Festo DGE-25-ZR-KF Setup guide

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

2 / 48 Festo 7DGE_25-63_ZR_KFb_en
Imprint
Version:
7DGE_25-63_ZR_KFb_en (11.2011)
Copyright:
©Festo AG & Co. KG
P.O. Box
D-73726 Esslingen
Editorial team:
SC-S
Tel.:
+49 (0) 711/347-0
E-mail:
[email protected]
Internet:
http://www.festo.com
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 le patent,
utility model or registered design ap-
plications.
All product designations and brand
names used are the property of the
owners and not explicitly identied
as such.
All technical data subject to change
according to technical updates.

3 / 48Festo 7DGE_25-63_ZR_KFb_en
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 modication status of the specic 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 interfer-
ence suppression as well as the stipulations contained in these repair instruc-
tions must be observed when working on the products.

4 / 48 Festo 7DGE_25-63_ZR_KFb_en
Table of contents
1 Important information 5
1.1 About these repair instructions 5
1.2 Pictograms used in these repair instructions 5
1.3 General safety information 6
2 General product description 6
2.1 Functional description 6
2.2 Types and part numbers 7
2.3 Overview of variants and mounting directions 7
3 Component overview 8
4 Repair steps 14
4.1 Dismantling the toothed belt axis 14
4.1.1 Disconnecting the slide from the piston (DGE-…-KF only) 14
4.1.2 Removing the cover strip 15
4.1.3 Removing the drive covers and the toothed belt 16
4.1.4 Removing and dismantling the piston 17
4.2 Linear recirculating ball bearing guide system (DGE-…-KF only) 18
4.2.1 Removing the guide rail 19
4.2.2 Replacing the roller bearing cartridges 20
4.2.3 Installing the guide rail with slide 22
4.3 Drive covers 24
4.3.1 Clamp pieces 24
4.3.2 Clamping sleeves (DGE-25 and DGE-40 only) and buffers 24
4.3.3 Toothed drive shafts 24
4.4 Replacing the toothed belt 26
4.5 Assembling the toothed belt axis 27
4.5.1 Preparing the cylinder barrel 28
4.5.2 Preparing the clamping bodies 28
4.5.3 Preparing the piston 28
4.5.4 Inserting the piston, clamp pieces and toothed belt 29
4.5.5 Checking and setting the toothed belt pretension 33
4.5.6 Additional information on checking the toothed belt pretension 36
4.5.7 Installing the cover strip 37
4.5.8 Connecting the slide to the piston (DGE-…-KF only) 38
4.6 Assembly and function check 40
4.6.1 Buffer and belt assembly 40
4.6.2 Switching characteristics of the magnet 40
4.6.3 No-load torque 40
5 Maintenance 41
5.1 Cleaning and lubricating the toothed belt axis 41
5.2 Lubricating the recirculating ball bearing guide 41
5.3 Toothed belt pretension 42
5.4 Moment compensator play 42
6 Tools 43
7 Liability 45

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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 consid-
ered in the case of larger defects.
Before carrying out a repair, the
relevant chapter in these instructions
should be read thoroughly and com-
plied 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 ange, 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
(www.Festo.com).
• Spare parts documentation
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 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
(www.Festo.com).
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.
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 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.

6 / 48 Festo 7DGE_25-63_ZR_KFb_en
1.3 General safety information
Warning
The toothed belt axis must only be repaired by authorised and trained persons in accordance with the specications 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 with-
out 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.
Note
Instead of carrying out the repair yourself, your local Festo sales ofce 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 transmis-
sion. 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
321 4 5 6 7 8 9 1Drive cover with corner pulley
2Cover
3Clamp piece for clamping the
cover strip
4Slide (DGE-…-KF only)
5Adapter
6Moment compensator
7Piston
8Cylinder barrel
9Cover strip
aJ Guiding bands on the piston
aA Toothed belt
aB Deep-groove ball bearing
aC Drive trunnion

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2.2 Types and part numbers
Type Part number
DGE-25-…-ZR 193742
DGE-40-…-ZR 193743
DGE-63-…-ZR 193744
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 (www.Festo.com).
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-
Drive shaft on left
Drive shaft on right
Versions:
GK = Standard slide
GV = Extended slide
…-KL = Additional slide on left
…-KR = Additional slide on right
Orientation:
O = Top
U = Underneath
R = Right
L = Left
V = Front
H = Rear
-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

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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).

