Dorner 3200 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]
851-520 Rev. I
3200 Series Cleated and
Sidewall Cleated Belt
LPZ Conveyors
Installation, Maintenance & Parts Manual

Dorner Mfg. Corp. 2 851-520 Rev. I
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Table of Contents
Introduction ......................................................................... 3
Warnings - General Safety .................................................. 4
Product Description ............................................................. 5
Specifications ...................................................................... 5
Models ............................................................................. 5
Conveyor Supports:...................................................... 5
Maximum Distances: ................................................ 5
Maximum Angle:...................................................... 5
Specifications:.................................................................. 6
Installation ........................................................................... 7
Required Tools................................................................. 7
Recommended Installation Sequence .............................. 7
Conveyors Up to 13 ft (3962 mm)................................... 7
Conveyors Longer Than 13 ft (3962 mm) ....................... 7
Mounting Brackets........................................................... 9
Return Rollers .................................................................. 9
Preventive Maintenance and Adjustment.......................... 10
Required Tools............................................................... 10
Standard Tools............................................................ 10
Checklist ........................................................................ 10
Lubrication..................................................................... 10
Maintaining Conveyor Belt ........................................... 10
Troubleshooting ......................................................... 10
Cleaning ..................................................................... 10
Conveyor Belt Replacement .......................................... 10
Conveyor Belt Replacement Sequence ...................... 10
Belt Removal for Conveyor Without Stands or
Gearmotor Mounting Package ................................... 11
Belt Removal for Conveyor With Stands and Gearmotor
Mounting Package...................................................... 12
Belt Installation for Conveyor without Stands or
Gearmotor Mounting Package ................................... 13
Belt Installation for Conveyor with Stands and
Gearmotor Mounting Package ................................... 14
Conveyor Belt Tensioning ............................................. 15
Conveyor Belt Tracking................................................. 17
V-Guided Belts........................................................... 17
Non V-Guided Belts................................................... 17
Conveyor Angle Adjustment ......................................... 18
Nose Over Angle Adjustment .................................... 18
Horizontal to Incline Angle Adjustment .................... 19
Pulley Removal.............................................................. 20
A −Idler Pulley Removal........................................... 20
B −Drive Pulley Removal ......................................... 21
C −Upper Knuckle Idler Pulley Removal ................. 24
D −Lower Knuckle Idler Pulley Removal................. 25
E −Knuckle Return Roller Removal ......................... 26
Bearing Replacement..................................................... 26
A −Idler Bearing Replacement.................................. 26
B −Drive Bearing Removal and Replacement .......... 26
Removal.................................................................. 26
Replacement ........................................................... 26
C −Nose Over Knuckle Idler Bearing Replacement . 27
D −Horizontal to Incline Knuckle Idler Bearing
Replacement ............................................................... 27
E −Knuckle Return Roller Bearing Replacement ..... 27
Pulley Replacement........................................................ 27
Idler Pulley.................................................................. 27
Drive Pulley ................................................................ 27
Knuckle Pulley............................................................ 27
Knuckle Return Roller ................................................ 27
Service Parts....................................................................... 28
Drive End Tail Assembly ............................................... 28
Idler End Assembly ........................................................ 29
Horizontal to Incline Knuckle Assembly ....................... 30
Nose Over Knuckle Assembly ....................................... 31
Frame Assembly............................................................. 32
Bed Plate and Frame Formulas................................... 33
Cleated Belt Conveyor Configurations .......................... 34
Section and Length Determination................................. 34
Z Frame −Section L1..................................................... 35
Inclining Belt Travel*................................................. 35
Declining Belt Travel*................................................ 35
Z Frame −Section L2..................................................... 36
Inclining Belt Travel*................................................. 36
Declining Belt Travel*................................................ 36
Z Frame −Section L3..................................................... 37
Inclining Belt Travel*................................................. 37
Declining Belt Travel*................................................ 37
L Frame −Section L2..................................................... 38
Inclining Belt Travel*................................................. 38
Declining Belt Travel*................................................ 38
L Frame −Section L3..................................................... 39
Inclining Belt Travel*................................................. 39
Declining Belt Travel*................................................ 39
P Frame −Section L1..................................................... 40
Inclining Belt Travel*................................................. 40
Declining Belt Travel*................................................ 40
P Frame −Section L2..................................................... 41
Inclining Belt Travel*................................................. 41
Declining Belt Travel*................................................ 41
Sidewall Cleated Belt Conveyor Configurations ........... 42
Section and Length Determination................................. 42
Z Frame −Cleated Sidewall Guiding............................. 43
Guides ......................................................................... 43
L Frame Horizontal to Incline
Cleated Sidewall Guiding............................................... 44
Guides ......................................................................... 44
P Frame Nose Over Cleated Sidewall Guiding .............. 45
Guides ......................................................................... 45
Cleated Belt Mounting Brackets .................................... 46
Connecting Assembly without Stand Mount.................. 46
Cleated Belt Connecting Assembly
with Stand Mount ........................................................... 47
4” (102 mm) to 24” (610 mm)
Cleated Belt Return Roller ............................................. 47
Conveyor Belt Part Number Configuration.................... 48
Cleated Belt Part Number Configuration.................... 48
Notes .................................................................................. 49
Return Policy...................................................................... 50

