Toothed belt axis DGE-25-ZR- (-KF) DGE-40-ZR- (-KF) DGE-63-ZR- (-KF) Repair instructions (en) 7DGE_25-63_ZR_KFb_en

Transcription

1 Toothed belt axis DGE-25-ZR- (-KF) DGE-40-ZR- (-KF) DGE-63-ZR- (-KF) Repair instructions (en) 7DGE_25-63_ZR_KFb_en

2 Imprint Version: 7DGE_25-63_ZR_KFb_en ( ) Copyright: Festo AG & Co. KG P.O. Box D Esslingen Editorial team: SC-S Tel.: +49 (0) 711/ Internet: The reproduction, distribution and utilisation of this document as well as the communication of its contents to others without explicit authorisation is prohibited. Offenders will be liable for damages. All rights reserved, in particular the right to file patent, utility model or registered design applications. All product designations and brand names used are the property of the owners and not explicitly identified as such. All technical data subject to change according to technical updates. 2 / 48 Festo 7DGE_25-63_ZR_KFb_en

3 Foreword These repair instructions are valid for the toothed belt axes listed on the title page to the exclusion of any liability claims. Deviations compared to the descriptions in these repair instructions may arise depending on the design and/or modification status of the specific toothed belt axis. The user must check this prior to carrying out the repair and take the deviations into consideration if necessary. These repair instructions have been prepared with care. Festo AG & Co. KG does not, however, accept liability for any errors in these repair instructions or their consequences. Likewise, no liability is accepted for direct or consequential damage resulting from improper use of the products. More detailed information on this can be found in chapter 7 Liability. The relevant regulations on occupational safety, safety engineering and interference suppression as well as the stipulations contained in these repair instructions must be observed when working on the products. Festo 7DGE_25-63_ZR_KFb_en 3 / 48

4 Table of contents 1 Important information About these repair instructions Pictograms used in these repair instructions General safety information 6 2 General product description Functional description Types and part numbers Overview of variants and mounting directions 7 3 Component overview 8 4 Repair steps Dismantling the toothed belt axis Disconnecting the slide from the piston (DGE- -KF only) Removing the cover strip Removing the drive covers and the toothed belt Removing and dismantling the piston Linear recirculating ball bearing guide system (DGE- -KF only) Removing the guide rail Replacing the roller bearing cartridges Installing the guide rail with slide Drive covers Clamp pieces Clamping sleeves (DGE-25 and DGE-40 only) and buffers Toothed drive shafts Replacing the toothed belt Assembling the toothed belt axis Preparing the cylinder barrel Preparing the clamping bodies Preparing the piston Inserting the piston, clamp pieces and toothed belt Checking and setting the toothed belt pretension Additional information on checking the toothed belt pretension Installing the cover strip Connecting the slide to the piston (DGE- -KF only) Assembly and function check Buffer and belt assembly Switching characteristics of the magnet No-load torque 40 5 Maintenance Cleaning and lubricating the toothed belt axis Lubricating the recirculating ball bearing guide Toothed belt pretension Moment compensator play 42 6 Tools 43 7 Liability 45 4 / 48 Festo 7DGE_25-63_ZR_KFb_en

5 1 Important information 1.1 About these repair instructions This document contains important information about the professional repair of the toothed belt axis of the type DGE- -ZR including the versions with recirculating ball bearing guide (variant KF) in the sizes 25, 40 and 63. The toothed belt axis DGE- -ZR is fully repairable. The costs of carrying out a repair must, however, be considered in the case of larger defects. Before carrying out a repair, the relevant chapter in these instructions should be read thoroughly and complied with in full. For reasons of clarity, these repair instructions do not contain complete, detailed information. The following documents should therefore also be available when repairing a toothed belt axis: Operating instructions Contain information about the installation and removal of the motor, motor flange, coupling and coupling housing of the toothed belt axis DGE- -ZR as well as the function, structure, application, installation, commissioning, care and maintenance, etc. Can be found on the Festo website ( Spare parts documentation Contains an overview of the spare and wearing parts as well as information on their installation. Can be found in the online spare parts catalogue on the Festo website (spareparts.festo.com). Assembly aids Contain an overview of available assembly aids such as lubricating greases, screw locking agents, maintenance tools, etc. (aids for assembly and maintenance). Can be found in the online spare parts catalogue on the Festo website ( 1.2 Pictograms used in these repair instructions Warning This sign indicates a dangerous situation for persons and/or the product. Failure to observe this warning can result in injury to persons and/or damage to the device. This sign provides important tips and information that can make your work easier. Environment This sign provides information on the steps required for environmentally friendly use of materials and equipment, as well as the guidelines and regulations that may need to be observed. Accessories This sign contains information on accessories and attachments relevant to the context. Documents This sign contains references to other sections or documents containing additional information. Festo 7DGE_25-63_ZR_KFb_en 5 / 48

6 1.3 General safety information Warning The toothed belt axis must only be repaired by authorised and trained persons in accordance with the specifications in the technical documentation and using genuine spare parts. Installation and repair by unauthorised and untrained persons, repairs using non-genuine spare parts as well as without the technical documentation required for installation and/or repair are dangerous and therefore not permitted. Repairs must only be carried out in conjunction with these repair instructions as well as the respective operating instructions for the device. Instead of carrying out the repair yourself, your local Festo sales office offers the option of having the repair carried out by Festo. Environment Components and equipment replaced as part of a repair must be disposed of in accordance with the locally valid environmental protection regulations. 2 General product description 2.1 Functional description The DGE- -ZR is a toothed belt axis based on the operational principle of a circulating toothed belt for power transmission. The rotary motion of a servo or stepper motor produces a linear motion in a toothed belt with a pulley at both ends of the axis that is then transmitted to the piston attached to the toothed belt. The slot in the cylinder barrel required for this is covered by a cover strip that protects the toothed belt inside the axis against the entry of dirt. By minimising the moving dead weight, a high dynamic response and shorter cycle times can be achieved. The DGE- -ZR is approved for slide operation and yoke operation (cantilever operation) aj aa ab ac 1 Drive cover with corner pulley 2 Cover 3 Clamp piece for clamping the cover strip 4 Slide (DGE- -KF only) 5 Adapter 6 Moment compensator 7 Piston 8 Cylinder barrel 9 Cover strip aj Guiding bands on the piston aa Toothed belt ab Deep-groove ball bearing ac Drive trunnion 6 / 48 Festo 7DGE_25-63_ZR_KFb_en

7 2.2 Types and part numbers Type Part number DGE-25- -ZR DGE-40- -ZR DGE-63- -ZR The complete overview of features, accessories, type codes, technical data and dimensions for the toothed belt axes DGE- -ZR can be found in the product catalogue or on the Festo website ( 2.3 Overview of variants and mounting directions This diagram provides an overview of the mounting directions and variants for the toothed belt axis. -H- -H- -H- Versions: GK = Standard slide GV = Extended slide -KL = Additional slide on left -KR = Additional slide on right Drive shaft on right Orientation: O = Top U = Underneath R = Right L = Left V = Front H = Rear Drive shaft on left -H- = Position of the insertion points for proximity sensors Drive shaft: LK = No drive shaft on left LV = Drive shaft on left, front LH = Drive shaft on left, rear LB = Drive shaft on left, front and rear RK = No drive shaft on right RV = Drive shaft on right, front RH = Drive shaft on right, rear RB = Drive shaft on right, front and rear Festo 7DGE_25-63_ZR_KFb_en 7 / 48

8 3 Component overview 3.1 DGE-25- -ZR This diagram is intended only to provide an overview of the individual components. To order spare and wearing parts, please use the online spare parts catalogue on the Festo website (spareparts.festo.com). 8 / 48 Festo 7DGE_25-63_ZR_KFb_en

9 Item Designation Type 1 Socket head screw DIN 912-M Tightening torque 2.9 Nm 2 Sealing cap 3 Coupling housing 4 Centring ring 5 Coupling housing module See operating instructions for assembly 6 Socket head screw DIN 912-M Tightening torque 2.9 Nm (with coupling KSE and EAMC ) 7 Coupling 8 Coupling module See operating instructions for assembly 9 Retaining ring I DIN Flange screw M5 58 Tightening torque 6.0 Nm, use LOCTITE Drive cover 12 Clamp piece 13 Threaded pin DIN 913-M5 6-45H Tightening torque 2.0 Nm 14 Socket head screw DIN 912-M Tightening torque 1.0 Nm 15 Cover 16 Clamping sleeve DIN Buffer 18 Gear drive Without drive trunnion, with pressed-on deep-groove ball bearings 19 Gear drive 1 drive trunnion, with pressed-on deep-groove ball bearings 20 Gear drive 2 drive trunnions, with pressed-on deep-groove ball bearings 21 Cylinder barrel Cover strip Slot nut Guide rail 31 Socket head screw DIN 912-M Tightening torque 2.9 Nm 32 Cover cap Guide rail module 35 Socket head screw DIN 7984-M Tightening torque 1.2 Nm, use LOCTITE Threaded pin DIN 913-M4 5-45H Use LOCTITE Slide 39 Threaded pin DIN 913-M H Hexagon pin 42 Bearing cartridge Slide module 45 Pin 46 Moment compensator 47 Countersunk screw DIN 7991-M Tightening torque 5.9 Nm 48 Piston with slide module Toothed belt 53 Clamping plate 54 Socket head screw DIN 912-M Clamp piece 56 Magnet 57 Clamp piece module 58 Cylindrical dowel pin DIN 7-M Guiding band 60 Sealing lip 61 Band guide 62 Piston 63 Piston module 64 Countersunk screw DIN 7991-M5 8-A2-70 Tightening torque 4.0 Nm 65 Pin 66 Scraper 67 Compression spring 68 Adapter Festo 7DGE_25-63_ZR_KFb_en 9 / 48

10 3.2 DGE-40- -ZR This diagram is intended only to provide an overview of the individual components. To order spare and wearing parts, please use the online spare parts catalogue on the Festo website (spareparts.festo.com). 10 / 48 Festo 7DGE_25-63_ZR_KFb_en

