Dorner LPZ Series User manual

851-520 Rev. D
Installation, Maintenance
& Parts Manual
LPZ Series Cleated and Sidewall
Cleated Belt Conveyors
Table of Contents
Warnings −General Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RequiredTools 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Installation Sequence 4. . . . . . . . . . . . . . . . .
Conveyors Up to 13 ft (3962 mm) 5. . . . . . . . . . . . . . . . . . .
Conveyors Longer Than 13 ft (3962 mm) 5. . . . . . . . . . . . .
Mounting Brackets 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Rollers 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance and Adjustment 7. . . . . . . . . . . . . . .
Required Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining Conveyor Belt 7. . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement 7. . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement Sequence 7. . . . . . . . . . . . . .
Belt Removal for Conveyor Without
Stands or Gearmotor Mounting Package 7. . . . . . . . . . . . . .
Belt Removal for Conveyor With
Stands and Gearmotor Mounting Package 9. . . . . . . . . . . . .
Belt Installation for Conveyor Without
Stands or Gearmotor Mounting Package 10. . . . . . . . . . . . .
Belt Installation for Conveyor With
Stands and Gearmotor Mounting Package 11. . . . . . . . . . . .
Conveyor Belt Tensioning 12. . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Tracking 13. . . . . . . . . . . . . . . . . . . . . . . . . .
V −Guided Belts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non V−Guided Belts 13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Angle Adjustment 14. . . . . . . . . . . . . . . . . . . . . . .
Nose Over Angle Adjustment 14. . . . . . . . . . . . . . . . . . . .
Horizontal to Incline Angle Adjustment 15. . . . . . . . . . . .
Pulley Removal 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A−Idler Pulley Removal 16. . . . . . . . . . . . . . . . . . . . . . .
B−Drive Pulley Removal 17. . . . . . . . . . . . . . . . . . . . . .
C−Upper Knuckle Idler Pulley Removal 20. . . . . . . . . .
D−Lower Knuckle Idler Pulley Removal 21. . . . . . . . . .
E−Knuckle Return Roller Removal 22. . . . . . . . . . . . . .
Bearing Replacement 23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
A−Idler Bearing Replacement 23. . . . . . . . . . . . . . . . . .
B −Drive Bearing Removal and Replacement 23. . . . . . .
C−Nose Over Knuckle Idler Bearing Replacement 23. .
D−Horizontal to Incline Knuckle Idler
Bearing Replacement 23. . . . . . . . . . . . . . . . . . . . . . . . . .
E−Knuckle Return Roller Replacement 24. . . . . . . . . . .
Pulley Replacement 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Pulley 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Pulley 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knuckle Pulley 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knuckle Return Roller 24. . . . . . . . . . . . . . . . . . . . . . . . .
Service Parts 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive End Tail Assembly 26. . . . . . . . . . . . . . . . . . . . . . . . .
Idler End Tail Assembly 27. . . . . . . . . . . . . . . . . . . . . . . . . .
Horizontal to Incline Knuckle Assembly 28. . . . . . . . . . . . .
Nose Over Knuckle Assembly 29. . . . . . . . . . . . . . . . . . . . .
Frame Assembly 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleated Belt Conveyor Configurations 32. . . . . . . . . . . . . . .
Section and Length Determination 32. . . . . . . . . . . . . . . .
Z Frame −Section L1 33. . . . . . . . . . . . . . . . . . . . . . . . . .
Z Frame −Section L2 34. . . . . . . . . . . . . . . . . . . . . . . . . .
Z Frame −Section L3 35. . . . . . . . . . . . . . . . . . . . . . . . . .
L Frame −Section L2 36. . . . . . . . . . . . . . . . . . . . . . . . . .
L Frame −Section L3 37. . . . . . . . . . . . . . . . . . . . . . . . . .
P Frame −Section L1 38. . . . . . . . . . . . . . . . . . . . . . . . . .
P Frame −Section L2 39. . . . . . . . . . . . . . . . . . . . . . . . . .
Sidewall Cleated Belt Conveyor Configurations 40. . . . . . .
Section and Length Determination 40. . . . . . . . . . . . . . . .
Z Frame −Cleated Sidewall Guiding 41. . . . . . . . . . . . . .
L Frame −Horizontal to Incline Cleated
Sidewall Guiding 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P Frame −Nose Over Cleated Sidewall Guiding 42. . . . .
