Set-up, Operation

& Maintenance Manual

2100 Series Center Drive Conveyors

Table of Contents
Warnings – General Safety . . . . . . . . . . . . . . . . . . . . 2 Conveyor Belt Replacement . . . . . . . . . . . . . . . . . 8
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Conveyor Belt Replacement Sequence . . . . . . . 8
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Belt Removal for Conveyor Without
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Gearmotor Mounting Package or Stands . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Belt Removal for Conveyor With Stands
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 and/or Gearmotor Mounting Package . . . . . . . . . 9
Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Center Drive Module Removal . . . . . . . . . . . . 11
Recommended Installation Sequence . . . . . . . . . . 5 Belt Removal from Center Drive Module . . . . . 11
Conveyors Up to 3962 mm . . . . . . . . . . . . . . . . . . 5 Installing a New Conveyor Belt . . . . . . . . . . . . . 12
Conveyors Longer Than 3962 mm . . . . . . . . . . . . 5 Conveyor Belt Tensioning . . . . . . . . . . . . . . . . . . 14
Mounting Brackets with Return Rollers . . . . . . . . 6 Pulley Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 14
44 mm to 152 mm Wide A – End Pulley Removal . . . . . . . . . . . . . . . . . 14
Flat Belt Conveyors . . . . . . . . . . . . . . . . . . . . . . 6 B – Drive Pulley Removal . . . . . . . . . . . . . . . . . 15
Preventative Maintenance & Adjustment . . . . . . . . . 7 C – Idler Pulley Removal . . . . . . . . . . . . . . . . . 15
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bearing Replacement End Pulleys . . . . . . . . . . . . 16
Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . 16
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bearing Installation . . . . . . . . . . . . . . . . . . . . . 17
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bearing Replacement for Drive Pulley . . . . . . . . 18
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . 18
End Pulley Bearings . . . . . . . . . . . . . . . . . . . . . . 7 Bearing Installation . . . . . . . . . . . . . . . . . . . . . 18
Drive Module Idler Pulley Bearings . . . . . . . . . 7 Bearing Replacement for Idler Pulleys . . . . . . . . 18
Drive Module Drive Pulley Bearings . . . . . . . . 7 Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . 18
Mounting Brackets with Return Rollers . . . . . . 7 Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintaining Conveyor Belt . . . . . . . . . . . . . . . . . . 8 Pulleys & Bearings . . . . . . . . . . . . . . . . . . . . . . . 19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 8 Configuring Conveyor Belt Part Number . . . . . . 20
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Return Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

851-179 Rev. C
Warnings – General Safety

WARNING
ÇÇ Ç
The safety alert symbol, black triangle with white
ÇÇ WARNING
Gearmotors may be HOT.
exclamation, is used to alert you to potential
personal injury hazards. DO NOT TOUCH Gearmotors.

ÇÇ WARNING
Dorner cannot control the
DANGER
ÇÇ
Climbing, sitting, walking or
physical installation and
application of conveyors.
Taking protective measures
riding on conveyor will is the responsibility of the
cause severe injury. user.
KEEP OFF CONVEYORS. When conveyors are used in
conjunction with other equip-
ment or as part of a multiple
conveyor system, CHECK
FOR POTENTIAL PINCH
DANGER
ÇÇ
POINTS and other mechani-
cal hazards before system
start-up.
DO NOT OPERATE
CONVEYORS IN AN
EXPLOSIVE ENVIRONMENT.
ÇÇ WARNING
Loosening stand height or
angle adjustment screws
may cause conveyor

ÇÇ WARNING
Exposed moving parts can
sections to drop down,
causing severe injury.
SUPPORT CONVEYOR
cause severe injury.
SECTIONS PRIOR TO
LOCK OUT POWER before LOOSENING STAND HEIGHT
removing guards or OR ANGLE ADJUSTMENT
performing maintenance. SCREWS.

Introduction
Dorner’s Limited Warranty applies.
IMPORTANT: Some illustrations may show guards Dorner 2100 Series conveyors are covered by Patent
removed. Do NOT operate equipment without guards. No. 5,174,435, 5,131,529 and corresponding patents
and patent applications in other countries.
Upon receipt of shipment:
Dorner reserves the right to make changes at any time
D Compare shipment with packing slip. Contact factory without notice or obligation.
regarding discrepancies.
D Inspect packages for shipping damage. Contact carrier
regarding damage.
D Accessories may be shipped loose. See accessory in-
structions for installation.