11 Item Designation Type 1 Socket head screw DIN 912-M Tightening torque 5.9 Nm 2 Sealing cap 3 Coupling housing 4 Centring ring 5 Coupling housing module See operating instructions for assembly 6 Socket head screw DIN 912-M Tightening torque 10.5 Nm (with coupling KSE and EAMC ) 7 Coupling 8 Coupling module See operating instructions for assembly 9 Retaining ring I DIN Flange screw M6 80 Tightening torque 11.0 Nm, use LOCTITE Drive cover 12 Clamp piece 13 Threaded pin DIN 913-M4 5-45H Tightening torque 2.0 Nm 14 Socket head screw DIN 912-M Tightening torque 1.0 Nm 15 Cover 16 Clamping sleeve DIN Buffer 18 Gear drive Without drive trunnion, with pressed-on deep-groove ball bearings 19 Gear drive 1 drive trunnion, with pressed-on deep-groove ball bearings 20 Gear drive 2 drive trunnions, with pressed-on deep-groove ball bearings 21 Cylinder barrel Cover strip Slot nut Guide rail 30 Socket head screw DIN 912-M Tightening torque 2.9 Nm, use LOCTITE Cover cap Guide rail module 34 Socket head screw DIN 7984-M Tightening torque 2.9 Nm, use LOCTITE Threaded pin DIN 913-M4 5-45H Use LOCTITE Slide 38 Threaded pin DIN 913-M H Hexagon pin 41 Bearing cartridge Slide 44 Pin 45 Moment compensator 46 Countersunk screw DIN 7991-M Tightening torque 9.9 Nm 47 Piston with slide module Toothed belt 51 Clamping plate 52 Socket head screw M Clamp piece 54 Magnet 55 Clamp piece module 56 Cylindrical dowel pin DIN 7-M Guiding band 58 Sealing lip 59 Band guide 60 Piston 61 Piston module 62 Countersunk screw DIN 7991-M6 10-A2-70 Tightening torque 8.0 Nm 63 Pin 64 Scraper 65 Compression spring 66 Adapter Festo 7DGE_25-63_ZR_KFb_en 11 / 48

12 3.3 DGE-63- -ZR This diagram is intended only to provide an overview of the individual components. To order spare and wearing parts, please use the online spare parts catalogue on the Festo website (spareparts.festo.com). 12 / 48 Festo 7DGE_25-63_ZR_KFb_en

13 Item Designation Type 1 Socket head screw DIN 912-M Tightening torque 24.0 Nm 2 Sealing cap 3 Coupling housing 4 Centring ring 5 Coupling housing module See operating instructions for assembly 6 Socket head screw DIN 912-M Tightening torque 25.0 Nm (with coupling KSE and EAMC ) 7 Coupling 8 Coupling module 9 Retaining ring I 62 2 DIN Flange screw M8 125 Tightening torque 15.0 Nm, use LOCTITE Drive cover 12 Clamp piece 13 Threaded pin DIN 913-M5 6-45H Tightening torque 3.0 Nm 14 Socket head screw DIN 912-M Tightening torque 2.0 Nm 15 Cover 16 Buffer 17 Gear drive Without drive trunnion, with pressed-on deep-groove ball bearings 18 Gear drive 1 drive trunnion, with pressed-on deep-groove ball bearings 19 Gear drive 2 drive trunnions, with pressed-on deep-groove ball bearings 20 Cylinder barrel Cover strip Slot nut Guide rail 29 Socket head screw DIN 912-M Tightening torque 5.9 Nm, use LOCTITE Cover cap Guide rail module 33 Socket head screw DIN 7984-M Tightening torque 9.9 Nm, use LOCTITE Threaded pin DIN 913-M5 6-45H Use LOCTITE Slide 37 Threaded pin M Hexagon pin 40 Bearing cartridge Slide module 43 Pin 44 Moment compensator 45 Countersunk screw DIN 7991-M Tightening torque 24.0 Nm 46 Piston with slide module Toothed belt 49 Clamping plate 50 Clamp piece 51 Magnet 52 Clamp piece module 53 Cylindrical dowel pin DIN 7-M Socket head screw DIN 912-M Washer DIN Guiding band 57 Sealing lip 58 Band guide 59 Piston 60 Piston module 61 Countersunk screw DIN 7991-M6 10-A2-70 Tightening torque 8 Nm 62 Spring pin DIN 7344-M Pin 64 Scraper 65 Compression spring 66 Adapter Festo 7DGE_25-63_ZR_KFb_en 13 / 48

14 4 Repair steps This chapter describes how to dismantle, repair and assemble the toothed belt axis DGE- -ZR. This is done by first dismantling the device into individual modules (subsequent sections deal with the repair of these modules). Depending on the cause of the defect to be eliminated it may be necessary to exchange several components. The cause of a defect must therefore always be determined before starting a repair. The repair should preferably be carried out on a stable and flat work surface with storage for small parts. It is also possible to repair the toothed belt axis in installed condition, if required. 4.1 Dismantling the toothed belt axis The toothed belt axis DGE- -ZR comprises the following modules: Cylinder barrel Drive cover with toothed belt pulley and drive as well as clamp for the cover strip Piston with adapter and cover strip guide Slide with recirculating ball bearings (only with version DGE- -KF) on guide rail, driven via moment compensator on the piston Disconnecting the slide from the piston (DGE- -KF only) Place the toothed belt axis on the work surface as shown with the slide facing upwards. Support the piston to the side of the hole for the securing pin with a sturdy object. Warning Driving out the securing pin without supporting the piston can result in damage to the piston (risk of breakage/deformation). Warning The securing pin is flattened on one side. Therefore do not use punches larger than those specified below to drive out the securing pin as the seat of the securing pin does not have a uniform diameter. Drive out the securing pin using a punch with a diameter as specified below. Use the following punches: DGE-25: 5 mm ø DGE-40: 7 mm ø DGE-63: 9 mm ø 14 / 48 Festo 7DGE_25-63_ZR_KFb_en

15 Place the toothed belt axis on the work surface in accordance with the mounting direction with the piston facing upwards. Loosen the two centre countersunk screws in the moment compensator and unscrew them. Move the slide to the left or right to have free access to the piston Removing the cover strip Lever off the blue plastic covers from the clamp pieces on the drive covers using a small knife or thin screwdriver. Loosen the threaded pins in the centre of the clamp pieces at both ends of the axis. The adapter in the piston is under spring tension and can fall out after the screws are removed. Secure it when removing the final screw. The screws can be loosened by tapping them gently on the head using a punch the same thickness as the screw head diameter and a hammer. Loosen the four screws in the piston and unscrew them. DGE-63 only: Drive out the two spiral spring pins using a punch. Festo 7DGE_25-63_ZR_KFb_en 15 / 48

16 Remove the adapter from the piston. Warning Risk of injury. The ends of the cover strip have very sharp edges. Handle with care. Pull the cover strip from the clamping jaws Removing the drive covers and the toothed belt Move the piston to the stop at one end of the cylinder barrel. Remove the cover cap in the drive cover. Guide an Allen key through the hole in the drive cover. Unscrew the tightening bolt fully from the piston. Loosen the screws in the drive cover and unscrew them. 16 / 48 Festo 7DGE_25-63_ZR_KFb_en

17 Pull the drive cover away from the cylinder barrel. (DGE-25 and DGE-40 only) The drive covers are connected to the cylinder barrel using spring pins. A certain amount of force is required to pull them away. Push the toothed belt into the clamp piece to relieve the load on the retaining pin. Remove the retaining pin from the clamp piece. Pull the toothed belt with the clamping plate from the clamp piece. Pull the toothed belt out of the drive cover. Repeat the last steps on the other end of the axis to remove the second drive cover. Pull the toothed belt out of the cylinder barrel. Documents A description of how to dismantle and repair the drive covers can be found in section 4.3 Drive covers Removing and dismantling the piston Carefully push the piston out of the cylinder barrel. Festo 7DGE_25-63_ZR_KFb_en 17 / 48

18 Pull the guiding bands away from the piston. Pull the band guides away from the piston. 4.2 Linear recirculating ball bearing guide system (DGE- -KF only) The linear recirculating ball bearing guide system comprises a guide rail and the associated double row of recirculating ball bearing units (roller bearing cartridges). The system has negative operating clearance in all sizes, i.e. it is pretensioned and therefore has no mechanical play. This results in high rigidity and load bearing capacity in all system directions, as well as more precise guiding. The pretension must be manually adjusted. It is recommended to replace both machine components (guide rail and roller bearing components) of the linear guide system. A defective machine component will always have a negative influence on the replaced component during subsequent operation. Removal and installation of the guide system can be necessary under the following circumstances, for example: The end of its useful life has been reached as a result of material fatigue and wear. Signs of fatigue appear on the material areas of the rolling components. Fine tears, pores and pits (depending on the wear condition) as well as deformation occur. Pitting on the bearing surface of the guide rail can be observed visually as the bearing surface is noticeably uneven. This can result in perceptible bearing clearance, impaired roll-off and increased operating noise, etc. The application must be checked for the following causes in the event of premature failure due to increased wear: Lack of lubrication; lubrication interval not adhered to (unlubricated operation). Use of a lubricating grease not contained in the specification. Dirty and corrosive ambient conditions (dust, etc.). Impact and vibration. Technical limit data exceeded (torques, forces, speed, temperature range, etc.). Displacement force of the slide with the piston disconnected The setting of the roller bearing guide can be assessed using the displacement force of the slide with the piston disconnected (see page 21 for the displacement force). This can only be done during assembly as connecting the piston and toothed belt significantly increases the displacement resistance. In addition to the subjective assessment of the operating behaviour and guide backlash, this method can also be used to confirm the correct assembly and pretensioning of the roller bearing cartridges. Follow the steps below to repair the linear recirculating ball bearing guide system: Remove the guide rail (see section 4.2.1). Replace the roller bearing cartridges (see section 4.2.2). Install the guide rail with slide (see section 4.2.3). 18 / 48 Festo 7DGE_25-63_ZR_KFb_en

