Dorner 2100 Series User manual

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]
851-279 Rev. J
2100, 2200, 2300, 4100, 6200 &
MPB Series Bottom Mount
Drive Pack. for Heavy Load 90°
Industrial Gearmotors
Installation, Maintenance & Parts Manual
Technology
Featuring:

Dorner Mfg. Corp. 2 851-279 Rev. J
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Table of Contents
Introduction ......................................................................... 2
Warnings −General Safety ................................................. 3
Product Description ............................................................. 4
Specifications ...................................................................... 5
Gearmotor Mounting Package Models: .......................... 5
Table 1: Gearmotor Specifications .................................. 5
US Version ................................................................... 5
CE Version ................................................................... 5
Table 2: Belt Speeds for Heavy Load Fixed Speed 90° 60
Hz Gearmotors on 2100, 2200 (Gang Drive), 4100 and
6200 Series Conveyors ................................................... 6
US Version ................................................................... 6
CE Version ................................................................... 6
Table 3: Belt Speeds for Heavy Load Fixed Speed 90° 60
Hz Gearmotors on 2200 Series Conveyors (Excluding
Gang Drive) .................................................................... 7
Table 4: Belt Speeds for Heavy Load Fixed Speed 90° 60
Hz Gearmotors on MPB Series Conveyors .................... 7
Table 5: Belt Speeds for Heavy Load Variable Speed 90°
VFD Gearmotors on 2100, 4100 and 6200 Series Convey-
ors .................................................................................... 8
Table 6: Belt Speeds for Heavy Load Variable Speed 90°
VFD Gearmotors on 2200 Series Conveyors (Excluding
Gang Drive) .................................................................... 8
Table 7: Belt Speeds for Heavy Load Variable Speed 90°
VFD Gearmotors on MPB Series Conveyors .................. 8
Table 8: Belt Speeds for Heavy Load Variable Speed 90°
DC Gearmotors on 2100, 2200 (Gang Drive), 4100 and
6200 Series Conveyors ................................................... 9
Table 9: Belt Speeds for Heavy Load Variable Speed 90°
DC Gearmotors on 2200 Series Conveyors (Excluding
Gang Drive) ..................................................................... 9
Table 10: Belt Speeds for Heavy Load Variable Speed 90°
DC Gearmotors on MPB Series Conveyors .................... 9
Installation.......................................................................... 10
Required Tools ............................................................... 10
Mounting ........................................................................ 10
Preventive Maintenance and Adjustment .......................... 14
Required Tools .............................................................. 14
Timing Belt Tensioning ................................................. 14
Timing Belt Replacement............................................... 14
Drive or Driven Pulley Replacement ............................. 15
Gear Reducer Replacement ............................................ 15
For eDrive style gearmotor ......................................... 16
For old style gearmotor prior to June 2011................. 18
Motor Replacement ....................................................... 19
Notes .................................................................................. 21
Service Parts....................................................................... 22
2100, 2200, 2300, 4100, 6200 Series
Bottom Mount Drive Package ...................................... 22
MPB Series Flat Belt Bottom Mount Drive Package
(Old Style Gearmotor Only) ......................................... 24
MPB Series Cleated Belt Bottom Mount Drive Package
(Old Style Gearmotor Only)........................................... 26
4100 Series Adapter Package ........................................ 28
U.S. Version Gearmotors ............................................... 28
CE Version Gearmotors ................................................. 28
Notes .................................................................................. 29
Return Policy...................................................................... 30
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 2200, 6200 Series conveyors are covered by patent
numbers: 6685009, 5174435, 6109427, 6298981, 6422382
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.
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
IMPORTANT
Some illustrations may show guards
removed. Do NOT operate equipment without
guards.

851-279 Rev. J 3 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial 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
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
Exposed moving parts can cause severe
injury.
REPLACE ALL GUARDS BEFORE RUNNING
CONVEYOR.
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
MPB Series Conveyors are not reversible.
Reversing creates pinch points which can
cause severe injury.
DO NOT REVERSE MPB SERIES
CONVEYORS.

