Dorner 2100 Series Maintenance and service guide

For other service manuals visit our website at:
www.dorner.com/service_manuals.asp
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]
851-261 Rev. I
2100, 2200, 4100, 6200 and
MPB Series Top Mount Drive
Package for Light Load 60 Hz
Gearmotors
Installation Maintenance & Parts Manual

851-261 Rev. I 2 Dorner Mfg. Corp.
2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Light Load 60 Hz Gearmotors
Table of Contents
Introduction.......................................................................... 2
Warnings −General Safety .................................................. 3
Product Description.............................................................. 4
Specifications ....................................................................... 4
Installation............................................................................ 7
Required Tools ................................................................. 7
Mounting .......................................................................... 7
Preventive Maintenance and Adjustment .......................... 10
Required Tools .............................................................. 10
Timing Belt Tensioning ................................................. 10
Timing Belt Replacement .............................................. 10
Drive or Driven Pulley Replacement ............................ 11
Gearmotor Replacement ............................................... 11
Service Parts ...................................................................... 14
2100, 2200, 4100, 6200 and MPB Series Top
Mount Drive Package .................................................... 14
4100 Series Adapter Package ..................................... 15
Gearmotors..................................................................... 15
Return Policy ..................................................................... 16
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 2100 Series conveyors are covered by the following
patent numbers: 5131529, 5174435, and corresponding
patents and patent applications in other countries.
Dorner 2200 and MPB Series conveyors are covered by
patent number 5174435 and corresponding patents and
patent applications in other countries.
Dorner 4100 Series conveyors are covered by patent number
3923148 and corresponding patents and patent applications
in other countries.
Dorner 6200 Series conveyors are covered by patent number
6685009, 5174435, 6109427 and corresponding patents and
patent applications in other countries.
Dorner’s Limited Warranty applies.
Dorner reserves the right to make changes at any time
without notice or obligation.
IMPORTANT
Some illustrations may show guards
removed. Do NOT operate equipment without
guards.

851-261 Rev. I 3 Dorner Mfg. Corp.
2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Light Load 60 Hz Gearmotors
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
DANGER
Hazardous voltage will cause severe injury or
death.
LOCK OUT POWER BEFORE WIRING.
A
WARNING
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
A
WARNING
Exposed moving parts can cause severe
injury.
LOCK OUT POWER before removing guards
or performing maintenance.
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 startup.
A
WARNING
MPB Series Conveyors are not reversible.
Reversing creates pinch points which can
cause severe injury.
DO NOT REVERSE MPB SERIES
CONVEYORS.

Dorner Mfg. Corp. 4 851-261 Rev. I
2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Light Load 60 Hz Gearmotors
Product Description
Refer to Figure 1 for typical components. Figure 1
Figure 1
Specifications
Gearmotor Mounting Package Models:
Example:
* See “Ordering and Specifications” Catalog for details.
Table 1: Gearmotor Specifications
AConveyor
B Mounting Bracket
C Gearmotor
D Belt Tensioner
ECover
F Timing Belt
G Drive Pulley
H Driven Pulley
CB
E
D
F
H
G
A
Language Code = U.S. English
Output Shaft Type = Parallel Shaft
Gearmotor Type: L = Fixed Speed,
V = Variable Speed
Mount Style = Top Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
2 M T P L WW A −32 32
2 = 2100 SeriesConveyor
22 = 2200 SeriesConveyor
4 = 4100 SeriesConveyor
6 = 6200 SeriesConveyor
2P = MPB SeriesConveyor
Belt Type: − = flat belt, A through J = cleated belt
Drive Pulley (see Belt Speed Tables)
Driven Pulley (see Belt Speed Tables)
D C
B
A
Single Phase DC Variable Speed
Output Power 0.03 hp (0.025 kw) 0.06 hp (0.04 kw)
Input Voltage 115 Volts A.C. 130 Volts D.C.
Input Frequency 60 Hz N/A
Full Load Amperes 0.49 Amperes 0.48 Amperes
Gearmotor Ratios 15:1 and 36:1 18:1 and 60:1