2100 Series Center Drive Conveyors Set-up, Operation & Maintenance Manual
851-179 Rev. C 2 Dorner Mfg. Corp.
 Product Description
Refer to Figure 1 for typical conveyor components. A B C D E

Typical Components
A Conveyor J
I
B Center Drive Module
F
C Gearmotor Mounting Package F
D Guiding & Accessories
E Gearmotor
F Mounting Brackets with Return Rollers H
G Support Stands
G
H Variable Speed Controller G
I Fixed End
J Tension End

Figure 1

Specifications
Models:
2100 Series Center Drive Conveyor
2150 M WW LL A 01 / 02
Belt Type*
Conveyor Profile*
Mount Position (A or D)*
Conveyor Length Reference
Conveyor Width Reference

* See “Ordering and Specifications” Catalog for details.

Conveyor Supports: K L K
Maximum Distances:
K = 457 mm
L = 1829 mm**
** For conveyors longer than 3962 mm, install
support at joint.

Figure 2

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Specifications
Specifications:
Conveyor Width
02 03 04 05 06 08 10 12
Reference (WW)
Conveyor Belt Width 44 mm 70 mm 95 mm 127 mm 152 mm 203 mm 254 mm 305 mm
Maximum Conveyor Load*
18 kg 23 kg 27 kg 34 kg 41 kg 47 kg 54 kg 54 kg
(See NOTE Below)
Conveyor Start-up Torque* 1.0 Nm 1.1 Nm 1.2 Nm 1.4 Nm 1.7 Nm 2.3 Nm 2.6 Nm 2.8 Nm
Belt Travel 88 mm per revolution of pulley
Maximum Belt Speed* 72 meters/minute
Belt Take-up 25 mm of stroke = 51 mm of belt take-up

Conveyor Length
02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Reference (LL)
Conveyor Length
1219 mm

1524 mm

1829 mm

2134 mm

2438 mm

2743 mm

3048 mm

3353 mm

3658 mm

3962 mm

4267 mm

4572 mm

4877 mm

5182 mm

5486 mm

5791 mm

6096 mm

6401 mm

6706 mm

7010 mm

7315 mm
610 mm

914 mm

* See “Ordering and Specifications” Catalog for details.

NOTE: Maximum conveyor loads based on:
D Non-accumulating product
D Product moving towards gearmotor
D Conveyor being mounted horizontal

Installation

Installation Component List

NOTE: Conveyor MUST be mounted straight, flat and N Conveyor frame without belt
level within confines of conveyor. Use a level (M of
O Conveyor frame with belt
Figure 3) for set-up.
P Connector Strips (2x) (Attached to conveyor section)
Q Mounting bracket with return roller
Z Roller guards (2x)
AA Mounting bracket end block (2x)
M

Figure 3

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851-179 Rev. C 4 Dorner Mfg. Corp.
 Installation
Required Tools 3. Slide the cam assemblies toward the center of the
Standard Tools conveyor and push the end (U of Figure 5) into the
conveyor frame.
D Hex key wrenches
– 4 mm 4. Roll out conveyor belt.
– 5 mm 5. Place conveyor frame (N of Figure 6) into belt loop.
D Level
V
D Torque wrench

Recommended Installation Sequence

N W
NOTE: See Table of Contents for beginning page
numbers of following procedures. Figure 6

6. Loosen connector strip screws (V) and mounting

D Assemble conveyor (if required) bracket screws (W) on both sides of the conveyor.
D Attach mounting bracket(s) with return roller to
7. Join conveyor sections (N and O of Figure 7).
conveyor
Position mounting bracket (P and Q) across convey-
D Install stands (see accessory instructions) or sections.
D Attach conveyor to stands
D Mount gearmotor mounting package (see accessory V
instructions)
D Attach guides/accessories (see accessory instructions)

Conveyors Up to 3962 mm P O
No additional assembly is required. N Q W
Figure 7
Conveyors Longer Than 3962 mm
1. Typical components (Figure 4) 8. Tighten connector strip screws (V) to 2 Nm. Tighten
bracket screws (W) to 9 Nm.
N
9. Insert a 5 mm hex key wrench into either end of the
pinion gear (X of Figure 8). Rotate the pinion gear to
extend the tensioning end gap (Y) to 30 mm.