19 4.2.1 Removing the guide rail Warning The roller bearing cartridges are pretensioned. Individual bearings can therefore easily fall out and get lost when pushing the slide from the guide rail. Carefully push the slide from the guide rail. Remove the covers of the screw holes in the guide rail by inserting a small screwdriver into them and levering them out. The covers must be replaced. It is not possible to remove them without damaging them. Unscrew all the socket head screws in the guide rail. Remove the guide rail from the cylinder barrel. The slot nuts can remain in the cylinder barrel. Festo 7DGE_25-63_ZR_KFb_en 19 / 48

20 4.2.2 Replacing the roller bearing cartridges Remove the threaded pins from the side of the slide. Warning The threaded pins are locked with Loctite 243 and can be damaged if not handled with care. If the internal hexagon is damaged (cam-out), it may still be possible to unscrew the threaded pin by using a hexalobular (Torx) screwdriver. Otherwise the threaded pin will need to be drilled out. Remove the eight socket head screws that secure the roller bearing cartridges to the slide. The screws can be loosened by tapping them gently on the head using a punch the same thickness as the screw head diameter and a hammer. Remove the roller bearing cartridges from the slide. Recut the tapped holes for the threaded pins on the side of the slide using a tapping drill (M3) to remove the residue of the locking agent. Make sure that the stop side (arrows) and the mounting surface of the slide do not exhibit any surface defects (burrs, chips, kinks, etc.) as flawless bearing and stop surfaces are required for the roller bearing cartridges. Insert four new roller bearing cartridges into the slide. The black edge at the ends of the roller bearing cartridges must be facing downwards. Apply Loctite 243 to the screws of the roller bearing cartridges and screw these in fully (do not tighten; the roller bearing cartridges still have to have some freedom of movement). Push the slide with the preassembled roller bearing cartridges carefully onto the removed guide rail. Make sure that no bearings come out of the roller bearing cartridges during this process. Bearings that have come out of the roller bearing cartridges must be replaced in the corresponding bearing. 20 / 48 Festo 7DGE_25-63_ZR_KFb_en

21 Setting the linear guide The roller bearing cartridge pairs must be set using the threaded pins so that the displacement resistance for the slide is as low as possible and it can move without backlash. The setting is made in pairs. The following description must be repeated in succession for both roller bearing cartridge pairs. Apply Loctite 243 to the three new threaded pins and screw these into the previously recut tapped holes of the roller bearing cartridge pair to be set. The tapped holes must be recut before the new threaded pins are screwed in. Residues from the old locking agent in the tapped holes result in uneven and increased torques for the threaded pins, which means it is more difficult to feel what is happening when setting the roller bearing cartridge pairs. Pretension the three threaded pins using the appropriate torque (see table). Type Torque DGE Ncm DGE Ncm DGE Ncm Check the guide backlash and the displacement resistance (see table) by moving the slide several times. The slide must move smoothly and without jerking on the guide rail. Type Min. displacement force Max. displacement force DGE-25 1 N 5 N DGE-40 1 N 5 N DGE-63 2 N 8 N The displacement force can be determined using an electronic hand-held force measuring device (pressure and tensile force meter). In general, the mechanical awareness of the user is important when setting the linear guide. Poor operating behaviour manifests itself through operating noise. Excessive pretensioning manifests itself through harsh, increased operating noise. Adjust the setting of the threaded pins until the operating behaviour is flawless. Festo 7DGE_25-63_ZR_KFb_en 21 / 48

22 Tighten the screws of the roller bearing cartridges using the appropriate torque (see table). Type Torque DGE Nm ± 10 % DGE Nm ± 10 % DGE Nm ± 10 % Check the guide backlash, operating behaviour and displacement force across the full length of the guide rail once more after tightening the screws. Proceed as follows in the event of deviations from the stipulations: Loosen the screws of the roller bearing cartridges opposite the stop side only. Loosen the threaded pins and repeat the setting procedure. Then tighten the screws of the roller bearing cartridges using the appropriate torque (see table). Fill the guide system with the specified grease (see section 5.2 Lubricating the recirculating ball bearing guide ) Installing the guide rail with slide Warning The play of the roller bearing cartridges must be set before installation (see section Replacing the roller bearing cartridges ). Carefully push the slide onto the guide rail if you have not already done so. Make sure that none of the bearings come out of the roller bearing cartridges. If necessary, insert the slot nuts into the cylinder barrel. Place the guide rail with slide on the cylinder barrel. 22 / 48 Festo 7DGE_25-63_ZR_KFb_en

23 Align the guide rail parallel as well as radially and axially centred with the cylinder barrel with the help of a vernier calliper. the tolerances indicated in the sketch. The use of two setting brackets, which you can fabricate yourself in accordance with the drawing in section 6.4 Devices for in-house assembly permits simplified parallel as well as axially centred alignment of the guide rail with the cylinder barrel. L R HL HR VL VR (HL = HR = VL = VR) ± 0.05 mm (L = R) ± 0.3 mm Apply Loctite 243 to all socket head screws and tighten these from the inside out using the appropriate torque (see table). Type Torque DGE Nm ± 10 % DGE Nm ± 10 % DGE Nm ± 10 % The slide must be moved on the guide rail so that all screw holes can be reached. So as not to displace the guide rail, the two innermost screws should be tightened first using the appropriate torque (see table). Insert new sealing caps into the holes in the guide rail. The sealing caps must be flush with the guide rail. Use a flat piece of wood or a wide plastic hammer, for example, so as not to damage the sealing caps or the guide rail. If necessary, remove any material chipped from the sealing caps with a cloth. Festo 7DGE_25-63_ZR_KFb_en 23 / 48

24 4.3 Drive covers The drive covers must be removed in order to work on them. To do this, carry out the steps described in section 4.1 Dismantling the toothed belt axis up to removing the drive covers Clamp pieces The clamp pieces are attached to the drive covers using four socket head screws. Loosen the four screws in the clamp piece and remove them. If necessary, replace the clamp piece and the threaded pins. Place the clamp piece on the drive cover, screw in the socket head screws and tighten them using the appropriate torque (see table). Type Torque DGE Nm ± 10 % DGE Nm ± 10 % DGE Nm ± 10 % Clamping sleeves (DGE-25 and DGE-40 only) and buffers The clamping sleeves (not included on the DGE-63) are inserted into the drive covers. Pull out these parts to replace them. Buffer, push-in (DGE-25) Pull the buffer out of the drive cover and replace it by inserting the spare part. Buffer, screw-in (DGE-40 and DGE-63) Unscrew the buffer from the drive cover and replace it by screwing in and hand tightening the spare part Toothed drive shafts The toothed drive shaft sits in a loose fit in the drive head with two pressed-on deep-groove ball bearings and is axially secured by two retaining rings. Removing the toothed drive shafts Remove the retaining ring opposite the drive trunnion. In the case of toothed drive shafts with two or no drive trunnions, you can remove any retaining ring. 24 / 48 Festo 7DGE_25-63_ZR_KFb_en

25 Push the toothed drive shaft with the two deep-groove ball bearings out of the drive cover. You do not need to pull off the deep-groove ball bearings as the spare part comprises the two bearings and the shaft. Check the inner raceways of the deep-groove ball bearings for a secure fit on the toothed drive shaft. If a bearing is not fitting securely, replace the module. Installing the toothed drive shaft Apply a light coating of grease to the outside of the deep-groove ball bearings and push the toothed drive shaft into the drive cover with the drive trunnion in front. If necessary, use a plastic hammer to carefully insert the toothed drive shaft into the drive cover. Any installation direction can be chosen for toothed drive shafts with two or no drive trunnions. Insert the retaining ring. Check that the retaining ring is correctly positioned. Festo 7DGE_25-63_ZR_KFb_en 25 / 48

26 4.4 Replacing the toothed belt If the toothed belt has to be changed, the cause of the failure must be investigated to prevent premature and repeated failure. A toothed belt axis that has been used as intended and sized correctly will not normally exhibit any premature signs of failure. This is not necessary in the case of non-premature failure (fatigue time). However, the condition of the toothed drive shaft (wear to the surface/shape of the teeth, radial play of the bearing inner raceway with respect to the bearing seat: tight fit in new condition) and also the condition of the deep-groove ball bearings (e.g. perceptible bearing clearance, impaired roll-off behaviour and increased operating noise, etc.) should always be checked. In case of uncertainty, it is recommended to replace all the components mentioned so as to rule out reciprocal effects during later operation. Possible visible signs of wear to the toothed belt: Tears on the back of the toothed belt are signs of wear, for example caused by operation outside the permitted temperature range, impermissible chemical influences or possibly fatigue. Wear to the nylon fabric (fabric coating) on the tooth side of the belt. This is indicated by lint formation and bobbling, for example, and constitutes primary wear (abrasion of the fabric). Visible individual glass fibre tensile strands in the tooth base are secondary signs of wear due to primary wear to the nylon fabric. If this happens, the toothed drive shaft must be carefully examined for wear since visible glass fibre tensile strands may have had a severe abrasive effect on the tooth tip sides of the toothed belt pulleys. A description of how to replace the toothed drive shafts together with the corresponding deep-groove ball bearings can be found in section Toothed drive shafts. If the toothed belt suffers premature failure, the operating conditions should be looked at more closely. The following possibilities should be considered among others: Overloading The elasticity of the toothed belt retards the acceleration and braking behaviour of the toothed belt axis and results in greater acceleration and deceleration than set in the controller (spring effect). Block-shaped acceleration and deceleration profiles (no jerk limitation) cause high peaks in the drive force that can lead to overloading of the drive. Positions outside of the permissible range can also occur. An acceleration and deceleration specification with jerk limitation reduces oscillations in the entire system and has a positive effect on the stresses to which the mechanical system is subjected. Check which closed-loop controller settings can be adapted (e.g. jerk limitation, smoothing of the acceleration profile). Incorrect set values for the braking ramp during STOP conditions (e.g. emergency stop, quick stop) result in overloading of the toothed belt axis and can destroy it or dramatically reduce its service life. Check the settings for all braking ramps in your controller or the higher-order control system (deceleration values and jerk). Make sure that the deceleration values (braking deceleration, deceleration times) for the speed, the load to be moved and the mounting position (horizontal/vertical) as well as the specified maximum driving torque or the feed force correspond to the permissible values for the toothed belt axis used. Use the Festo Positioning Drives sizing software, available via the Festo website ( to size the toothed belt axis. Ambient conditions/material resistance Check whether the ambient temperature is within the permissible range. Check the chemical and physical ambient conditions for hazardous substances such as dust, abrasive particles, cooling lubricants, solvents, ozone, radiation, water-soluble greases and oils, etc. The toothed belt is ordered from the online spare parts catalogue (spareparts.festo.com) using the appropriate part number (dependent on the size and version of the toothed belt axis). The part number is an x-stroke part number. You must specify the stroke of your toothed belt axis in addition to the part number when ordering. The stroke can be determined from the type codes on the name plate of the toothed belt axis (see order example below). You can use this information to calculate the necessary toothed belt length. 26 / 48 Festo 7DGE_25-63_ZR_KFb_en

