Dorner 6100 Series User manual

851-268 Rev. F
Installation, Maintenance
& Parts Manual
6100 Series Industrial End Drive Conveyors
Table of Contents
Warnings – General Safety 2. . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RequiredTools 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tools 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Installation Sequence 5. . . . . . . . . . . . . .
Conveyors Up to 13 ft (3962 mm) 5. . . . . . . . . . . . . . . . .
Conveyors Longer Than 13 ft (3962 mm) 5. . . . . . . . . . .
Mounting Brackets with Return Rollers 6. . . . . . . . . . . .
Cleated Belt Conveyors 6. . . . . . . . . . . . . . . . . . . . . . .
2¨ to 6¨ (44 mm to 152 mm) Wide
Flat Belt Conveyors 6. . . . . . . . . . . . . . . . . . . . . . . . .
8¨ (203 mm) & Wider Flat Belt Conveyors 7. . . . . . . .
Preventative Maintenance & Adjustment 7. . . . . . . . . . . . . .
Required Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyors with Standard 0.47¨ (12 mm) Diameter
Output Shaft 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor with Optional Gang Drive Pulley 8. . . . . . .
Mounting Brackets with Return Rollers 8. . . . . . . . . .
Maintaining Conveyor Belt 8. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement 9. . . . . . . . . . . . . . . . . . . . .
Conveyor Belt Replacement Sequence 9. . . . . . . . . . .
Belt Removal for Conveyor Without
Gearmotor Mounting Package or Stands 9. . . . . . . . . . .
Belt Removal for Conveyor With Stands
and/or Gearmotor Mounting Package 10. . . . . . . . . . . .
Belt Removal for Conveyor With
Optional Gang Drive Pulley 11. . . . . . . . . . . . . . . . .
Belt Installation for Conveyor Without
Gearmotor Mounting Package or Stands 11. . . . . . . . . .
Belt Installation for Conveyor With Stands
and/or Gearmotor Mounting Package 12. . . . . . . . . . . .
Belt Installation for Conveyor With
Optional Gang Drive Pulley 12. . . . . . . . . . . . . . . . .
Conveyor Belt Tensioning 12. . . . . . . . . . . . . . . . . . . . . .
Pulley Removal 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A – Removal of Drive Pulley with Standard
0.47¨ (12 mm) Diameter Outboard Shaft 13. . . . . . . . .
B – Idler Pulley Removal 13. . . . . . . . . . . . . . . . . . . .
C – Removal of Idler Pulley with Tool-less Belt Release 14
D – Gang Drive Pulley Removal 14. . . . . . . . . . . . . . .
Bearing Replacement for Drive Pulley with
Standard 0.47¨ (12 mm) Diameter Output Shaft
or Idler Pulley 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Removal 15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Installation 15. . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Replacement for a Gang Drive Pulley 16. . . . . .
Bearing Removal 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Installation 17. . . . . . . . . . . . . . . . . . . . . . . . .
Pulley Replacement 18. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Parts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6100 Industrial End Drive Conveyor 20. . . . . . . . . . . . . .
6100 Industrial End Drive Conveyor Extension 20. . . . . .
6100 Gang Drive Through Shaft Option 22. . . . . . . . . . . .
–02 .5” Bolt on High Side 23. . . . . . . . . . . . . . . . . . . . . .
–03 Bolt on Side Wiper 23. . . . . . . . . . . . . . . . . . . . . . . .
–04 3” Bolt on High Side 24. . . . . . . . . . . . . . . . . . . . . .
–05 1.5” Bolt on High Side 25. . . . . . . . . . . . . . . . . . . . .
–13 Fully Adjustable UHMW Guide 26. . . . . . . . . . . . . .
–20 Adjustable Width UHMW Guide 27. . . . . . . . . . . . .
1” Cleated Belt End Drive Conveyor 28. . . . . . . . . . . . . .
2” Cleated Belt End Drive Conveyor 29. . . . . . . . . . . . . .
2” Through 6” Wide Flat Belt Mounting
Bracket with Return Roller 30. . . . . . . . . . . . . . . . . . . . .