851-261 Rev. I 5 Dorner Mfg. Corp.
2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Light Load 60 Hz Gearmotors
Specifications
Table 2: Belt Speeds for Light Load Fixed Speed Parallel Shaft 60 Hz
Gearmotors on 2100, 2200 Gang Drive, 4100 and 6200 Series Conveyors
* 115V, 1 phase, non−reversing
Table 3: Belt Speeds for Light Load Fixed Speed Parallel Shaft 60 Hz
Gearmotors on 2200 Series Conveyors (Excluding Gang Drive)
* 115V, 1 phase, non−reversing
Table 4: Belt Speeds for Standard Load Fixed Speed Parallel Shaft 60 Hz
Gearmotors on MPD Series Conveyors
* 115V, 1 phase, non−reversing
Table 5: Belt Speeds for Light Load Variable Speed Parallel Shaft DC
Gearmotors on 2100, 4100 and 6200 Series Conveyors
* 130VDC
Gearmotors*Belt Speed Drive
Pulley
Driven
Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
62M036PL4FN 36:1 42 36 4.1 8 2.4 22 32
62M036PL4FN 36:1 42 36 4.1 12 3.7 32 32
62M036PL4FN 36:1 42 36 4.1 17 5.2 32 22
62M036PL4FN 36:1 42 36 4.1 24 7.3 44 22
62M015PL4FN 15:1 100 15 1.7 29 8.8 32 32
62M015PL4FN 15:1 100 15 1.7 41 12.5 32 22
Gearmotors*Belt Speed Drive
Pulley
Driven
Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
62M036PL4FN 36:1 42 36 4.1 13 4.0 28 32
62M036PL4FN 36:1 42 36 4.1 15 4.6 28 28
62M036PL4FN 36:1 42 36 4.1 21 6.4 32 22
62M036PL4FN 36:1 42 36 4.1 29 8.8 44 22
62M015PL4FN 15:1 100 15 1.7 35 10.7 28 28
62M015PL4FN 15:1 100 15 1.7 55 16.8 44 28
Gearmotors*Belt Speed Drive
Pulley
Driven
Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
62M036PL4FN 36:1 42 36 4.1 25 7.5 28 32
62M036PL4FN 36:1 42 36 4.1 28 8.6 28 28
62M036PL4FN 36:1 42 36 4.1 45 13.6 44 28
62M036PL4FN 36:1 42 36 4.1 57 17.3 44 22
Gearmotors*Belt Speed Drive
Pulley
Driven
Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
62M060PLD3DEN 60:1 42 65 7.4 1.0−8.2 .3−2.5 22 32
62M060PLD3DEN 60:1 42 65 7.4 1.4−12 .4−3.6 32 32
62M018PLD3DEN 18:1 139 21 2.4 4.8−40 1.5−12 32 32
62M018PLD3DEN 18:1 139 21 2.4 7−58 2.1−18 32 22

Dorner Mfg. Corp. 6 851-261 Rev. I
2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Light Load 60 Hz Gearmotors
Specifications
Table 6: Belt Speeds for Standard Load Variable Speed Parallel Shaft DC
Gearmotors on 2200 Series Conveyors (Excluding Gang Drive)
* 130VDC
Table 7: Belt Speeds for Standard Load Variable Speed Parallel Shaft DC
Gearmotors on MPB Series Conveyors
* 130VDC
Gearmotors*Belt Speed Drive
Pulley
Driven
Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
62M060PLD3DEN 60:1 42 65 7.4 1.8−14 .5−4.5 28 28
62M060PLD3DEN 60:1 42 65 7.4 2.8−23 .8−744 28
62M018PLD3DEN 18:1 139 21 2.4 6−49 1.8−15 28 28
62M018PLD3DEN 18:1 139 21 2.4 9−77 2.8−23 44 28
Gearmotors*Belt Speed Drive
Pulley
Driven
Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
62M060PLD3DEN 60:1 42 65 7.4 2.3−19 .7−5.9 22 32
62M060PLD3DEN 60:1 42 65 7.4 3.4−28 1−8.6 28 28
62M060PLD3DEN 60:1 42 65 7.4 5.3−44 1.6−13 44 28
62M018PLD3DEN 18:1 139 21 2.4 11−94 3.5−28 28 28
62M018PLD3DEN 18:1 139 21 2.4 16−148 5−45 44 28
NOTE
For belt speed other than those listed, contact
factory for details.