27 Cutting the new toothed belt to length The exact length of the toothed belt in mm is the product of a basic length (L 0 ) for the relevant type and the stroke of the toothed belt axis, multiplied by a factor (F). The stroke can be determined from the type codes on the name plate. Check the length of the new toothed belt and shorten it if necessary to the length specified in the table (F (L 0 + stroke), see order example: Type Length L 0 Factor F DGE mm DGE-25- -GK 1) 314 mm DGE-25- -GV 2) 414 mm DGE-25- -HD 3) mm DGE-25- -HD 3) mm DGE mm DGE-40- -GK 1) 489 mm DGE-40- -GV 2) 659 mm DGE-40- -HD 3) mm DGE mm DGE-63- -GK 1) 785 mm DGE-63- -GV 2) 1,035 mm ) GK: Standard slide 2) GV: Extended slide 3) HD: Heavy-duty version Example: DGE ZR- -GK Length L 0 : 314 mm Stroke: 500 mm Factor F: Toothed belt length = F (L 0 + stroke) = 1,619 mm Sturdy general purpose scissors or metal shears are best for cutting the toothed belt. Warning Do not bend or fold the toothed belt, as this can result in damage to the tensile bodies and shorten its service life by tearing it. the minimum bending radius for assembly and storage: DGE-25: R min = 6 mm DGE-40: R min = 10 mm DGE-63: R min = 20 mm 4.5 Assembling the toothed belt axis If you have not already done so, assemble the guide rail with slide on the cylinder barrel as described in section Installing the guide rail with slide. Festo 7DGE_25-63_ZR_KFb_en 27 / 48

28 4.5.1 Preparing the cylinder barrel Clean the cylinder barrel using a cloth and an air gun. Blow out the cylinder hole and the toothed belt throughfeed using an air gun. Apply a continuous film of lubricant to the bearing surface of the cylinder hole and the guide slot of the piston using a grease brush. Documents The greases to be used are described in section 5.1 Cleaning and lubricating the toothed belt axis Preparing the clamping bodies One of the two clamp pieces must contain a magnet (see chapter 3 Component overview ). The north pole of a new magnet is indicated with a red dot. The north pole must be pointing towards the clamp piece during installation. If necessary, insert a magnet in one of the clamp pieces using Loctite Preparing the piston For new pistons for toothed belt axes with slide only: In the case of newly ordered pistons, the 90 countersinks in the inner holes must be reworked for use in toothed belt axes with slide. The following values apply for this: Type Countersink diameter D DGE-25 ø 11 H13 DGE-40 ø 13 H13 DGE-63 ø 17.2 H13 D 90 Check the following wearing parts on the piston and replace them if necessary: Guiding bands Band guides Lateral scrapers 28 / 48 Festo 7DGE_25-63_ZR_KFb_en

29 HELICOIL plus SCREWLOCK inserts are screwed into the pistons. These have a screw-clamping area that serves as a locking agent. Multiple windings have a clamping effect on the edges of the screwed-in adjusting screws for the toothed belt pretension. The result is flexible frictional locking. This keeps the setting for the toothed belt pretension from being changed (automatic unscrewing). Warning The clamping effect can damage the thread profile of the adjusting screw, therefore the use of new adjusting screws is recommended for assembly. The use of the HELICOIL plus SCREWLOCK inserts and the dynamic load on the adjusting screw call for the use of only original spare parts from Festo with the appropriate strength class. Otherwise the screws can break prematurely. The clamping effect of the HELICOIL plus SCREWLOCK insert makes it hard to screw in the adjusting screw, particularly with the size 63. To make this easier, a screw should be screwed in and unscrewed before inserting a new piston for the first time. This screw should not be used for final assembly Inserting the piston, clamp pieces and toothed belt In the case of toothed belt axes with slide, the guide rail with slide must be assembled before assembling the toothed belt (see section Installing the guide rail with slide ). Place the cylinder barrel on the work surface as shown. The guide slot must be pointing upwards, the recesses must be on the right-hand side. Guide the toothed belt cut to the correct length (see section 4.4 Replacing the toothed belt ) through the toothed belt guide in the cylinder barrel as shown. The toothed profile must be facing upwards. Warning the minimum bending radii when handling the toothed belt (see section 4.4 Replacing the toothed belt ). Apply grease to the piston, the piston guide rings and the lower band guides (see section 5.1 Cleaning and lubricating the toothed belt axis ) and carefully insert the piston into the cylinder barrel. Pay attention to the position of the piston in the case of toothed belt axes with slide. The side with the countersunk inner holes must be opposite the slide. Festo 7DGE_25-63_ZR_KFb_en 29 / 48

30 Guide the left-hand end of the toothed belt through the prepared drive cover for the left-hand side as shown. the marking on the name plate and the resulting position of the drive trunnion (see section 2.3 Overview of variants and mounting directions ). Insert the left-hand end of the toothed belt together with the clamping plate into the clamping body equipped with a magnet. (DGE-25 only) Pay attention to the position of the clamping plate. The flattened side of the slot and the chamfered end must be pointing away from the toothed belt. Warning The toothed belt must be placed correctly on the clamping plate. It must not protrude and must make contact with eight teeth. Insert the cylindrical dowel pin into the recess and align it centrally. Warning The cylindrical dowel pin must not protrude past the side of the clamping body as otherwise the piston will be damaged. Insert the clamping body into the piston. Screw the socket head screw into the piston through the clamp piece. (DGE-63 only) The socket head screw must be fitted with a washer. 30 / 48 Festo 7DGE_25-63_ZR_KFb_en

31 Set the distance X between the piston and clamp piece according to the values in the table by turning the socket head screw: Type Distance X DGE-25 2 mm DGE-40 3 mm DGE-63 5 mm Place the left-hand drive cover on the cylinder barrel. (DGE-25 and DGE-40 only) The drive cover is centred with respect to the cylinder barrel by means of two clamping sleeves. A certain amount of force may need to be applied for assembly. Apply Loctite 243 to the flange screws and screw them into the cylinder barrel through the drive cover. (DGE-63 only) The drive cover is secured by means of four screws and must be aligned centrally with respect to the cylinder barrel before being tightened. Tighten the flange screws using the appropriate torque (see table). Type Torque DGE Nm ± 10 % DGE Nm ± 10 % DGE Nm ± 10 % Move the piston to the left-hand end of the cylinder barrel. Guide the right-hand end of the toothed belt through the prepared drive cover for the right-hand side as shown. the marking on the name plate and the resulting position of the drive trunnion (see section 2.3 Overview of variants and mounting directions ). Insert the right-hand end of the toothed belt together with the clamping plate into the clamping body without a magnet. (DGE-25 only) Pay attention to the position of the clamping plate. The flattened side of the slot and the chamfered end must be pointing away from the toothed belt. Festo 7DGE_25-63_ZR_KFb_en 31 / 48

32 Warning The toothed belt must be placed correctly on the clamping plate. It must not protrude and must make contact with eight teeth. Insert the cylindrical dowel pin into the recess and align it centrally. Warning The cylindrical dowel pin must not protrude past the side of the clamping body as otherwise the piston will be damaged. Screw the socket head screw into the piston through the clamp piece. (DGE-63 only) The socket head screw must be fitted with a washer. Move the piston as far as possible to the right. Insert the clamp piece a few millimetres into the piston. Place the right-hand drive cover on the cylinder barrel. (DGE-25 and DGE-40 only) The drive cover is centred with respect to the cylinder barrel by means of two clamping sleeves. A certain amount of force may need to be applied for assembly. Pretension the toothed belt by tightening the socket head screw by feel. Apply Loctite 243 to the flange screws and screw them into the cylinder barrel through the drive cover. (DGE-63 only) The drive cover is secured by means of four screws and must be aligned centrally with respect to the cylinder barrel before being tightened. 32 / 48 Festo 7DGE_25-63_ZR_KFb_en

33 Tighten the flange screws using the appropriate torque (see table). Type Torque DGE Nm ± 10 % DGE Nm ± 10 % DGE Nm ± 10 % Checking and setting the toothed belt pretension The toothed belt pretension is determined by measuring the basic oscillation (natural frequency) of the toothed belt with a fixed and freely oscillating strand length (L). Since the freely oscillating strand length (L) cannot be measured directly, the distance from the piston to one of the drive covers (L1) is set by moving the piston and the distance (X) is set by turning the tightening bolt. The oscillation measurement is then carried out at this point. L1 X Warning The toothed belt pretension has a direct influence on the service life of the toothed belt and the performance of the toothed belt axis. Extreme care must therefore be exercised when checking it. Before the toothed belt pretension can be measured, the piston must be moved back and forth a number of times so that the toothed belt can fully settle and differences in tension can be equalised. L Documents The easiest way to check the toothed belt pretension is using the toothed belt pretension test equipment (see section 6.3 Devices and meters ). The work instructions required for this as well as the setting values can be found in the associated operating instructions in the appendix to this document. Checking the toothed belt pretension Check the distance between the piston and clamp piece (X) and adjust it if necessary (see table). Set the distance between the drive cover and piston (L1) (see table). Type Distance L1 Distance X DGE mm/90 mm 1) 2 mm DGE mm/90 mm 1) 3 mm DGE mm/90 mm 1) 5 mm 1) Alternatives for toothed belt axes with very short stroke. L1 X The longer strand length should preferably be set if possible. A longer freely oscillating strand length reduces the variation of the measurement results. Festo 7DGE_25-63_ZR_KFb_en 33 / 48