8” Through 18” Wide Flat Belt Mounting
Bracket with Return Roller 30. . . . . . . . . . . . . . . . . . . . .
Cleated Belt Mounting Bracket with Return Roller 31. . .
Return Policy 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-268 Rev. F 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
Ç
Climbing, sitting, walking or
riding on conveyor will
cause severe injury.
KEEP OFF CONVEYORS.
DANGER
Ç
Ç
DANGER
DO NOT OPERATE
CONVEYORS IN AN
EXPLOSIVE ENVIRONMENT.
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
Ç
Gearmotors may be HOT.
DO NOT TOUCH Gearmotors.
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
equipment or as part of a
multiple conveyor system,
CHECK FOR POTENTIAL
PINCH POINTS and other
mechanical hazards before
system start-up.
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 with-
out 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 6100 Series conveyors are covered by Patent
Nos. 5174435, 6109427 and corresponding patents and
patent applications in other countries.
Dorner reserves the right to make changes at any time
without notice or obligation.
Warnings – General Safety

6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 3851-268 Rev. F
Refer to Figure 1 for typical conveyor components.
A Conveyor
B Gearmotor Mounting Package
C Gearmotor
D Guiding & Accessories
E Mounting Brackets with Return Rollers
F Support Stands
G Variable Speed Controller
H Drive End
I Idler/Tension End
Typical Components
A
BC
E
F
G
H
I
F
Figure 1
E
D
Specifications
Models:
Flat Belt 6100 Series Industrial Conveyor
6 WW LL
Conveyor Width Reference
Conveyor Length Reference
Belt Type*
A 01 / 02
Mount Position (–, A, or D)
Conveyor Profile*
1= Standard or G=Gang Drive
100 M Cleated Belt 6100 Series Industrial Conveyor
6140 M WW LL A XXXX
Conveyor Width Reference
Conveyor Length Reference
A
Cleat Type*
Mount Position (A or D)
Cleat Spacing
* See “Ordering and Specifications”Catalog for details.
Conveyor Supports:
Maximum Distances:
J = 18¨(457 mm)**
K= 6 ft (1829 mm)***
L= 18¨(457 mm)
** For Heavy Load Bottom Mount Package, mount
support under gear head.
*** For conveyors longer than 13 ft (3962 mm), install
support at joint.
Figure 2
KJ L
Product Description

6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-268 Rev. F 4Dorner Mfg. Corp.
Specifications:
Conveyor Width
Reference (WW) 02 03 04 05 06 08 10 12 18
Conveyor Belt Width 1.75¨
(44 mm) 2.75¨ (70 mm) 3.75¨ (95 mm) 5¨ (127 mm) 6¨ (152 mm) 8¨ (203 mm) 10¨ (254 mm) 12¨ (305 mm) 18¨ (457 mm)
Maximum Conveyor Load*
(See NOTE Below) 30 lb (14 kg) 35 lb (16 kg) 42 lb (19 kg) 50 lb (23 kg) 60 lb (27 kg) 70 lb (32 kg) 80 lb (36 kg) 80 lb (36 kg) 80 lb (36 kg)
Conveyor Start-up Torque* 4 in-lb
(0.5 Nm) 5 in-lb (0.6 Nm) 6 in-lb (0.7 Nm) 7 in-lb (0.8 Nm) 8 in-lb (0.9 Nm) 10 in-lb (1.1 Nm) 12 in-lb (1.4 Nm) 14 in-lb (1.5 Nm) 15 in-lb (1.7 Nm)
Belt Travel 3.5¨(88 mm) per revolution of pulley
Maximum Belt Speed* 235 feet/minute (72 meters/minute)
Belt Take-up 0.38¨ (10 mm) of stroke = 0.75¨(19 mm) of belt take-up
Conveyor Length
Reference (LL) 02 03 04 05 06 07 08 09 10 11 12 13** 14** 15** 16** 17** 18**
Conveyor Length
2-ft (610 mm) 3-ft (914 mm)
4-ft (1219 mm) 5-ft (1524 mm) 6-ft (1829 mm) 7-ft (2134 mm) 8-ft (2438 mm) 9-ft (2743 mm)
10-ft (3048 mm) 11-ft (3353 mm) 12-ft (3658 mm)
13-ft (3962 mm)** 14-ft (4267 mm)** 15-ft (4572 mm)** 16-ft (4877 mm)** 17-ft (5182 mm)** 18-ft (5486 mm)**
NOTE: Maximum conveyor loads based on:
DNon-accumulating product
DProduct moving towards gearmotor
DConveyor being mounted horizontal
* See “Ordering and Specifications”Catalog for details.