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Item Designation Type Note
1 Socket head screw DIN 912-M4×40-8.8 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-M4×12-8.8 Tightening torque 2.9 Nm
(with coupling KSE-30-35-… and EAMC-30-35-…)
7 Coupling
8 Coupling module See operating instructions for assembly
9 Retaining ring I 30×1.2 DIN 472
10 Flange screw M5×58 Tightening torque 6.0 Nm, use LOCTITE 243
11 Drive cover
12 Clamp piece
13 Threaded pin DIN 913-M5×6-45H Tightening torque 2.0 Nm
14 Socket head screw DIN 912-M3×8-8.8 Tightening torque 1.0 Nm
15 Cover
16 Clamping sleeve DIN 7346-4.5×16
17 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
22 - 25 Cover strip
26 - 28 Slot nut
29 - 30 Guide rail
31 Socket head screw DIN 912-M4×8-8.8 Tightening torque 2.9 Nm
32 Cover cap
33 - 34 Guide rail module
35 Socket head screw DIN 7984-M3×12-8.8 Tightening torque 1.2 Nm, use LOCTITE 243
36 Threaded pin DIN 913-M4×5-45H Use LOCTITE 243
37 - 38 Slide
39 Threaded pin DIN 913-M12×14-45H
40 - 41 Hexagon pin
42 Bearing cartridge
43 - 44 Slide module
45 Pin
46 Moment compensator
47 Countersunk screw DIN 7991-M5×35-8.8 Tightening torque 5.9 Nm
48 Piston with slide module
49 - 52 Toothed belt
53 Clamping plate
54 Socket head screw DIN 912-M4×25-8.8
55 Clamp piece
56 Magnet
57 Clamp piece module
58 Cylindrical dowel pin DIN 7-M6×10
59 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

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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).

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Item Designation Type Note
1 Socket head screw DIN 912-M5×65-10.9 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-M6×16-10.9 Tightening torque 10.5 Nm
(with coupling KSE-40-66-… and EAMC-40-66-…)
7 Coupling
8 Coupling module See operating instructions for assembly
9 Retaining ring I 40×1.75 DIN 472
10 Flange screw M6×80 Tightening torque 11.0 Nm, use LOCTITE 243
11 Drive cover
12 Clamp piece
13 Threaded pin DIN 913-M4×5-45H Tightening torque 2.0 Nm
14 Socket head screw DIN 912-M3×8-8.8 Tightening torque 1.0 Nm
15 Cover
16 Clamping sleeve DIN 1481-5×22
17 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
22 - 24 Cover strip
25 - 27 Slot nut
28 - 29 Guide rail
30 Socket head screw DIN 912-M4×12-8.8 Tightening torque 2.9 Nm, use LOCTITE 243
31 Cover cap
32 - 33 Guide rail module
34 Socket head screw DIN 7984-M4×12-8.8 Tightening torque 2.9 Nm, use LOCTITE 243
35 Threaded pin DIN 913-M4×5-45H Use LOCTITE 243
36 - 37 Slide
38 Threaded pin DIN 913-M14×16-45H
39 - 40 Hexagon pin
41 Bearing cartridge
42 - 43 Slide
44 Pin
45 Moment compensator
46 Countersunk screw DIN 7991-M6×35-8.8 Tightening torque 9.9 Nm
47 Piston with slide module
48 - 50 Toothed belt
51 Clamping plate
52 Socket head screw M4×40-12.9
53 Clamp piece
54 Magnet
55 Clamp piece module
56 Cylindrical dowel pin DIN 7-M6×25
57 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

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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).

