Festo EGC-...-TB-KF Series Repair Instructions Download

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Festo 7EGC_TB_KFb_en

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

Plastic hammer

–

Pliers for retaining rings
(interior protection for hole)

20 – 100 mm

Ruler

–

Internal hexagon screwdriver
(Allen key)

1.5 – 6 mm

Torque wrench

1 – 30 Nm

Torque screwdriver

10 – 50 Ncm

Screwdriver bits

Internal hexagon socket (Allen socket): 1.5 – 6 mm

Flat pliers

–

Sturdy general purpose
scissors or metal shears

For cutting the toothed belt to length

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-
shaped lubrication
nipple and lubricating
holes

647 958

See “Assembly aids” in the online spare parts catalogue on the Festo website (

www.Festo.com

Summary of Contents for EGC-...-TB-KF Series

Page 1: ...Repair instructions en Toothed belt axis EGC TB KF 7EGC_TB_KFb_en ...

Page 2: ... 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 technic...

Page 3: ...iations 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 rel...

Page 4: ... toothed belt pretension 23 4 1 3 Additional information on checking the toothed belt pretension 25 4 1 4 Cutting the toothed belt to length 26 4 2 Dismantling the toothed belt axis 27 4 2 1 Removing the drive covers 27 4 2 2 Repairing the drive covers 29 4 3 Linear recirculating ball bearing guide system 31 4 3 1 Renewing the roller carriages 32 4 4 Assembling the toothed belt axis 35 4 4 1 Prepa...

Page 5: ...ntation Contains an overview of the spare and wearing parts as well as infor mation 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 lubricat ing greases locking agents maintenance tools etc aids for assembly and maintenance Can be found in the online spare parts cat...

Page 6: ...ving 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 envi ronmental protection regulations 2 General product description 2 1 Functional description The EGC TB KF is a toothed belt axis based on the operational principle of a circulating toothed belt for power trans mission The rotary motion o...

Page 7: ...gue or on the Festo website www Festo com 2 3 Overview of variants and mounting directions This diagram provides an overview of the mounting directions and slide variants for the toothed belt axis H L U V R O GK GP KR KL H L U V R O KL KR GV GQ H L U V R O Versions GK Standard slide GV Extended slide not EGC 50 GP Protected standard slide not EGC 50 or EGC 185 GQ Protected extended slide not EGC 5...

Page 8: ... 5 5 5 5 2 3 3 4 4 1 1 6 6 7 7 17 8 8 8 8 11 12 15 13 16 9 14 10 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 ...

Page 9: ...IN 472 21 1 5 Sealing disc 6 Cover cap 7 Buffer element 8 Clamping sleeve DIN 7346 2 5 10 9 Cylinder barrel module Aluminium extruded profile with bonded and roller swaged steel guide rail 10 Drive cover 11 Threaded pin DIN 913 M3 4 45H Tightening torque 0 1 Nm use LOCTITE 243 12 Clamping plate 13 Socket head screw DIN 912 M3 25 8 8 14 Clamping body 15 Clamping body module 16 Slide module Slide an...

Page 10: ...21 8 8 8 8 7 7 2 10 3 3 6 6 1 1 4 4 5 5 5 5 18 16 17 20 19 20 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 ...

Page 11: ...ing sleeve DIN 7346 3 18 9 Cylinder barrel module Aluminium extruded profile with bonded and roller swaged steel guide rail 10 Drive cover 11 Threaded pin DIN 913 M5 6 45H Tightening torque 0 3 Nm use LOCTITE 243 12 Clamping plate 13 Socket head screw DIN 912 M4 25 8 8 14 Clamping body 15 Clamping body module 16 Roller carriage Standard design 17 Roller carriage Protected version 18 Slide Standard...

Page 12: ...8 8 8 8 7 7 2 10 6 6 1 1 3 3 4 4 5 5 5 5 21 18 16 17 19 20 20 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 ...

