Dorner AquaPruf 7400 Ultimate CE 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]
7400 Ultimate Series Nose Bar
Conveyors
Installation, Maintenance and Parts Manual
851-670 Rev. A

Dorner Mfg. Corp. 2 851-670 Rev. A
7400 Ultimate Series Nose Bar Conveyors
Table of Contents
Introduction ......................................................................... 2
Warnings – General Safety.................................................. 3
Product Description............................................................. 4
Specifications ...................................................................... 4
Flat Belt 7400 Series Conveyor ................................... 4
Flat Belt 7400 Series LPZ Conveyor ........................... 4
Conveyor Supports .......................................................... 5
Specifications................................................................... 5
Installation........................................................................... 6
Required Tools................................................................. 6
Recommended Installation Sequence.............................. 6
Conveyors Longer than 10 ft (3048 mm) ........................ 6
LPZ Conveyors................................................................ 7
Knuckles....................................................................... 7
Belt ............................................................................... 7
Guides........................................................................... 8
All Conveyors.................................................................. 8
Stand Installation.......................................................... 8
Tail Assembly Installation ........................................... 9
Nose Bar Drive Tail.................................................. 9
Tip Up Assembly...................................................... 9
Idler Tail ................................................................. 10
Nose Bar Idler Tail ................................................. 10
Lifter Installation........................................................ 11
Wear Strip Installation ............................................... 11
Belt Installation .......................................................... 12
Belt Return Installation .............................................. 13
Preventive Maintenance and Adjustment.......................... 14
Required Tools............................................................... 14
Checklist ........................................................................ 14
Cleaning......................................................................... 14
Routine Cleaning........................................................ 14
Standard Conveyors................................................ 14
Conveyors with Lifters........................................... 15
Periodic Cleaning....................................................... 15
Lubrication..................................................................... 15
Conveyor Bearings..................................................... 15
Wearstrips and Belt Returns .......................................... 15
Maintaining the Conveyor Belt...................................... 15
Troubleshooting.......................................................... 15
Conveyor Belt Replacement.......................................... 16
Conveyors with Guides............................................... 16
Standard Belts............................................................. 16
Replacing a Section of Belt..................................... 16
Replacing the Entire Belt ........................................ 17
Specialty Intralox 1100 Series Belts........................... 17
Replacing a Section of Belt..................................... 17
Replacing the Entire Belt ........................................ 18
Conveyor Belt Tensioning.............................................. 18
Sprocket and Puck Removal........................................... 18
A - Drive Sprocket Removal ...................................... 19
B - Idler Puck Removal .............................................. 20
C - Nose Bar Puck Removal....................................... 21
Reassembling Tail Assembly......................................... 21
Nose Bar Idler............................................................. 21
Idler Tail ..................................................................... 22
Drive Tail.................................................................... 23
Bearing Replacement ..................................................... 23
LPZ Knuckles................................................................. 23
Wearstrips and Belt Returns ....................................... 23
Service Parts....................................................................... 24
Nose Bar Drive End Components.................................. 24
Tip Up Idler End............................................................. 26
Nose Bar Tip Up Idler End............................................. 27
Upper Knuckle for 5° - 15° ............................................ 28
Upper Knuckle for 30° ................................................... 29
Lower Knuckle for 5° - 15°............................................ 30
Lower Knuckle for 30°................................................... 31
Conveyor Frame and Extension ..................................... 32
3" (76 mm) High Sides................................................... 33
Flat Belt Returns............................................................. 34
Flat Belt Chain Repair Kit.............................................. 34
Belt Removal Tool ......................................................... 34
Ordering a Replacement Chain ...................................... 35
Configuring a Conveyor Part Number ........................... 35
Return Policy 36
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 instructions for installation.
The Dorner Limited Warranty applies.
Dorner 7400 Series conveyors have patents pending.
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 .
Intralox is a registered trademark of Laitram L.L.C. in the
United States and / or other countries.
Introduction
CAUTION
Some illustrations may show guards
removed. DO NOT operate equipment without
guards.
NOTE
Proper conveyor application, cleaning, and
sanitation are the responsibility of the end
user.