Dorner Mfg. Corp. 4 851-279 Rev. J
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Product Description
Refer to Figure 1 for typical conveyor components.
Figure 1
Figure 1
Figure 2
Mount Packages with Old Style Gearmotors prior to
June 2011
Figure 2
Figure 3
Mount Packages with eDrive Gearmotors
Figure 3
1Conveyor
2 Mounting Bracket
3 Gearmotor
4 Timing Belt Tensioner
5Cover
6 Timing Belt
7DrivePulley
8 Driven Pulley
5
1
2
8
6
7
3
4
NOTE
The 90° industrial gearhead changed
configuration in 2011. See below for
configuration details.

851-279 Rev. J 5 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Specifications
Gearmotor Mounting Package Models:
Example:
Table 1: Gearmotor Specifications
US Version
CE Version
Language Code: M = U.S. English
Output Shaft Type : E= 90 eDrive Gearmotors
Gearmotor Type: H = Heavy Load, Industrial
Mount Style : B= Bottom Mount
Conveyor Width Reference*
Mount Position = A, B, C or D
(see detail to the right)
2 = 2100 Series Conveyor
22 = 2200 & 2300 Series Conveyors
4 = 4100 Series Conveyor
6 = 6200 Series Conveyor
2P = MPB Series Conveyor
Drive Pulley (see Table 2 & 3)
Driven Pulley (see Table 2 & 3)
Belt Type ( = flat belt, A through J = cleated belt )
2 M B H H WW A 32 32
* See“Ordering and Specifications”Catalog for details.
H = 90 Old Style Gearmotors Prior to June 2011
U = CE English
DC
B
A
Single Phase Three Phase DC Variable Speed VFD Variable Speed
Output Power 0.50 hp (0.37 kw)
Input Voltage 115 VAC 208 – 230 / 460 VAC 90 VDC 230 VAC
Input Frequency 60 Hz N/A 10 – 60 Hz
Input Current 7.4 Amperes 2.1 – 2/ 1 Amperes 5.0 Amperes 1.6 Amperes
Motor RPM 1725 2500 1725
Gearmotor Ratios 5:1, 10:1, 20:1, 40:1, 60:1
Frame Size NEMA 56C
Motor Type Totally enclosed, Fan-cooled
Three Phase
Output Power 0.19 kw
Input Voltage 230 / 400 Volts A.C.
Input Frequency 50 Hz
Full Load Amperes 1.2 / 0.7 Amperes
Gearmotor Ratios 5:1, 10:1, 20:1
Protection Ratings IP55 for Gearmotor and Motor Starter
Frame Size 71B5

Dorner Mfg. Corp. 6 851-279 Rev. J
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Specifications
Table 2: Belt Speeds for Heavy Load Fixed Speed 90° 60 Hz Gearmotors on
2100, 2200 (Gang Drive), 4100 and 6200 Series Conveyors
US Version
(vp) = voltage and phase:
11 = 115 V, 1-phase
23 = 230V, 3-phase
(n) = reversing capability:
N = no reversing switch
R = with reversing switch (115V, 1 phase only)
CE Version
(c) = electrical configuration
(vp) = voltage and phase
(r) = output shaft orientation
G = CE German
U = CE Great Britain
23 = 230V, 3-phase
43 = 400 V, 3-phase
L = Left Hand
R = Right Hand
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
32M060ES4(vp)F(n) 60:1 29 270 30.5 6 1.7 22 32
32M060ES4(vp)F(n) 60:1 29 270 30.5 8 2.4 32 32
32M060ES4(vp)F(n) 60:1 29 270 30.5 12 3.7 48 32
32M040ES4(vp)F(n) 40:1 43 247 27.9 12 3.7 32 32
32M040ES4(vp)F(n) 40:1 43 247 27.9 18 5.5 48 32
32M020ES4(vp)F(n) 20:1 86 90 10.2 25 7.6 32 32
32M020ES4(vp)F(n) 20:1 86 90 10.2 37 11.3 48 32
32M010ES4(vp)F(n) 10:1 173 45 5.1 49 14.9 32 32
32M010ES4(vp)F(n) 10:1 173 45 5.1 74 22.6 48 32
32M005ES4(vp)F(n) 5:1 345 25 2.8 99 30.2 32 32
32M005ES4(vp)F(n) 5:1 345 25 2.8 148 45.1 48 32
32M005ES4(vp)F(n) 5:1 345 25 2.8 169 51.5 48 28
32M005ES4(vp)F(n) 5:1 345 25 2.8 197 60.0 44 22
32M005ES4(vp)F(n) 5:1 345 25 2.8 215 65.5 48 22
32M005ES4(vp)F(n) 5:1 345 25 2.8 249 75.9 48 19
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number RPM N-m Ft/min M/min
62(c)050(r)E4(vp)FN 29 50.1 5 1.5 19 32
62(c)050(r)E4(vp)FN 29 50.1 8 2.4 32 32
62(c)050(r)E4(vp)FN 29 50.1 12 3.7 48 32
62(c)050(r)E4(vp)FN 29 50.1 18 5.5 48 22
62(c)015(r)E4(vp)FN 97 19.9 28 8.5 32 32
62(c)015(r)E4(vp)FN 97 19.9 41 12.5 48 32
62(c)015(r)E4(vp)FN 97 19.9 60 18.3 48 22
62(c)005(r)E4(vp)FN 290 7.2 83 25.3 32 32
62(c)005(r)E4(vp)FN 290 7.2 124 37.8 48 32
62(c)005(r)E4(vp)FN 290 7.2 155 47.2 60 32
62(c)005(r)E4(vp)FN 290 7.2 181 55.2 48 22
62(c)005(r)E4(vp)FN 290 7.2 226 68.9 60 22