851-520 Rev. I 3 Dorner Mfg. Corp.
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Introduction
Upon receipt of shipment:
• Compare shipment with packing slip. Contact factory
regarding discrepancies.
• Inspect packages for shipping damage. Contact carrier
regarding damage.
• Accessories may be shipped loose. See accessory instruc-
tions for installation.
Dorner’s Limited Warranty applies.
Dorner 3200 series conveyors are covered by Patent
Numbers 5,156,260, 6,871,737B2, 6,910,571B1,
6,971,509B2, 6,298,981, 6,971,509, 6,901,571, 6,871,737
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.
IMPORTANT
Some illustrations may show guards
removed. DO NOT operate equipment
without guards.

Dorner Mfg. Corp. 4 851-520 Rev. I
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
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
LPZ Series Conveyors are not reversible.
Reversing creates pinch points which can
cause severe injury.
DO NOT REVERSE LPZ SERIES
CONVEYORS.
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 start-up.
A
WARNING
Loosening stand height or angle adjustment
screws may cause conveyor sections to drop
down, causing severe injury.
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.
SUPPORT CONVEYOR SECTIONS PRIOR TO
LOOSENING STAND HEIGHT OR ANGLE
ADJUSTMENT SCREWS.

851-520 Rev. I 5 Dorner Mfg. Corp.
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Product Description
Refer to Figure 1 for typical conveyor components. Figure 1
Figure 1
Specifications
Models Conveyor Supports:
Maximum Distances:
1 = 24” (610 mm) (Drive End)
2 = 12 ft (3658 mm)
3 = 36” (914 mm) (Idler End)
Maximum Angle:
4 = 0 and 25 to 60 degrees
Figure 2
Figure 2
1Conveyor
2 Gearmotor Mounting Package
3 Gearmotor
4 Mounting Brackets
5 Lower Knuckle
6 Upper Knuckle
7 Support Stand
8DriveEnd
9 Idler/Tension End
2
8
5
9
1
3
4
6
7
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.
4
1
4
23

Dorner Mfg. Corp. 6 851-520 Rev. I
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Specifications
Specifications:
* Not available on 18″& 24″(457 & 610 mm) width conveyors
Conveyor Width
Reference (WW) 08 10 12 18 24
Conveyor Belt Width 8” (203mm) 10” (254mm) 12” (305mm) 18” (457mm) 24” (610mm)
Conveyor Startup
Torque* 10 in-lb (1.1Nm) 13 in-lb (1.5Nm) 15 in-lb (1.7Nm) 25 in-lb (2.8Nm) 34 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:
• Non-accumulating product
• Product moving towards gearmotor
• Conveyor being mounted horizontal
NOTE
Refer to the table provided for maximum
recommended tension pinion torque values
and maximum conveyor loads for different
angles. Choose the appropriate value which
relates to your particular requirements.
Transition Angle Standard Cleated Belt Sidewall Cleated Belt 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