851-670 Rev. A 3 Dorner Mfg. Corp.
7400 Ultimate Series Nose Bar Conveyors
Warnings – General Safety
DANGER
SEVERE HAZARD!
KEEP OFF CONVEYORS. Climbing, sitting,
walking or riding on conveyor will result in
death or serious injury.
DANGER
EXPLOSION HAZARD!
• DO NOT OPERATE CONVEYORS IN AN
EXPLOSIVE ENVIRONMENT. The electric
gearmotor generates heat and could ignite
combustible vapors.
• Failure to comply will result in death or
serious injury.
WARNING
CRUSH HAZARD!
• DO NOT place hands or fingers inside the
conveyor while it is running.
• DO NOT wear loose garments while
operating the conveyor. Loose garments
can become caught up in the conveyor.
• Failure to comply could result in serious
injury.
WARNING
CRUSH HAZARD!
• SUPPORT CONVEYOR SECTIONS PRIOR
TO LOOSENING STAND HEIGHT OR ANGLE
ADJUSTMENT SCREWS.
• Loosening stand height or angle
adjustment screws may cause conveyor
sections to drop down, causing serious
injury.
WARNING
SEVERE HAZARD!
LOCK OUT POWER before removing guards
or performing maintenance. Exposed moving
parts can cause serious injury.
WARNING
BURN HAZARD!
DO NOT TOUCH the motor while operating, or
shortly after being turned off. Motors may be
HOT and can cause serious burn injuries.
WARNING
PUNCTURE HAZARD!
Handle drive shaft keyway with care. It may
be sharp and could puncture the skin,
causing serious injury.
WARNING
SEVERE HAZARD!
• 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.
• Failure to comply could result in serious
injury.

Dorner Mfg. Corp. 4 851-670 Rev. A
7400 Ultimate Series Nose Bar Conveyors
Product Description
Refer to (Figure 1) for typical conveyor components.
Figure 1
Flat Belt 7400 Series Conveyor Flat Belt 7400 Series LPZ Conveyor
Typical Components
1Conveyor
2 Gearmotor
3Belt
4 Return
5 Support Stands
6 Motor Controller
7DriveEnd
8 Tension End
3
2
7
5
6
4
1
8
Specifications
Document Language

851-670 Rev. A 5 Dorner Mfg. Corp.
7400 Ultimate Series Nose Bar Conveyors
Specifications
Conveyor Supports
Figure 2
Specifications
Maximum Distances:
1 = 3ft (914 mm)
2 = 8 ft (2438 mm)**
3= 3ft (914 mm)
** For conveyors longer than 10 ft (3.05 m), install
support at frame joint.
1 2 3
Conveyor Width Reference (WW)06 – 36 in 02 increments
Conveyor Belt Width 6" (152 mm) – 36" (914 mm) in 2" (51 mm) increments
Maximum Conveyor Load 20 lb / ft2(97 kg / m2) with a maximum of 1000 lb / ft2(4882 kg / m2)
Belt Travel 12" (305 mm) per revolution of pulley
Maximum Belt Speed 233 ft / minute (71 m / minute)
Belt Take-up 2" (51 mm)
Conveyor Length Reference (LLL)036 – 999 in 001 increments
Conveyor Length 36" (914 mm) – 999" (25.4 m) in 1" (25 mm) increments
LPZ Section Lengths (LLL)024 – 252 in 001 increments
LPZ Section Length 24" (610 mm) – 252" (6401 mm) in 1" (25 mm) increments
Total LPZ Conveyor Length (L1 +L2 + L3) = Maximum 38' (11.6 m) long conveyor
IMPORTANT
Maximum conveyor loads are based on:
• Non-accumulating product
• Product moving toward gearmotor
• Conveyor being mounted horizontally
• Conveyor being located in a dry environment
• Conveyor equipped with standard belt only