P O
Q
Figure 4

2. On tension end of the conveyor, identified with

label (R of Figure 5), loosen tracking cam
assemblies (S) and cover plate screws (T) on both
sides of the conveyor.
T Y
U
X
T

Figure 8
S
R
10. While holding the pinion gear (X), tighten cover plate
Figure 5 screws (T) to 2 Nm.

2100 Series Center Drive Conveyors Set-up, Operation & Maintenance Manual
Dorner Mfg. Corp. 5 851-179 Rev. C
Installation
Mounting Brackets with Return Rollers 2. Loosen screws (AC of Figure 10) and remove screws
44 mm to 305 mm Wide Flat Belt Conveyors and washers (AD).
1. Typical components (Figure 9). Roller guards (Z) are AD AC
shipped fastened to one end block (AA). Do NOT
fasten to other block.
AC
AA
Z

AD

Figure 10
3. Attach clamp plates on each side of conveyor (Figure
11). Tighten the screws (AC) to 9 Nm.

AC

Figure 9

AC
AD
AD

Figure 11
4. Attach to support stand. Tighten screws (AD) to
9 Nm. Make sure belt is free to move.

2100 Series Center Drive Conveyors Set-up, Operation & Maintenance Manual
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 Preventive Maintenance and Adjustment
Required Tools
Standard Tools
D Hex key wrenches
– 2 mm – 2.5 mm – 3 mm
– 4 mm – 5 mm – 6 mm AE
AF
D Small flat blade screwdriver
Figure 12
D Adjustable wrench
D Arbor press 2. Install Dorner greasing adapter (AG of Figure 13),
part number 200046M. Make sure the adapter
Special Tools shoulder is seated against the conveyor tail plate.
D 2500M–ENG, 2100 Tool Kit
D 450282, Sealed Bearing Installation Tool

Checklist
D Keep service parts on hand. (See “Service Parts” for
recommendations.) AG
D Keep supply of belt cleaner (part number 625619)
D Clean entire conveyor and knurled pulley while dis-
assembled
D Replace worn or damaged parts Figure 13

Lubrication 3. Use Dorner red grease, 397 gram cartridge (part #

829-002) or 397 gram can (part number 829-003).

Ç WARNING
Exposed moving parts can
Lubricate pulley bearing every 750 hours or more
frequently, depending on operating conditions.

cause severe injury. NOTE: Lubricate pulley bearing every 750 hours or
LOCK OUT POWER before more frequently, depending on operating conditions.
removing guards or When lubricating pulley bearings, use a conventional
performing maintenance. hand grease gun with a maximum of one pump per
application. Do not over-lubricate. Do not use a power
grease gun.
Pulley Bearings
4. Grease bearing with one (1) pump from a manual
NOTE: grease gun. Do not over-lubricate.
Optional permanent grease fittings (part number
200398M) may be installed. 5. Remove grease adapter and install on opposite side
of pulley. Repeat steps 2 and 4.

Drive Module Idler Pulley Bearings

NOTE: No lubrication is required. Replace pulley if worn.
44 mm wide conveyors use shielded ball bearings and
do not require lubrication. Drive Module Drive Pulley Bearings
No lubrication is required. Replace bearings if worn.

1. With a small flat-bladed screwdriver, remove plug Mounting Brackets with Return Rollers
(AE of Figure 12) from retainer (AF). No lubrication is required. Replace bearings if worn.

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Preventive Maintenance and Adjustment
Maintaining Conveyor Belt Conveyor Belt Replacement Sequence
Troubleshooting
Inspect conveyor belt for: NOTE: See Table of Contents for beginning page
numbers of following procedures.
D Surface cuts or wear
D Stalling or slipping
D Remove old conveyor belt
Surface cuts and wear indicate:
D Sharp or heavy parts impacting belt - Conveyor without Gearmotor Mounting Package
or Stands
D Jammed parts
D Improperly installed bottom wiper - Conveyor with Stands and/or Gearmotor
Mounting Package
D Accumulated dirt in wiper
D Foreign material inside the conveyor D Center Drive Module Removal
D Improperly positioned accessories D Conveyor Belt Removal from Center Drive Module
D Bolt-on guiding is pinching belt D Install New Conveyor Belt
Stalling or slipping indicates: D Tension Conveyor Belt
D Excessive load on belt
D Conveyor belt or drive timing belt are not properly Belt Removal for Conveyor Without Gearmotor
tensioned Mounting Package or Stands
D Worn knurl or impacted dirt on drive pulley 1. From the discharge end, remove tail cover plate
D Intermittent jamming or drive train problems screws (AJ of Figure 14) from one side of the
conveyor.
NOTE: Visit www.dorner.com for complete list of
troubleshooting solutions.

