ITEM KLE 6 Operating instructions

Linear Units KLE
Notes on Use and Installation

2
Linear Units KLE ― Notes on Use and Installation
Contents
Symbols, safety. .......................................................................................................................................................................................................3
General safety information ....................................................................................................................................................................................3
Correct use................................................................................................................................................................................................................4
Improper use.............................................................................................................................................................................................................5
Selecting suitable Linear Units KLE ....................................................................................................................................................................5
Design... .....................................................................................................................................................................................................................5
Article names, geometry........................................................................................................................................................................................6
General technical data......... ..................................................................................................................................................................................8
Assembly. ..................................................................................................................................................................................................................8
Tool..............................................................................................................................................................................................................................8
Shaft and prole machining..................................................................................................................................................................................9
Press-tting the Shafts. ....................................................................................................................................................................................... 10
Timing Belt, Strip. ................................................................................................................................................................................................. 12
Carriage .................................................................................................................................................................................................................. 14
Timing-Belt Reverse Unit, Timing-belt drive.................................................................................................................................................... 16
Calculating Timing Belt tension......................................................................................................................................................................... 18
Tightening the Timing Belt. ................................................................................................................................................................................ 19
Support system, Carriage Plate......................................................................................................................................................................... 21
Drive, synchronisation. ........................................................................................................................................................................................22
Drive.........................................................................................................................................................................................................................22
Synchronising two Linear Units KLE ................................................................................................................................................................26
Prepared KLE Drive Set.......................................................................................................................................................................................28
Proximity switches................................................................................................................................................................................................ 31
Commissioning...................................................................................................................................................................................................... 31
Maintenance. .........................................................................................................................................................................................................32
Disposal...................................................................................................................................................................................................................33
Product development and documentation .....................................................................................................................................................33

3
Linear Units KLE ― Notes on Use and Installation
Symbols, safety
Important information
Warning! Failure to observe this safety instruction can result in material damage, serious injury or death
Caution! Failure to observe this safety instruction can result in material damage, serious injury or death
Caution! Failure to observe this safety instruction can result in material damage or injury
Note! Failure to observe this safety instruction can result in material damage
Maintenance
Observe directions for disposal
Observe directions for disposal
General safety information
The details and information in this assembly guide are provided for the purposes of describing the product and its assembly
only. This information does not discharge the user from the obligation to carry out his own assessments and checks. It is im-
portant to bear in mind that our products are subject to a natural process of wear and ageing. These notes contain important
information that will enable you to use the product safely and appropriately. When sold, rented out or otherwise passed on to
another party, this product must be handed over with the assembly guide.
When assembling, operating and maintaining the KLE (compact Linear Unit), it is important to ensure that all moving elements
are secured so that they cannot be switched on and moved unintentionally. Rotating and moving parts can cause serious
injury! You must therefore read and follow the safety instructions set out below.
All work on and with the KLE must be performed with “safety rst” in mind.
▪Always switch off the drive assembly before you start working on the KLE.
▪ Ensure the drive unit is not switched on unintentionally, e.g. by a󹟠xing warning notices at the activation point or by remo-
ving the fuse from the power supply.
▪Do not place your hand within the operating range of the moving parts on the KLE when the unit is still switched on.
▪Fit guards and covers to the moving parts of the KLE to ensure they are not touched unintentionally.
▪Observe the regulations pertaining to accident prevention and environmental protection that apply in the country and place
of work where the product is being used.
▪Use only item products that are in perfect working order.
▪Failure to use original spare parts will invalidate the product warranty!
▪Check the product for obvious defects.
▪Use the product only within the performance range described in the technical data.