Dorner Mfg. Corp. 6 851-670 Rev. A
7400 Ultimate Series Nose Bar Conveyors
Installation
Figure 3
Required Tools
• 17 mm wrench (for hexagonal head fasteners)
• 4 mm hex wrench (for bearing shaft assembly fasteners)
• Level
• Torque wrench
Recommended Installation
Sequence
1. Attach the stands to the conveyor. Refer to “Stand
Installation” on page 8.
2. Attach the tail assemblies to the frame. Refer to “Tail
Assembly Installation” on page 9.
3. Attach the lifters, if applicable. Refer to “Lifter
Installation” on page 11.
4. Install the gearmotor, if applicable. Refer to the “7400
Series Drive Package Installation, Maintenance and
Parts Manual.”
5. Attach the wearstrips. Refer to “Wear Strip Installation”
on page 11.
6. Install the belt. Refer to “Belt Installation” on page 12.
7. Attach the belt returns. Refer to “Belt Return
Installation” on page 13.
8. Attach any guides / accessories. Refer to the "Service
Parts" section starting on page 24.
Conveyors Longer than 10 ft
(3048 mm)
Typical Connection Components (Figure 4)
Figure 4
CAUTION
Dorner recommends cleaning all the “food
zones” prior to placing conveyor into service.
Ensure adequate access is provided for
cleaning and servicing equipment so that the
required level of hygiene can be maintained.
NOTE
Proper conveyor application, cleaning, and
sanitation are the responsibility of the end
user.
CAUTION
Conveyor MUST be mounted straight, flat,
and level within confines of conveyor. Use a
level (Figure 3, item 1), during setup.
1
1 M10 x 1.5 mm hex head cap screws (x4)
2 Connector hex rods (x2)
3 Conveyor frames
4 O-rings (x8)
2
1
4
3

851-670 Rev. A 7 Dorner Mfg. Corp.
7400 Ultimate Series Nose Bar Conveyors
Installation
1. Locate the section number sequence etched on each
section of frame (Figure 5, item 1)
Figure 5
2. Position the frame sections in the correct order.
3. Connect the frame sections by bolting the hex post
connectors (Figure 6, item 1) the sections of frame.
Figure 6
LPZ Conveyors
Knuckles
1. Attach upper knuckle (Figure 7, item 1) to frame
(Figure 7, item 2) with hex rods (Figure 7, item 3) and
bolts (Figure 7, item 4).
Figure 7
2. Install wear strips (Figure 7, item 5).
3. Attach lower knuckle (Figure 8, item 1) to frame
(Figure 8, item 2) with hex rods (Figure 8, item 3) and
bolts (Figure 8, item 4).
Figure 8
4. Install wear strips (Figure 8, item 5).
Belt
1. Slide belt (Figure 9, item 1) over knuckles on top of the
wear strips.
Figure 9
1
1
2
2
3
4
5
6
1
2
23
4
5
1

Dorner Mfg. Corp. 8 851-670 Rev. A
7400 Ultimate Series Nose Bar Conveyors
Installation
Guides
1. Slide guides (Figure 10, item 1) on to the knuckle
frame, and secure with pull pins (Figure 10, item 2).
Figure 10
2. Install return guides and secure with pull pin
(Figure 10, item 3).
3. Slide guides (Figure 11, item 1) onto lower knuckle
frame, and secure with pull pins (Figure 11, item 2).
Figure 11
All Conveyors
Stand Installation
Typical Stand Components (Figure 12)
Figure 12
1. Position the stands on a flat, level surface.
2. Attach the stands to the frame (Figure 13).
Figure 13
3. Tighten hex screws (Figure 13, item 1).
1
2
3
1
2
1 Conveyor frame
2 Stand
3 M10 - 1.5 x 16 mm hex head cap screws (x4)
1
3
2
1