** Lengths available only in 6¨(152 mm) & wider convey-
ors.
Installation
NOTE: Conveyor MUST be mounted straight, flat
and level within confines of conveyor. Use a level (M
of Figure 3) for set-up.
Figure 3
M
M Level
N Conveyor frame without belt
O M6 x 10 mm Low Head Socket Head Screws (6x)
(shipped loose)
P Connector Strips (2x) (Attached to conveyor sec-
tion)
Q Conveyor frame with belt
R M6 x 12 mm Socket Head Screws (4x)
S M6 x 18 mm Socket Head Screw & Hard Washer
Assemblies (4x)
Illustration References
Specifications

6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 5851-268 Rev. F
Required Tools
Standard Tools
DHex key wrenches
–4 mm
–5 mm
DLevel
DTorque wrench
Recommended Installation Sequence (see
Table of Contents for page number)
DAssemble conveyor (if required)
DAttach mounting bracket(s) with return roller to
conveyor (see page 6)
DInstall stands (see accessory instructions)
DAttach conveyor to stands
DMount gearmotor mounting package (see accessory
instructions)
DAttach guides/accessories (see “Service Parts”sec-
tion, pages 20 through NO TAG)
Conveyors Up to 13 ft (3962 mm)
No additional assembly is required.
Conveyors Longer Than 13 ft (3962 mm)
1.Typical components (Figure 4)
Figure 4
O
PQ
N
2.Compress tension end (Figure 5). Refer to steps 3,
4 & 5 under the “Belt Removal for Conveyor
Without Gearmotor Mounting Package or Stands”
on page 9.
Figure 5
3.Roll out conveyor belt.
4.Place conveyor frame (N Figure 6) into belt loop.
Figure 6
N
5.Join conveyor sections (N and Q of Figure 7). Install
screws (O) on both sides. Tighten to 60 in-lb (7 Nm).
Figure 7
O
N
Q
6.Tension conveyor belt. Refer to “Conveyor Belt
Tensioning”on page 12.
Installation

6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-268 Rev. F 6Dorner Mfg. Corp.
Mounting Brackets with Return Rollers
Cleated Belt Conveyors
1.Typical components (Figure 8)
Figure 8
2.Loosen screws (R of Figure 9) and remove screws
and washers (S).
Figure 9
RS
3.Attach clamp plates on each side of conveyor (Figure
10). Tighten the screws (R) to 80 in-lb (9 Nm).
Figure 10
S
R
4.Attach to support stand. Tighten screws (S) to 80
in-lb (9 Nm). Make sure belt is free to move.
2¨to 6¨(44 mm to 152 mm) Wide Flat Belt
Conveyors
1.Typical components (Figure 11)
Figure 11
2.Loosen screws (R of Figure 12) and remove screws
and washers (S).
Figure 12
R
S
3.Attach clamp plates on each side of conveyor (Figure
13). Tighten the screws (R) to 80 in-lb (9 Nm).
Figure 13
R
S
4.Attach to support stand. Tighten screws (S) to 80
in-lb (9 Nm). Make sure belt is free to move.
Installation

6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 7851-268 Rev. F
8¨(203 mm) & Wider Flat Belt Conveyors
1.Typical components (Figure 14)
Figure 14
2.Loosen screws (R of Figure 15) and remove screws
and washers (S).
Figure 15
R
S
3.Attach clamp plates on each side of conveyor (Figure
16). Tighten the screws (R) to 80 in-lb (9 Nm).