4
Linear Units KLE ― Notes on Use and Installation
▪Ensure that all the safety equipment associated with the product is present, properly installed and in full working order.
▪Do not alter the position of safety equipment, circumvent it or render it ineffective.
KLE 6 60x60 LR and KLE 8 80x80 LR, as described here, corresponds to the state of the art and takes into account the gene-
ral principles of safety applicable at the time this assembly guide was published. Nevertheless, failure to observe the
safety instructions and warning notices in this assembly guide may result in personal injury and damage to property. We will
assume no liability for any resulting damage or injury.
We reserve the right to make technical changes that represent technical advances. Keep this assembly guide in a place
where it can be easily accessed by all users. Observe the directions contained in the main user guide for the completed
machine. The general safety information applies to the entire lifecycle of the partly completed machine.
1. During transportation
Observe the handling instructions on the packaging. Until it is assembled, the product must be stored in its original packaging,
protected from moisture and damage. Ensure that moving parts are secured when in transit and cannot cause any damage.
2. During assembly
Always deactivate the power to the relevant system part and ensure it is not live before installing the product and/or plugging
it in or unplugging it. Ensure the system cannot be switched back on. Lay cables and lines in such a way that they cannot be
damaged and do not represent a trip hazard. Avoid areas that pose slip, trip and fall hazards.
3. During commissioning
Allow the product to acclimatise for a few hours before starting to use it. Ensure that the partly completed machine is securely
and safely integrated into the completed machine. Only start up a product that has been installed in full.
4. During operation
Ensure that only persons who have been authorised by the operator have access to the immediate operating area of the
system. This also applies when the system is not in operation. It must not be possible to actuate moving parts unintentionally.
During emergencies, malfunctions or other irregularities, deactivate the system and ensure that it cannot be switched back on.
Prevent the possibility of persons becoming trapped in the system’s hazard zone.
5. During cleaning
Close all openings with suitable protective equipment to ensure that cleaning agents cannot penetrate the system. Do not use
aggressive cleaning substances. Do not use a high-pressure cleaner when cleaning the system.
6. During maintenance and servicing work
Carry out the prescribed maintenance work at the intervals stipulated in the user guide. Ensure that no cable links, connec-
tions or components are removed while the system is live and under pressure. Ensure the system cannot be switched back on.
7. During disposal
Dispose of the product in accordance with the national and international regulations that apply in your country.
The KGT 6 60 P20 is designed for indoor operation.
Correct use
The compact linear unit is a component and must only be used in accordance with the technical data and safety requirements
set out in this document. If the compact linear unit is combined with a motor and control unit, an incomplete machine is
generated in the sense of the MRL 2006/42/EC. The Declaration of Incorporation is enclosed for the version with motors and
controls, from item GmbH. Internal company requirements and the regulations that apply in the country where the product is
being used must be observed. You must not make any design modications to the KLE yourself. We will assume no liability for
any resulting damage or injury.
You may only assemble, operate and maintain the KLE if:
The compact Linear Unit has been integrated properly and safely into the completed machine,
You have carefully read and understood the assembly guide,
You are appropriately qualied,
You are authorised to do so by your company,
You are using only original equipment from the manufacturer.

5
Linear Units KLE ― Notes on Use and Installation
Unsafe or inappropriate use of the compact Linear Unit runs a risk of serious injury through crushing and cuts.
The KGT 6 60 P20 is designed for indoor operation.
Improper use
Improper use is dened as any use of the product for purposes other than those authorised in the assembly guide and under
the denition of correct use. We will assume no liability for any resulting damage or injury.
Selecting suitable Linear Units KLE
Design
Linear Unit KLE 6 60x60 LR 0.0.605.07
Linear Unit KLE 8 80x80 LR 0.0.605.02
KLE 6 60x60 KLE 8 80x80
L [mm] Max. overall length 6,150 6,200
L [mm] Min. overall length 400 600
LS[mm] Slide length visible 190 262
LG[mm] Slide length 198 273
B [mm] Reverse Unit length 75 100
A [mm] Reverse Unit hight 60 80
Smin [mm] Minimum safety 26 63.5
H [mm]
Hmax
Travel
Max. travel at min. safety 5,750 5,600
Table 1 Geometry
B
SH
A
S
L
G
B
L
S
L
The safety distance S is a reserve distance to accommodate tolerances and carriage overtravel under high loads and acceler-
ations at the reversal point. It must be factored into the equation depending on the capabilities of the drive and Controller, but
in any event should not be smaller than shown!