851-670 Rev. A 9 Dorner Mfg. Corp.
7400 Ultimate Series Nose Bar Conveyors
Installation
Tail Assembly Installation
Nose Bar Drive Tail
Typical Nose Bar Drive Tail Components (Figure 14)
Figure 14
1. Install the drive package, if applicable. Refer to the
“7400 Series Drive Package Installation, Maintenance
and Parts Manual.”
Tip Up Assembly
Typical Tip Up Assembly Components (Figure 15)
Figure 15
1. Slide stop keys (Figure 16, item 1) and tip up sleeves
(Figure 16, item 2) onto hex shaft (Figure 16, item 3).
The tabs on the tip up sleeves face outward and align
with the slotted ends of the hex shaft as shown.
Figure 16
2. Place hex shaft assembly (Figure 17, item 1) through
the conveyor frame tip up holes (Figure 17, item 2) and
center with conveyor.
Figure 17
3. Hex shaft assembly will need to be rotated (Figure 18)
for stop keys (Figure 18, item 1) to pass by the frame
stops (Figure 18, item 2).
Figure 18
1 Nose bar drive tail assembly
2 Conveyor frame
1HexBar
2 Stop Key (x2)
3 Tip Up Sleeve (x2)
2
1
3
2
1
2
3
2
2
1
3
1
2
2
1
2

Dorner Mfg. Corp. 10 851-670 Rev. A
7400 Ultimate Series Nose Bar Conveyors
Installation
4. Slide the tip up sleeves (Figure 19, item 1) and stop
keys (Figure 19, item 1) outward on hex shaft assembly
(Figure 19, item 3) until the sleeves seat in the holes of
the frame and stop keys are seated against frame stops
(Figure 19, item 4).
Figure 19
Idler Tail
Typical Idler Tail Components (Figure 20).
Figure 20
1. Place the idler tail assembly (Figure 21, item 1) against
the holes in the tip up hex shaft assembly
(Figure 21, item 2) and secure with a pull pin
(Figure 21, item 3) on each side.
Figure 21
Nose Bar Idler Tail
Typical Nose Bar Tip Up Tail Components (Figure 22).
Figure 22
2. Attach nose bar idler shaft hands (Figure 23, item 1) to
the tip up shaft (Figure 23, item 2) with a pull pin
(Figure 23, item 3).
Figure 23
1 Tip up tail assembly
2 Pull pin (x2)
3 Conveyor frame
CAUTION
CAUTION
To avoid injury and damage to parts, have an
assistant hold opposite end of idler tail when
removing or installing it.
3
2
4
2
1
1
3
2
1
1 Tip up tail assembly
2 Pull pin (x2)
3 Conveyor frame
3
3
2
1
1
32
1
2
3

851-670 Rev. A 11 Dorner Mfg. Corp.
7400 Ultimate Series Nose Bar Conveyors
Installation
3. Attach the nose bar transfer post (Figure 24, item 1) to
the nose bar idler shaft hands (Figure 24, item 2).
Figure 24
4. Ensure that the nose bar pucks (Figure 25, item 1) are
in line with the conveyor frame (Figure 25, item 2).
Figure 25
Lifter Installation
Typical Lifter Components (Figure 26)
Figure 26
1. Slide the belt lift pivot bar (Figure 27, item 1) through
the designated holes in the frame.
Figure 27
2. Attach the lifter bars (Figure 27, item 2) to the belt lift
pivot bar (Figure 27, item 1). Make sure the hooked
ends of the lifter bars are facing down when resting
against the frame.
3. Attach the lifter handle (Figure 27, item 3) to the belt
lift pivot rod.
Wear Strip Installation
Typical Wear Strip Components (Figure 28)
Figure 28
1 Belt lift pivot bar
2 Lifter bars
3 Belt lift handle
4 M8 - 1.25 x 16 mm hex head cap screw
2
1
2
1
180˚
1
2
3
4
1 Wear strip
3
2
1
1
1

Dorner Mfg. Corp. 12 851-670 Rev. A
7400 Ultimate Series Nose Bar Conveyors
Installation
1. Position the wear strips (Figure 29, item 1) on the
frame.
Figure 29
2. Make sure the wear strips are situated securely in the
frame slots (Figure 29, item 2).
Belt Installation
Typical Belt Components (Figure 30)
Figure 30
1. Position the belt on the conveyor frame (Figure 31).
Figure 31
2. Wrap the belt around the conveyor, making sure the
sprocket teeth have engaged the belt.
3. Bring the ends of the belt together (Figure 32).
Figure 32
4. Insert the belt rod (Figure 33, item 1).
Figure 33
5. Push the belt rod in as far as possible.
6. Lightly tap the head of the rod with a hammer until it
snaps into position.
1 Chain belt
2Beltrod
1
2
1
2
1
2
1