Figure 16
RS
4.Attach to support stand. Tighten screws (S) to 80
in-lb (9 Nm). Make sure belt is free to move.
Preventative Maintenance & Adjustment
Required Tools
Standard Tools
DHex key wrenches
–2 mm
–4 mm
–2.5 mm
–5 mm
–3 mm
–6 mm
DManual grease gun
DAdjustable wrench
DArbor press
Special Tools
D807-1043 Narrow-headed 11/16¨Wrench (supplied
with conveyor)
D450281 Sealed Bearing Removal Tool
D450282 Sealed Bearing Installation Tool
D2500M Tool Kit for Gang Drive Bearings
Checklist
DKeep service parts on hand (see “Service Parts”sec-
tion for recommendations)
DKeep supply of belt cleaner (part # 625619)
DFor optional gang-driven conveyors, keep supply of
bearing grease [for 14 oz (397 gram) cartridge (part #
829-002)or for 14 oz (397 gram) can(part # 829-003)]
DClean entire conveyor and knurled pulley while dis-
assembled
DReplace worn or damaged parts
Installation

6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-268 Rev. F 8Dorner Mfg. Corp.
Lubrication
Conveyor with Standard 0.47¨(12 mm)
Diameter Output Shaft
No lubrication is required. Replace bearings if worn.
Conveyor with Optional Gang Drive Pulley
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
DOnly drive pulley bearings require lubrication. See
steps that follow. All other bearings, replace if worn.
1.Disassemble the support (T of Figure 17) and
remove the hex shaft and shaft guard sections (U).
Figure 17
T
U
NOTE: Optional permanent grease fittings (part #
200398M) may be installed.
2.Install Dorner greasing adapter (part # 200046M) (V
of Figure 18). Make sure the adapter shoulder is
seated against the conveyor tail plate.
Figure 18
V
3.Use Dorner red grease, 14 oz (397 gram) cartridge
(part #829-002) or 14 oz (397 gram) can (part #
829-003). Lubricate pulley bearing every 750 hours
or more frequently, depending on operating condi-
tions.
NOTE: Lubricate pulley bearing every 750 hours or
more frequently, depending on operating condi-
tions. When lubricating pulley bearings, use a con-
ventional hand grease gun with a maximum of one
pump per application. Do not over-lubricate. Do not
use a power grease gun.
4.Grease bearing with one (1) pump from a manual
grease gun. Do not over-lubricate.
5.Remove grease adapter and install on opposite side
of pulley. Repeat steps 2 and 4.
6.Re-assemble hex shaft with guards and support (T of
Figure 17).
Mounting Brackets with Return Rollers
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 wiper(s)
DAccumulated dirt in wiper(s)
DForeign material inside the conveyor
DImproperly positioned accessories
DBolt-on guiding is pinching belt
Preventive Maintenance and Adjustment

6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 9851-268 Rev. F
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 con-
tain 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 (see
Table of Contents for page number)
DRemove old conveyor belt
- Conveyor without Gearmotor Mounting Package
or Stands
- Conveyor with Stands and/or Gearmotor
Mounting Package
- Conveyor with Optional Gang Drive Pulley
DInstall new conveyor belt
DTension conveyor belt
Belt Removal for Conveyor Without
Gearmotor Mounting Package or Stands
1.For a flat belt conveyor, remove and retain the
bottom wiper(s) (W of Figure 19).
Figure 19
W
2.If conveyor is equipped with guiding and accesso-
ries, remove them from one side.
NOTE: If conveyor is equipped with optional
Tool-less Belt Release, sequence is the same and no
tools are required.
3.On tension end of the conveyor identified with a
label (X Figures 20 & 21), insert a 5 mm hex
key wrench to engage pinion gear (Yof Figure 20).
Figure 20
XY
4.With pinion gear engaged, insert a 4 mm hex key
wrench into lock screw (Z of Figure 21).
Figure 21
X
Z
Preventive Maintenance and Adjustment

6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-268 Rev. F 10 Dorner Mfg. Corp.
5.While maintaining tension on pinion gear (Y of
Figure 22) loosen lock screw (Z). Rotate pinion gear
(Y) clockwise to release conveyor belt tension.