6
Linear Units KLE ― Notes on Use and Installation
Article names, geometry
110
349
2568
7
1 2 3 4 5 6 7 8 9 10
Article name Order number
1Timing Belt Drive KLE 6 60x60 LR 0.0.605.18
Timing Belt KLE 8 80x80 LR 0.0.604.95
2 Prole 6 60x60 KLE 0.0.603.83
Prole 8 80x80 KLE 0.0.600.42
3Timing Belt R 25 AT5 PAR 0.0.604.06
Timing Belt R 34 AT10 PAR 0.0.600.28
4Cover Plate KLE 60x60
Cover Plate KLE 80x80
5Carriage KLE 6 60x60 0.0.604.23
Carriage KLE 8 80x80 0.0.600.26
6Roller D10/D14, eccentric bearing
7Roller D10/D14, centric bearing
8End Cap and Lubricating System with three grease nipples
9Shaft D10/D14
10 Reverse Unit KLE 6 60x60 LR 0.0.604.21
Reverse Unit KLE 8 80x80 LR 0.0.600.49
Strip KLE 6 60x60 (see page 10) 0.0.608.29
Strip KLE 8 80x80 0.0.608.30
Cover Prole KLE 6 60x60 0.0.603.88
Cover Prole KLE 8 80x80 section on Proximity Switches) 0.0.600.54

7
Linear Units KLE ― Notes on Use and Installation
f max
LaLa
BB
ww
L s
L
F
KLE 6 60x60 KLE 8 80x80
Ls
[mm] Carriage length 198 273
B[mm] Width of Reverse Units 75 100
W[mm] Distance between maintenance
holes 85.5 119
La
[mm] Minimum distance from support
to Reverse Unit 10 10
L[mm] Max. overall length 6,150 6,200
L[mm] Min. overall length 400 600
fmax
[mm/m] Prole deection ≤ 1 ≤ 1
Table 2 Geometry
The maximum deection, f
max
of the system is governed by
the dimension of the prole
cross-section, the free prole
length and the force applied.
The KLE housing must be given appropriate support if the linearity of movement has to be very precise.
Z
Y
KLE 6 60x60 KLE 8 80x80
I
y
44.32 cm
4
135.59 cm
4
I
z
57.46 cm
4
179.77 cm
4
l
t
7.23 cm
4
20.31 cm
4
W
y
13.08 cm
3
29.88 cm
3
W
z
19.15 cm
3
44.94 cm
3
Table 3 Prole data
Deection f
max
is calculated
using the mass moments of
inertia of the prole.

8
Linear Units KLE ― Notes on Use and Installation
General technical data
KLE 6 60x60 KLE 8 80x80
Static load factor per Roller Co[N] 2,470 4,400
Dynamic load factor per Roller C [N] 4,400 7,800
Repeatability [mm] ± 0.1 ± 0.1
Vmax [m/s] 10 10
Table 4 Technical data
L
x
y
z
Fz
Mz Fx
Mx
Fy
My
If loads are combined, the general rule governing the total load
also applies:
KLE Mx max
[Nm]
My max
[Nm]
Mz max
[Nm]
Fx max
[N]
Fy max
[N]
Fz max
[N]
6
60x60 25 50 100 500 750 500
8
80x80 50 100 150 1.500 1,500 1.000
Table 5 Simplied maximum load data for 10,000km duty cycle
1
maxmaxmaxmaxmax
≤++++
z
z
y
y
z
z
y
y
x
x
F
F
F
F
M
M
M
M
M
M
Assembly
The KLE is constructed from assemblies and cut-to-size elements and must be checked for completeness prior to actual
assembly.
Tool
Assembly Set KLE LR (0.0.612.72) is used to support assembly and maintenance of both sizes of system. It consists of the
following parts:
▪Drilling Jig KLE 8 80x80 LR 0.0.611.21
▪Drilling Jig KLE 6 60x60 LR 0.0.611.53
▪Pin Spanner KLE 0.0.611.82
▪Torque Spanner 0.0.612.73
▪Mounting Aid KLE 0.0.610.91
▪Shaft Assembly Lever KLE 0.0.610.92