851-670 Rev. A 13 Dorner Mfg. Corp.
7400 Ultimate Series Nose Bar Conveyors
Installation
7. Check belt sag by measuring from the top of the return
(Figure 34).
Figure 34
Belt Return Installation
Typical Belt Return Components (Figure 35)
Figure 35
1. Attach the chain return shoes (Figure 36, item 1) to the
return shaft (Figure 36, item 2).
Figure 36
2. Slide the return shaft (Figure 37, item 1) up and
through the large slot (Figure 37, item 2) in the frame
(picture shown without the belt or wear strips).
Figure 37
3. Push up on the return shaft (Figure 37, item 1)and slide
the notched end of the shaft through the small slot on the
opposite side of the frame.
4. Check belt sag by measuring from the top of the return
(Figure 38). Belt sag should not exceed 4" (102 mm).
Follow steps 7 – 9 in the “Belt Installation” section on
page 12 to remove slack from the belt.
Figure 38
CAUTION
CAUTION
Belt sag should not exceed 4" (102 mm) from
the top of the returns.
1 Return shaft
2 Chain return shoe
(102 mm)
Up to 4"
1
2
1
2
1
2
CAUTION
CAUTION
Belt sag should not exceed 4" (102 mm) from
the top of the returns.
1
2
(102 mm)
Up to 4"

Dorner Mfg. Corp. 14 851-670 Rev. A
7400 Ultimate Series Nose Bar Conveyors
Preventive Maintenance and Adjustment
Preventive M aintenance and Adju stment
Required Tools
• 17 mm wrench (or adjustable wrench)
• 4 mm hex wrench (for bearing shaft assembly fasteners)
• 3 mm hex wrench
• Punch and hammer (to remove belt rod)
Checklist
• Keep service parts on hand. Refer to the "Service Parts"
section starting on page 24 for recommendations.
• Replace any worn or damaged parts.
Cleaning
Routine Cleaning
Dorner recommends cleaning the inside and the outside of
the conveyor on a daily basis. Refer to the following steps to
access the inside of the conveyor.
Standard Conveyors
1. Remove the guides, if applicable, by removing the pull
pins (Figure 39, item 1) that connect the guide
(Figure 39, item 2) to the frame.
Figure 39
2. Tip up idler tail assembly (Figure 40).
Figure 40
3. Lift up on the belt (Figure 41).
Figure 41
NOTE
Proper conveyor application, cleaning, and
sanitation are the responsibility of the end
user.
CAUTION
CAUTION
Dorner recommends cleaning all the “food
zones” prior to placing conveyor into service.
Ensure adequate access is provided for
cleaning and servicing equipment so that the
required level of hygiene can be maintained.
WARNING
SEVERE HAZARD!
LOCK OUT POWER before removing guards
or performing maintenance. Exposed moving
parts can cause serious injury.
1
2