Page 13: ...g sleeve DIN 7346 4 5 16 9 Cylinder barrel module Aluminium extruded profile with bonded and roller swaged steel guide rail 10 Drive cover 11 Threaded pin DIN 913 M5 6 45H Tightening torque 0 5 Nm use LOCTITE 243 12 Clamping plate 13 Socket head screw DIN 912 M5 25 10 9 14 Clamping body 15 Clamping body module 16 Roller carriage Standard design 17 Roller carriage Protected version 18 Slide Standar...

Page 14: ... 8 8 8 8 7 7 2 10 3 3 4 4 5 5 5 5 1 1 6 6 21 18 16 17 19 20 20 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 ...

Page 15: ...ing sleeve DIN 7346 5 20 9 Cylinder barrel module Aluminium extruded profile with bonded and roller swaged steel guide rail 10 Drive cover 11 Threaded pin DIN 913 M8 8 45H Tightening torque 4 Nm use LOCTITE 243 12 Clamping plate 13 Socket head screw DIN 912 M6 40 10 9 14 Clamping body 15 Clamping body module 16 Roller carriage Standard design 17 Roller carriage Protected version 18 Slide Standard ...

Page 16: ...20 6 6 10 2 3 3 4 4 1 1 5 5 5 5 7 7 8 8 8 8 9 17 16 18 19 19 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 ...

Page 17: ...er element 8 Clamping sleeve DIN 73467 28 9 Cylinder barrel module Aluminium extruded profile with bonded and roller swaged steel guide rail 10 Drive cover 11 Threaded pin DIN 913 M12 12 45H Tightening torque 5 Nm use LOCTITE 243 12 Clamping plate 13 Socket head screw DIN 912 M8 40 10 9 14 Clamping body 15 Clamping body module 16 Roller carriage Standard design 17 Slide Standard slide 18 Slide Ext...

Page 18: ...mended 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 tem perature range impermissible chemical influences or possibly fatigue Wear to the nylon fabric fabric coating on the tooth side o...

Page 19: ...nce 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 cool ing lubricants solvents ozone radiation water soluble greases and oils etc 4 1 1 Replacing the toothed belt Note This description presupposes that the toothed belt is not torn or that the tear is located in the vi...

Page 20: ...elt Remove the clamping plates from the toothed belt Note Do not pull the old toothed belt out of the axis before you have joined it to the new toothed belt as otherwise you will need to remove the drive covers Join the ends of the old and new toothed belts using adhesive tape Documents A description of how to determine the correct toothed belt length can be found in section 4 1 4 Cutting the toot...

Page 21: ...ially with the centre of the clamping body Apply Loctite 243 to the threaded pin and screw it into the clamping body Push the clamping plate against the stop a on the clamping body Note The clamping plate must make contact with the stop as otherwise the toothed belt pretension will diminish during operation Tighten the threaded pin using the appropriate torque see table Note It is critical that th...

Page 22: ...ended for assembly The use of threaded inserts with SCREWLOCK and the dynamic load on the adjusting screw mean that only original spare parts from Festo with the appropriate strength class may be used Otherwise the screws can break prematurely The clamping bodies must not touch the slide when they are being screwed in as otherwise the toothed belt could become overstretched and the service life of...

Page 23: ...asured the slide 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 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...

Page 24: ...ing 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 If the measured natural frequency of the toothed belt is outside the specified range the toothed belt pretension must be set as follows Adjust th...

Page 25: ...d length m FV Pretension force N m 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 FV EGC 50 0 0154 kg m 20 mm L11 51 53 N EGC 70 0 0345 kg m 30 mm L11 102 109 N EGC 80 0 0459 kg m 35 mm L11 408 426 N EGC 120 0 1179 kg m 50 mm L11 816 852 N EGC 185...

Page 26: ... B which is then multiplied by the factor A The factors are dependent on the size and type of slide used see table The stroke the stroke reserve and the slide type 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 calculated length A stroke 2 stroke reserve B see order example Type A dependent on the stroke B depende...