851-279 Rev. J 7 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Specifications
Table 3: Belt Speeds for Heavy Load Fixed Speed 90° 60 Hz Gearmotors on
2200 Series Conveyors (Excluding Gang Drive)
(vp) = voltage and phase:
11 = 115 V, 1-phase
23 = 230V, 3-phase
(n) = reversing capability:
N = no reversing switch
R = with reversing switch (115V, 1 phase only)
Table 4: Belt Speeds for Heavy Load Fixed Speed 90° 60 Hz Gearmotors on
MPB Series Conveyors
(vp) = voltage and phase
11 = 115 V, 1-phase
23 = 230V, 3-phase
(n) = reversing capability
N = no reversing switch
R = with reversing switch (115V, 1 phase only)
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
32M060ES4(vp)F(n) 60:1 29 270 30.5 6 1.7 19 32
32M060ES4(vp)F(n) 60:1 29 270 30.5 10 3.0 28 28
32M040ES4(vp)F(n) 40:1 43 247 27.9 15 4.6 28 28
32M060ES4(vp)F(n) 60:1 29 270 30.5 16 4.9 44 28
32M040ES4(vp)F(n) 40:1 43 247 27.9 24 7.3 44 28
32M020ES4(vp)F(n) 20:1 86 90 10.2 30 9.1 28 28
32M020ES4(vp)F(n) 20:1 86 90 10.2 48 14.6 44 28
32M010ES4(vp)F(n) 10:1 173 145 5.1 61 18.6 28 28
32M010ES4(vp)F(n) 10:1 173 45 5.1 95 29.0 44 28
32M010ES4(vp)F(n) 10:1 173 45 5.1 104 31.7 48 28
32M005ES4(vp)F(n) 5:1 345 25 2.8 121 36.9 28 28
32M005ES4(vp)F(n) 5:1 345 25 2.8 138 42.1 32 28
32M005ES4(vp)F(n) 5:1 345 25 2.8 176 53.6 32 22
32M005ES4(vp)F(n) 5:1 345 25 2.8 208 63.4 48 28
32M005ES4(vp)F(n) 5:1 345 25 2.8 242 73.8 44 22
32M005ES4(vp)F(n) 5:1 345 25 2.8 264 80.5 48 22
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
32M060ES4(vp)F(n) 60:1 29 270 30.5 13 4.0 22 32
32M060ES4(vp)F(n) 60:1 29 270 30.5 20 6.0 28 28
32M040ES4(vp)F(n) 40:1 43 247 27.9 29 8.9 28 28
32M040ES4(vp)F(n) 40:1 43 247 27.9 44 13.4 48 32
32M020ES4(vp)F(n) 20:1 86 90 10.2 59 17.9 28 28