Cleaning

IMPORTANT: Do not use belt cleaners that contain

alcohol, acetone, Methyl Ethyl Ketone (MEK) or other
harsh chemicals.

Use Dorner Belt Cleaner (part number 625619). Mild

AL
soap and water may also be used. Do not soak the belt.
For /05 woven polyester and /06 black anti-static belts, AJ
AI AK
use a bristled brush to improve cleaning.

Conveyor Belt Replacement Figure 14

ÇÇ
ÇÇ WARNING 2. Remove tail cover plate (AK).
Exposed moving parts can 3. Slide bottom wiper (AI) through side slot of tail plate
cause severe injury. (AL).
LOCK OUT POWER before
4. If the conveyor is equipped with guiding and
removing guards or
performing maintenance. accessories, remove them from one side.

2100 Series Center Drive Conveyors Set-up, Operation & Maintenance Manual
851-179 Rev. C 8 Dorner Mfg. Corp.
 Preventive Maintenance and Adjustment
5. Loosen corner screws (AN of Figure 15), on each
side of the center drive module (AO). NOTE: On 1219 mm and shorter by 203 mm and wider
conveyors, it will be necessary to remove the center
drive module at the same time the conveyor belt is
AO removed. See “Center Drive Module Removal” on page
11.

AN 10. Remove conveyor belt.

AP
11. Proceed to “Center Drive Module Removal” on page
11.

Belt Removal for Conveyor With Stands and/or

Gearmotor Mounting Package
1. From the discharge end, remove tail cover plate
screws (AJ of Figure 14) from one side of the
AR
AQ conveyor.
2. Remove tail cover plate (AK).
3. Slide bottom wiper (AI) through side slot of tail plate
(AL).
Figure 15 4. If the conveyor is equipped with guiding and
accessories, remove them from one side.

6. Remove tension door screws (AP) on each side of the NOTE: Figures 17 & 18 show a vertical mount in the A
center drive module. position with a parallel shaft gearmotor. Horizontal
7. Using finger grip holes (AQ), open the tension door mount, D position and/or 905 gearmotor are similar.
(AR) to release conveyor belt tension.
5. Remove cover screws (AV of Figure 17) and remove
8. On tension end of the conveyor, identified with cover (AW).
label (AS of Figure 16), loosen tracking cam
assemblies (AT) and cover plate screws (AU) on both
sides of the conveyor.

AU AV AV
AV

AT
AS

Figure 16
AW
9. Slide the cam assemblies toward the center of the
conveyor and push the end (AV) into the conveyor
frame. Figure 17

2100 Series Center Drive Conveyors Set-up, Operation & Maintenance Manual
Dorner Mfg. Corp. 9 851-179 Rev. C
Preventive Maintenance and Adjustment
6. Loosen belt tensioner (AX of Figure 18) then
remove the belt (AY).

BE

AY

AX

Figure 18
Figure 20
8. Loosen corner screws (AN of Figure 15), on each
NOTE: If the timing belt does not slide over the side of the center drive module (AO).
pulley flange, loosen the driven pulley set screws 9. Remove tension door screws (AP) on each side of the
(AZ of Figure 19) and remove the pulley (BA) with the center drive module.
belt (BB).

NOTE: With vertical mounts, two cover screws (BE of

Figure 20) were removed in step 7.

AZ
10. Using finger grip holes (AQ), open the tension door
BA (AR) to release conveyor belt tension.
11. On tension end of the conveyor, identified with
BB
label (AS of Figure 16), loosen tracking cam
assemblies (AT) and cover plate screws (AU) on both
sides of the conveyor.
12. Slide the cam assemblies toward the center of the
conveyor and push the end (AV) into the conveyor
frame.

Figure 19
ÇÇ WARNING
To prevent injury from the support stand
Ç
7. Remove three mounting screws (BE of Figure 20) tipping-over when conveyor is uncoupled, anchor
and remove gearmotor package. stand to floor or otherwise stabilize the stand.

2100 Series Center Drive Conveyors Set-up, Operation & Maintenance Manual
851-179 Rev. C 10 Dorner Mfg. Corp.
 Preventive Maintenance and Adjustment

NOTE: On 1219 mm and shorter by 203 mm and wider

conveyors, it will be necessary to remove the center
drive module at the same time the conveyor belt is BG
removed. See “Center Drive Module Removal” (next
section).