Page 27: ...er with toothed belt pulley and drive 4 2 1 Removing the drive covers Place the toothed belt axis on the work surface as shown with the slide facing upwards Lever off the cover caps at both ends from the drive covers Loosen the socket head screw in the clamping bodies and unscrew it Move the slide to the left and right to release the clamping bodies from the slide Push the two clamping bodies out ...

Page 28: ...ll out Pull the clamping bodies from the toothed belt Remove the clamping plates from the toothed belt Carefully pull the toothed belt out of the axis Loosen the socket head screws in the drive cover and unscrew them Pull the drive cover away from the cylinder barrel Note The drive covers are connected to the cylinder barrel using spring pins A certain amount of force is required to pull them away...

Page 29: ...however the clamping sleeves can also be located in the cylinder barrel following disassembly of the drive covers Pull out these parts to replace them Toothed belt pulley module The toothed belt pulley module sits in a clearance fit in the drive cover with two pressed on deep groove ball bearings and is axially secured by a retaining ring Removing the toothed belt pulley module Lever the sealing d...

Page 30: ...fitting securely replace the module Installing the toothed belt pulley module Apply a light coating of grease to the outside of the deep groove ball bearings and push the toothed belt pulley module into the drive cover as shown with the long end of the shaft in front Note If necessary use a plastic hammer to carefully insert the toothed drive shaft into the drive cover Insert the retaining ring No...

Page 31: ...tting 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 Note 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 unlubrica...

Page 32: ...ge to the guide rail The roller carriages can only be renewed with axes below a specific stroke length see table Type Maximum stroke length incl 2 stroke reserve EGC 50 GK No restriction EGC 70 GK GP 3 469 mm EGC 70 GV GQ 3 369 mm EGC 80 GK GP 4 644 mm EGC 80 GV GQ 4 544 mm EGC 120 GK GP 5 754 mm EGC 120 GV GQ 5 654 mm EGC 185 GK 5 668 mm EGC 185 GV 5 568 mm In the case of toothed belt axes with l...

Page 33: ...lation position when positioning the new roller carriages The partially ground side stop side of the roller carriage must face the front side of the toothed belt axis Warning New roller carriages standard version with the variant GK and GV must be lubricated before the toothed belt axis is commissioned See section 5 2 Lubricating the recirculating ball bearing guide If this is not done the toothed...

Page 34: ...t the stop side and mounting surface of the slide have no sur face defects To provide a perfect support and contact surface for the roller carriages there must be no burrs chips kinks etc and no residues of the locking agent a Stop side b Mounting surface b a Place the slide on the roller carriages Apply Loctite 243 to the socket head screws and screw them into the roller carriages through the sli...

Page 35: ...belt to length Guide the left hand end of the toothed belt through the prepared drive cover for the left hand side as shown Place the clamping plate on the left hand end of the new toothed belt Note The clamping plate must be aligned axially with the centre of the toothed belt to prevent damage to the toothed belt during operation Align the clamping plate axially with the centre of the toothed bel...

Page 36: ...ld the toothed belt as this can result in damage to the tensile bodies and shorten its service life by tearing it Note the minimum bending radius for assembly and storage see section 4 1 4 Cutting the toothed belt to length Insert the clamping body into the groove in the cylinder barrel Note The drive cover is centred with respect to the cylinder barrel by means of two clamping sleeves A certain a...

Page 37: ...justing screws is recommended for assembly The use of threaded inserts with SCREWLOCK and the dynamic load on the adjusting screw mean that only original spare parts from Festo with the appropriate strength class may be used Otherwise the screws can break prematurely The clamping bodies must not touch the slide when they are being screwed in as otherwise the toothed belt could become overstretched...

Page 38: ...ntle detergent Lubricate the surface of the guide rail if there is no longer any sign of lubrication Lubricants for assembly and maintenance of the toothed belt axis Application Designation Assembly Festo LUB KC11 Maintenance Festo LUB KC11 1 See Assembly aids in the online spare parts catalogue on the Festo website www Festo com 5 2 Lubricating the recirculating ball bearing guide The recirculati...

