tool part #456063 (Figure
12, item 1) below bearing (Figure 12, item 2) with lip
(Figure 12, item 3) located in gap (Figure 12, item 4)
between bearing and spindle hub (Figure 12, item 5) as
shown.
Figure 12
Figure 12
2. Using puller part #807−1716 (Figure 13, item 1),
remove and discard bearing.
Figure 13
Figure 13
Replacement
1. Inspect the head plates bearing seating surface (Figure
14, item 1). If they are worn or damaged, replace. See
“Service Parts” on page 14.
Figure 14
Figure 14
2. Inspect spindle (Figure 15, item 1). Replace if worn.
3. Slide bearing (Figure 15, item 2) onto spindle.
Figure 15
Figure 15
4. Slide sleeve (Figure 16, item 1) of tool (part #456085)
over bearing.
Figure 16
Figure 16
IMPORTANT
Do not use any removed bearings. Replace
them.
21
54
3
1
1
2
1
1

851-824 Rev. A 9 Dorner Mfg. Corp.
Allegro 18" Integral Conveyor
Preventive Maintenance and Adjustment
5. Place open end of pusher (Figure 17, item 1) into
sleeve.
Figure 17
Figure 17
6. Using an arbor press or similar device, press bearing
onto pulley shaft (Figure 18).
Figure 18
Figure 18
7. Repeat steps 1 through 5 for each bearing.
Gearmotor Mounting Package
Removal
1. Remove conveyor belt. See “Conveyor Belt
Replacement” on page 5.
2. Loosen four screws (Figure 19, item 1) and remove
timing belt covers (Figure 19, item 2).
Figure 19
Figure 19
3. Remove tension on timing belt (Figure 20, item 1) by
loosening tensioner screw (Figure 20, item 2).
Figure 20
Figure 20
4. Loosen set screw (Figure 20, item 3) on driven pulley
(Figure 20, item 4). Remove driven pulley and timing
belt.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
1
A
WARNING
Drive shaft keyway may be sharp. HANDLE
WITH CARE.
1
1
2
1
2
34

Dorner Mfg. Corp. 10 851-824 Rev. A
Allegro 18" Integral Conveyor
Preventive Maintenance and Adjustment
5. Loosen set screw on drive pulley (Figure 21, item 1).
Remove pulley.
Figure 21
Figure 21
6. Using a wrench to hold the hex bars underneath, remove
two M6 screws (Figure 22, item 1). Remove whole
gearmotor mounting package (Figure 22, item 2) and
spacer (Figure 22, item 3).
Figure 22
Figure 22
7. Remove four screws (Figure 23, item 1) and drive
mounting plate (Figure 23, item 2).
Figure 23
Figure 23
8. Remove four screws (Figure 24, item 1) from
gearmotor and mount plates (Figure 24, item 2).
Figure 24
Figure 24
9. Remove eight screws (Figure 25, item 1). Remove
gearmotor (Figure 25, item 2) and mount plates
(Figure 25, item 3) from motor mount plate (Figure
25, item 4).
Figure 25
Figure 25
1
2
1
3
1
1
2
1
2
2
1
1
3
2
1
3
4

851-824 Rev. A 11 Dorner Mfg. Corp.
Allegro 18" Integral Conveyor
Preventive Maintenance and Adjustment
Timing Belt Tensioning
1. Loosen four screws (Figure 26, item 1) and remove
timing belt covers (Figure 26, item 2).
Figure 26
Figure 26
2. Loosen screw (Figure 27, item 1). Add tension against
timing belt (Figure 27, item 2) by moving bearing
(Figure 27, item 3).Tighten screw.
Figure 27
Figure 27
3. Install timing belt covers and tighten four screws.
Timing Belt Replacement
1. Complete steps 2-3 of “Gearmotor Mounting Package
Removal” on page 9.
2. Install new timing belt and place driven pulley back on
spindle. Tighten set screw.
3. Add tension against timing belt (Figure 27, item 2) by
moving bearing (Figure 27, item 3).Tighten screw.
4. Install timing belt covers (Figure 26, item 2) and
tighten four screws (Figure 26, item 1).
Drive or Driven Timing Pulley
Replacement
1. Complete steps 2-5 of “Gearmotor Mounting Package
Removal” on page 9.
2. Replace drive or driven pulley. Tighten set screws.
3. Complete steps 2-4 of “Timing Belt Replacement” on
page 11.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
1
1
2
1
2
3
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.

Dorner Mfg. Corp. 12 851-824 Rev. A
Allegro 18" Integral Conveyor
Preventive Maintenance and Adjustment
Gearmotor Replacement
1. For single phase motor, unplug power cord from outlet.
2. For variable speed motor, unplug cord at disconnect
(Figure 28, item 1).
Figure 28
Figure 28
3. Replace gearmotor. See “Gearmotor Mounting Package
Removal” on page 9.
A
WARNING
Exposed moving parts can cause severe
injury. LOCK OUT POWER before removing
guards or performing maintenance.
A
DANGER
Hazardous voltage will cause severe injury or
death.
LOCKOUT POWER BEFORE before wiring.
1

851-824 Rev. A 13 Dorner Mfg. Corp.
Allegro 18" Integral Conveyor
Notes

Dorner Mfg. Corp. 14 851-824 Rev. A
Allegro 18" Integral Conveyor
Service Parts
Drive Package and Gearmotor
NOTE
For replacement parts other than those shown in this section, contact an authorized Dorner Service Center
or the factory. Key Service Parts and Kits are identified by the Performance Parts Kits logo . Dorner
recommends keeping these parts on hand.
1
3
2
4
5
6
7
8
9
10
11 12
13
14
15 16
17
18
19 19
20
21
22