Dorner Mfg. Corp. 8 851-279 Rev. J
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Specifications
Table 5: Belt Speeds for Heavy Load Variable Speed 90° VFD Gearmotors on
2100, 4100 and 6200 Series Conveyors
* At 60 Hz
Table 6: Belt Speeds for Heavy Load Variable Speed 90° VFD Gearmotors on
2200 Series Conveyors (Excluding Gang Drive)
Table 7: Belt Speeds for Heavy Load Variable Speed 90° VFD Gearmotors on
MPB Series Conveyors
* At 60 Hz
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
32M060ES423EN 60:1 29 226 35.5 0.6−5.6 0.2−1.7 22 32
32M060ES423EN 60:1 29 226 35.5 0.8−8.2 0.3−2.5 32 32
32M040ES423EN 40:1 43 247 27.9 1.2−12 0.4−3.8 28 28
32M020ES423EN 20:1 86 248 27.9 2.5−25 0.8−7.5 32 32
32M010ES423EN 10:1 173 156 17.6 4.9−49 1.5−15 32 32
32M005ES423EN 5:1 345 81 9.1 9.9−99 3−30 32 32
32M005ES423EN 5:1 345 81 9.1 14−148 4.5−45 48 32
32M005ES423EN 5:1 345 58 6.5 19−197 6−60 44 22
32M005ES423EN 5:1 345 58 6.5 24−249 7.6−76 48 19
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
32M060ES423EN 60:1 29 270 30.5 0.6−6 0.2−1.8 19 32
32M060ES423EN 60:1 29 270 30.5 1−10 0.3−3.1 28 28
32M040ES423EN 40:1 43 247 27.9 1.5−15 0.5−4.6 28 28
32M020ES423EN 20:1 86 167 18.9 3−30 0.9−9.2 28 28
32M010ES423EN 10:1 173 115 13 6−60 1.8−18 28 28
32M010ES423EN 10:1 173 115 13 10−104 3.2−32 48 28
32M005ES423EN 5:1 345 58 6.5 12−121 3.7−37 28 28
32M005ES423EN 5:1 345 58 6.5 26−264 8.1−81 48 22
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
32M060ES423EN 60:1 29 270 30.5 1.3−13.4 0.4−4.1 22 32
32M060ES423EN 60:1 29 270 30.5 2−19 0.9−5.9 28 28
32M040ES423EN 40:1 43 247 27.9 2.9−29 0.9−8.9 28 28
32M020ES423EN 20:1 86 167 18.9 5.9−59 1.8−18 28 28
32M010ES423EN 10:1 173 115 13 11−117 3.6−36 28 28
32M010ES423EN 10:1 173 115 13 17−175 5.4−54 48 32
32M005ES423EN 5:1 345 58 6.5 23−234 7.1−71 28 28