34 Direct the acoustic frequency meter towards the centre of the toothed belt as described in the accompanying operating instructions. Documents Additional information on measuring the toothed belt pretension can also be found in section Additional information on checking the toothed belt pretension. Make the toothed belt oscillate by striking it with a narrow and heavy object, for example an Allen key or punch. The belt must be able to oscillate freely. To assess the toothed belt pretension, several measurements should be made to balance out any measurement tolerances. Compare the measurement result with the specified value (see table). Type Frequency (f) DGE Hz/ Hz 1) DGE Hz/ Hz 1) DGE Hz/ Hz 1) 1) Alternatives for toothed belt axes with very short stroke. Setting the toothed belt pretension If the measured natural frequency of the toothed belt is outside the specified range, the toothed belt pretension must be set as follows: Move the piston to the other end of the toothed belt axis. Warning The toothed belt pretension must not be set on the same side of the piston where the measurement was carried out, since otherwise the distance (X) between the clamp piece and piston relevant for the measurement would be changed. The piston must therefore be moved to the other end of the toothed belt axis. Adjust the toothed belt pretension by turning the tightening bolt. Turning the tightening bolt clockwise increases the tension in the toothed belt, and with this its oscillation frequency. Turning the tightening bolt anticlockwise decreases the tension in the toothed belt, and with this its oscillation frequency. 34 / 48 Festo 7DGE_25-63_ZR_KFb_en

35 Warning The maximum distance between the piston and clamp piece (see table) must not be exceeded as otherwise the minimum screw-in depth of the socket head screw will not be achieved. This can lead to the screw being pulled out. Type DGE-25 DGE-40 DGE-63 Maximum distance X 3 mm 5 mm 7 mm Measure the toothed belt pretension again at the other end of the toothed belt axis as described above. Repeat the procedure until the measured value corresponds to the value in the table. Warning The pretension of the toothed belt is not an indicator of wear! The values specified here are based on a new toothed belt. The pretension of the toothed belt diminishes during storage and operation. This is a normal process and not an indication of wear. Insert the sealing caps into the holes in the drive covers at both ends of the toothed belt axis. Festo 7DGE_25-63_ZR_KFb_en 35 / 48

36 4.5.6 Additional information on checking the toothed belt pretension The correct toothed belt pretension is of critical importance for the service life of the toothed belt as well as the positioning accuracy and performance of the toothed belt axis. The conventional method for measuring the toothed belt pretension via the deflection force is too inaccurate and can therefore not be used. Accurate results are achieved by measuring the oscillation frequency. The natural frequency of a belt is based on its tension (strand force), mass and strand length. The strand length is the oscillating length of a belt. Since the strand length cannot be determined directly at the toothed belt axis by easy means, the length L1 is used instead for positioning the piston. A pulse is applied to the toothed belt to start it oscillating. The natural frequency of the toothed belt generated in this way is recorded using a meter and displayed as a frequency value in hertz. The frequency value is calculated using the specified values for strand force (pretension force), belt mass and length of the free belt strand according to the following formula: f L F V m Natural frequency of the freely oscillating strand [Hz] Strand length [m] Pretension force [N] Weight per metre of the toothed belt [kg/m] The frequency to be set can be calculated using the data from the following table: Type Weight per metre m Freely oscillating strand length L Pretension force F V DGE kg/m 14 mm + L1 1) 240 N DGE kg/m 14 mm + L1 1) 750 N DGE kg/m 21 mm + L1 1) 1,300 N 1) See section Checking and setting the toothed belt pretension on measurement using the acoustic belt tension meter If the toothed belt is excited by means of a force stimulus, the strand oscillates with its natural frequency; this dies down reasonably quickly depending on the attenuation. The frequency meter measures the natural frequency generated (transverse oscillation) using the acoustic operating principle. Due to the design, the toothed belt is in an almost entirely enclosed fitting space; this means that harmonic oscillations can also be generated in addition to the basic oscillation (natural frequency). From experience it is always the first harmonic oscillation. In other words, a further oscillation node is generated and therefore in addition to the basic oscillation frequency, values that are twice the natural frequency can also be measured. For this reason, several measurements should always be carried out to differentiate the necessary basic oscillation (natural frequency) from the harmonic oscillation. Only this frequency can be used to extrapolate the force acting along the strand. 36 / 48 Festo 7DGE_25-63_ZR_KFb_en

37 4.5.7 Installing the cover strip Cutting the new cover strip to length If the cover strip is to be replaced, cut the new cover strip to the total length of the toothed belt axis X - 2 mm. X X - 2 mm Installing and tensioning the cover strip Insert the cover strip into a clamp piece at one end of the toothed belt axis. Align the cover strip so that there is a gap of approx. 1 mm from the edge of the drive block. Clamp the cover strip by tightening the threaded pins using the appropriate torque (see table). Type Torque DGE Nm ± 10 % DGE Nm ± 10 % DGE Nm ± 10 % Place the cover strip in the recess of the piston and guide it into the clamp piece at the other end of the toothed belt axis. The cover strip must be replaced if it is kinked. In the case of axes without slide, insert the locking pin into the piston. Apply grease to the scrapers (see section 5.1 Cleaning and lubricating the toothed belt axis ). Insert the adapter with the scrapers and springs into the piston. Festo 7DGE_25-63_ZR_KFb_en 37 / 48

38 Tension the cover strip by pressing the adapter down until the scrapers are flush with the top edge of the piston. Clamp the cover strip at the other end of the toothed belt axis by tightening the threaded pins using the appropriate torque (see table). Type Torque DGE Nm ± 10 % DGE Nm ± 10 % DGE Nm ± 10 % Check the position of the scrapers relative to the top edge of the piston (see above) once more and adjust the tension of the cover strip if necessary. Seal the threaded pins at both ends of the toothed belt axis with locking paint. Press the adapter down until it is flush with the top edge of the piston. Screw the countersunk screws into the adapter through the piston and tighten them using the appropriate torque (see table). Type Torque DGE Nm ± 10 % DGE Nm ± 10 % DGE Nm ± 10 % Place the cover caps on the clamp pieces at both ends of the toothed belt axis Connecting the slide to the piston (DGE- -KF only) Loosen the two threaded pins in the slide so that the moment compensator is loose and then remove it. 38 / 48 Festo 7DGE_25-63_ZR_KFb_en

39 Move the slide next to the piston. Insert the moment compensator into the slide as shown. It must have some play between the two hexagon pins. If necessary, unscrew one of the threaded pins by half a revolution. Pay attention to the position of the moment compensator (holes on top). Screw the two countersunk screws into the moment compensator through the piston and tighten them using the appropriate torque (see table). Type Torque DGE Nm ± 10 % DGE Nm ± 10 % DGE Nm ± 10 % Place the toothed belt axis on the work surface as shown with the linear guide facing upwards. Support the piston to the side of the hole for the securing pin with a sturdy object. Warning Driving in the securing pin without supporting the piston can result in damage to the piston (risk of breakage/deformation). You can place the pin in a freezer compartment for a few minutes to make assembly easier. Align the pin so that the flattened side is parallel with the edge of the slide. Slowly drive the pin through the moment compensator and piston using a punch. Festo 7DGE_25-63_ZR_KFb_en 39 / 48

40 Align the moment compensator towards the centre of the slide by turning the two threaded pins. The distance between the moment compensator and slide must be identical on both sides. Set the moment compensator by adjusting the threaded pins by feel so that there is no perceptible longitudinal play between the slide and moment compensator. Move the moment compensator and slide against each other during setting. Avoid bracing the moment compensator with the slide since this can have a negative influence on the running characteristics of the guide. 4.6 Assembly and function check After completing the assembly work on the toothed belt axis, the correct function must be checked by following the steps below Buffer and belt assembly Move the piston to each of the end positions of the toothed belt axis in turn and then check the distance from the piston to the corresponding drive cover (Y). Y Type Minimum distance Y Maximum distance Y DGE mm 23 mm DGE mm 35 mm DGE mm 51 mm If the distance (Y) is smaller than the specified minimum, the buffer may not have been correctly assembled. Check the assembly of the buffer and fix the problem if necessary (see section 4.3 Drive covers ). If the distance (Y) is greater than the specified maximum, the toothed belt is too short and the clamp piece cannot be screwed in far enough. Check the length of the toothed belt and replace it if necessary (see section 4.4 Replacing the toothed belt ) Switching characteristics of the magnet Move the piston to the right-hand end of the toothed belt axis (recess in the slot). Transverse the full slot using a suitable proximity sensor (type SME-8 or SMT-8). The proximity sensor must respond in the area of the left-hand piston side that is opposite the slot recess No-load torque It must be possible to move the piston without much resistance or jerking when idle, without a drive attached or load connected. This check is based on the technician's instinct and experience. It is not possible to specify precise test values. 40 / 48 Festo 7DGE_25-63_ZR_KFb_en

41 5 Maintenance This chapter contains key technical information about how to carry out maintenance work on the toothed belt axis. A detailed description of the steps for care and maintenance can be found in the operating instructions. Additional information on assembly aids and lubricants can be found on the Festo website ( 5.1 Cleaning and lubricating the toothed belt axis If necessary, clean the cover strip using a soft cloth and a gentle detergent. Lubricate the surfaces of the guide rail or cover strip if there is no longer any sign of lubrication. Lubricants for assembly and maintenance of the toothed belt axis Application Designation Assembly Festo LUB-KC1 1) Maintenance Festo LUB-KC1 1) 1) See Assembly aids in the online spare parts catalogue on the Festo website ( 5.2 Lubricating the recirculating ball bearing guide The recirculating ball bearing guide must be relubricated at set intervals using a grease gun. The press-fitted lubrication nipples are funnel-type lubrication nipples based on DIN Festo offers a one-hand high-pressure grease gun with a suitable pinpoint nozzle for greasing these lubrication nipples (see section 6.2 Special tools ). Lubrication intervals for each roller bearing cartridge design and lubricant Warning There are two different designs of roller bearing cartridge, which can be distinguished by the colour of the scraper plates on the sides. Old design: Black scraper plates New design: Light grey scraper plates Old design A lubrication interval of 400 km applies in any case for toothed belt axes with roller bearing cartridges of the old design (black scraper plates). New design The following lubrication intervals apply to toothed belt axes with roller bearing cartridges of the new design (light grey scraper plates): Festo LUB-KC1 1) Festo LUB-RN2 1) 1st interval 5,000 km 5,000 km 2nd nth interval 400 km 5,000 km 1) See Assembly aids in the online spare parts catalogue on the Festo website ( Festo 7DGE_25-63_ZR_KFb_en 41 / 48