851-824 Rev. A 15 Dorner Mfg. Corp.
Allegro 18" Integral Conveyor
Service Parts
Item Part Number Description
1 75052608 Drive Mounting Plate
2 75052609 Cover Bracket
3 450178MSS Slide Bar
4 639971MSS Drop-In Tee Bar
5 75060573 Spacer Plate
6 911-201 Washer
7 75052611 Mount Plate
8 75052610 Motor Mount Plate
9 75052614 Washdown Cover
10 75052615 Washdown Cover
11 802-123 Bearing
12 450102 Pulley, 22 Tooth
13 807-2784 Pulley, 48 Tooth
14 814-101 Timing Belt
15 820-823 Gearmotor
16 807-968 Hex Flange Screw, M5-0.80 x 10 mm
17 960512MSS Hex Head Cap Screw,
M5-0.80 x 12 mm
18 930514MSS Hex Head Cap Screw,
M5-0.80 x 14 mm
19 960616MSS Hex Head Cap Screw,
M6-1.00 x 16 mm
20 960625MSS Hex Head Cap Screw,
M6-1.00 x 25 mm
21 960645MSS Hex Head Cap Screw,
M6-1.00 x 45 mm
22 960816MSS Hex Head Cap Screw,
M8-1.25 x 16 mm

Dorner Mfg. Corp. 16 851-824 Rev. A
Allegro 18" Integral Conveyor
Service Parts
Frame Assembly
1
10
2
3
4
5
6
7
8
9
10
11 12
13
14
15 16
17
18
19 20
21
24
23
25
26
27
22

851-824 Rev. A 17 Dorner Mfg. Corp.
Allegro 18" Integral Conveyor
Service Parts
Item Part Number Description
1 75054102 Belt
2 75063841 Frame Weldment
3 75063836 Infeed Bedplate
4 75063837 Bedplate
5 75063835 Hex Post
6 75057111 Encoder Mount Spacer
7 75057110 Encoder Mount Plate
8 75066686 Spring Plunger
9 75066687 Thin Nut
10 240338 Bearing
11 75052586 Drive Spindle
12 75054099 Head Plate
13 807-1263 Plug
14 980422MSS Square Key
15 75053385 Spacer
16 75057027 Tip Up Tail Mount Bar
17 75057030 Hex Crossmember
18 75057033 Tip Up Post
19 75057107 Head Plate
20 75057113 Idler Spindle
21 807-2781 Socket Head Shoulder Screw
22 911-708 Washer
23 960516MSS Hex Head Cap Screw,
M5-0.80 x 16 mm
24 960620MSS Hex Head Cap Screw,
M6-1.00 x 20 mm
25 960625MSS Hex Head Cap Screw,
M6-1.00 x 25 mm
26 960630MSS Hex Head Cap Screw,
M6-1.00 x 30 mm
27 960640MSS Hex Head Cap Screw,
M6-1.00 x 40 mm

851-824 Rev. A Printed in U.S.A.
Dorner Mfg. Corp. reserves the right to change
or discontinue products without notice. All
products and services are covered in
accordance with our standard warranty. All
rights reserved. © Dorner Mfg. Corp. 2013
DORNER MFG. CORP.
975 Cottonwood Ave., PO Box 20
Hartland, WI 53029-0020 USA
TEL [phone] (USA)
FAX [phone] (USA)
Internet: www.dorner.com
Outside the USA:
TEL [phone]
FAX [phone]
Return Policy
Returns must have prior written factory authorization or they will not be accepted. Items that are returned to Dorner without
authorization will not be credited nor returned to the original sender. When calling for authorization, please have the following
information ready for the Dorner factory representative or your local distributor:
1. Name and address of customer.
2. Dorner part number(s) of item(s) being returned.
3. Reason for return.
4. Customer's original order number used when ordering the item(s).
5. Dorner or distributor invoice number (if available, part serial number).
A representative will discuss action to be taken on the returned items and provide a Returned Goods Authorization (RMA)
number for reference. RMA will automatically close 30 days after being issued. To get credit, items must be new and
undamaged. There will be a return charge on all items returned for credit, where Dorner was not at fault. It is the customer’s
responsibility to prevent damage during return shipping. Damaged or modified items will not be accepted. The customer is
responsible for return freight.
Returns will not be accepted after 60 days from original invoice date. The return charge covers inspection, cleaning,
disassembly, disposal and reissuing of components to inventory. If a replacement is needed prior to evaluation of returned item,
a purchase order must be issued. Credit (if any) is issued only after return and evaluation is complete.
Dorner has representatives throughout the world. Contact Dorner for the name of your local representative. Our Customer
Service Team will gladly help with your questions on Dorner products.
For a copy of Dorner's Warranty, contact factory, distributor, service center or visit our website at www.dorner.com.
For replacement parts, contact an authorized Dorner Service Center or the factory.
Product Type
Standard Products Engineeredto
order parts
Product Line Conveyors Gearmotors
& Mounting
Packages
Support
Stands Accessories SpareParts (non-belt) SpareBelts - Standard
Flat Fabric
Spare Belts -
Cleated &
Specialty
Fabric
Spare Belts -
Plastic Chain All equipment
and parts
1100
30% return fee for all products except:
50% return fee for conveyors with modular belt,
cleated belt or specialty belts non-returnable case-by-case
2200
2200 Modular Belt
2200 Precision Move
2300
2300 Modular Belt
3200
3200 LPZ
3200 Precision Move
4100
5200
5300
6200
Controls
7200 / 7300 50% return fee for all products
7350
non-returnable
7360
7400
7600