Cleated Belt Mounting Brackets 43. . . . . . . . . . . . . . . . . . . .
Connecting Assembly without Stand Mount 43. . . . . . . . . .
Cleated Belt Connecting Assembly with Stand Mount 44. . .
4” (102mm) to 24” (610mm) Return Roller 44. . . . . . . . . . .
Conveyor Belt Part Number Configuration 45. . . . . . . . . . .
Return Policy 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
851-520 Rev. D 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
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
LPZ Series Conveyors are
not reversible. Reversing
creates pinch points which
can cause severe injury.
DO NOT REVERSE LPZ SE-
RIES CONVEYORS.
WARNING
Ç
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
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
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 3200 series conveyors are covered by Patent
Numbers 5,156,260, 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 .
Warnings −General Safety

LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 3851-520 Rev. D
Refer to Figure 1 for typical conveyor components.
A Conveyor
B Gearmotor Mounting Package
C Gearmotor
D Mounting Brackets
E Lower Knuckle
F Upper Knuckle
G Support Stand
H Drive End
I Idler/Tension End
Typical Components
Figure 1
A
BC
D
I
E
H
G
F
Specifications
Models:
Cleated Belt LPZ Series End Drive Conveyor
Conveyor Width Reference
Conveyor Section Length
Reference
Output Shaft Position*
Cleat Spacing
1 = Manual tracking and supports
2 = V-guide tracking and supports
3 = Manual tracking
4 = V−guide tracking
Document Language, M = English
3E 1 A M WW LLLL−LLLL−LLLL A LLLL
Cleat Type*
Conveyor Section Length
Reference
Conveyor Section Length Reference
E = Elevating
D = Declining
* See Ordering and Specifications Catalog for details.
Conveyor Supports:
Maximum Distances:
K = 24¨ (610 mm) (Drive End)
L = 12 ft (3658 mm)
M = 36¨ (914 mm) (Idler End)
Maximum Angle:
N = 0 and 25 to 60 degrees
L
Figure 2
N
N
M
K
Product Description

LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
851-520 Rev. D 4Dorner Mfg. Corp.
Specifications:
Conveyor Width
Reference (WW) 08 10 12 18 24
Conveyor Belt
Width
8¨
(203mm)
10¨
(254mm)
12¨
(305mm)
18¨
(457mm)
24¨
(609mm)
Conveyor
Startup Torque*
10 in-lb
(1.1Nm)
13 in-lb
(1.5Nm)
15 in-lb
(1.7Nm)
25 in-lb
(2.8Nm)
0 in-lb
(3.9Nm)
Conveyor
Section Length
Reference (LLLL)
0200 to 1300 in 0001 increments
(2 ft to 13 ft in 0.12” increments)
Total Conveyor
Length
4 ft (1219mm) to 25 ft (7620mm) in 0.12”
(0.31mm) increments
Belt Travel 9.7¨(246 mm) per revolution of pulley
Maximum Belt
Speed* 275 ft/minute (84 m/minute)
Belt Takeup 1.62” (41 mm) of Belt Takeup
NOTE: Maximum conveyor loads based on:
DNon-accumulating product
DProduct moving towards gearmotor
DConveyor being mounted horizontal
NOTE: Refer to the table provided for maximum rec-
ommended tension pinion torque values and maxi-
mum conveyor loads for different angles. Choose
the appropriate value which relates to your particu-
lar requirements.
Transition
Standard
Cleated Belt
Sidewall
Cleated Belt
Transition
Angle Tension
Pinion
Torque
Maximum
Conveyor
Load
Tension
Pinion
Torque
Maximum
Conveyor
Load
in-lb Nm lb kg in-lb Nm lb kg
25°* 25 2.8 25 11.3 50 5.6 75 34
30°* 35 3.9 50 22.7 60 6.8 100 45.4
35°50 5.6 75 34 70 7.9 100 45.4
40°75 8.5 100 45.4 80 9.0 100 45.4
45°75 8.5 100 45.4 80 9.0 100 45.4
50°75 8.5 100 45.4 80 9.0 100 45.4
55°75 8.5 100 45.4 80 9.0 100 45.4
60°75 8.5 100 45.4 80 9.0 100 45.4
* Not available on 18″& 24″(457 & 610 mm) width conveyors
Installation
Ç
LPZ Series Conveyors are
not reversible. Reversing
creates pinch points which
can cause severe injury.