851-279 Rev. J 9 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Specifications
Table 8: Belt Speeds for Heavy Load Variable Speed 90° DC Gearmotors on
2100, 2200 (Gang Drive), 4100 and 6200 Series Conveyors
Table 9: Belt Speeds for Heavy Load Variable Speed 90° DC Gearmotors on
2200 Series Conveyors (Excluding Gang Drive)
Table 10: Belt Speeds for Heavy Load Variable Speed 90° DC Gearmotors on
MPB Series Conveyors
* = Cleated and Sidewall Cleated belts operate at a
maximum of 150 Ft/min (45.7 m/min)
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
32M060PSD3DEN 60:1 42 270 30.5 1.0−8.2 0.3−2.5 22 32
32M060PSD3DEN 60:1 42 270 30.5 1.4−12 0.4−3.6 32 32
32M040PSD3DEN 40:1 63 215 24.3 2.1−18 0.7−5.4 32 32
32M020PSD3DEN 20:1 125 90 10.2 4.3−36 1.3−11 32 32
32M010PSD3DEN 10:1 250 72 8.1 9−71 2.6−22 32 32
32M005PSD3DEN 5:1 500 25 2.8 17−143 5.2−43 32 32
32M005PSD3DEN 5:1 500 25 2.8 26−214 7.8−65 48 32
32M005PSD3DEN 5:1 500 25 2.8 29−245 9.0−75 48 28
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
32M060PSD3DEN 60:1 42 270 30.5 1.8−14 0.5−4.5 28 28
32M040PSD3DEN 40:1 63 215 24.3 2.6−22 0.8−6.7 28 28
32M060PSD3DEN 60:1 42 270 30.5 2.8−23 0.8−744 28
32M020PSD3DEN 20:1 125 90 10.2 5.3−44 1.6−13 28 28
32M010PSD3DEN 10:1 250 72 8.1 10−88 3.2−27 28 28
32M005PSD3DEN 5:1 500 25 2.8 17−138 5−42 44 28
32M005PSD3DEN 5:1 500 25 2.8 21−176 6.4−54 28 28
32M005PSD3DEN 5:1 500 25 2.8 33−276 10−84 44 28
Gearmotors Belt Speed Drive
Pulley Driven Pulley
Part Number Gear Ratio RPM In-lb N-m Ft/min M/min
32M060PSD3DEN 60:1 42 270 30.5 2.3−19 0.7−5.9 22 32
32M060PSD3DEN 60:1 42 270 30.5 3.4−28 1−8.6 28 28
32M040PSD3DEN 40:1 63 215 24.3 5.1−42 1.6−12.9 28 28
32M060PSD3DEN 60:1 42 270 30.5 5.3−44 1.6−13 44 28
32M020PSD3DEN 20:1 125 90 10.2 10−85 3−26 28 28
32M020PSD3DEN 20:1 125 90 10.2 15−127 4.7−39 48 32
32M010PSD3DEN 10:1 250 72 8.1 20−170 6−52 28 28
32M010PSD3DEN 10:1 250 72 8.1 31−255 9−77 48 32
NOTE
For belt speed other than those listed, contact
factory for details.

Dorner Mfg. Corp. 10 851-279 Rev. J
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Installation
Required Tools
• Hex key wrenches:
2 mm, 2.5 mm, 3 mm, 5 mm
• Torque wrench
Mounting
Installation Component List:
1. Typical components (Figure 4).
Figure 4
Figure 4
Figure 5
Figure 5
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.
1DriveAssembly
2 M6x12 Socket Head Screws (2x)
3 Plastic Cover
4 M6x18 Socket−Head Screws & Hard Washers (4x)
5 Extrusion
6 Support Plate
7 M6x25 Socket−Head Screws & M6 Nuts (4x)
8Cover
9 Driven Pulley
10 Timing Belt
11 Drive Pulley
12 Mounting Plate
13 M6x18 Socket Head Screws (4x)
14 Support Plate Spacer
15 Output Shaft
NOTE
2100, 2200, MPB and 6200 2” & 3” (51mm &
76mm) and 4100 1” through 6” (25mm –
152mm) conveyors do not include (Figure
4, item R through W).
NOTE
Gearmotor may be operated in positions 1 &
3 (Figure 5).
1
10 9
6
5
8
3
2
7
4
11
12
13
14 15
13

851-279 Rev. J 11 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Installation
2. If required, change gearmotor position by removing four
screws (Figure 6, item 1) from bottom mount assembly.
Rotate gearmotor to other position and install screws.
Tighten screws to 103 in-lb (12 Nm).
Figure 6
Figure 6
3. For your reference, the following figures show the
attachment area of complete mounting packages for the
various conveyor series.
• Gearmotor bottom mount assembly is mounted to head
plate (Figure 7, item 1) and (Figure 8, item 1).
Figure 7
2100 & 2200 Series
Figure 7
Figure 8
MPB Series
Figure 8
• Gearmotor bottom mount assembly is mounted to drive
spacer (Figure 9, item 1).
Figure 9
6200 Series
Figure 9
• Gearmotor bottom mount assembly is mounted to drive
adapter plate (Figure 10, item 1).
Figure 10
4100 Series
Figure 10
1
1
1
1
1
1