NOTE: To remove the belt, complete steps 13 & 14, at BH

each stand location.

13. Loosen the mounting clamp plates (BF of Figure 21)

on both sides of the conveyor. Raise the conveyor
and remove the belt. Figure 22
2. Remove the module.

Belt Removal from Center Drive Module

1. Remove drive plate screws (BI of Figure 23). Re-
move the tension drive plate (BJ).

BF
BI

Figure 21
BJ
14. With the belt removed, secure the conveyor with
clamp plates (BF).
Figure 23
15. Proceed to “Center Drive Module Removal”, (next
section). 2. Remove drive pulley (BK of Figure 24).

Center Drive Module Removal

Ç Ç
BK
WARNING
Before loosening clamps (BG of Figure 22), provide
a support (BH) under center drive module.

NOTE: If desired, mark center drive module location BM

on conveyor.

BN BL
1. Loosen clamp screws (BG of Figure 22) in each cor-
ner of the module. Figure 24

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Preventive Maintenance and Adjustment
3. Remove grooved idler pulley:
BK D For 44 mm, 70 mm or 95 mm wide conveyor, detach
BO
E-ring clip (BL of Figure 24). Remove pulley shaft
(BM) and remove pulley (BN).
D For 127 mm or wider conveyor, depress both sides of
spring-loaded shaft and remove pulley (BO of Figure
25).
4. Remove the conveyor belt.

Figure 25

Installing a New Conveyor Belt BP

IMPORTANT: On a center drive conveyors, belt trav-

el direction is identified by an arrow decal on the side
of the conveyor (BP of Figures 26 & 27).

Figure 26

BP

Figure 27

1. Orient the conveyor belt so that the splice leading

fingers (BQ of Figure 28) point in the direction of
belt travel as identified by the label (BP of Figure
26).
BQ

Figure 28
2. Place loop of belt into the drive module (Figure 29).

2100 Series Center Drive Conveyors Set-up, Operation & Maintenance Manual
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 Preventive Maintenance and Adjustment

BT

BR
BS
Figure 29

3. Place grooved idler pulley (BN of Figure 24 or BO Figure 30

of Figure 25) into the belt loop and install it in the
drive module. Refer to “Belt Removal from Center 10. While holding the pinion gear (BR), tighten cover plate
Drive Module” on page 12 and reverse step 3. screws (BS) to 2 Nm.

4. Place drive pulley (BK of Figure 24 or 25) into the

belt loop and install it in the drive module. Refer to
“Belt Removal from Center Drive Module” on page
Ç
Ç WARNING
11 and reverse steps 1 and 2. Tighten screws (BI of
Figure 23) to 9 Nm. Tension door closes quickly,
may cause injury.
NOTE: On 1219 mm and shorter by 203 mm and wider KEEP FINGERS CLEAR OF
conveyors, it will be necessary to replace the center TENSION DOOR.
drive module at the same time the conveyor belt is
replaced.
11. Carefully close the tension door (BU of Figure 31).
5. Replace the center drive module onto the conveyor
and attach clamps (BG of Figure 22) in each corner.
Tighten screws to 9 Nm.

NOTE: On conveyor with stands, complete steps 6, 7

& 8 at each stand location.

6. Loosen the mounting clamp plates (BF of Figure 21),

on both sides of the conveyor. Raise the conveyor
and replace the belt.
7. Lower the conveyor onto the mounting blocks. Use
care not to pinch belt. BU
8. Tighten clamp plate screws to 9 Nm.
9. Insert a 5 mm hex key wrench into either end of the
pinion gear (BR of Figure 30). Rotate the pinion gear
to extend the tensioning end gap (BU) to 30 mm. Figure 31

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Preventive Maintenance and Adjustment
12. Tighten corner screws (BU of Figure 32) on each Pulley Removal
side of the drive module to 9 Nm.

ÇÇ WARNING
Exposed moving parts can
BW
BV cause severe injury.
LOCK OUT POWER before
BU removing guards or
performing maintenance.

Figure 32 Remove the conveyor belt to access the pulley(s).