Figure 22
Z
Y
6.Remove conveyor belt.
Belt Removal for Conveyor With Stands
and/or Gearmotor Mounting Package
NOTE: For conveyor with a Heavy Load Bottom or
Top Mount Package, bracket (AB of Figure 23) must
be removed.
DRemove two (2) M6 x 16 mm socket head
screws (AA).
DRemove two (2) M6 x 12 mm socket head
screws (AC).
DRemove bracket (AB).
Figure 23
AA
AB
AC
1.For a flat belt conveyor, remove and retain the bottom
wiper(s) (W of Figure 19).
2.If conveyor is equipped with guiding and accesso-
ries, remove them from one side.
NOTE: If conveyor is equipped with optional
Tool-less Belt Release, sequence is the same and no
tools are required.
3.On tension end of the conveyor identified with a
label (X Figures 20 & 21), insert a 5 mm hex
key wrench to engage pinion gear (Yof Figure 20).
4.With pinion gear engaged, insert a 4 mm hex key
wrench into lock screw (Z of Figure 21).
5.While maintaining tension on pinion gear (Y of
Figure 22) loosen lock screw (Z). Rotate pinion gear
(Y) clockwise to release conveyor belt tension.
Ç
ÇÇ
The weight of the gearmotor is all on one end of the
conveyor which could cause it to tip off the stands
when the mounting clamp plates are loosened. Be
sure to provide support (AD of Figure 24)
underneath the gearmotor while changing the belt.
6.Temporarily support conveyor at gearmotor mount-
ing package (AD of Figure 24).
Figure 24
R
AD
NOTE: To remove belt, complete steps 7 & 8, at
each stand location.
Preventive Maintenance and Adjustment

6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 11 851-268 Rev. F
Ç
Ç
To prevent injury from the support stand
tipping-over when conveyor is uncoupled, anchor
stand to floor or otherwise stabilize the stand.
7.Loosen the mounting clamp plates (R of Figures 24
and 25), on both sides of the conveyor. Raise the
conveyor and remove the belt.
Figure 25
R
8.With belt removed, secure conveyor with clamp
plates (R).
Belt Removal for Conveyor With Optional
Gang Drive Pulley
1.Disassemble support (T of Figure 17) and remove the
hex shaft and shaft guard sections (U).
2.Remove and retain the bottom wiper(s) (W of Figure
19).
3.If conveyor is equipped with guiding and accesso-
ries, remove them from one side.
NOTE: If conveyor is equipped with optional
Tool-less Belt Release, sequence is the same and no
tools are required.
4.On tension end of the conveyor identified with a
label (X Figures 20 & 21), insert a 5 mm hex
key wrench to engage pinion gear (Yof Figure 20).
5.With pinion gear engaged, insert a 4 mm hex key
wrench into lock screw (Z of Figure 21).
6.While maintaining tension on pinion gear (Y of
Figure 22) loosen lock screw (Z). Rotate pinion gear
(Y) clockwise to release conveyor belt tension.
7.Remove conveyor belt.
Belt Installation for Conveyor without
Gearmotor Mounting Package or Stands
IMPORTANT: On a flat belt conveyor, the wiper is
installed on discharge end. Belt travel direction is
identified by an arrow decal on the side of the con-
veyor (AE of Figure 26). With a reversing gearmotor,
a second bottom wiper must be installed on oppo-
site end.
AE
Figure 26
1.Orient the conveyor belt so that the splice leading
fingers (AF of Figure 27) point in the direction of
belt travel (AG) as identified by the label (AE of Fig-
ure 26).
Figure 27
AF
AG
2.Slide belt onto the conveyor frame assembly.
3.On a flat belt conveyor, install bottom wiper(s) (W of
Figure 19). Center set screws in frame and tighten to
33 in-lb (3.7 Nm).
4.Tension belt. Refer to “Conveyor Belt Tensioning”on
page 12.
5.Where applicable, replace guiding.
Preventive Maintenance and Adjustment

6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-268 Rev. F 12 Dorner Mfg. Corp.