Dorner Mfg. Corp. 12 851-279 Rev. J
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Installation
4. Locate drive output shaft (Figure 11, item 1) and
remove two screws (Figure 11, item 2).
Figure 11
Figure 11
5. On side opposite drive output shaft, remove two screws
(Figure 12, item 1).
Figure 12
Figure 12
6. Install spacer (Figure 13, item 1) and gearhead/
conveyor support plate (Figure 13, item 2) with screws
(Figure 13, item 3).
Figure 13
Figure 13
7. Install support plate (Figure 13, item 2) with screws
(Figure 13, item 4). Tighten screws (Figure 13, item 3)
and (Figure 13, item 4) to 80 in-lb (9 Nm).
8. Install opposite end support plate (Figure 14, item 1)
with screws (Figure 14, item 2). Tighten screws to 80
in-lb (9 Nm).
Figure 14
Figure 14
9. Install key onto top shaft (Figure 15, item 1).
Figure 15
Figure 15
NOTE
6200 conveyor shown below, other Series
similar.
NOTE
Refer to Figure 7 through Figure 10 while
doing step 6.
1
2
1
4
3
2
1
A
WARNING
Drive shaft keyway may be sharp.
HANDLE WITH CARE.
2
1
3
2
4
1
5

851-279 Rev. J 13 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Installation
10. Wrap timing belt (Figure 15, item 2) around driven
pulley (Figure 15, item 3) and drive pulley (Figure
15, item 4). Install driven pulley (Figure 15, item 3)
onto conveyor shaft.
11. Remove cam bearing and spacer (Figure 15, item 5).
Place cam bearing and spacer (Figure 16, item 1) next
to driven pulley (Figure 16, item 2). Ensure flanges of
driven pulley are aligned with cam bearing. Tighten
driven pulley set screws (Figure 16, item 3). This will
allow for proper belt alignment while conveyor is in use.
Install cam bearing and spacer (Figure 16, item 1).
Figure 16
Figure 16
12. Depending on direction of conveyor belt travel (Figure
17, item 1) or (Figure 17, item 2), position belt
tensioner (Figure 17, item 3) as shown. Tension belt to
obtain 0.125¨ (3 mm) deflection for 1.0 lb (456 grams)
of force at belt mid-point (Figure 17, item 4). Tighten
tensioner screw to 103 in-lb (12 Nm).
Figure 17
Figure 17
13. Install cover (Figure 18, item 1) with four screws
(Figure 18, item 2). Tighten to 35 in-lb (4 Nm).
Figure 18
Figure 18
14. Mount assembly to support structure with four hard
washers and screws (Figure 19, item 1). Tighten to 80
in-lb (9 Nm).
Figure 19
Figure 19
2
1
3
3
44
1
2
2
1
11

Dorner Mfg. Corp. 14 851-279 Rev. J
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Preventive Maintenance and Adjustment
Required Tools
• Hex key wrenches:
2 mm, 2.5 mm, 3 mm, 5 mm
• Adjustable wrench (for hexagon head screws)
• Torque wrench
Timing Belt Tensioning
1. Remove four (4) screws (Figure 18, item 2) and
remove cover (Figure 18, item 1).
2. Loosen tensioner (Figure 20, item 1).
Figure 20
Figure 20
3. Depending on direction of conveyor belt travel (Figure
17, item 1) or (Figure 17, item 2), position belt
tensioner (Figure 20, item 1) as shown. Tension belt to
obtain 0.125¨ (3 mm) deflection for 1.0 lb (456 grams)
of force at belt mid-point (Figure 20, item 2). Tighten
tensioner screw to 103 in-lb (12 Nm).
4. Install cover (Figure 18, item 1) with four (4) screws
(Figure 18, item 2). Tighten to 35 in-lb (4 Nm).
Timing Belt Replacement
1. Remove four (4) screws (Figure 18, item 2) and
remove cover (Figure 18, item 1).
2. Loosen tensioner (Figure 20, item 1).
3. Remove timing belt (Figure 21, item 1).
Figure 21
Figure 21
4. Install new timing belt.
5. Depending on direction of conveyor belt travel (Figure
17, item 1) or (Figure 17, item 2), position belt
tensioner (Figure 20, item 1) as shown. Tension belt to
obtain 0.125¨ (3 mm) deflection for 1.0 lb (456 grams)
of force at belt mid-point (Figure 20, item 2). Tighten
tensioner screw to 103 in-lb (12 Nm).
6. Install cover (Figure 18, item 1) with four (4) screws
(Figure 18, item 2). Tighten to 35 in-lb (4 Nm).
A
WARNING
Exposed moving parts can cause severe
injury.
LOCK OUT POWER before removing guards
or performing maintenance.
2
1
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 (Figure 21, item 2) set
screws and remove pulley with belt (Figure
21, item 1). For re-installation, see step 10
and Figure 15 on page 13.
2
1