Perform the indicated steps of one of the following
procedures:
NOTE: If equipped with gearmotor mounting package, D “Belt Removal for Conveyor Without Gearmotor
replace by completing in reverse order steps 3 through Mounting Package or Stands”, page 8, steps 1
5 of “Belt Removal for Conveyor With Stands and/or through 10.
Gearmotor Mounting Package” on page 9.
D “Belt Removal for Conveyor With Stands and/or
Gearmotor Mounting Package”, page 9, steps 1
13. Re-install tension door screws (BV of Figure 32) on through 14.
each side of the module. Tighten screws to 9 Nm.
Remove the desired pulley following procedures A, B or
14. Re–install discharge bottom wiper (AI of Figure 14):
C:
Reverse steps 1 through 3 of “Belt Removal for
Conveyor Without Gearmotor Mounting Package or D A – End Pulley Removal
Stands”, page 8.
D B – Drive Pulley Removal
15. Replace guiding, if applicable.
D C – Idler Pulley Removal
Conveyor Belt Tensioning
A – End Pulley Removal
NOTE: For a new belt, the tension plate will be in
position indicated in Figure 32 (BW). When the tension
plate extends to position indicated in Figure 33 (BW), NOTE: Bearing removal tools (part numbers 25–09
the conveyor belt must be replaced. and 906–278 included in Tool Kit 2500M–ENG) are
required to remove end pulleys.

1. With a small flat bladed screwdriver, remove plug

(BX of Figure 34) from retainer (BY).
BW

BX
Figure 33 BY
The conveyor is equipped with an automatic tensioning
Figure 34
cylinder. No tensioning adjustment is required.

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2. Remove the tail cover plate screws (BZ of Figure 35) 2. Remove the drive pulley. Refer to “Belt Removal
and tail cover plates (CA) on both sides of the from Center Drive Module”, page 11, steps 1 and 2.
conveyor.
BZ
C – Idler Pulley Removal
1. Remove the gearmotor drive package. Refer to “Belt
CA Removal for Conveyor With Stands and/or Gearmo-
tor Mounting Package”, page 9, steps 5 through 7.
2. Detach the center drive module. Refer to ”Center
CA Drive Module Removal”, page 11.
CB 3. Remove the grooved idler pulley. Refer to “Belt
CC CD Removal from Center Drive Module”, step 3, page 12.
CB BZ
Figure 35
4. Remove smooth idler pulleys:
D For 44 mm, 70 mm or 95 mm wide conveyor, detach
3. Position bearing anvil/sleeve removal tool (CJ of E-ring clips and remove washers (CL of Figure 37).
Figure 36), part number 25-09, over the retaining
Remove pulley shafts (CM) and pulleys (CN).
sleeve (CB of Figure 35 or Figure 36).

CC
CK

CL
CM
CM

CF CJ
CB
CA CN

Figure 36 Figure 37

4. Insert threaded bolt (CK of Figure 36), part number D For 127 mm or wider conveyor, depress both sides of
906-278, through the bearing anvil/sleeve removal each spring-loaded shaft (CO of Figure 38). Remove
tool (CJ) and into the retaining sleeve (CB). pulleys (CP).
5. Tighten the bolt (CK) until the retaining sleeve (CB)
is free of the tail pulley plate (CA). CO
6. Remove the retaining sleeve (CB) from the bolt
(CK) and repeat for the other side.
7. Remove the pulley (CC).

B – Drive Pulley Removal CP

1. Remove the gearmotor drive package. Refer to “Belt
Removal for Conveyor With Stands and/or Gearmo-
tor Mounting Package”, page 9, steps 5 through 7. Figure 38

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Preventive Maintenance and Adjustment
Bearing Replacement for End Pulleys 3. While maintaining extension tool (CU) position, use
a wrench (CW of Figure 40) to rotate the bearing
IMPORTANT: Once removed, do not re-use removal tool (CQ) to expand the flare end of the tool.
bearings.

NOTE: Bearing removal and installation tools (part

numbers 25–05, 25–08, 25–09 and 25–10 included in CQ
CW
Tool Kit 2500M–ENG) are required to remove and install
bearings.

Bearing Removal
CU

NOTE: The bearings of a 44 mm wide gang drive

pulley cannot be replaced. Order pulley assembly (part Figure 40
number 204002).

1. Insert bearing removal tool (CQ of Figure 39), part 4. Orient bearing anvil/sleeve removal tool (CX of
number 25–05, into the pulley (CR) until shoulder (CS) Figure 41), part number 25–09, with cavity facing up
seats against bottom of bearing (CT). and place pulley (CR) onto tool.