9
Linear Units KLE ― Notes on Use and Installation
Also available:
▪Track Oil 0.0.612.75
▪Oil Can with Tip for KLE 0.0.612.74
The various tools and how they are used are described on the following pages.
Shaft and prole machining
Cutting to size of Prole 6 60x60 KLE 0.0. 603.83
Prole 8 80x80 KLE 0.0.600.42
Determining the prole lengths while factoring in the various system geometries and variable stroke length H, where:
KLE 6 60x60: LProle = 2 x S + H + 198 mm
KLE 8 80x80: LProle = 2 x S + H + 273 mm
Safety distance S of KLE 6 60x60: Smin = 26.0 mm
KLE 8 80x80: Smin = 63.5 mm
Cutting Shaft D10 (KLE 6 60x60) / D14 (KLE 8 80x80) approx. 5 mm shorter than prole length:
KLE 6 60x60: LShaft = LProle - 5 mm
KLE 8 80x80: LShaft = LProle - 5 mm
Next, tap threads into the core bores of the prole end
faces.
Threaded bore: KLE 6 60x60: M5x15
KLE 8 80x80: M6x20
The ends of the proles in the areas marked red
must be free of burrs in order to prevent damage to
the Timing Belt. The cut edges must be machined
accordingly!
Maintenance holes are then drilled into the prole.
Assembly Set KLE-LR (0.0.612.72) contains a Drilling
Jig for this purpose. This maps out the precise gauge
for holes.
The Drilling Jig is tted with a stop that ensures the
minimum dimension required between the maintenan-
ce holes and the end of the prole.
KLE 6 60x60: M5*15
KLE 8 80x80: M6*20
KLE 6 60x60: M5*15
KLE 8 80x80: M6*20

10
Linear Units KLE ― Notes on Use and Installation
The maintenance holes can be cut at any accessible point as long as the gauge for the holes is adhered to.
A pillar drill is recommended.
Distance between maintenance holes: w [mm]
KLE 6 60x60: w = 85.5 mm ⌀ 6 mm
KLE 8 80x80: w = 119 mm ⌀ 8 mm
The maintenance holes need only be cut into the prole from one side so that the carriage grease nipples can be accessed.
Press-fitting the Shafts
Press Shafts D10 (KLE 6 60x60) / D14 (KLE 8 80x80) into the prole geometry using the Mounting Aid, Shaft Assembly
Lever (part of Assembly Set KLE-LR, 0.0.612.72) and a suitable second Line 8 prole.
With the prole laid on its side, insert the Shafts into the prole geometry and arrange them so that both ends of each Shaft
are approx. 2.5 mm shorter than the prole.

11
Linear Units KLE ― Notes on Use and Installation
Next, use the Shaft Assembly Lever to press the Shafts, every 100 mm or so (the width of a hand), into the prole geometry
until you can clearly feel or hear them engage.
The Shaft should be greased lightly to make it easier to press in.
Next, pin the Shafts at one end using the drill template that is part of Assembly Set KLE-LR (0.0.612.72).
To do this, suitable drill bushes are provided in the Drilling Jig at a distance of 30 mm (KLE 60) / 40 mm (KLE 80) from the
prole edge.
As the Shaft is hardened, lay the prole on its side and cut a hole from above on a pillar drill.
KLE 6 60x60: Carbide spiral drill ⌀ 4 mm
Recommended speed 3000 rpm
KLE 8 80x80: Carbide spiral drill ⌀ 6 mm
Recommended speed 2000 rp
Next, remove all the shavings and clean the prole and Shafts of all residual material.
Drilling aid for pinning the Shaft
B
øZ
A
C
KLE 6 60x60 KLE 8 80x80
A [mm] 31.0 41.5
B [mm] 15.8 19.8
C [mm] 8.0 11.0
⌀ Z [mm] 4.0 6.0
Table 6 Geometry for pinning