DO NOT REVERSE LPZ SE-
RIES CONVEYORS.
WARNING
NOTE: Conveyor MUST be mounted straight, flat and
level within confines of conveyor. Use a level (O of
Figure 3) for setup.
O
Figure 3
Required Tools
DHex-key wrenches:
4 mm, 5 mm
DLevel
DTorque wrench
D8mm hex, open end wrench
Recommended Installation Sequence
DInstall support stands (see accessory instructions)
DAssemble conveyor (if required)
DAttach mounting brackets to conveyor (see page 6
for instructions)
DAdjust angle (see page 14 for instructions)
DAttach conveyor to stands (see “Mounting Brackets”
section on page )
DInstall return rollers on conveyor (see page 6 for in-
structions)
DMount gearmotor mounting package (see accessory
instructions)
DAttach guides/accessories (see page 32 through 42 of
“Service Parts” section for details)
Specifications

LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 5851-520 Rev. D
Conveyors Up to 13 ft (3962 mm)
No assembly is required. Install mounting brackets and
return rollers. Refer to “Mounting Brackets” on page 6
and “Return Rollers” on page 6.
Conveyors Longer Than 13 ft (3962 mm)
1.Locate components (see Figure 4).
E Lower knuckle
F Upper knuckle
P Conveyor frame with upper knuckle
Q Conveyor frame with idler end and lower knuckle
R Belt
S Conveyor frame with lower knuckle
Installation Component List
Figure 4 P
Q
F
R
SE
2.On tension end of the conveyor, identified by the
pinion locking screw (T of Figure 5), push in head
plate assembly (V): Loosen the pinion locking screw
(T), adjust the pinion torque screw (W of Figure 6).
On both sides of conveyor, loosen the two tail clamp
bolts (U of Figure 5), and push head plate assembly
(V) inward.
Figure 5
UV
T
Figure 6
W
3.Roll out conveyor belt (R of Figure 7). Loosen (4)
screws (X) on both sides of knuckle (E). Slide frame
(Q) into knuckle (E). Tighten screws (X) to 60 in-lb
(7 N−m) on both sides of conveyor.
Figure 7
Q
F
X
R
4.Slide frame (Q of Figure 8) into lower knuckle (E).
Tighten screws (X) to 60 in-lb (7 N−m) on both sides
of conveyor.
Figure 8
Q
EX
5.Join additional conveyor sections if necessary and
install connector brackets (Y of Figure 9) or
connector/mount brackets (YA) and screws (Z) on
both sides as indicated. Tighten screws to 60 in-lb (7
Nm).
Installation

LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
851-520 Rev. D 6Dorner Mfg. Corp.
Figure 9
Y
Z
YA
6.Slide belt (R of Figure 10) over assembled conveyor
sections (AA).
Figure 10
R
AA
7.Tension conveyor belt, refer to “Conveyor Belt
Tensioning” on page 12.
8.Install mounting brackets and return rollers. Refer to
“Mounting Brackets” on page 6 and “Return
Roller” on page 6.
9.Conveyors are shipped flat. Adjust conveyor angle.
See “Conveyor Angle Adjustment” on page 14.
Mounting Brackets
1.Locate brackets. Exploded views shown in Figure 11.
AB
AF
AE
AD
AC
Mounting Brackets for Cleated Belt Conveyor
Figure 11
2.Remove screws (AB & AC of Figure 11), washers
(AD), nuts (AE) and T-bars (AF) from brackets.
3.Insert T-bars (AF of Figure 11) into conveyor side
slots (AF of Figure 12). Fasten brackets (AG of
Figure 12) to conveyor with mounting screws (AB).
Figure 12
AD
AC
AF
AB
AG
AE
4.Fasten brackets to support stand with mounting
screws (AC of Figure 12), washers (AD) and nuts
(AE).
5.Tighten screws (AB & AC of Figure 12) to 60 in-lb
(7 Nm).
Return Rollers
1.Locate return rollers. Exploded views shown in
Figures 13.
Figure 13
Return Rollers for Cleated Belt Conveyor
AI
AH
AI
AH
2.Remove screws (AH of Figure 13) and clips (AI)
from roller assembly.
3.Install roller assemblies (AJ of Figure 14) as shown.