851-670 Rev. A 15 Dorner Mfg. Corp.
7400 Ultimate Series Nose Bar Conveyors
Preventive Maintenance and Adjustment
Conveyors with Lifters
1. Remove the guides, if applicable, by removing the pull
pins (Figure 39, item 1) that connect the guide
(Figure 39, item 2) to the frame.
2. Use the lifter handle (Figure 42, item 1) to raise the
lifters (Figure 42, item 2) and raise the tip up tail
(Figure 42, item 3).
Figure 42
Periodic Cleaning
Dorner recommends complete disassembly of the conveyor
periodically for thorough cleaning.
For conveyor disassembly and reassembly instructions:
• Refer to “Conveyor Belt Replacement” on page 16.
• Refer to “Sprocket and Puck Removal” on page 18.
• Refer to “Reassembling Tail Assemblies” on page 22.
Lubrication
Conveyor Bearings
Conveyor bearing lubrication is required. Dorner
recommends using an H-1 food grade grease.
1. Add grease to the bearing using the zerk fitting
(Figure 43, item 1) on the exterior of the bearing shaft
assembly.
Figure 43
2. Replace the bearings if they become worn.
Wearstrips and Belt Returns
Replace the wearstrips and belt returns if they become worn.
For wearstrip and belt return installation instructions:
• Refer to “Wear Strip Installation” on page 11.
• Refer to “Belt Return Installation” on page 13.
Maintaining the Conveyor Belt
Troubleshooting
Inspect conveyor belt for:
• Surface cuts or wear
• Skipping
Damage to belt links or rods, surface cuts and / or
wear indicate:
• Sharp or heavy parts impacting belt
• Jammed parts
• Accumulated dirt
• Foreign material inside the conveyor
• Improperly positioned accessories
Skipping indicates:
• Excessive load on belt
• Worn sprockets or impacted dirt on drive pulley
CAUTION
CAUTION
DO NOT submerge or soak bearing
assemblies. This will reduce the life of the
bearing.
NOTE
Although bearings are sealed, re-greasing is
recommended to increase bearing life. An
H-1 food grade grease is recommended. The
frequency of bearing re-greasing is
dependent upon the application in which the
conveyor is being used. Frequency of re-
greasing will increase with the frequency of
conveyor washing.
3
2
1
NOTE
Visit www.dorner.com for complete list of
troubleshooting solutions.
1

Dorner Mfg. Corp. 16 851-670 Rev. A
7400 Ultimate Series Nose Bar Conveyors
Preventive Maintenance and Adjustment
Damage to belt links or rods indicate:
• Excessive load on belt
• Dirt impacted on sprockets
• Excessive or improper side loading
• Improperly positioned accessories
Conveyor Belt Replacement
Conveyors with Guides
1. Remove the pull pins (Figure 44, item 1) that connect
the guide (Figure 44, item 2) to the frame.
Figure 44
2. Remove the guide (Figure 45, item 1).
Figure 45
3. Follow the belt replacement procedures described in
“Standard Belts” on page 16, “Specialty Intralox 1100
Series Belts” on page 17, or “Specialty Intralox 1600
Series Belts” on page 17.
Standard Belts
Replacing a Section of Belt
1. Tip up idler tail assembly (Figure 46).
Figure 46
WARNING
SEVERE HAZARD!
LOCK OUT POWER before removing guards
or performing maintenance. Exposed moving
parts can cause serious injury.
1
2
1

851-670 Rev. A 17 Dorner Mfg. Corp.
7400 Ultimate Series Nose Bar Conveyors
Preventive Maintenance and Adjustment
2. Secure the retaining head side of the belt. Use the belt
removal tool (Figure 47, item 1) for 1" pitch belts. For
all other belts, position the section of belt so that it is
braced by the flanged puck (Figure 47, item 2).
Figure 47
3. Use a punch and hammer to push the belt rod out by
striking the rod end opposite the retaining head
(Figure 48).
Figure 48
4. Remove the belt rods on both sides of the section of belt
being replaced.
5. Replace the old section with a new section of belt.
Replacing the Entire Belt
1. Remove the belt returns by pushing up on the return
shaft (Figure 49, item 1)and sliding it through the large
hole (Figure 49, item 2) in the frame.
Figure 49
2. Lower the opposite end of the return shaft
(Figure 49, item 1) and slide it out of the frame.
3. Follow steps 1 – 3 in "Standard Belts: Replacing a
Section of Belt" on page 16.
4. Remove the belt.
5. Replace the damaged or worn belt. Refer to “Belt
Installation” on page 12 and “Belt Return Installation”
on page 13.
Specialty Intralox 1100 Series Belts
Replacing a Section of Belt
1. Place the edge of a flat head screwdriver between the
the two belt links and turn clockwise (Figure 50).
Figure 50
CAUTION
CAUTION
Secure the retaining head side of the belt
prior to removing a belt rod in order to
prevent damaging the belt.
CAUTION
CAUTION
DO NOT reuse belt rods that are damaged or
show signs of wear.
21
1
2