851-520 Rev. I 7 Dorner Mfg. Corp.
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Installation
Figure 3
Figure 3
Required Tools
• Hex-key wrenches:
4 mm, 5 mm
• Level
• Torque wrench
• 8 mm hex, open end wrench
Recommended Installation
Sequence
• Install support stands (see accessory instructions)
• Assemble conveyor (if required)
• Attach mounting brackets to conveyor (see page 9 for
instructions)
• Adjust angle (see page 18 for instructions)
• Attach conveyor to stands
• Install return rollers on conveyor (see page 13 for instruc-
tions)
• Mount gearmotor mounting package (see accessory
instructions)
• Attach guides/accessories (see page 34 through page 45 of
“Service Parts” section for details)
Conveyors Up to 13 ft (3962 mm)
No assembly is required. Install mounting brackets and
return rollers. Refer to “Mounting Brackets” on page 9 and
“Return Rollers” on page 13.
Conveyors Longer Than 13 ft
(3962 mm)
Installation Component List:
1. Locate and arrange conveyor sections by section labels
(Figure 4, item 2).
Figure 4
Figure 4
2. On tension end of the conveyor, identified by the pinion
locking screw (Figure 5, item 1), push in head plate
assembly (Figure 5, item 2): Loosen the pinion locking
screw (Figure 5, item 1), adjust the pinion torque screw
(Figure 6, item 1). On both sides of conveyor, loosen
the two tail clamp bolts (Figure 5, item 3), and push
head plate assembly (Figure 5, item 2) inward.
Figure 5
Figure 5
A
WARNING
LPZ Series Conveyors are not reversible.
Reversing creates pinch points which can
cause severe injury.
DO NOT REVERSE LPZ SERIES
CONVEYORS.
NOTE
Conveyor MUST be mounted straight, flat and
level within confines of conveyor. Use a level
(Figure 3, item 1) for setup.
1
1 Conveyor frame
2 Section Label
12
2
1
3
2

Dorner Mfg. Corp. 8 851-520 Rev. I
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Installation
Figure 6
Figure 6
3. Roll out conveyor belt (Figure 7, item 1). Loosen (4)
screws (Figure 7, item 2) on both sides of knuckle
(Figure 7, item 3). Slide frame (Figure 7, item 4) into
knuckle (Figure 7, item 3). Tighten screws (Figure
7, item 2) to 60 in-lb (7 Nm) on both sides of conveyor.
Figure 7
Figure 7
4. Slide frame (Figure 8, item 1) into lower knuckle
(Figure 8, item 2). Tighten screws (Figure 8, item 3) to
60 in-lb (7 Nm) on both sides of conveyor.
Figure 8
Figure 8
5. Join additional conveyor sections if necessary and
install connector brackets (Figure 9, item 1) or
connector/mount brackets (Figure 9, item 2) and
screws (Figure 9, item 3) on both sides as indicated.
Tighten screws to 60 in-lb (7 Nm).
Figure 9
Figure 9
6. Slide belt (Figure 10, item 1) over assembled conveyor
sections (Figure 10, item 2).
Figure 10
Figure 10
7. Tension conveyor belt, refer to “Conveyor Belt
Tensioning” on page 15.
8. Install mounting brackets and return rollers. Refer to
“Mounting Brackets” on page 9 and “Return Roller” on
page 11.
9. Conveyors are shipped flat. Adjust conveyor angle. See
“Conveyor Angle Adjustment” on page 18.
1
1
43
2
31
2
1
32
1
2

851-520 Rev. I 9 Dorner Mfg. Corp.
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Installation
Mounting Brackets
1. Locate brackets. Exploded views shown in Figure 11.
Figure 11
Figure 11
2. Remove screws (Figure 11, item 1 & 2), washers
(Figure 11, item 3), nuts (Figure 11, item 4) and T-bars
(Figure 11, item 5) from brackets.
3. Insert T-bars (Figure 11, item 1) into conveyor side
slots (Figure 12, item 1). Fasten brackets (Figure
12, item 2) to conveyor with mounting screws (Figure
12, item 3).
Figure 12
Figure 12
4. Fasten brackets to support stand with mounting screws
(Figure 12, item 4), washers (Figure 12, item 5) and
nuts (Figure 12, item 6).
5. Tighten screws (Figure 12, item 3 & 4) to 60 in-lb (7
Nm).
Return Rollers
1. Locate return rollers. Exploded views shown in Figure
13.
Figure 13
Figure 13
2. Remove screws (Figure 13, item 1) and clips (Figure
13, item 2) from roller assembly.
3. Install roller assemblies (Figure 14, item 1) as shown.
Tighten screws (Figure 14, item 2) to 60 in-lb (7 Nm).
Figure 14
Figure 14
15
4
3
2
1
3
2
6
5
4
12
2
1
21
1