12
Linear Units KLE ― Notes on Use and Installation
dd
We recommend the following dowel for pinning
purposes:
KLE 6 60x60 Dowel Pin DIN 6325-4x14
KLE 8 80x80 Dowel Pin DIN 6325-6x18
For KLE units with Shaft lengths in excess of 3m, Shafts D10 (KLE 6 60x60) / Shaft D14 (KLE 8 80x80) must be butt-joined.
There must be no more than one butt joint. The recommended minimum Shaft length is
LShaft min = 300 mm
The butt joints thus created on the Shafts can be opposite each other, i.e. they do not have to be offset to each other, since the
rollers of the Carriage are offset.
The ends of the Shafts must be clean and free of burrs and chamfered edges.
Use the Drilling Jig (part of Assembly Set KLE-LR 0.0.612.72) to pin the butt-jointed Shafts at the joints but not at the ends of
the proles too. The recommended distance d from the xing bore to the butt joint is:
KLE 6 60x60: d = 30 mm
KLE 8 80x80: d = 40 mm
Timing Belt, Strip
The length of the Timing Belt and Strip is calculated as follows:
1. Timing Belt: KLE 6 60x60: LTB = 2 x Lprole + 162 mm
KLE 8 80x80: LTB = 2 x Lprole + 246 mm
The formula already factors in an additional tooth as a safety factor
plus a tooth of Timing Belt R25 AT5 PAR: + 5 mm
plus a tooth of Timing Belt R34 AT10 PAR: + 10 mm
2. Strip: LStrip = Lprole - 2 mm
The Strip at the bottom of the prole reduces the frictional losses of the moving Timing Belt.

13
Linear Units KLE ― Notes on Use and Installation
The ends of the Strip must be free of burrs.
Insert the Strip all the way into the bottom of the prole
(with the curved side facing down).
The Timing Belt can be cut with conventional metal
shears.
After it has been cut, slide the Timing Belt over the
Strip in the bottom of the prole so that it projects at
both sides.

14
Linear Units KLE ― Notes on Use and Installation
Carriage
Carriage KLE 6 60x60 / Carriage KLE 8 80x80 is supplied pre-assembled.
4x Hexagon Socket Head Cap Screws
DIN 7984, bright zinc-plated
Cover Plate Contact plate
2x Hexagon Socket Head
Cap Screws DIN 7984,
black
(located under contact
plate)
Disassemble the contact plate. Do this by removing the
two Countersunk Screws DIN 7997.
Remove the Cover Plate from the Carriage. To do this,
remove the four Hexagon Socket Head Cap Screws DIN
7984 (bright zinc-plated) on the outside and the two
Hexagon Socket Head Cap Screws DIN 7984 (black)
under the contact plate.
Next, push the Carriage without the lubricating felt
inserts into the track between the Shafts.
Use the two (central) eccentrically adjustable pins to
set the rollers, eliminating play and applying a gentle
preload over the entire length of travel.
To do this, push the Carriage along the prole to check
it is running smoothly and to adjust the play.
It is important to check that the Carriage runs easily
and quietly.

15
Linear Units KLE ― Notes on Use and Installation
u
When pushing in the Carriage, the two central rollers
are adjusted with an Allan key A/F 4 so that the Carria-
ge can be slid into the Prole with ease.
When adjusting the Carriage in the prole, the hexa-
gon sockets bolts of the rollers may only be moved in
anti-clockwise direction.
A small mark on the hexagon socket denes the
position of the roller between the Shafts and thus axial
offset. During the adjustment process, this mark moves
anti-clockwise in a circular arc that must be smaller
than 360°.
The result is the maximum possible axial offset (u) of
the outer roller relative to the inner Roller of:
KLE 6 60x60: umax = 1 mm
KLE 8 80x80: umax = 2 mm
Caution! If you exert too much pressure on the rollers, the roller bearings may be damaged.
When running without play, the rollers are secured in
position using a special pin torque spanner (part of
Assembly Set KLE-LR 0.0.612.72).
To secure the lock nut, turn the pin torque spanner
clockwise and, at the same time, turn the Allan key
anti-clockwise.
Tightening torque applied by torque spanner:
KLE 6 60x60: T = 10 Nm
KLE 8 80x80: T = 20 Nm
Remove the Carriage from the guide track and t the
springs and felt inserts of the End Cap and Lubricating
System into the positions provided for this purpose on
the Carriage.
Before the Carriage is inserted into place, the mainte-
nance lines should be completely lled from both sides
in a one-off step.
The lines of the central lubrication system must be charged by the person commissioning it.
Insert the lubricating felt inserts in pairs into the plastic housings. Insert a compression spring between the felt pieces.