Page 39: ...e environment e g grinding dust etc Positioning profile delta operation frequent acceleration and braking EGC more than 3 years old 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 carriages 5 3 Toothed belt pretension Warning The toothed belt is set to the specified value in the factory and is th...

Page 40: ...en key 1 5 6 mm Torque wrench 1 30 Nm Torque screwdriver 10 50 Ncm Screwdriver bits Internal hexagon socket Allen socket 1 5 6 mm Flat pliers Sturdy general purpose scissors or metal shears For cutting the toothed belt to length 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 hi...

Page 41: ... alternatives Type Optibelt TT mini S plus Available exclusively from Schaefer Technik GmbH www schaefer technik de Acoustic belt tension meter frequency meter for measurement without test equipment Not available via Festo Manufacturer supply Optibelt GmbH www optibelt com or comparable meter from other manufacturers 200926 O ring 10x1 Mounts the acoustic test probe in the test equipment by means ...

Page 42: ...ty 1 Festo products are being continuously developed with regard to hardware and soft ware The hardware status and where appli cable 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 g...

Page 43: ...Operating instructions en Toothed belt pretension test equipment 7Tension01_TBb_en ...

Page 44: ...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 tech...

Page 45: ...n sion 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 L...

Page 46: ...istance DGE ZR KF only 8 6 1 2 Inserting clamp pieces DGE 25 40 ZR RF only 8 6 2 Preparing the test equipment 9 6 2 1 Attaching the extension sleeves 9 6 2 2 Attaching the stop bolts 10 6 2 3 Attaching the test equipment 11 6 3 Checking and setting the toothed belt pretension 14 6 3 1 Checking the toothed belt pretension 14 6 3 2 Setting the toothed belt pretension 15 6 3 3 Additional information ...

Page 47: ...rams 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 Note 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 o...

Page 48: ...nce with the locally valid envi ronmental protection regulations 2 Control elements and connections 2 1 Test equipment 6 7 8 1 2 3 4 5 9 aJ aA aC aD aE aF aB 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 ...

Page 49: ...ipment in a dry place where it is protected from corrosion ideally in the match ing 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 ind...

Page 50: ... 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 L L1 6 1 Preparing the toothed belt axis 6 1 1 Checking the piston distance DGE ZR KF only Check the distance between the piston and clamp piece...

Page 51: ...erent 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...

Page 52: ...ans 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 K...

Page 53: ...ELGA TB G 80 S L or S R 1 ELGA TB G 120 S L or S R 1 1 Note 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 Note The position stops are necessary to align the test equipment with the toothed belt axis Place the position stops on t...

Page 54: ...t 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...

Page 55: ...top 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 app...

Page 56: ...ation 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...

Page 57: ...ied in the relevant chapter in the respective operating instructions 6 3 3 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 position ing accuracy and performance of the toothed belt axis The conventional method for measuring the toothed belt pretension via the deflect...

Page 58: ...Preparing the toothed belt axis 7 2 DGE ZR RF Note 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 6 1 2 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 155 4 Hz...

Page 59: ...ting kit for ELGA TB Type Frequency f Sleeve for plunger Slide position Stop bolt ø position ELGA TB G 70 146 2 Hz 25 mm S L or S R 11 mm E ELGA TB G 80 133 3 Hz 25 mm S L or S R 11 mm E ELGA TB G 120 138 2 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 ...

Page 60: ...elt 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 www schaefer technik de 200926 O ring 10x1 Mounts the acoustic test probe in the test equipment by means of clamping friction Included in the scope of deli...

Page 61: ...e repair instructions for the respective toothed belt axis for an overview of the tools and aids for setting the toothed belt pretension 12 Liability The General Terms and Conditions of Festo AG Co KG which can be viewed on the Festo website www Festo com apply ...

Page 62: ...anty 1 Festo products are being continuously developed with regard to hardware and soft ware The hardware status and where appli cable 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...

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