Dorner Mfg. Corp. 10 851-520 Rev. I
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Preventive Maintenance and Adjustment
Required Tools
Standard Tools
• Hex-key wrenches:
2.5 mm, 4 mm, 5 mm
• 8 mm hex, open end wrench
Checklist
• Keep service parts on hand (see “Service Parts” section for
recommendations)
• Keep supply of belt cleaner
• Clean entire conveyor and knurled pulley while dis-
assembled
• Replace worn or damaged parts
Lubrication
No lubrication is required. Replace bearings if worn.
Maintaining Conveyor Belt
Troubleshooting
Inspect conveyor belt for:
• Surface cuts or wear
• Stalling or slipping
• Damage to V-guide
Surface cuts and wear indicate:
• Sharp or heavy parts impacting belt
• Jammed parts
• Improperly installed bottom wipers (if installed)
• Accumulated dirt in wipers (if installed)
• Foreign material inside the conveyor
• Improperly positioned accessories
• Bolt-on guiding is pinching belt
Stalling or slipping indicates:
• Excessive load on belt
• Conveyor belt or drive timing belt are not properly ten-
sioned
• Worn knurl or impacted dirt on drive pulley
• Intermittent jamming or drive train problems
Damage to V-guide indicates:
• Twisted or damaged conveyor frame
• Dirt impacted on pulleys
• Excessive or improper side loading
Cleaning
Use Dorner Belt Cleaner. 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
Conveyor Belt Replacement Sequence
• Release Tension
• Remove old conveyor belt:
- Conveyor without Stands or Gearmotor Mounting Pack-
age
- Conveyor with Stands and Gearmotor Mounting Pack-
age
• Install new conveyor belt
• Tension conveyor belt
A
WARNING
Exposed moving parts can cause severe
injury.
LOCK OUT POWER before removing guards
or performing maintenance.

851-520 Rev. I 11 Dorner Mfg. Corp.
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Preventive Maintenance and Adjustment
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.
2. On tension end of the conveyor, identified by the pinion
locking screw (Figure 15, item 1), push in head plate
assembly (Figure 15, item 2): Loosen the pinion
locking screw (Figure 15, item 3), adjust the pinion
torque screw (Figure 16, item 1). On both sides of
conveyor, loosen the two tail clamp bolts (Figure
15, item 3), and push head plate assembly (Figure
15, item 2) inward.
Figure 15
Figure 15
Figure 16
Figure 16
3. If equipped with a lower knuckle, remove screws
(Figure 17, item 1) and remove lower knuckle return
roller assembly (Figure 17, item 2) on both sides of
conveyor, note the position of the meshing teeth.
Figure 17
Figure 17
4. If equipped with an upper knuckle, remove screws
(Figure 18, item 1) and remove guard (Figure
18, item 2) on both sides of knuckle.
Figure 18
Figure 18
5. Remove screws (Figure 19, item 1) and remove roller
bearing (Figure 19, item 2).
Figure 19
Figure 19
1
32
1
1
2
1
2
1
2