Belt Installation for Conveyor with Gearmotor
Mounting Package and/or Stands
1.Orient the conveyor belt so that the splice leading
fingers (AF of Figure 27) point in the direction of
belt travel (AG) as identified by the label (AE of Fig-
ure 26).
NOTE: To install belt, complete steps 2, 3 & 4, at
each stand location.
2.Loosen the mounting clamp plates (R of Figures 24
and 25), on both sides of the conveyor. Raise the
conveyor and replace the belt.
3.Lower the conveyor onto the mounting blocks being
careful not to pinch belt.
4.Tighten clamp plates screws (R) to 80 in-lb (9 Nm).
5.On a flat belt conveyor, install bottom wiper(s) (W of
Figure 19). Center set screws in frame and tighten to
33 in-lb (3.7 Nm).
6.For a conveyor with a Heavy Load Bottom or Top
Mounting package, re-install bracket(AB of Figure
23).
7.Tension belt. Refer to “Conveyor Belt Tensioning”on
page 12.
8.Where applicable, replace guiding.
Belt Installation for Conveyor With Optional
Gang Drive Pulley
1.Orient the conveyor belt so that the splice leading
fingers (AF of Figure 27) point in the direction of
belt travel (AG) as identified by the label (AE of Fig-
ure 26).
2.Slide belt onto the conveyor frame assembly.
3.On a flat belt conveyor, install bottom wiper(s) (W of
Figure 19). Center set screws in frame and tighten to
33 in-lb (3.7 Nm).
4.Tension belt. Refer to “Conveyor Belt Tensioning”on
page 12.
5.Where applicable, replace guiding.
6.Re-assemble hex shaft with guards sections (U of
Figure 17). Re-assemble support (T).
Conveyor Belt Tensioning
Ç
Exposed moving parts can
cause severe injury.
LOCK OUT POWER before
removing guards or
performing maintenance.
NOTE: If conveyor is equipped with optional
Tool-less Belt Release, sequence is the same and no
tools are required.
1.On tension end of the conveyor identified with a
label (X Figures 20 & 21), insert a 5 mm hex
key wrench to engage pinion gear (Yof Figure 20).
2.With pinion gear engaged, insert a 4 mm hex key
wrench into lock screw (Z of Figure 22).
NOTE: On pinion gear (Yof Figure 20), do not ex-
ceed a torque of 25 in-lb (2.8 Nm) for 2¨to 12¨(44 mm
to 305 mm) wide conveyors and 40 in-lb (4.5 Nm) for
an 18¨(457 mm) wide conveyor . Over-tensioning the
conveyor belt could cause excessive pulley bearing
load and early failure.
3.Loosen lock screw (Z of Figure 22).
4a. For existing belt:
With V-guide seated in pulley, rotate the pinion gear
(Y) counter-clockwise to sufficiently tension the belt
to handle the conveyor load.
NOTE: If the maximum take-up stroke is achieved,
replace the conveyor belt.
4b. For a new belt:
With V-guide seated in pulley, rotate the pinion gear
(Y) counter-clockwise to a distance of 1¨(25 mm)
(AH of Figure 28).
Figure 28
AH
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6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 13 851-268 Rev. F
5. Secure lock screw (Z of Figure 22) to 40 in-lb (4.5
Nm).
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 9. Remove the desired
pulley following instructions:
DA–Drive Pulley with Standard 0.47¨(12 mm) Diam-
eter Output Shaft
DB–Idler Pulley
DC–Idler Pulley with Tool-less Belt Release
DD–Gang Drive Pulley
A–Removal of Drive Pulley with Standard
0.47¨(12 mm) Diameter Output Shaft
Ç
Drive shaft keyway may be
sharp.
HANDLE WITH CARE.
1.Remove the gearmotor mounting package. See
accessory instructions.
2.For 10¨(254 mm), 12¨(305 mm) or 18¨(457 mm)
wide conveyors, use the narrow-headed 11/16¨
wrench (part # 808-1043) (AJ of Figure 29) to
remove the outboard bearing (AK).
3.Remove screw (AI).