851-279 Rev. J 15 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Preventive Maintenance and Adjustment
Drive or Driven Pulley Replacement
1. Complete steps 1 through 3 of “Timing Belt
Replacement” section on page 14.
2. Loosen set screws and remove drive or driven pulley.
3. Complete steps 11 through 14 of “Installation” section
on page 13.
Gear Reducer Replacement
Figure 22
Old Style Gearmotor prior to June 2011
Figure 22
Figure 23
eDrive Gearmotor
Figure 23
1. Remove four (4) screws (Figure 24, item 2) and
remove cover (Figure 24, item 1).
Figure 24
Figure 24
A
WARNING
Exposed moving parts can cause severe
injury.
LOCK OUT POWER before removing guards
or performing maintenance.
NOTE
If drive pulley (Figure 25, item 2) is replaced,
wrap timing belt around drive pulley and
complete step 3.
A
WARNING
Exposed moving parts can cause severe
injury.
LOCK OUT POWER before removing guards
or performing maintenance.
NOTE
The 90° industrial gearhead changed
configuration in 2011. See below for
configuration details. See Service Parts
section to ensure proper replacement parts
are installed.
2
1

Dorner Mfg. Corp. 16 851-279 Rev. J
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Preventive Maintenance and Adjustment
2. Loosen tensioner (Figure 25, item 1).
Figure 25
Figure 25
3. Loosen drive pulley set screws (Figure 25, item 2).
Remove drive pulley (Figure 25, item 3) and timing
belt (Figure 25, item 4).
For eDrive style gearmotor
1. Remove screws (Figure 26, item 1) and gearmotor
(Figure 26, item 2).
Figure 26
Figure 26
2. Loosen four (4) socket head screws (Figure 27, item 1)
and detach spacer (Figure 27, item 2) from gear reducer
(Figure 27, item 3).
Figure 27
Figure 27
3. Remove four screws (Figure 28, item 1). Detach motor
(Figure 28, item 2) from gear reducer (Figure
28, item 3). Retain shaft key (Figure 28, item 4).
Figure 28
Figure 28
4. Remove two (2) screws (Figure 29, item 1) and detach
output shaft cover (Figure 29, item 2).
Figure 29
Figure 29
5. Remove gear reducer components:
NOTE
Follow proper procedure below depending
upon old or new style gearmotor assembly.
NOTE
Step 2 and (Figure 27, item 2) is required for
standard load VFD gearmotors only.
4
3
2
1
2
1
3
1
2
1
4
23
2
1

851-279 Rev. J 17 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Preventive Maintenance and Adjustment
6. Hold the driveshaft with a wrench (Figure 30, item 1)
as shown to keep shaft from turning, while removing
screw (Figure 30, item 2) with hex wrench (Figure
30, item 3).
Figure 30
Figure 30
7. Remove driveshaft (Figure 31, item 1) and key (Figure
31, item 2).
Figure 31
Figure 31
8. Replace gear reducer (Figure 31, item 3).
9. Apply anti-seize (Figure 32, item 1) to shaft.
Figure 32
Figure 32
10. Replace the original shaft components into new gear
reducer (Figure 31).
11. Hold the driveshaft with a wrench (Figure 30, item 2)
as shown to keep shaft from turning, while installing
screw with hex wrench (Figure 30, item 3). Tighten
screw to 350 in-lb (39.5 Nm).
12. Apply anti-seize to motor shaft before assembling to
gearbox. With key (Figure 28, item 4) in keyway, slide
motor (Figure 28, item 2) and gear reducer (Figure
28, item 3) together. Install screws (Figure 28, item 1)
and tighten.
13. Reverse steps 1 through 5 beginning on page 15.
14. Complete installation steps 10 through 14 of
“Installation” section on pages 12-13.
1
32
1
2
3
IMPORTANT
Be extremely careful when coupling motor to
gear reducer. Avoid misalignment and forcing
the connection causing possible permanent
gear reducer seal damage.
1