Dorner Mfg. Corp. 12 851-520 Rev. I
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Preventive Maintenance and Adjustment
6. Remove belt (Figure 20, item 1) from conveyor.
Figure 20
Figure 20
Belt Removal for Conveyor With Stands
and Gearmotor Mounting Package
1. Place temporary support stands (Figure 21, item 1) at
both ends of the conveyor. Place an additional support
stand (Figure 21, item 2) under the drive motor (Figure
21, item 3), if equipped. See WARNING.
Figure 21
Figure 21
2. Remove mounting brackets (Figure 21, item 4) from
one side of conveyor. (Reverse steps 3 & 4 of
“Mounting Brackets” section on page 9).
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 (Figure 22, item 1), push in head plate
assembly (Figure 22, item 2): Loosen the pinion
locking screw (Figure 22, item 1), adjust the pinion
torque screw (Figure 23, item 1). On both sides of
conveyor, loosen the two tail clamp bolts (Figure
22, item 3), and push head plate assembly (Figure
22, item 2) inward.
Figure 22
Figure 22
Figure 23
Figure 23
5. If equipped, remove screws (Figure 24, item 1) and
remove lower knuckle return roller assembly (Figure
24, item 2) on both sides of conveyor, note the position
of the meshing teeth.
Figure 24
Figure 24
A
WARNING
Removing mounting brackets without
support under gearmotor will cause
conveyor to tip, causing severe injury.
PROVIDE SUPPORT UNDERNEATH THE
GEARMOTOR WHEN CHANGING THE BELT
11
2
4
114
3
1
3
2
1
2
1

851-520 Rev. I 13 Dorner Mfg. Corp.
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Preventive Maintenance and Adjustment
6. If equipped, remove screws (Figure 25, item 1) on both
sides of knuckle and remove guard (Figure 25, item 2).
Figure 25
Figure 25
7. Remove screws (Figure 26, item 1) and remove roller
bearing (Figure 26, item 2).
Figure 26
Figure 26
8. Remove belt (Figure 27, item 1) from conveyor.
Figure 27
Figure 27
Belt Installation for Conveyor without
Stands or Gearmotor Mounting Package
1. Orient belt so splice leading fingers (Figure 28, item 1)
point in the direction of belt travel as identified by the
conveyor directional label (Figure 28, item 2).
Figure 28
Figure 28
2. Slide belt onto the conveyor frame assembly.
3. If equipped, install return roller bearing (Figure
29, item 1) into knuckle plate (Figure 29, item 2) using
screws (Figure 29, item 3).
Figure 29
Figure 29
4. Install knuckle guard (Figure 30, item 1) on both sides
of knuckle with screws (Figure 30, item 2). Tighten
screws to 25 in-lb (3 Nm).
Figure 30
Figure 30
1
2
1
2
11
1
2
32
1
2
1

Dorner Mfg. Corp. 14 851-520 Rev. I
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Preventive Maintenance and Adjustment
5. If equipped, install lower knuckle return roller assembly
(Figure 31, item 1) with screws (Figure 31, item 2) on
both sides of knuckle, note the position of the meshing
teeth.
Figure 31
Figure 31
6. Tension belt. Refer to “Conveyor Belt Tensioning” on
page 15.
7. If equipped, install return rollers and guiding.
Belt Installation for Conveyor with Stands
and Gearmotor Mounting Package
1. Ensure temporary support stands (Figure 21, item 1)
are placed at both ends of the conveyor. Place an
additional support stand (Figure 21, item 2) under the
drive motor (Figure 21, item 3), if equipped. See
WAR N ING.
2. Orient belt so splice leading fingers (Figure 28, item 1)
point in the direction of belt travel as identified by the
conveyor directional label (Figure 28, item 2).
3. Install belt (Figure 32, item 1) on conveyor. Lift
conveyor slightly to avoid pinching belt on temporary
support stands.
Figure 32
Figure 32
4. Re-install conveyor mounting brackets. Refer
“Mounting Brackets” on page 9, steps 3 through 5.
5. If equipped, install return roller bearing (Figure
33, item 1) into knuckle plate (Figure 33, item 2) using
screws (Figure 33, item 3).
Figure 33
Figure 33
A
WARNING
Removing mounting brackets without
support under gearmotor will cause
conveyor to tip, causing severe injury.
PROVIDE SUPPORT UNDERNEATH THE
GEARMOTOR WHEN CHANGING THE BELT
1
2
11
32
1