Tighten screws (AH) to 60 in-lb (7 Nm).
InstallationInstallation

LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 7851-520 Rev. D
Figure 14
AH
AJ
AJ
Required Tools
Standard Tools
DHex-key wrenches:
2.5 mm, 4 mm, 5 mm
D8mm hex, open end wrench
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
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 wipers (if installed)
DAccumulated dirt in wipers (if installed)
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
DRelease Tension
DRemove old conveyor belt:
-Conveyor without Stands or Gearmotor Mounting
Package
-Conveyor with Stands and Gearmotor Mounting
Package
DInstall new conveyor belt
DTension conveyor belt
Belt Removal for Conveyor Without Stands or
Gearmotor Mounting Package
1.If equipped, remove return rollers and guiding and
accessories from one side of conveyor.
Preventive Maintenance and Adjustment

LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
851-520 Rev. D 8Dorner Mfg. Corp.
2.On tension end of the conveyor, identified by the
pinion locking screw (T of Figure 15), push in head
plate assembly (V): Loosen the pinion locking screw
(T), adjust the pinion torque screw (W of Figure 16).
On both sides of conveyor, loosen the two tail clamp
bolts (U of Figure 15), and push head plate assembly
(V) inward.
Figure 15
U
V
T
Figure 16
W
3.If equipped with a lower knuckle, remove screws
(AK of Figure 17) and remove lower knuckle return
roller assembly (AL) on both sides of conveyor, note
the position of the meshing teeth.
Figure 17
AK
AL
4.If equipped with an upper knuckle, remove screws
(AM of Figure 18) and remove guard (AN) on both
sides of knuckle.
Figure 18
AN
AM
5.Remove screws (AO of Figure 19) and remove roller
bearing (AP).
Figure 19
AP
AO
Preventive Maintenance and Adjustment

LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 9851-520 Rev. D
6.Remove belt (AQ of Figure 20) from conveyor.
Figure 20
AQ AQ
Belt Removal for Conveyor With Stands and
Gearmotor Mounting Package
Ç
Removing mounting brackets
without support under gear-
motor will cause conveyor to
tip, causing severe injury.
PROVIDE SUPPORT UNDER-
NEATH THE GEARMOTOR
WHEN CHANGING THE BELT
1.Place temporary support stands (AR of Figure 21) at
both ends of the conveyor. Place an additional
support stand under the drive motor (AS), if
equipped. See WARNING.
Figure 21
AR
AS AR
AT
AT
2.Remove mounting brackets (AT of Figure 21) from
one side of conveyor. (Reverse steps 3 & 4 of
“Mounting Brackets” section on page 6).
3.If equipped, remove return rollers, guiding and
accessories from side opposite drive cover.
4.On tension end of the conveyor, identified by the
pinion locking screw (T of Figure 22), push in head
plate assembly (V): Loosen the pinion locking screw
(T), adjust the pinion torque screw (W of Figure 23).
On both sides of conveyor, loosen the two tail clamp
bolts (U of Figure 22), and push head plate assembly
(V) inward.
Figure 22
U
V
T
Figure 23
W
5.If equipped, remove screws (AK of Figure 24) and
remove lower knuckle return roller assembly (AL)
on both sides of conveyor, note the position of the
meshing teeth.
Figure 24
AK
AL
Preventive Maintenance and AdjustmentPreventive Maintenance and Adjustment

LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
851-520 Rev. D 10 Dorner Mfg. Corp.
6.If equipped, remove screws (AM of Figure 25) on
both sides of knuckle and remove guard (AN).
AN
AM
Figure 25
7.Remove screws (AO of Figure 26) and remove roller
bearing (AP).
Figure 26
AP
AO
8.Remove belt (AQ of Figure 27) from conveyor.
AQ AQ
Figure 27
Belt Installation for Conveyor without Stands or
Gearmotor Mounting Package
1.Orient belt so splice leading fingers (AU of Fig-
ure 28) point in the direction of belt travel as identi-
fied by the conveyor directional label (AV).
Figure 28
AU
AV
2.Slide belt onto the conveyor frame assembly.
3.If equipped, install return roller bearing (AP of
Figure 29) into knuckle plate (AW) using screws
(AO).
AP
AO
AW
Figure 29
4.Install knuckle guard (AN of Figure 30) on both
sides of knuckle with screws (AM). Tighten screws
to 25 in−lbs (3 N−m).