CV CT CS

CQ
CR
CR
CU
Figure 39
CX
2. While holding bearing removal tool (CQ) in posi-
tion, insert extension tool (CU), part number 25–08,
into opposite end of pulley (CR). Rotate bearing
removal tool (CQ) to engage hex tip of extension tool Figure 41
(CU) into screw (CV) of bearing removal tool.

2100 Series Center Drive Conveyors Set-up, Operation & Maintenance Manual
851-179 Rev. C 16 Dorner Mfg. Corp.
 Preventive Maintenance and Adjustment
5. With arbor press (CY of Figure 42) or similar device, 3. Place and hold bearing (CT of Figure 45), part
press bearing out of pulley (CR). number 21–33, onto insertion tool (CZ) in position
over pulley (CR).
CY
CZ

CT

CR
CR

Figure 42
Figure 45

NOTE: If a severely worn bearing breaks apart during

removal, pulley must be replaced.
IMPORTANT: Bearing and pulley alignment is
critical.
Bearing Installation
1. Orient bearing anvil/sleeve removal tool (CX of 4. Press bearing (CT of Figure 46) into pulley (CR)
Figure 43), part number 25–09, with cavity facing up until seated.
and place pulley (CR) onto tool.

CR
CT
CR

CX

Figure 43
Figure 46

2. Install bearing insertion tool (CZ of Figure 44), part

number 25–10, into arbor press (CY) or similar
device.

CY
CZ

Figure 44

2100 Series Center Drive Conveyors Set-up, Operation & Maintenance Manual
Dorner Mfg. Corp. 17 851-179 Rev. C
Preventive Maintenance and Adjustment
Bearing Replacement for Drive Pulley 3. Place the shaft of the tool (part number 450282) (DG
of Figure 49) over pulley shaft (DH).
IMPORTANT: Once removed, do not re-use
bearings.
DG

Bearing Removal
1. Position the drive pulley (DA of Figure 47) in a
standard bearing separator (DB) as shown.
DI
DH

DC

DB Figure 49

4. Using an arbor press or similar device, press the

bearing (DI) onto pulley shaft as shown.

DA
Bearing Replacement for Idler Pulleys

Figure 47 NOTE: Bearings can not be removed from idler pul-

2. Using an arbor press or similar device, press-off the leys. Replace entire pulley, when worn. See “Service
Parts”, page 19.
bearing (DC).
Bearing Installation

Pulley Replacement

DD DE End Pulleys
Reverse removal procedure “A” (see page 14).

Drive Pulley
DF Reverse removal procedure “B” (see page 15).

Idler Pulley
Figure 48 Reverse removal procedure “C” (see page 15).

2100 Series Center Drive Conveyors Set-up, Operation & Maintenance Manual
851-179 Rev. C 18 Dorner Mfg. Corp.
 Service Parts
25 mm Diameter Drive/Idler Pulley Assembly (1)
NOTE: For replacement parts other than those
shown in this document, contact an authorized 4
Dorner Service Center or the factory. 4
3

Pulleys & Bearings Part Number

Nominal Drive/Idler Pulley
Conveyor Assembly (1) with Drive/Idler
Width 21-33 Bearings3 (4) Pulley Only 4(3)
44 mm 204802 Not Applicable
70 mm 204803 204703
95 mm 204804 204704
127 mm 204805 204705
2 152 mm 204806 204706
178 mm 204807 204707
1 203 mm 204808 204708
2
254 mm 204810 204710
305 mm 204812 204712
Item Part No. Part Description
1 See Chart Pulley Assembly
2 200035 Pulley Retaining Sleeve

Center Drive Module for 44 mm, 70 mm & Center Drive Module for 127 mm
95 mm Wide Conveyor or Wider Conveyor
5
6 12
7
8 5
6 13
5 9
8
5
11 15