851-520 Rev. I 15 Dorner Mfg. Corp.
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Preventive Maintenance and Adjustment
6. Install knuckle guard (Figure 34, item 1) on both sides
of knuckle with screws (Figure 34, item 2). Tighten
screws to 25 in-lb (3 Nm).
Figure 34
Figure 34
7. If equipped, install lower knuckle return roller assembly
(Figure 35, item 1). To properly align teeth, ensure the
first gear of the pinion plate (Figure 36, item 1)
matches with the first pocket of the rack plate (Figure
36, item 2). Secure with screws (Figure 35, item 2) on
both sides of the conveyor.
Figure 35
Figure 35
Figure 36
Figure 36
8. Tension belt. Refer to “Conveyor Belt Tensioning” on
page 15.
9. If equipped, re-install return rollers and guiding.
Conveyor Belt Tensioning
1. On tension end of the conveyor, identified by the pinion
locking screw (Figure 37, item 1), loosen the two tail
clamp bolts (Figure 37, item 2), on both sides of
conveyor.
Figure 37
Figure 37
2. With 5mm hex wrench, hold pinion torque screw
(Figure 38, item 1). Loosen the pinion locking screw
(Figure 37, item 1) and turn the pinion torque screw
(Figure 38, item 1) to extend head plate assembly.
2
1
1
2
1
2
A
WARNING
Exposed moving parts can cause severe
injury.
LOCK OUT POWER before removing guards
or performing maintenance.
NOTE
Refer to the table provided for maximum
recommended tension pinion torque values
and maximum conveyor loads for different
angles. Choose the appropriate value which
relates to your particular requirements.
1
2

Dorner Mfg. Corp. 16 851-520 Rev. I
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Preventive Maintenance and Adjustment
* Not available on 18” & 24” (457 & 610 mm) width conveyors
Figure 38
Figure 38
Figure 39
Figure 39
3. Extend head plate assembly until proper tension in the
belt is achieved. If proper tensioning can not be obtained
before the belt life indicator is all black (Figure
40, item 1) the belt must be replaced.
Figure 40
Figure 40
4. After adjusting proper tensioning, tighten the pinion
locking screw (Figure 37, item 1) to 69 in−lbs (7.8 N−
m), and tighten tail clamp bolts (Figure 37, item 2) on
both sides of conveyor to 146 in-lb (16.5 N−m).
5. If belt tracking is necessary, refer to “Conveyor Belt
Tracking” on page 17.
Transition Angle
Standard Cleated Belt Sidewall Cleated Belt
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
NOTE
Bowing of the belt (Figure 39, item 1) may
occur if excessive tension is applied to the
belt. Do not over tension the belt.
1
1
NOTE
On pinion gear, do not exceed a torque of 100
in-lb (11.3 Nm). Over tensioning the conveyor
belt could cause excessive pulley bearing
load and early failure.
1

851-520 Rev. I 17 Dorner Mfg. Corp.
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Preventive Maintenance and Adjustment
Conveyor Belt Tracking
V-Guided Belts
V-guides on belts help maintain proper belt tracking. Track
as needed to reduce belt bulge from center of belt (Figure
41). See steps below in “Non V-guided Belts” procedure for
adjusting for any belt bulging. Belt bulge will be minimal
when belt is properly tracked.
Figure 41
Figure 41
Non V-Guided Belts
Non V-guided belt conveyors are equipped with belt tracking
assemblies.
When adjusting belt tracking, always adjust the discharge
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
(Figure 37, item 1) and rotate the pinion torque screw
(Figure 38, item 1) clockwise until contact with the
head plate is made, then tighten the pinion locking
screw (Figure 42, item 1) to 69 in-lb (7.8 Nm)
2. On the side of conveyor to be adjusted, loosen two (2)
tail clamp screws (Figure 42, item 2).
Figure 42
Figure 42
3. With the conveyor running, use wrench (Figure
43, item 1) to rotate the tracking screw (Figure
44, item 1) in small increments until the belt tracks in
the center of the conveyor.
Figure 43
Figure 43
Figure 44
Figure 44
4. Re-tighten the head plate fastening screws (Figure
45, item 1) with a 5 mm hex-key wrench to 100 in-lb
(12 Nm).
Figure 45
Figure 45
1
2
1
1
1