AN
AM
Figure 30
5.If equipped, install lower knuckle return roller
assembly (AK of Figure 31) with screws (AL) on
Preventive Maintenance and Adjustment

LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 11 851-520 Rev. D
both sides of knuckle, note the position of the
meshing teeth.
Figure 31
AK
AL
6.Tension belt. Refer to “Conveyor Belt Tensioning” on
page 12.
7.If equipped, install return rollers and guiding.
Belt Installation for Conveyor with Stands and
Gearmotor Mounting Package
Ç
Removing mounting brackets
without support under gear-
motor will cause conveyor to
tip, causing severe injury.
PROVIDE SUPPORT UNDER-
NEATH THE GEARMOTOR
WHEN CHANGING THE BELT
1.Ensure temporary support stands (AR of Figure 21)
are placed at both ends of the conveyor. Place an
additional support stand under the drive motor (AS),
if equipped. See WARNING.
2.Orient belt so splice leading fingers (AU of Fig-
ure 28) point in the direction of belt travel as identi-
fied by the conveyor directional label (AV).
3.Install belt (AQ of Figure 32) on conveyor. Lift
conveyor slightly to avoid pinching belt on tempo-
rary support stands.
AQ AQ
Figure 32
4.Re-install conveyor mounting brackets. Refer
“Mounting Brackets” on page 6, steps 3 through 5.
5.If equipped, install return roller bearing (AP of
Figure 33) into knuckle plate (AW) using screws
(AO).
AP
AO
AW
Figure 33
6.Install knuckle guard (AN of Figure 34) on both
sides of knuckle with screws (AM). Tighten screws
to 25 in−lbs (3 N−m).
AN
AM
Figure 34
7.If equipped, install lower knuckle return roller
assembly (AL of Figure 35). To properly align teeth,
ensure the first gear of the pinion plate (AY of Figure
36) matches with the first pocket of the rack plate
Preventive Maintenance and Adjustment

LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
851-520 Rev. D 12 Dorner Mfg. Corp.
(AZ). Secure with screws (AK of Figure 35) on both
sides of the conveyor.
Figure 35
AK
AL
Figure 36
AZ
AY
8.Tension belt. Refer to “Conveyor Belt Tensioning” on
page 12.
9.If equipped, re-install return rollers and guiding.
Conveyor Belt Tensioning
Ç
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
1.On tension end of the conveyor, identified by the
pinion locking screw (T of Figure 37), loosen the
two tail clamp bolts(U), on both sides of conveyor.
Figure 37
U
V
T
2.With 5mm hex wrench, hold pinion torque screw (W
of Figure 38). Loosen the pinion locking screw (T of
Figure 37) and turn the pinion torque screw(W) to
extend head plate assembly.
NOTE: Refer to the table provided for maximum rec-
ommended tension pinion torque values and maxi-
mum conveyor loads for different angles. Choose
the appropriate value which relates to your particu-
lar requirements.
Transition
Standard
Cleated Belt
Sidewall
Cleated Belt
Transition
Angle Tension
Pinion
Torque
Maximum
Conveyor
Load
Tension
Pinion
Torque
Maximum
Conveyor
Load
in-lb Nm lb kg in-lb Nm lb kg
25°* 25 2.8 25 11.3 50 5.6 75 34
30°* 35 3.9 50 22.7 60 6.8 100 45.4
35°50 5.6 75 34 70 7.9 100 45.4
40°75 8.5 100 45.4 80 9.0 100 45.4
45°75 8.5 100 45.4 80 9.0 100 45.4
50°75 8.5 100 45.4 80 9.0 100 45.4
55°75 8.5 100 45.4 80 9.0 100 45.4
60°75 8.5 100 45.4 80 9.0 100 45.4
* Not available on 18″& 24″(457 & 610 mm) width conveyors
Figure 38
W
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LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 13 851-520 Rev. D
NOTE: Bowing of the belt (BA of Figure 39) may occur
if excessive tension is applied to the belt. Do not over
tension the belt.
Figure 39
BA
NOTE: On pinion gear, do not exceed a torque of
100 in-lb (11.3 N−m). Over tensioning the conveyor
belt could cause excessive pulley bearing load and
early failure.
3.Extend head plate assembly until proper tension in
the belt is achived. If proper tensioning can not be
obtained before the belt life indicator is all black (BB
of Figure 40) the belt must be replaced.