Figure 29
AJ
AK
AI
NOTE: With a Heavy Load Mount Package, two (2)
screws (AA of Figure 23) were removed in step 1.
4.Remove three (3) screws (AL of Figure 30) on the
side opposite the drive shaft.
Figure 30
AL
5.Remove the drive tail assembly.
6.Remove screw (AM of Figure 31).
7.Remove headplate (AN).
8.Remove pulley (AO).
Figure 31
AM
AO
AN
B–Idler Pulley Removal
1.Remove screw (Z of Figure 32).
2.Remove four (4) tail plate mounting screws (AP of
Figures 32 & 33).
Figure 32
AP
Z
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6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-268 Rev. F 14 Dorner Mfg. Corp.
Figure 33
AP
3.Remove tail assembly (AQ of Figure 34).
Figure 34
AQ
4.Locate magnet (AR of Figure 35). Remove screw
(AM).
Figure 35
AM
AR AS
AT
5.Remove headplate (AS).
6.Remove pulley (AT).
C–Removal of Idler Pulley with Tool-less Belt
Release
1.Remove handle(AU of Figure 36).
Figure 36
AP
AU
2.Remove two (2) screws (AP of Figure 36).
3.Remove two (2) screws (AP of Figure 37). Remove
handle assembly (AV).
Figure 37
AP
AV
AQ
4.Remove tail assembly (AQ).
5.Locate magnet (AR of Figure 35). Remove screw
(AM).
6.Remove headplate (AS).
7.Remove pulley (AT).
D–Gang Drive Pulley Removal
1.Remove the two (2) screws (AW of Figure 38).
Figure 38
AW
AW
AX
AY
AZ
AX
AY
BA
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6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 15 851-268 Rev. F
2.Remove two clips (AX).
3.Install bolt (part # 906-278k) (BA of Figure 38) into
bearing sleeve(s) (AY). Remove bearing sleeve(s)
(AY).
NOTE: If retaining sleeve (AY of Figure 38) does not
slide out:
DRemove tail following steps 3, 4 & 5 of Removal
of Drive Pulley with Standard 0.47¨(12 mm)
Diameter Output Shaft on page 13
DAssemble pulley (AZ of Figure 39), removal tool
(part # 25-09k) (BB), and bolt (part # 906-278k)
(BA), as shown
DTighten bolt (BA) to remove bearing sleeve (AY)
Figure 39
AZ
BB BA
Bearing Replacement for Drive Pulley with
Standard 0.47¨(12 mm) Diameter Output Shaft
or Idler Pulley
IMPORTANT: Once removed, do not re-use
bearings.
Bearing Removal
1.Place bearing removal tool (part # 450281) over
bearing(s) with lip (BD of Figure 40) located in
Bearing gap (BE) as shown.
Figure 40
BD
BE
2.Using 3/16¨hex key wrench (BC of Figure 41),
tighten tool.
Figure 41
BC
3.Using a puller (BF of Figure 42), remove and discard
bearing(s).
Figure 42
BF
Bearing Installation
IMPORTANT: Install bearings one at a time.
1.Inspect seating surface(s) for damage. Replace if
damaged.
2.Slide bearing (part # 802-121) (BG of Figure 43) onto
pulley shaft.
Figure 43
BG
k- Part of Tool Kit, part # 2500M.
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6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-268 Rev. F 16 Dorner Mfg. Corp.
3.Slide the sleeve of tool (part # 450282) (BH of Figure
44) over bearing.
Figure 44
BH
4.Place open end of shaft (BI of Figure 45) into sleeve.
Figure 45
BI
5.Using arbor press or similar device, press bearing onto
pulley shaft (see Figure 46).
Figure 46
6.Repeat steps 1 through 5 for each bearing.
Bearing Replacement for Gang Drive Pulley
IMPORTANT: Once removed, do not re-use
bearings.
Bearing Removal
NOTE:The bearings of a 2¨(44 mm) wide gang drive
pulley cannot be replaced. Order pulley assembly
(part # 454702).
1.Insert bearing removal tool (part # 25-05k) (BK of
Figure 47) into the pulley (BN) until shoulder (BJ) seats
against bottom of bearing (BO).