42 Warning The lubrication intervals are reduced under the following operating conditions: Extremely short strokes < 50 mm Long strokes > 2,000 mm Speeds > 2 m/s Increased dirt in the environment (e.g. grinding dust, etc.) The toothed belt axis must be relubricated at least every 3 years. Warning The slide must be moved forwards and backwards on the guide rail during lubrication so that the grease penetrates all the spaces in the roller bearing cartridges. 5.3 Toothed belt pretension Warning The toothed belt is set to the specified value in the factory and is thus maintenance-free over its entire service life. The pretension of the toothed belt diminishes during storage and operation. This is a normal process and not an indication of wear. 5.4 Moment compensator play Check as part of maintenance if there is any play between the moment compensator and the hexagon pins in the slide. If necessary, adjust the two threaded pins to ensure the moment compensator fits free of play (see section Installing the cover strip ). 42 / 48 Festo 7DGE_25-63_ZR_KFb_en

43 6 Tools This chapter provides an overview of the tools and aids required to repair and maintain the toothed belt axis. 6.1 Standard tools The following standard tools are required to repair and maintain the toothed belt axis: Designation Additional information Engineer's hammer Plastic hammer Punch DGE-25: 5 mm DGE-40: 7 mm DGE-63: 9 mm Pliers for retaining rings mm (interior protection for hole) Ruler Internal hexagon screwdriver 2 8 mm (Allen key) Torque wrench 1 25 Nm Torque screwdriver 10 Ncm Screwdriver bits Internal hexagon socket (Allen socket): 2 8 mm Flat pliers Sturdy general purpose scissors For cutting the toothed belt to length or metal shears 6.2 Special tools The following special tools are required to repair and maintain the toothed belt axis: Designation Additional information Festo order no. Photo One-hand high-pressure grease gun Pinpoint nozzle for miniature funnel-type lubrication nipple ) 1) See Assembly aids in the online spare parts catalogue on the Festo website ( Festo 7DGE_25-63_ZR_KFb_en 43 / 48

44 6.3 Devices and meters The following devices and meters are required to repair and maintain the toothed belt axis: Part no. Description Photo Type TB-TE-EQ2 Basic device for checking the toothed belt pretension, in a Systainer with foam insert. Suitable for toothed belt axes of the type DGE-25/40/63-ZR-(KF), DGE-25/40/63-ZR-RF, EGC-TB-KF. Holds the test probe of the acoustic frequency meter of the type TB-TE-EQ3 and excites the toothed belt by means of a plunger TB-TE-EQ-3 Acoustic belt tension meter (frequency meter) for measurement with and without test equipment. Special bonding of the test probe for use with the test equipment. Order alternatives: Type: Optibelt TT mini S plus Available exclusively from Schaefer Technik GmbH Acoustic belt tension meter (frequency meter) for measurement without test equipment. Not available via Festo. Manufacturer/supply: Optibelt GmbH or comparable meter from other manufacturers O-ring 10x TB-TE-EQ0 Mounts the acoustic test probe in the test equipment by means of clamping friction. Included in the scope of delivery of the frequency meter TB-TE-EQ3. Empty Systainer with foam insert. Space for basic test equipment TB-TE-EQ2/ (DGE-25/40/63-ZR-(KF), DGE-25/40/63-ZR-RF, EGC-TB-KF), frequency meter TB-TE-EQ3/760459, mounting kit TB-TE-EQ4/ (ELGA-TB) and test equipment TB-TE-EQ5/ (ERMB/EHMB). 44 / 48 Festo 7DGE_25-63_ZR_KFb_en

45 6.4 Devices for in-house assembly Designation Dimensions DGE-25 Dimensions DGE-40 Dimensions DGE-63 Picture Mounting bracket For easy alignment of the guide rail with the cylinder barrel. Material: Aluminium a=30 mm b=50 mm c=40.5 mm d=30 mm a=30 mm b=67 mm c=55 mm d=42 mm a=30 mm b=105 mm c=92 mm d=75 mm b c d a e= mm e= mm e= mm e f= mm g=70 mm f= mm g=90 mm f= mm g=136 mm f g 7 Liability The General Terms and Conditions of Festo AG & Co. KG, which can be viewed on the Festo website ( apply. Festo 7DGE_25-63_ZR_KFb_en 45 / 48

46 Conditions of use for electronic documentation I. Protection rights and scope of use The file of your choice is subject to protection provisions. Festo or third parties have protection rights concerning this electronic documentation which Festo makes available on portable data storage devices (floppy disks, CD-ROM, removable disks) as well as on the Internet and/or Intranet, hereinafter referred to as electronic documentation. Provided third parties are entitled to partial or full rights concerning this electronic documentation, Festo shall have the corresponding rights of use. Festo permits the user to use the electronic documentation under the following conditions: 1. Scope of use a) The user of the electronic documentation is allowed to use this documentation for his own, exclusively company-internal purposes on any number of machines within his business premises (location). This right of use includes exclusively the right to save the electronic documentation on the central processors (machines) used at the location. b) The electronic documentation may be printed out on a printer at the location of the user as often as desired, providing this printout is printed with or kept in a safe place together with these conditions of use and other user instructions. c) With the exception of the Festo logo, the user has the right to use pictures and texts from the electronic documentation for creating his own machine and system documentation. The use of the Festo logo requires written consent from Festo. The user himself is responsible for ensuring that the pictures and texts used match the machine/system or the relevant product. d) Further uses are permitted within the following framework: Copying exclusively for use within the framework of machine and system documentation from electronic documents of all documented supplier components. Demonstrating to third parties exclusively under guarantee that no data material is stored wholly or partly in other networks or other data storage devices or can be reproduced there. Passing on printouts to third parties not covered by the provision stated in item 3, as well as any processing or other use, is not permitted. 2. Copyright note Every electronic document receives a copyright note. This note must be included on every copy and every printout. Example: E 2003, Festo AG & Co. KG, D Esslingen 3. Transferring the authorisation of use The user can transfer the authorisation of use in the scope of and with the limitations of the conditions in accordance with items 1 and 2 completely to a third party. The third party must be made explicitly aware of these conditions of use. II. Exporting the electronic documentation When exporting the electronic documentation, the licence holder must observe the export regulations of the exporting country and those of the purchasing country. III. Warranty 1. Festo products are being continuously developed with regard to hardware and software. The hardware status and, where applicable, the software status of the product can be found on the name plate of the product. If the electronic documentation, in whatever form, is not supplied with the product, i. e. is not supplied on a portable data storage device (floppy disk, CD-ROM, removable disk), Festo does not guarantee that the electronic documentation corresponds to every hardware and software status of the product. In this case, the printed documentation from Festo accompanying the product alone is decisive for ensuring that the hardware and software status of the product matches that of the electronic documentation. 2. The information contained in this electronic documentation can be amended by Festo without prior notice and does not commit Festo in any way. IV. Liability/Limitations of liability 1. Festo supplies this electronic documentation in order to assist the user in creating his machine and system documentation. In the case of electronic documentation that does not directly accompany a product in the form of portable data storage devices (floppy disk, CD-ROM, removable disk), i. e. that is not automatically supplied together with that product, Festo does not guarantee that the electronic documentation available/supplied separately matches the product actually used by the user. The latter applies particularly to extracts of the documents for the user s own documentation. The guarantee and liability for separately available/supplied data storage devices, i. e. except for the electronic documentation available via the Internet/Intranet, is limited exclusively to proper duplication of the software, whereby Festo guarantees that in each case the data storage device or software contains the latest update of the documentation. Concerning electronic documentation available on the Internet/Intranet, there is no guarantee that it will have the same version status as the last printed edition. 2. Furthermore, Festo cannot be held liable for the lack of economic success or for damage or claims by third parties resulting from the use of the documentation by the user, with the exception of claims arising from infringement of the protection rights of third parties concerning the use of the electronic documentation. 3. The limitations of liability as per paragraphs 1 and 2 do not apply if, in cases of intent or gross negligence or the lack of warranted quality, liability is compulsory. In such a case, Festo s liability is limited to the damage discernable by Festo when the definitive circumstances are made known. V. Safety guidelines/documentation Warranty and liability claims in conformity with the aforementioned regulations (items III and IV) may be raised only if the user has observed the safety guidelines of the documentation in conjunction with the use of the machine and its safety guidelines. The user himself is responsible for ensuring that the electronic documentation, when not supplied with the product, matches the product actually used by the user. 46 / 48 Festo 7DGE_25-63_ZR_KFb_en

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48

49 Toothed belt pretension test equipment Operating instructions (en) 7Tension01_TBb_en

50 Imprint Version: 7Tension01_TBb_en ( ) Copyright: Festo AG & Co. KG P.O. Box D Esslingen Editorial team: SC-S Tel.: +49 (0) 711/ Internet: The reproduction, distribution and utilisation of this document as well as the communication of its contents to others without explicit authorisation is prohibited. Offenders will be liable for damages. All rights reserved, in particular the right to file patent, utility model or registered design applications. All product designations and brand names used are the property of the owners and not explicitly identified as such. All technical data subject to change according to technical updates. 2 / 20 Festo 7Tension01_TBb_en

51 Foreword These operating instructions are valid for the toothed belt pretension test equipment listed on the title page to the exclusion of any liability claims. Deviations compared to the descriptions in these operating instructions may arise depending on the modification status of the toothed belt pretension test equipment. The user must check this prior to setting the toothed belt pretension and take any deviations into consideration. These operating instructions have been prepared with care. Festo AG & Co. KG does not, however, accept liability for any errors in these operating instructions or their consequences. Likewise, no liability is accepted for direct or consequential damage resulting from improper use of the product. More detailed information on this can be found in chapter 12 Liability. The relevant regulations on occupational safety, safety engineering and interference suppression as well as the stipulations contained in these operating instructions must be observed when working on the products. Festo 7Tension01_TBb_en 3 / 20