Figure 40
BB
4.After adjusting proper tensioning, tighten the pinion
locking screw (T of Figure 37) to 69 in−lbs (7.8
N−m), and tighten tail clamp bolts (U of Figure 37)
on both sides of conveyor to 146 in-lb (16.5 N−m).
5.If belt tracking is neccesary, refer to “Conveyor Belt
Tracking” on page 13.
Conveyor Belt Tracking
V-Guided Belts
V-guided belts do not require tracking adjustment.
Non V-Guided Belts
Non V-guided belt conveyors are equipped with belt
tracking assemblies.
When adjusting belt tracking, always adjust the dis-
charge end of the conveyor first. To adjust belt tracking:
1.Ensure tensioning racks are extended and touching
the idler pulley headplates: loosen the pinion locking
screw (T of Figure 37) and rotate the pinion torque
screw (W of Figure 38) clockwise until contact with
the head plate is made, then tighten the pinion
locking screw (T) to 69 in−lbs (7.8 N−m)
2.On the side of conveyor to be adjusted, loosen two
(2) tail clamp screws(U of Figure 41).
U
T
Figure 41
3.With the conveyor running, use wrench (BC of
Figure 42) to rotate the tracking screw (BD of Figure
43) in small increments until the belt tracks in the
center of the conveyor.
Figure 42
BC
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LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
851-520 Rev. D 14 Dorner Mfg. Corp.
Figure 43
BD
4.Re-tighten the head plate fastening screws (U) with
a 5 mm hex-key wrench to 100 in-lb (12 Nm).
U
Figure 44
Conveyor Angle Adjustment
Nose Over Angle Adjustment
Ç
Removing mounting brackets
or adjustment screws without
support under gearmotor and
conveyor will cause conveyor
to tip or drop, causing severe
injury.
PROVIDE SUPPORT UNDER-
NEATH THE GEARMOTOR
WHEN ADJUSTING THE CON-
VEYOR ANGLE
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
NOTE: If just changing the angle of an installed con-
veyor skip to step 2.
NOTE: .Special-colored “05Angle” screws must be
removed when making the initial adjustment from
(or to) the (05) shipping position. When sections of
conveyor are flat, the “05Angle” screw locks-out and
prevents operation between 05and 255. Special-col-
ored “05Angle” screws need only to be loosened,
when making the “transition angle” (see table on
page 12) adjustments. LPZ conveyors should never
be operated with the “05Angle” screws removed.
1.Conveyor is shipped from factory locked in the flat
position, to unlock conveyor knuckle remove the
gold screw (BE of Figure 45) on both sides of the
conveyor.
Figure 45
BE
2.Place temporary support (BF of Figure 46) under
conveyor sections.
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LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 15 851-520 Rev. D
Figure 46
BF
3.Loosen screws (BG of Figure 47) on both sides of
knuckle.
Figure 47
BG
4.Move conveyor to desired angle as indicated by
angle label (BH of Figure 48).
Figure 48
BH
5.Tighten screws (BG of Figure 47) on both sides of
knuckle to 100 in−lbs (12 N−m). If aplicable, replace
the gold locking screw (BE of Figure 45).
Horizontal to Incline Angle Adjustment
Ç
Ç
Removing mounting brackets
or adjustment screws without
support under gearmotor and
conveyor will cause conveyor
to tip or drop, causing severe
injury.
PROVIDE SUPPORT UNDER-
NEATH THE GEARMOTOR
WHEN ADJUSTING THE CON-
VEYOR ANGLE
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
NOTE: If just changing the angle of an installed con-
veyor skip to step 2.
NOTE: .Special-colored “05Angle” screws must be
removed when making the initial adjustment from
(or to) the (05) shipping position. When sections of
conveyor are flat, the “05Angle” screw locks-out and
prevents operation between 05and 255. Special-col-
ored “05Angle” screws need only to be loosened,
when making the “transition angle” (see table on
page 12) adjustments. LPZ conveyors should never
be operated with the “05Angle” screws removed.
1.Conveyor is shipped from factory locked in the flat
position, to unlock conveyor knuckle remove the
gold screw (BE of Figure 45) on both sides of the
conveyor.
2.Place temporary support (BF of Figure 49) under
conveyor sections.