16
Linear Units KLE ― Notes on Use and Installation
When subsequently inserting the Carriage into place, press the felts together to prevent them from being damaged.
The plastic element must be correctly positioned
before the Carriage is slotted on.
The plastic element is used to cover the gap and must
be assembled with the tooth-shaped ends pointing
downwards.
Ends of the plastic element pointing downwards in
line with tooth shape
Timing-Belt Reverse Unit, Timing-belt drive
The rerouting units for the Timing Belt of the KLE-LR differ in design – one is a Drive Unit and the other a Reverse Unit.
A Drive Unit KLE is tted to one end of Prole KLE and a Reverse Unit KLE to the other.
A motor can only be connected to a Drive Unit.
The ends of the Timing Belt emerging from the lower prole are routed through the two rerouting units and, in cases where
these units are unsecured and have not been dismantled, are run into the prole’s upper guide groove.
The tensioning axle at the Reverse Unit end makes it easier to introduce the Timing Belt.

17
Linear Units KLE ― Notes on Use and Installation
Align the Reverse Units with the end faces of Prole
KLE and secure them in place:
Tightening torque KLE 6 60x60 (M5): 6 Nm
Tightening torque KLE 8 80x80 (M6): 10 Nm
Lift the Timing Belt up out of the guide groove and
press it onto the toothing on the end of the Carriage.
It is important to ensure that the Timing Belt is located centrally on the Carriage. The Carriage has a marking to indicate this.
The tter must mark the centre of the Timing Belt.
All teeth of the Timing Belt must mesh into the toothing
on the Carriage.
Screw six Hexagon Socket Head Cap Screws DIN 7984 into the Cover Plate again:
KLE 60: 4 x M4x12 (bright zinc-plated) and 2 x M4x8 (black)
KLE 80: 4 x M5x14 (bright zinc-plated) and 2 x M5x12 (black)
Tightening torque M4: 3 Nm
Tightening torque M5: 6 Nm
The Cover Plate of the Carriage can only be secured in one position! It is important to ensure that the holes in the Cover Plate
coincide with the threads in the Carriage and that the gap is symmetrical.

18
Linear Units KLE ― Notes on Use and Installation
4x Hexagon Socket Head Cap Screws
DIN 7984 bright zinc-plated
2x Hexagon Socket Head Cap Screws
DIN 7984 black (under contact plate)
To correct (shorten) the length of a Timing Belt, move the Carriage backwards and forwards several times so that the belt
teeth can align correctly in the pulleys of the Reverse Units.
If the Carriage is di󹟠cult to move, the teeth are not yet positioned correctly in the pulley of the Reverse Unit.
You can shorten the Timing Belt if necessary by unscrewing the Cover Plate, shortening the Timing Belt and retting it. Next,
screw the Cover Plate back in place.
Calculating and setting timing-belt tension
If the KLE has been supplied fully preassembled, you will need to adjust the pre-tensioning or check it against the order speci-
cations.
To increase tension, use the tensioning screw at the rear of the Timing-Belt Reverse Unit to pull back the movable tensioning
axle. How far you need to pull back the tensioning axle in the Reverse Unit varies according to the operating load of the KLE.
Conventional calculation:
Following applies: FP+ FX< FBperm
and: FP> FX
Where: FX= m x a+ m x g +FF
Where: ΔL = (LBx FP) / (Cspez)
Where: ΔT = ½ ΔL
FP= Pre-tensioning force for Timing Belt [N]
FX= operating load [N]
FBperm = Permissible force for Timing Belt R10 T5 [N] = 300N
FF= Frictional force, loss of friction when running light (for Linear Unit KLE 8 80x80 [N]: 75N
Linear Unit KLE 6 60x60 [N]: 40,5N
ΔL = Necessary elongation of the overall Timing Belt length [mm]