Dorner Mfg. Corp. 18 851-520 Rev. I
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Preventive Maintenance and Adjustment
Conveyor Angle Adjustment
Nose Over Angle Adjustment
1. Conveyor is shipped from factory locked in the flat
position, to unlock conveyor knuckle remove the gold
screw (Figure 46, item 1) on both sides of the conveyor.
Figure 46
Figure 46
2. Place temporary support (Figure 47, item 1) under
conveyor sections.
Figure 47
Figure 47
3. Loosen screws (Figure 48, item 1) on both sides of
knuckle.
Figure 48
Figure 48
A
WARNING
Removing mounting brackets without
support under gearmotor will cause
conveyor to tip, causing severe injury.
PROVIDE SUPPORT UNDERNEATH THE
GEARMOTOR WHEN CHANGING THE BELT
A
WARNING
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
conveyor skip to step 2.
NOTE
.Special-colored “0° Angle” screws must be
removed when making the initial adjustment
from (or to) the (0°) shipping position. When
sections of conveyor are flat, the “0° Angle”
screw locks-out and prevents operation
between 0° and 25°. Special-colored “0°
Angle” screws need only to be loosened,
when making the “transition angle” (see table
on page 16) adjustments. LPZ conveyors
should never be operated with the “0° Angle”
screws removed.
1
1
1

851-520 Rev. I 19 Dorner Mfg. Corp.
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Preventive Maintenance and Adjustment
4. Move conveyor to desired angle as indicated by angle
label (Figure 49, item 1).
Figure 49
Figure 49
5. Tighten screws (Figure 48, item 1) on both sides of
knuckle to 100 in-lbs (12 Nm). If applicable, replace the
gold locking screw (Figure 46, item 1).
Horizontal to Incline Angle Adjustment
1. Conveyor is shipped from factory locked in the flat
position, to unlock conveyor knuckle remove the gold
screw (Figure 46, item 1) on both sides of the conveyor.
2. Place temporary support (Figure 50, item 1) under
conveyor sections.
Figure 50
Figure 50
3. Loosen screws (Figure 51, item 1 and 2) on both sides
of knuckle.
Figure 51
Figure 51
A
WARNING
Removing mounting brackets without
support under gearmotor will cause
conveyor to tip, causing severe injury.
PROVIDE SUPPORT UNDERNEATH THE
GEARMOTOR WHEN CHANGING THE BELT
A
WARNING
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
conveyor skip to step 2.
1
NOTE
Special-colored “0° Angle” screws must be
removed when making the initial adjustment
from (or to) the (0°) shipping position. When
sections of conveyor are flat, the “0° Angle”
screw locks-out and prevents operation
between 0° and 25°. Special-colored “0°
Angle” screws need only to be loosened,
when making the “transition angle” (see table
on page 16) adjustments. LPZ conveyors
should never be operated with the “0° Angle”
screws removed.
1
12

Dorner Mfg. Corp. 20 851-520 Rev. I
3200 Series Cleated and Sidewall Cleated Belt LPZ Conveyors
Preventive Maintenance and Adjustment
4. Move conveyor to desired angle as indicated by angle
label (Figure 52, item 1).
Figure 52
Figure 52
5. Tighten screws (Figure 48, item 1) on both sides of
knuckle to 100 in-lbs (12 Nm).
Pulley Removal
Remove conveyor belt to access pulley(s). See “Conveyor
Belt Replacement” on page 10. Remove the desired pulley
following the corresponding instructions below:
•A−Idler Pulley Removal
•B−Drive Pulley Removal
•C−Upper Knuckle Idler Pulley Removal
•D−Lower Knuckle Idler Pulley Removal
•E−Knuckle Return Roller Removal
A −Idler Pulley Removal
1. Temporarily support the idler pulley.
Figure 53
Figure 53
2. On one side of conveyor, loosen the two (2) back
fastening screws (Figure 54, item 1) and remove two
(2) front fastening screws (Figure 54, item 2).
Figure 54
Figure 54
3. Pull back the outer headplate (Figure 55, item 1) and
remove the inner spacer (Figure 55, item 2).
Figure 55
Figure 55
A
WARNING
Exposed moving parts can cause severe
injury.
LOCK OUT POWER before removing guards
or performing maintenance.
1
12
12