52 Table of contents 1 Important information About these operating instructions Pictograms used in these operating instructions General safety information 6 2 Control elements and connections Test equipment Mounting kit for ELGA-TB 6 3 Function and application 7 4 Storage 7 5 Test requirements 7 6 Application and operation Preparing the toothed belt axis Checking the piston distance (DGE- -ZR(-KF) only) Inserting clamp pieces (DGE-25/40-ZR-RF only) Preparing the test equipment Attaching the extension sleeves Attaching the stop bolts Attaching the test equipment Checking and setting the toothed belt pretension Checking the toothed belt pretension Setting the toothed belt pretension Additional information on checking the toothed belt pretension 15 7 Quick guide DGE- -ZR(-KF) DGE- -ZR-RF EGC- -TB-KF ELGA-TB-G Maintenance and care 17 9 Accessories and ordering data Assembly and function check Tools Liability 19 4 / 20 Festo 7Tension01_TBb_en

53 1 Important information 1.1 About these operating instructions This document contains important information on how to use the toothed belt pretension test equipment professionally. Before checking the toothed belt pretension, these instructions must be read in full and followed consistently. The same applies when setting and checking the toothed belt pretension. 1.2 Pictograms used in these operating instructions Warning This sign indicates a dangerous situation for persons and/or the product. Failure to observe this warning can result in injury to persons and/or damage to the device. This sign provides important tips and information that can make your work easier. Environment This sign provides information on the steps required for environmentally friendly use of materials and equipment, as well as the guidelines and regulations that may need to be observed. Documents This sign contains references to other sections or documents containing additional information. Festo 7Tension01_TBb_en 5 / 20

54 1.3 General safety information Warning The toothed belt pretension must only be set by authorised and trained persons in accordance with the specifications in the technical documentation. Setting of the toothed belt pretension by persons without the necessary authorisation and training as well as without the technical documentation required is dangerous and therefore not permitted. Setting of the toothed belt pretension using the toothed belt pretension test equipment must only be carried out in conjunction with these operating instructions as well as the respective repair instructions for the device. Environment Components and equipment replaced as part of a repair must be disposed of in accordance with the locally valid environmental protection regulations. 2 Control elements and connections 2.1 Test equipment aj aa ab ac ad ae af 1 Position stop for DGE-25/40/63 2 Extension sleeve 10 mm 3 Stop bolt 8 22 mm 4 Extension sleeve 25 mm 5 Slide mechanism, indexing by means of spring pressure elements 6 Measurement head holder for acoustic belt tension meter 7 Plunger with 2-spring package 8 Plunger housing 9 Clamp piece for DGE-25-ZR-RF aj Stop bolt mm aa Clamp piece for DGE-40-ZR-RF ab Stop bolt mm ac Knurled screw for securing the position stop ad Test equipment ae Recesses for the elastomer buffers af M5 threaded holes for the stop bolts 2.2 Mounting kit for ELGA-TB Position stop bolt 2 Position stop, left 3 Position stop, right 4 Distance piece for ELGA-TB-G Distance piece for ELGA-TB-G-80 6 Distance piece for ELGA-TB-G-70 7 Transport holder for distance pieces 6 / 20 Festo 7Tension01_TBb_en

55 3 Function and application A plunger attached to the toothed belt pretension test equipment makes the toothed belt oscillate by applying a force stimulus. The natural frequency of the toothed belt generated in this way is recorded using a meter and displayed as a frequency value in hertz. The freely oscillating toothed belt strand length defined by the toothed belt pretension test equipment enables accurate comparison of the specified measured values without the risk of measuring errors during positioning of the slide/piston. This toothed belt pretension test equipment can be used for the following toothed belt axes: DGE-25/40/63-ZR(-KF) DGE-25/40/63-ZR-RF EGC- -TB-KF ELGA-TB-G-70/80/120 4 Storage Store the toothed belt pretension test equipment in a dry place where it is protected from corrosion, ideally in the matching Systainer (see section 9 Accessories and ordering data ). 5 Test requirements Warning Checking and setting the toothed belt pretension is only required and permissible after a new toothed belt is installed. The pretension of the toothed belt diminishes during storage and operation. This is a normal process and not an indication of wear. Retensioning the toothed belt can result in premature wear. Before the toothed belt pretension can be measured, the slide/piston must be moved back and forth a number of times to allow the toothed belt to fully settle and differences in tension to be equalised. Checking and setting the toothed belt pretension must only be performed on toothed belt axes whose electric power units have been disconnected. The information in the corresponding repair instructions for the respective toothed belt axis apply to the steps described in these operating instructions. Festo 7Tension01_TBb_en 7 / 20

56 6 Application and operation Excitation of the natural oscillation of the toothed belt via the plunger by means of a force stimulus is possible with the test equipment in all positions due to the absence of non-captive parts and the 2-spring system in the plunger housing. Space permitting, there are no restrictions with respect to the position of the toothed belt axis when using the test equipment. The test equipment can be secured using fastening clamps if necessary for testing from below or with the toothed belt axis in an inclined or vertical installation position. The toothed belt pretension is determined by measuring the basic oscillation (natural frequency) of the toothed belt with a fixed and freely oscillating strand length (L). The distance from the clamping body to one of the drive covers (L1) is set by inserting the test equipment and the corresponding stop bolt. The oscillation measurement is then performed using the test equipment. L1 L 6.1 Preparing the toothed belt axis Checking the piston distance (DGE- -ZR(-KF) only) Check the distance between the piston and clamp piece (X) and adjust it if necessary (see table). Type Distance X DGE-25- -ZR(-KF) 2 mm DGE-40- -ZR(-KF) 3 mm DGE-63- -ZR(-KF) 5 mm Inserting clamp pieces (DGE-25/40-ZR-RF only) It is imperative to attach an additional clamp piece to the toothed belt axes DGE-25-ZR-RF and DGE-40-ZR-RF so that the toothed belt can oscillate freely and does not strike the cylinder barrel. If necessary, push the relevant clamp piece through the recess in the cylinder barrel between the toothed belt and the cylinder barrel. It must touch the clamping body. 8 / 20 Festo 7Tension01_TBb_en

57 6.2 Preparing the test equipment Depending on the design and size of the toothed belt axis, different extension sleeves and stop bolts must be attached at different points on the test equipment and different settings must be made Attaching the extension sleeves The distance from the test equipment to the rear of the toothed belt varies depending on the toothed belt axis. The different distances are compensated by the extension sleeves to optimise the force stimulus applied by the plunger. Loosen the plunger housing and then unscrew it from the test equipment. Screw the appropriate extension sleeve onto the plunger housing (see table). Type Extension sleeve length DGE-25-ZR(-KF) 10 mm DGE-40-ZR(-KF) 10 mm DGE-63-ZR(-KF) No extension sleeve DGE-25-ZR-RF 25 mm DGE-40-ZR-RF 25 mm DGE-63-ZR-RF 25 mm EGC-50-TB-KF 25 mm EGC-70-TB-KF 25 mm EGC-80-TB-KF 25 mm EGC-120-TB-KF 25 mm EGC-185-TB-KF 25 mm ELGA-TB-G mm ELGA-TB-G mm ELGA-TB-G mm Screw the plunger housing back into the test equipment. Festo 7Tension01_TBb_en 9 / 20

58 6.2.2 Attaching the stop bolts The test equipment is placed on the left or right of the slide/piston on the toothed belt axisdepending on the size and design of the toothed belt axis (see table in section Attaching the test equipment ). Observe the prescribed test position when screwing the respective stop bolt into the test equipment. The designations in the table refer to the side where the slide/piston is attached to the test equipment or the stop bolt. S.L. means that the slide/piston is attached on the left of the test equipment, S.R. means that the slide/piston is attached on the right of the test equipment. The designations are engraved into the test equipment. Unscrew the relevant stop bolt from the top of the test equipment and screw it into the specified thread on the front side of the test equipment (see table). Type Stop bolt diameter Item DGE-25-ZR(-KF) 13 mm E DGE-40-ZR(-KF) No stop bolt - DGE-63-ZR(-KF) No stop bolt - DGE-25-ZR-RF 13 mm E DGE-40-ZR-RF 13 mm E DGE-63-ZR-RF 13 mm F EGC-50-TB-KF 8 mm A EGC-70-TB-KF 11 mm B EGC-80-TB-KF 13 mm C EGC-120-TB-KF 13 mm S.L.: C, S.R.: F EGC-185-TB-KF 13 mm E ELGA-TB-G mm E ELGA-TB-G mm E ELGA-TB-G mm E 10 / 20 Festo 7Tension01_TBb_en

59 6.2.3 Attaching the test equipment Warning Read the test requirements in chapter 5 Test requirements. (DGE- -ZR(-KF) only) The test equipment must be positioned on the side where the piston distance was set. This is the only way to ensure that the freely oscillating strand length is correct. Refer to the table for the position of the test equipment. Type Test equipment position DGE-25-ZR(-KF) S.L. or S.R. DGE-40-ZR(-KF) S.L. or S.R. DGE-63-ZR(-KF) S.L. or S.R. DGE-25-ZR-RF S.L. or S.R. 1) DGE-40-ZR-RF S.L. or S.R. 1) DGE-63-ZR-RF S.R. EGC-50-TB-KF S.L. EGC-70-TB-KF S.R. EGC-80-TB-KF S.L. EGC-120-TB-KF S.L. or S.R. 1) EGC-185-TB-KF S.L. or S.R. 1) ELGA-TB-G-70 S.L. or S.R. 1) ELGA-TB-G-80 S.L. or S.R. 1) ELGA-TB-G-120 S.L. or S.R. 1) 1) the position of the stop bolt Depending on the design of the toothed belt axis, the following methods can be used to ensure the correct position of the test equipment on the toothed belt axis: With position stops (DGE- -ZR- ) The position stops are necessary to align the test equipment with the toothed belt axis. Place the position stops on the test equipment as appropriate to the size of the toothed belt axis. Secure the position stops using the knurled screws. Place the test equipment on the toothed belt axis to the left or right of the slide/piston (S.L. or S.R.) in accordance with the table. Push the test equipment forwards so that the position stops on the cylinder barrel touch the toothed belt axis. (DGE- -ZR-KF) The guide rail of the toothed belt axis must be pointing forwards to check the toothed belt pretension. Festo 7Tension01_TBb_en 11 / 20