19
Linear Units KLE ― Notes on Use and Installation
LB= Overall Timing Belt length when not under tension [mm]
K = Cspez = Constant of elongation [N] :
KLE 6 = 0,35 x 106N
KLE 8 = 1,13 x 106N
ΔT = Necessary adjustment on tensioning axle [mm]
Use the tensioning screw to adjust the movable tensioning axle in the Timing-Belt Reverse Unit. Moving this axle makes the
Timing Belt tighter or slacker, pulling the tensioning axle back by 1mm elongates the Timing Belt by 2mm. There are various
ways to check the calculated tensioning adjustment. Typical tools for this purpose include frequency analysis tools, strain
gauges and other length measuring devices.
▪e.g.:
LB = 1250mm
FX= m x a + m x g + FF = 100N
▪item recommends increasing pre-tensioning force by 20%: FP= 1.2 x FX= 120N
▪ ΔL = (FPx LB) / (Cspez) = 2mm
▪ ΔT = ½ ΔL = 1mm
Test:FP+ FX< FBperm
▪120N + 100N = 220N < 300N
and: FP> FX
▪120N > 100N
When setting the timing-belt tension based on a tensioning axle adjustment that has been derived from a calculation, you must
rst identify the exact position at which the tensioning axle starts to elongate the Timing Belt.
Tightening the Timing Belt
You can tighten the Timing Belt using Reverse Unit KLE 6 60x60 or Reverse Unit KLE 8 80x80.
Two Hexagon Socket Head Cap Screws DIN 912 are provided for this purpose on the end of the Reverse Unit.
The rst step when tightening the Timing Belt is to nd the zero point at which the untightened belt has no sag at all and
pre-tensioning begins.
To do this, pull back the movable tensioning axle in the Reverse Unit and then x it in position using the screws.
A scale on the Reverse Unit can be used to adjust the tensioning axle travel from this reference position.
A calliper between the end of the prole and the marking on the tensioning axle enables precise pre-tensioning on both sides
of the Reverse Unit.
Tighten the Timing Belt by tightening the two screws alternately and evenly.
It is vital that the tightening is not uneven, i.e. that the tensioning axle is not skew by > 0.05 mm!
The tensioning screws are secured (micro-encapsulated) to prevent them from being adjusted or working themselves loose
unintentionally.

20
Linear Units KLE ― Notes on Use and Installation
Tip:
Instead of measuring the movement of the tensioning axle, it is advisable to measure the actual elongation of the Timing Belt.
When using this approach, the exact position of the tensioning axle before you make any adjustments is irrelevant and measu-
rement errors can be minimised.
This approach uses the fact that the entire Timing Belt elongates evenly as tension is applied.
This means, for example, that when a timing belt that is 10,000mm long is elongated by 10mm, each 1,000mm section
of the belt is stretched to a length of 1001mm. The ten sections, each measuring 1001mm in length, add up to the overall
length of 10 x 1001mm = 10,010mm.
To measure the actual elongation of any timing belt, rst select and mark a section of the belt that is freely accessible, making
sure the section is as large as possible and that the timing belt is not under any tension. Now calculate the relative elongation
L’ for the belt section you marked and move the tensioning axle back until the marked section has stretched by the right
amount for this partial belt length.
Example:
A steel ruler was used to make marks 300mm apart on the timing belt in our example while it was not under any tension.
Calculating the elongation for this section of the belt:
▪ ΔL = 2mm based on the overall length of the timing belt, which is 1250mm
This means that the measurable elongation on a 300mm section of the belt will be:
▪ ΔL’ = (ΔL / 1250) x 300 = 0.48mm ≈ 0.5mm
If we now pull back the tensioning axle in the Reverse Unit, the timing belt begins to elongate at a certain point and the marks
move further apart.
We continue to pull back the tensioning axle until the marks have moved 0.5mm further apart or, to put it another way, until
the gap between the marks has increased from 300mm to 300.5mm. At this point, the elongation on the timing belt as a
whole is correct and the calculated pre-tensioning force has been applied.