851-261 Rev. I 7 Dorner Mfg. Corp.
2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Light Load 60 Hz Gearmotors
Installation
Required Tools
• Hex key wrenches:
2.5 mm, 3 mm, 5 mm
• Torque wrench
Installation Component List:
Mounting
1. Typical components (Figure 2)
Figure 2
Figure 2
2. Locate drive output shaft (Figure 3, item P) and remove
two screws (Q).
Figure 3
Figure 3
3. For your reference, the following five figures show the
attachment area of complete mounting packages for
various conveyor series.
Figure 4
2200 Series
Figure 4
I Top Mount Assembly
J Driven Pulley
K Cover
L M4 Socket Head Screws (4x)
M Timing Belt
NKey
O M6 Socket Head Screws (2x)
A
WARNING
Exposed moving parts can cause severe
injury.
LOCK OUT POWER before removing guards
or performing maintenance.
A
WARNING
MPB Series Conveyors are not reversible.
Reversing creates pinch points which can
cause severe injury.
DO NOT REVERSE MPB SERIES
CONVEYORS.
NOTE
6200 conveyor shown, other Series similar.
K
L
M
I
J
O
N
Q
P
Gearmotor
is mounted
to Head
Plate

Dorner Mfg. Corp. 8 851-261 Rev. I
2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Light Load 60 Hz Gearmotors
Installation
Figure 5
6100 Series
Figure 5
Figure 6
4100 Series
Figure 6
Figure 7
2100 Series
Figure 7
Figure 8
MPB Series
Figure 8
4. Attach mount assembly (Figure 9, item I) with two
screws (O). Tighten screws to 80 in-lb (9 Nm).
Figure 9
Figure 9
5. Install key (Figure 10, item N).
Figure 10
Figure 10
Gearmotor
is mounted to
Drive Spacer
Gearmotor
is mounted
to Drive
Adapter
Plate
Gearmotor
is mounted
to Head
Plate
Gearmotor
is mounted
to Head
Plate
A
WARNING
Drive shaft keyway may be sharp.
HANDLE WITH CARE.
I
O
U
N
R
J
M

851-261 Rev. I 9 Dorner Mfg. Corp.
2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Light Load 60 Hz Gearmotors
Installation
6. Wrap timing belt (M) around driven pulley (J) and drive
pulley (R). Install driven pulley (J) onto conveyor shaft.
7. Remove cam bearing and spacer (Figure 9, item U).
Place the cam bearing and spacer (Figure 11, item U)
next to the driven pulley (M). Ensure the flanges of the
driven pulley are aligned with the cam bearing. Tighten
set screws on driven pulley (J). This will allow for
proper belt alignment while conveyor is in use. Install
cam bearing and spacer (U).
Figure 11
Figure 11
8. Depending on direction of conveyor belt travel (1 or 2
of Figure 12), position timing belt tensioner (U) as
shown. Tension timing belt to obtain 1/8” (3 mm)
deflection for 1 lb (456 grams) of force at timing belt
mid-point (V). Tighten tensioner screw to 106 in-lb (12
Nm).
Figure 12
Figure 12
9. Install cover (Figure 13, item K) with four (4) screws
(L). Tighten to 35 in-lb (4 Nm).
Figure 13
Figure 13
U
M J
V
V1
2
U
U
L
K
L

851-261 Rev. I 10 Dorner Mfg. Corp.
2100, 2200, 4100, 6200 and MPB Series Top Mount Drive Package for Light Load 60 Hz Gearmotors
Preventive Maintenance and Adjustment
Required Tools
• Hex key wrenches:
2.5 mm, 3 mm, 5 mm
• Screwdriver (for terminal box screws)
• Torque wrench
Timing Belt Tensioning
1. Remove four screws (Figure 14, item L) and remove
cover (K).
Figure 14
Figure 14
2. Loosen tensioner (Figure 15, item U).
Figure 15
Figure 15
3. Depending on direction of conveyor belt travel (1 or 2
of Figure 16), position timing belt tensioner (U) as
shown. Tension timing belt to obtain 1/8” (3 mm)
deflection for 1 lb (456) grams of force at timing belt
mid-point (V). Tighten tensioner screw to 106 in-lb (12
Nm).
Figure 16
Figure 16
4. Install cover (Figure 14, item K) with four (4) screws
(L). Tighten screws to 35 in-lb (4 Nm).
Timing Belt Replacement
1. Remove four (4) screws (Figure 14, item L) and remove
cover (K).
2. Loosen tensioner (Figure 15, item U).
3. Remove timing belt (Figure 17, item M).
A
WARNING
Exposed moving parts can cause severe
injury.
LOCK OUT POWER before removing guards
or performing maintenance.
L
K
L
U
A
WARNING
Exposed moving parts can cause severe
injury.
LOCK OUT POWER before removing guards
or performing maintenance.
NOTE
If timing belt does not slide over pulley flange,
loosen driven pulley set screws (Figure
17, item T) and remove pulley with belt. For
re-installation, see steps 6 through 9 on
page 9.
1
2
V
V
U
U