60 With position stops and distance pieces (ELGA-TB-G- ) The position stops are necessary to align the test equipment with the toothed belt axis. Place the position stops for the ELGA toothed belt axis on the test equipment and secure it using the knurled screws. Place the position stop bolts in the position stops as appropriate to the size of the toothed belt axis. Place the appropriate distance piece for the size of the toothed belt axis on the free side of the test equipment and secure it at the position E using the 7 mm ø stop bolt. Place the test equipment to the left or right of the slide/piston (S.L. or S.R.) as appropriate to the position of the distance piece (must be facing the slide) in accordance with the table. Push the test equipment forwards so that the position stops on the cylinder barrel touch the toothed belt axis. Without position stops (EGC- -TB-KF) Remove the position stops from the test equipment. Place the test equipment on the toothed belt axis in front of the guide rail to the left or right of the slide in accordance with the table. Push the test equipment backwards so that it is touching the guide rail. The test equipment is attached to the guide rail by means of integrated magnets. 12 / 20 Festo 7Tension01_TBb_en

61 All variants There must be no visible gap between the individual components, as otherwise the length of the freely oscillating strand and the toothed belt pretension measurement will be incorrect. Move the test equipment outwards until it touches the drive cover without any visible gap. Push the slide/piston against the test equipment until (depending on the toothed belt axis) the stop bolt or the front side of the test equipment is touching the piston, the clamping body or the clamp piece with no visible gap. Move the holder for the plunger housing so that the plunger is centred above the toothed belt or profile slot. Warning Inserted in the groove of the measurement head is an O-ring that also holds the meter inverted in the holder. This O-ring must have lubricating grease applied to it as otherwise the measurement head can be damaged by the high force applied when it is pulled out. Push the measurement head of the acoustic belt tension meter all the way into the holder on the test equipment. Festo 7Tension01_TBb_en 13 / 20

62 6.3 Checking and setting the toothed belt pretension Warning Checking and setting the toothed belt pretension is only required and permissible after a new toothed belt is installed. The pretension of the toothed belt diminishes during storage and operation. This is a normal process and not an indication of wear. Retensioning the toothed belt can result in premature wear. The toothed belt pretension has a direct influence on the service life of the toothed belt and the performance of the toothed belt axis. Extreme care must therefore be exercised when checking it. Before the toothed belt pretension can be measured, the slide/piston must be moved back and forth a number of times to allow the toothed belt to fully settle and differences in tension to be equalised Checking the toothed belt pretension on measurement using the acoustic belt tension meter If the toothed belt is excited by means of a force stimulus, the strand oscillates with its natural frequency; this dies down reasonably quickly depending on the attenuation. The frequency meter measures the natural frequency generated (transverse oscillation) using the acoustic operating principle. In addition to the basic oscillation (natural frequency), harmonic oscillation can also occur. From experience it is always the first harmonic oscillation. In other words, a further oscillation node is generated and therefore in addition to the basic oscillation frequency, values that are twice the natural frequency can also be measured. For this reason, several measurements should always be carried out to differentiate the necessary basic oscillation (natural frequency) from the harmonic oscillation. Only this frequency can be used to extrapolate the force acting along the strand. Pull the plunger upwards and then release it. The distance that the plunger has to be pulled out to generate the optimum force stimulus depends on the size and design of the toothed belt axis and must be established during the test. The magnitude of the force stimulus does not influence the measured natural frequency oscillation, it only changes the magnitude of the oscillation amplitude. Smaller toothed belt axes tend to require a smaller force stimulus. The belt must be able to oscillate freely. Push clamp pieces into the toothed belt axis if necessary (see section 6.2 Preparing the test equipment ). To assess the toothed belt pretension, several measurements should be made to balance out any measurement tolerances. 14 / 20 Festo 7Tension01_TBb_en

63 Compare the measurement with the specified value (see table). Type Frequency (f) DGE-25-ZR(-KF) Hz DGE-40-ZR(-KF) Hz DGE-63-ZR(-KF) Hz DGE-25-ZR-RF Hz DGE-40-ZR-RF Hz DGE-63-ZR-RF Hz EGC-50-TB-KF Hz EGC-70-TB-KF Hz EGC-80-TB-KF Hz EGC-120-TB-KF Hz EGC-185-TB-KF Hz ELGA-TB-G Hz ELGA-TB-G Hz ELGA-TB-G Hz Setting the toothed belt pretension Warning The toothed belt is set to the specified value in the factory and is thus maintenance-free over its entire service life. The pretension of the toothed belt diminishes during storage and operation. This is a normal process and not an indication of wear. Documents If the measured natural frequency of the toothed belt is outside the specified range, adapt the toothed belt pretension as specified in the relevant chapter in the respective operating instructions Additional information on checking the toothed belt pretension The correct toothed belt pretension is of critical importance for the service life of the toothed belt as well as the positioning accuracy and performance of the toothed belt axis. The conventional method for measuring the toothed belt pretension via the deflection force is too inaccurate and can therefore not be used. Accurate results are achieved by measuring the oscillation frequency. The natural frequency of a belt is based on its tension (strand force), mass and strand length. The strand length is the oscillating length of a belt. Since the strand length cannot be determined directly at the toothed belt axis by easy means, the toothed belt pretension test equipment is used to position the clamping body. A force stimulus is applied to the toothed belt to start it oscillating. The natural frequency of the toothed belt generated in this way is recorded using a meter and displayed as a frequency value in hertz. Festo 7Tension01_TBb_en 15 / 20

64 7 Quick guide This chapter contains all the relevant information for the individual toothed belt axes at a glance. 7.1 DGE- -ZR(-KF) The test equipment must be positioned on the side where the piston distance was set. This is the only way to ensure that the freely oscillating strand length is correct. (DGE- -ZR-KF only) The guide rail of the toothed belt axis must be pointing forwards (compared to the position stops) to check the toothed belt pretension. Type Frequency (f) Sleeve for plunger Slide position Stop bolt ø/position Distance between piston and clamp piece 1) DGE-25-ZR(-KF) Hz 10 mm S.L. or S.R. 13 mm/e 2 mm DGE-40-ZR(-KF) Hz 10 mm S.L. or S.R. 3 mm DGE-63-ZR(-KF) Hz S.L. or S.R. 5 mm 1) See section 6.1 Preparing the toothed belt axis 7.2 DGE- -ZR-RF It is imperative to attach an additional clamp piece to the toothed belt axes DGE-25-ZR-RF and DGE-40-ZR-RF so that the toothed belt can oscillate freely and does not strike the cylinder barrel (see section Inserting clamp pieces (DGE-25/40-ZR-RF only) ). Type Frequency (f) Sleeve for plunger Slide position Stop bolt ø/position DGE-25-ZR-RF Hz 25 mm S.L. or S.R. 13 mm/e DGE-40-ZR-RF Hz 25 mm S.L. or S.R. 13 mm/e DGE-63-ZR-RF Hz 25 mm S.R. 13 mm/f 7.3 EGC- -TB-KF The test equipment is positioned without position stops using the magnets inserted in the test equipment on the guide rail. Type Frequency (f) Sleeve for plunger Slide position Stop bolt ø/position EGC-50-TB-KF Hz 25 mm S.L. 8 mm/a EGC-70-TB-KF Hz 25 mm S.R. 11 mm/b EGC-80-TB-KF Hz 25 mm S.L. 13 mm/c EGC-120-TB-KF Hz 25 mm S.L. or S.R. 13 mm/s.l.: C, S.R.: F EGC-185-TB-KF Hz 25 mm S.L. or S.R. 13 mm/e 16 / 20 Festo 7Tension01_TBb_en

65 7.4 ELGA-TB-G- The Mounting kit for toothed belt axis ELGA-TB is needed to position the test equipment (see section 2.2 Mounting kit for ELGA-TB ). Type Frequency (f) Sleeve for plunger Slide position Stop bolt ø/position ELGA-TB-G Hz 25 mm S.L. or S.R. 11 mm/e ELGA-TB-G Hz 25 mm S.L. or S.R. 11 mm/e ELGA-TB-G Hz 25 mm S.L. or S.R. 13 mm/e 8 Maintenance and care If necessary, clean the toothed belt pretension test equipment using a soft cloth and gentle detergent. Festo 7Tension01_TBb_en 17 / 20

66 9 Accessories and ordering data You will need the following accessories to measure the toothed belt pretension. Part no. Description Type Basic device for checking the toothed belt pretension, in a TB-TE-EQ2 Systainer with foam insert. Suitable for toothed belt axes of the type DGE-25/40/63-ZR-(KF), DGE-25/40/63-ZR-RF, EGC-TB-KF. Holds the test probe of the acoustic frequency meter of the type TB-TE-EQ3 and excites the toothed belt by means of a plunger. Photo TB-TE-EQ4 Mounting kit for toothed belt axis ELGA-TB. Additionally requires the basic device of the type TB-TE-EQ2 for checking the toothed belt pretension TB-TE-EQ O-ring 10x TB-TE-EQ0 Acoustic belt tension meter (frequency meter) for measurement with and without test equipment. Special bonding of the test probe for use with the test equipment. Order alternatives: Type: Optibelt TT mini S plus Available exclusively from Schaefer Technik GmbH Mounts the acoustic test probe in the test equipment by means of clamping friction. Included in the scope of delivery of the frequency meter TB-TE-EQ3. Empty Systainer with foam insert. Space for basic test equipment TB-TE-EQ2/ (DGE-25/40/63-ZR-(KF), DGE-25/40/63-ZR-RF, EGC-TB-KF), frequency meter TB-TE-EQ3/760459, mounting kit TB-TE-EQ4/ (ELGA-TB) and test equipment TB-TE-EQ5/ (ERMB/EHMB). 10 Assembly and function check After completing the setting work on the toothed belt axis, the correct function must be checked using the relevant chapters in the repair instructions. 18 / 20 Festo 7Tension01_TBb_en