Figure 47
BJ
BL
BM
BN
BO
BK
2.While holding bearing removal tool (BK) in posi-
tion, insert extension tool (part # 25-08k) (BL) into
opposite end of pulley (BN). Rotate bearing removal
tool (BK) to engage hex tip of extension tool (BL)
into screw (BM).
3.While maintaining extension tool (BL) position, use
a wrench to rotate bearing removal tool (BK) to
expand flare.
Figure 48
BL
BK
4.Orient bearing anvil/sleeve removal tool (part #
25-09k) (BP of Figure 49) with cavity facing up and
place pulley onto tool.
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6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 17 851-268 Rev. F
Figure 49
BP
NOTE:If a severely worn bearing breaks apart dur-
ing removal, pulley must be replaced.
5.Press bearing out of pulley.
Figure 50
BL
Bearing Installation
1.Orient bearing anvil/sleeve removal tool (part #
25-09k) (BP of Figure 51) with cavity facing up and
place pulley (BN) onto tool.
Figure 51
BP
BN
2.Install bearing insertion tool (part # 25-10k) (BQ of
Figure 52) into arbor press or similar device.
BQ
Figure 52
3.Place and hold bearing (part # 21-33) (BO) onto tool
(BQ).
Figure 53
BO
k- Part of Tool Kit, part # 2500M.
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6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-268 Rev. F 18 Dorner Mfg. Corp.
IMPORTANT: Bearing and pulley alignment is
critical.
4.Press bearing (BO of Figure 54) into pulley (BN)
until seated.
Figure 54
BO
BN
Pulley Replacement
Drive Pulley with Standard 0.47¨(12 mm)
Diameter Output Shaft Replacement
1.Reverse the removal procedure “A”(see page 13).
Idler Pulley Replacement
IMPORTANT: On a tension tail assembly, orient
both pinion housings (BR of Figure 55) so they
engage the same tooth positions on their respective
racks.
Figure 55
BR
1.Reverse the removal procedure “B”(see page 13).
Idler Pulley with Tool-less Belt Release
Replacement
IMPORTANT: On a tension tail assembly, orient
both pinion housings (BR of Figure 55) so they
engage the same tooth positions on their respective
racks.
1.Reverse the removal procedure “C”(see page 14).
Gang Drive Pulley Replacement
1.Reverse the removal procedure “D”(see page 14).
Preventive Maintenance and Adjustment

6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
Dorner Mfg. Corp. 19 851-268 Rev. F
Notes

6100 Series Industrial End Drive Conveyors Installation, Maintenance & Parts Manual
851-268 Rev. F 20 Dorner Mfg. Corp.
NOTE: For replacement parts other than those shown in this section, contact an authorized Dorner Service
Center or the factory.
6100 Industrial End Drive Conveyor
2
7
4
21
18
10
9
17
19
5
8
1
3
6
12
11
15
13
17
16
23
24 12
22
22
6100 Industrial End
Drive Conveyor
Extension
20
14
Item Part Number Description
1 450231M Plate Tension RH 2–3”Wide
450031M Plate Tension RH 4–18”Wide
2 450232M Plate Tension LH 2–3”Wide
450032M Plate Tension LH 4–18”Wide
3 450233M Plate Fixed RH 2–3”Wide
450355M Plate Fixed RH 4–18”Wide
4 450234M Plate Fixed LH 2–3”Wide
450356M Plate Fixed LH 4–18”Wide
5 450039M Block Retainer Pinion
6 452502M Post Support Frame 2”(51mm)
452503M Post Support Frame 3”(76mm)
452504M Post Support Frame 4”(102mm)
452505M Post Support Frame 5”(127mm)
452506M Post Support Frame 6”(152mm)
452508M Post Support Frame 8”(203mm)
452510M Post Support Frame 10”(254mm)
452512M Post Support Frame 12”(305mm)
452518M Post Support Frame 18”(457mm)
7 452602M Pinion 2”(51mm)
452603M Pinion 3”(76mm)
452604M Pinion 4”(102mm)
Service Parts