10 14

Item Part No. Part Description

Item Part No. Part Description 12 807-1009 Idler Pulley, 127 mm
5 915-215 E-Ring Clip (0.44 diameter) 807-1010 Idler Pulley, 152 mm
6 801-115 Washer 807-1011 Idler Pulley, 203 mm
7 463046 Idler Pulley, 44 mm 807-1012 Idler Pulley, 254 mm
807-1007 Idler Pulley, 70 mm 807-1013 Idler Pulley, 305 mm
807-1008 Idler Pulley, 95 mm 13 807-1002 Grooved Idler Pulley, 127 mm
8 463402 Pulley Shaft, 44 mm 807-1003 Grooved Idler Pulley, 152 mm
463403 Pulley Shaft, 70 mm 807-1004 Grooved Idler Pulley, 203 mm
463404 Pulley Shaft, 5 mm 807-1005 Grooved Idler Pulley, 254 mm
9 463044 Grooved Idler Pulley, 44 mm 807-1006 Grooved Idler Pulley, 305 mm
463045 Grooved Idler Pulley, 70 mm 14 802-124 Pulley Bearings
807-1001 Grooved Idler Pulley, 95 mm 15 463105M Drive Pulley, 127 mm
10 802-124 Pulley Bearings 463106M Drive Pulley, 152 mm
11 463102M Drive Pulley, 44 mm 463108M Drive Pulley, 203 mm
463103M Drive Pulley, 70 mm 463110M Drive Pulley, 254 mm
463104M Drive Pulley, 95 mm 463112M Drive Pulley, 305 mm

2100 Series Center Drive Conveyors Set-up, Operation & Maintenance Manual
Dorner Mfg. Corp. 19 851-179 Rev. C
Service Parts
Item Part No. Part Description
Stand Mounting Components
16 202348P Bearing Pin
17 202311P Return Roller Bearing
17 18 207702 Return Roller Tube, 44 mm Long
207703 Return Roller Tube, 70 mm Long
18
207704 Return Roller Tube, 95 mm Long
207705 Return Roller Tube, 127 mm Long
207706 Return Roller Tube, 152 mm Long
16 17
207708 Return Roller Tube, 203 mm Long
207710 Return Roller Tube, 254 mm Long
207712 Return Roller Tube, 305 mm Long
207718 Return Roller Tube, 457 mm Long
207724 Return Roller Tube, 610 mm Long

Configuring Conveyor Belt Part Number

2150 M WW LL D 01 / TT

SERIAL MAX. LOAD

MODEL VOLTS
HARTLAND, WI 53029–0020 AMPS HZ
(262) 367–7600 MADE IN U. S. A. MFG. DATE

Figure 50

Conveyor Belt
Refer to serial and model number plate (Figure 50).
Determine conveyor length (“LL”), width (“WW”) and belt
type (“TT”).

25 – WW LL / TT

25– __ __ __ __ / __ __
(Fill In)

2100 Series Center Drive Conveyors Set-up, Operation & Maintenance Manual
851-179 Rev. C 20 Dorner Mfg. Corp.
 Notes

2100 Series Center Drive Conveyors Set-up, Operation & Maintenance Manual
Dorner Mfg. Corp. 21 851-179 Rev. C
Return Policy
No returns will be accepted without prior written factory authorization. When calling for authorization, please
have the following information ready for the Dorner Factory representative or your local distributor:
1. Name and address of customer.
2. Item(s) being returned.
3. Reason for return.
4. Customer’s original order number used when ordering the item(s).
5. Dorner or distributor invoice number.
A representative will discuss action to be taken on the Returned items and provide a Returned Goods
Authorization Number to reference.
There will be a 15% restocking charge on all new items returned for credit where Dorner was not at fault. These
will not be accepted after 60 days from original invoice date. The restocking charge covers inspection, cleaning,
disassembly, and reissuing to inventory.
If a replacement is needed prior to evaluation of returned item, a purchase order must be issued. Credit
(if any) is issued only after return and evaluation is complete.
Dorner has representatives throughout the world. Feel free to contact Dorner for the name of your local representative.
Our technical sales and service staff will gladly help with your questions on Dorner products.
For a copy of Dorner’s Limited Warranty, contact factory, distributor, service center or visit our website @
www.dorner.com

For replacement parts, contact an authorized

Dorner Service Center or the factory.

DORNER MFG. CORP. DORNER

975 Cottonwood Ave. PO Box 20 Arnold-Sommerfeld-Ring 2
Hartland, WI 53029-0020 USA D-52499 Baesweiler
USA Germany
Dorner Mfg. Corp. reserves the right to change or TEL 1-800-397-8664 (USA) TEL (02401) 80 52 90
discontinue products without notice. All products and FAX 1-800-369-2440 (USA) FAX (02401) 80 52 93
services are covered in accordance with our standard Outside the USA:
warranty. All rights reserved. Dorner Mfg. Corp. 2000 TEL 1-262-367-7600, FAX 1-262-367-5827 Internet: www.dorner.com

851-179 Rev. C Printed in U.S.A. 300