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Item Designation Type Note
1 Socket head screw DIN 912-M8×90-10.9 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-M8×25-10.9 Tightening torque 25.0 Nm
(with coupling KSE-65-90-… and EAMC-65-90-…)
7 Coupling
8 Coupling module
9 Retaining ring I 62×2 DIN 472
10 Flange screw M8×125 Tightening torque 15.0 Nm, use LOCTITE 243
11 Drive cover
12 Clamp piece
13 Threaded pin DIN 913-M5×6-45H Tightening torque 3.0 Nm
14 Socket head screw DIN 912-M4×12-8.8 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
21 - 22 Cover strip
23 - 26 Slot nut
27 - 28 Guide rail
29 Socket head screw DIN 912-M5×20-8.8 Tightening torque 5.9 Nm, use LOCTITE 243
30 Cover cap
31 - 32 Guide rail module
33 Socket head screw DIN 7984-M6×16-8.8 Tightening torque 9.9 Nm, use LOCTITE 243
34 Threaded pin DIN 913-M5×6-45H Use LOCTITE 243
35 - 36 Slide
37 Threaded pin M16×1.5×18
38 - 39 Hexagon pin
40 Bearing cartridge
41 - 42 Slide module
43 Pin
44 Moment compensator
45 Countersunk screw DIN 7991-M8×40-8.8 Tightening torque 24.0 Nm
46 Piston with slide module
47 - 48 Toothed belt
49 Clamping plate
50 Clamp piece
51 Magnet
52 Clamp piece module
53 Cylindrical dowel pin DIN 7-M6×45
54 Socket head screw DIN 912-M5×50-12.9
55 Washer DIN 433-5.3
56 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-M6×22
63 Pin
64 Scraper
65 Compression spring
66 Adapter

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4 Repair steps
This chapter describes how to dismantle, repair and assemble the toothed belt axis DGE-…-ZR. This is done by rst dis-
mantling 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.
Note
The repair should preferably be carried out on a stable and at work surface with storage for small parts. It is also pos-
sible 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.
4.1.1 Disconnecting the slide from the piston (DGE-…-KF only)
• Place the toothed belt axis on the work surface as shown with the slide fac-
ing 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 attened on one side. Therefore do not use punches
larger than those specied 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 specied below.
• Use the following punches:
– DGE-25: 5 mm ø
– DGE-40: 7 mm ø
– DGE-63: 9 mm ø

15 / 48Festo 7DGE_25-63_ZR_KFb_en
• 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.
4.1.2 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.
Note
The adapter in the piston is under spring tension and can fall out after the
screws are removed. Secure it when removing the nal screw.
Note
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.

16 / 48 Festo 7DGE_25-63_ZR_KFb_en
• 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.
4.1.3 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.

17 / 48Festo 7DGE_25-63_ZR_KFb_en
• Pull the drive cover away from the cylinder barrel.
Note (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 retain-
ing 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”.
4.1.4 Removing and dismantling the piston
• Carefully push the piston out of the cylinder barrel.

18 / 48 Festo 7DGE_25-63_ZR_KFb_en
• 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.
Note
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 inuence 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 un-
even. 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 (unlubricated operation).
• Use of a lubricating grease not contained in the specication.
• 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 discon-
nected (see page 21 for the displacement force). This can only be done during assembly as connecting the piston and
toothed belt signicantly increases the displacement resistance.
In addition to the subjective assessment of the operating behaviour and guide backlash, this method can also be used to
conrm 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).

19 / 48Festo 7DGE_25-63_ZR_KFb_en
4.2.1 Removing the guide rail
Warning
The roller bearing cartridges are pretensioned. Individual bearings can there-
fore 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.
Note
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.

20 / 48 Festo 7DGE_25-63_ZR_KFb_en
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) screw-
driver. Otherwise the threaded pin will need to be drilled out.
• Remove the eight socket head screws that secure the roller bearing car-
tridges to the slide.
Note
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.
Note
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 awless bear-
ing 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.
Note
Bearings that have come out of the roller bearing cartridges must be re-
placed in the corresponding bearing.