Dorner Mfg. Corp. 18 851-279 Rev. J
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Preventive Maintenance and Adjustment
For old style gearmotor prior to June 2011
1. Remove screws (Figure 33, item 1 and 2) and remove
support bracket (Figure 33, item 3), support plate
(Figure 33, item 4) and spacer (Figure 33, item 5).
Figure 33
Figure 33
2. Remove hex support posts (Figure 34, item 1).
Figure 34
Figure 34
3. Remove two (2) bracket screws (Figure 35, item 1) and
remove bracket (Figure 35, item 2).
Figure 35
Figure 35
4. Remove four (4) gear reducer mounting screws (Figure
36, item 1). Remove gear reducer and gearmotor
assembly.
Figure 36
Figure 36
5. Remove four screws (Figure 37, item 1). Detach motor
(Figure 37, item 2) from gear reducer (Figure
37, item 3). Retain motor output shaft key (Figure
37, item 4).
Figure 37
Figure 37
6. Remove two (2) screws (Figure 37, item 5) and detach
output shaft cover (Figure 37, item 6).
7. Remove gear reducer output shaft key (Figure
37, item 7).
5
1
4
2
3
1
1
2
1
2
4
7
1
1
5
6
3

851-279 Rev. J 19 Dorner Mfg. Corp.
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Preventive Maintenance and Adjustment
8. Loosen six (6) set screws (Figure 38, item 1). Remove
drive shaft (Figure 38, item 2) and key (Figure
38, item 3).
Figure 38
Figure 38
9. Apply anti-seize (Figure 39, item 1) to shaft.
Figure 39
Figure 39
10. Replace the original shaft components into new gear
reducer (Figure 38).
11. Apply anti-seize to motor shaft before assembling to
gearbox. With key (Figure 37, item 4) in keyway, slide
motor (Figure 37, item 2) and gear reducer (Figure
37, item 3) together. Install screws (Figure 37, item 1)
and tighten.
12. Reverse steps 1 through 7 beginning on page 15.
13. Complete installation steps 10 through 14 of
“Installation” section on pages 12-13.
Motor Replacement
1. For single phase motor, unplug power cord from outlet.
2. For three phase and VFD variable speed motor:
a. Loosen terminal box screws (Figure 40, item 1)
and remove cover (Figure 40, item 2).
Figure 40
Figure 40
b. Record wire colors on terminals 1, 2 and 3. Loosen
wire nuts and remove wires 1, 2 and 3.
c. Loosen cord grip and remove cord.
IMPORTANT
Be extremely careful when coupling motor to
gear reducer. Avoid misalignment and forcing
the connection causing possible permanent
gear reducer seal damage.
2
3
1
1
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.
2
1

Dorner Mfg. Corp. 20 851-279 Rev. J
2100, 2200, 2300, 4100, 6200 & MPB Series Bottom Mount Drive Pack. for Heavy Load 90° Industrial Gearmotors
Preventive Maintenance and Adjustment
3. For DC variable speed motor, unplug motor cord at
disconnect (Figure 41, item 1).
Figure 41
Figure 41
4. Remove four screws (Figure 42, item 1). Detach motor
(Figure 42, item 2) from gear reducer (Figure
42, item 3). Retain motor output shaft key (Figure
42, item 4).
Figure 42
Figure 42
5. Apply anti-seize to motor shaft before assembling to
gearbox. With key (Figure 43, item 1) in keyway, slide
motor and gear reducer together. Install screws (Figure
43, item 2) and tighten.
Figure 43
Figure 43
6. Replace wiring:
• For a single phase motor, reverse step 1 on page 19.
• For a three phase and VFD variable speed motor, reverse
step 2 on page 19.
• For a DC variable speed motor, reverse step 3 on page 20.
IMPORTANT
Be extremely careful when coupling motor to
gear reducer. Avoid misalignment and forcing
the connection causing possible permanent
gear reducer seal damage.
1
1
4
23
2
1