Dorner Mfg. Corp. 18 851-670 Rev. A
7400 Ultimate Series Nose Bar Conveyors
Preventive Maintenance and Adjustment
2. Use a second belt rod of the same size to push on the
opposite end of the belt rod. (Figure 51).
Figure 51
3. Remove the belt rods on both sides of the section of belt
being replaced.
4. Replace the old section with a new section of belt.
Replacing the Entire Belt
1. Remove the belt returns.
2. Follow steps 1 – 2 in "Specialty Intralox 1100 Series
Belts: Replacing a Section of Belt" on page 17.
3. Remove the belt.
4. Replace the damaged or worn belt. Refer to “Belt
Installation” on page 12 and “Belt Return Installation”
page 13.
Conveyor Belt Tensioning
1. Check belt for proper sag. Refer to step 7 of “Belt
Installation” on page 12.
2. If belt has excessive sag, remove one or more belt links
to take up the tension. Refer to “Replacing a Section of
Belt” on page 16.
Sprocket and Puck Removal
1. Remove the conveyor belt to access the sprockets /
pucks. Refer to “Conveyor Belt Replacement” starting
on page 16.
2. Remove the desired sprocket / puck by following these
instructions:
• A - Drive Sprocket Removal
• B - Nose Bar Puck Removal
• C - Idler Puck Removal
CAUTION
CAUTION
DO NOT reuse belt rods that are damaged or
show signs of wear.
WARNING
SEVERE HAZARD!
LOCK OUT POWER before removing guards
or performing maintenance. Exposed moving
parts can cause serious injury.
CAUTION
CAUTION
Belt sag should not exceed 4" (102 mm) from
the top of the returns.
WARNING
SEVERE HAZARD!
LOCK OUT POWER before removing guards
or performing maintenance. Exposed moving
parts can cause serious injury.

851-670 Rev. A 19 Dorner Mfg. Corp.
7400 Ultimate Series Nose Bar Conveyors
Preventive Maintenance and Adjustment
A - Drive Sprocket Removal
1. Loosen the fasteners (Figure 52, item 1) that connect
the gearmotor to the drive spindle using a hex wrench
(Figure 52, item 2).
Figure 52
2. Remove the bolts that connect the motor to the drive
assembly (Figure 53).
3. Remove the motor (Figure 53, item 1) from the drive
assembly (Figure 53, item 2).
Figure 53
4. Unbolt the drive assembly and slide it off the bearing
spindle (Figure 54).
Figure 54
5. Remove the bearing cover.
6. Loosen the 3 hole flange (Figure 55, item 1) with
bearing fasteners using a hex wrench
(Figure 55, item 2).
Figure 55
WARNING
PUNCTURE HAZARD!
Handle drive shaft keyway with care. It may
be sharp and could puncture the skin,
causing serious injury.
2
1
1
2
1
2

Dorner Mfg. Corp. 20 851-670 Rev. A
7400 Ultimate Series Nose Bar Conveyors
Preventive Maintenance and Adjustment
7. Disconnect the 3 hole flange bearing
(Figure 56, item 1) from the nose bar drive weldment
(Figure 56, item 2).
Figure 56
8. Lower the entire drive assembly.
9. Slide the 3 hole flange with bearing (Figure 57, item 1)
and flanged puck (Figure 57, item 2) off the drive
spindle.
Figure 57
10. Slide the sprockets (Figure 58, item 1) and the sprocket
alignment bar (Figure 58, item 2) off the drive spindle
(Figure 58, item 3).
Figure 58
B - Idler Puck Removal
1. Remove the pull pins (Figure 59, item 1) from tip up
hex shaft assembly (Figure 59, item 2).
Figure 59
2. Slide the idler tail assembly (Figure 59, item 3) out of
the tip up hex shaft assembly.
3. Remove the shaft assembly (Figure 60, item 1) from
idler shaft (Figure 60, item 2) and pinch guard shaft
(Figure 60, item 3).
Figure 60
4. Remove tracking plate (Figure 60, item 4) from idler
shaft and pinch guard shaft.
5. Remove pinch guard shaft (Figure 60, item 2).
1
2
1
2
1
1
2
3
1
4
3
2