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LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
851-520 Rev. D 16 Dorner Mfg. Corp.
Figure 49
BF
3.Loosen screws (AK and BI of Figure 50) on both
sides of knuckle.
Figure 50
AK BI
4.Move conveyor to desired angle as indicated by
angle label (BH of Figure 48).
Figure 51
BH
5.Tighten screws (BG of Figure 47) on both sides of
knuckle to 100 in−lbs (12 N−m).
Pulley Removal
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
Remove conveyor belt to access pulley(s). See “Convey-
or Belt Replacement” on page 7. Remove the desired
pulley following the corresponding instructions below:
DA−Idler Pulley Removal
DB−Drive Pulley Removal
DC−Upper Knuckle Idler Pulley Removal
DD−Lower Knuckle Idler Pulley Removal
DE−Knuckle Return Roller Removal
A−Idler Pulley Removal
1.Temporarily support the idler pulley.
Figure 52
2.On one side of conveyor, loosen the two (2) back
fastening screws (U of Figure 53) and remove two
(2) front fastening screws (BJ).
Figure 53
U
BJ
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LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 17 851-520 Rev. D
3.Pull back the outer headplate (V of Figure 54) and
remove the inner spacer (BK).
Figure 54
BK
V
4.Slide the idler pulley assembly (BL of Figure 55) out
of the headplate on the opposite side.
Figure 55
BL
5.Remove the pulley shaft assembly: remove the clip
ring (BM of Figure 56) and washer (BN) from one
side of the pulley assembly.
Figure 56
BM
BN
6.Slide the shaft assembly (BO of Figure 57) out of the
pulley (BL).
Figure 57
BO
BL
B−Drive Pulley Removal
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
1.Remove the gearmotor mounting package:
a−Top and Bottom Mount Drives
b−Side Mount Drives
a. Top and Bottom Mount Drives
1) Use a temporary support (BP of Figure 58)to
support Gearmotor.
Figure 58
BP
2) Remove four (4) screws (BQ of Figure 59) and
remove cover (BR).
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LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
851-520 Rev. D 18 Dorner Mfg. Corp.
Figure 59
BR
BQ
BQ
3) Loosen tensioner (BS of Figure 60).
Figure 60
BS
BT
4) Remove taper-lock screws (BU of Figure 61) on the
driven pulley (BT of Figure 60). Insert one (1) of
taper lock screws (BU of Figure 61) in remaing hole
(BV). Tighten screw (BU) until pulley is loose.
Remove pulley, taper hub assembly and timing belt.
Figure 61
BU
BV
5) Remove four (4) M5 mounting screws (BW of
Figure 62) and two (2) M8 mounting screws (BX).
Figure 62
BX
BW
BY
6) Remove gearmotor and mounting plate assembly
(BY of Figure 62).
b. Side Mount Drives
1) Temporarily support Gearmotor
2) Loosen the four (4) lock screw (BZ of Figure 63).
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LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 19 851-520 Rev. D
Figure 63
BZ
3) Rotate and remove the grear motor and guard
assembly (CA of Figure 64).
Figure 64
CA
4) Remove the four (4) lock screws (BZ of Figure
65) and the short side drive guard (CB).
Figure 65
CB
BZ
2.Temporarily support the drive pulley.
Figure 66
3.Remove four shaft cover screws (CC of Figure 67).
Remove the shaft cover (CD).
Figure 67
CC
CD
4.Loosen the bearing collar set screw (CE of Figure
68) and remove bearing collar (CF). Repeat on drive
shaft side of pulley (CE and CF of Figure 69).
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LPZ Series Cleated and Side Wall Cleated Belt Conveyor Installation, Maintenance & Parts Manual
851-520 Rev. D 20 Dorner Mfg. Corp.
Figure 68
CE
CF
Figure 69
CE
CF
5.On the drive headplate, remove two (2) screws (U of
Figure 70).
Figure 70
U
6.Remove the outer headplate assembly (CG of Figure
71), and inner spacer (BK).
Figure 71
CG
BK
7.Slide the drive pulley (CH of Figure 72) out of the
headplate on the opposite side.
Figure 72
CH
C−Upper Knuckle Idler Pulley Removal
1.Ensure knuckle return roller and guard are removed,
see “Knuckle Return Roller Removal” on page 22.
2.Temporarily support the knuckle idler pulley.
Preventive Maintenance and Adjustment