Operating Instructions - KL4000 V10 en

Linear units
KL 4000; KL 4000 S
Operating Instructions
Issued: 31.10.2022
BA KL 4000 V10
KUKA Deutschland GmbH
KL 4000; KL 4000 S
© Copyright 2022
KUKA Deutschland GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties
without the express permission of KUKA Deutschland GmbH.
Other functions not described in this documentation may be operable in the controller. The user
has no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and soft-
ware described. Nevertheless, discrepancies cannot be precluded, for which reason we are not
able to guarantee total conformity. The information in this documentation is checked on a regu-
lar basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS5-DOC
Translation of the original documentation
Publication: Pub BA KL 4000 (PDF) en

PB7514
Book structure: BA KL 4000 V10.1

BS6887
Version: BA KL 4000 V10
2/231 | www.kuka.com BA KL 4000 V10 | Issued: 31.10.2022

KL 4000; KL 4000 S
Contents
1 Introduction.............................................................................................. 7
1.1 Target group.......................................................................................................... 7
1.2 Documentation for the linear unit......................................................................... 7
1.3 Representation of warnings and notes................................................................. 7
2 Product description................................................................................. 9
2.1 Overview of the linear unit system....................................................................... 9
2.2 Description of the linear unit................................................................................. 10
2.3 Intended use.......................................................................................................... 14
3 Safety......................................................................................................... 17
3.1 General.................................................................................................................. 17
3.1.1 Liability................................................................................................................... 17
3.1.2 EC declaration of conformity, declaration of incorporation and acceptance....... 17
3.1.3 Terms in the “Safety” chapter............................................................................... 18
3.2 Personnel............................................................................................................... 20
3.3 Workspace, safety zone and danger zone........................................................... 21
3.4 Overview of protective equipment........................................................................ 21
3.4.1 Mechanical end stops........................................................................................... 21
3.4.2 Labeling on the linear unit.................................................................................... 21
3.5 Safety measures.................................................................................................... 22
3.5.1 General safety measures...................................................................................... 22
3.5.2 Transportation........................................................................................................ 23
3.5.3 Start-up and recommissioning.............................................................................. 23
3.5.4 Manual mode......................................................................................................... 24
3.5.5 Automatic mode..................................................................................................... 24
3.5.6 Maintenance and repair........................................................................................ 25
3.5.7 Decommissioning, storage and disposal.............................................................. 26
4 Technical data.......................................................................................... 27
4.1 Basic data.............................................................................................................. 27
4.2 Dimensions, KL 4000............................................................................................ 29
4.3 Axis data................................................................................................................ 45
4.4 Foundation loads................................................................................................... 49
4.5 Foundation loads, strengthened foundation......................................................... 52
4.6 Foundation loads for mounting bases with lateral joint, longitudinal compensa-
tion......................................................................................................................... 55
4.7 Foundation loads for mounting bases with lateral joint, longitudinal compensa-
tion, strengthened foundation................................................................................ 57
4.8 Foundation loads for mounting bases with longitudinal joint, lateral compensa-
tion......................................................................................................................... 61
4.9 Foundation loads for mounting bases with longitudinal joint, lateral compensa-
tion, reinforced foundation..................................................................................... 64
4.10 Plates and labels................................................................................................... 70
4.11 REACH duty to communicate information acc. to Art. 33................................... 71
4.12 Stopping distances and times............................................................................... 71
4.12.1 General information............................................................................................... 71
4.12.2 Stopping distances and stopping times, STOP 0................................................ 72
BA KL 4000 V10 | Issued: 31.10.2022 www.kuka.com | 3/231

KL 4000; KL 4000 S
4.12.3 Stopping distances and stopping times, STOP 1................................................ 73
5 Planning.................................................................................................... 75
5.1 Information for planning........................................................................................ 75
5.2 Beam fastening...................................................................................................... 75
5.2.1 Standard mounting base....................................................................................... 75
5.2.2 Standard mounting base, reinforced..................................................................... 78
5.2.3 Mounting base with lateral or longitudinal joint.................................................... 81
5.2.4 Mounting base with lateral or longitudinal joint, strengthened............................. 86
5.2.5 Adjusting plates for mounting base...................................................................... 92
5.2.6 Hilti anchoring kit................................................................................................... 93
5.2.7 Hilti anchoring kit, strengthened foundation......................................................... 95
5.2.8 Fischer anchoring kit............................................................................................. 96
5.2.9 Anchoring kit, strengthened foundation................................................................ 97
5.2.10 Anchoring kit, adjusting plate (strengthened foundation)..................................... 99
5.2.11 Machine frame mounting....................................................................................... 100
5.3 Connecting cables and interfaces......................................................................... 101
6 Transportation.......................................................................................... 103
7 Start-up and recommissioning............................................................... 105

7.1 Installing the mounting base................................................................................. 106
7.1.1 Installing the standard mounting base.................................................................. 106
7.1.2 Installing the reinforced mounting base................................................................ 107
7.1.3 Installing the mounting base with lateral or longitudinal joint.............................. 109
7.1.4 Installing the mounting base, reinforced, with lateral or longitudinal compensa-
tion......................................................................................................................... 111
7.2 Installing the anchoring kit.................................................................................... 115
7.2.1 Installing the Hilti anchoring kit............................................................................. 115
7.2.2 Installing the Hilti anchoring kit, strengthened foundation................................... 117
7.2.2.1 Installing the anchoring kit, strengthened foundation........................................... 121
7.2.3 Fischer anchoring kit, installing............................................................................. 124
7.2.4 Installing the anchoring kit, adjusting plate (strengthened foundation)............... 127
7.2.5 Installing the anchoring kit with lateral or longitudinal joint................................. 130
7.3 Installing the machine frame mounting assembly................................................ 135
7.4 Installing the linear unit......................................................................................... 137
7.5 Installing the energy supply system..................................................................... 141
7.6 Installing the energy supply system on the beam............................................... 147
7.7 KR C4/KR C5, connecting control cable XP7...................................................... 153
7.8 Description of the connecting cables.................................................................... 155
7.9 Description of the applications.............................................................................. 166
7.9.1 Control and signal cable KFL XLUB for "permanent lubrication unit ‘pre-
mium’"XLUB1......................................................................................................... 166
7.9.2 Connecting cable, Power supply XD1.................................................................. 167
7.9.3 Connecting cable, Profinet XF1............................................................................ 168
7.9.4 Connecting cable, welding cable XD73................................................................ 169
7.9.5 Connecting cable, signal cable XG79.................................................................. 170
7.10 Moving the linear unit without drive energy......................................................... 171
8 Configuration............................................................................................ 173
8.1 Configuration data................................................................................................. 173

KL 4000; KL 4000 S
9 Maintenance.............................................................................................. 181
9.1 Maintenance table................................................................................................. 182
9.2 Adjusting the backlash.......................................................................................... 185
9.2.1 Measuring the backlash........................................................................................ 186
9.2.2 Adjusting the backlash.......................................................................................... 186
9.3 Cleaning the linear unit......................................................................................... 187
10 Repair........................................................................................................ 189
10.1 Exchanging the drive............................................................................................. 190
10.1.1 Removing the drive unit........................................................................................ 191
10.1.2 Installing the drive unit.......................................................................................... 192
10.2 Exchanging the servomotor.................................................................................. 193
10.2.1 Removing the servomotor..................................................................................... 194
10.2.2 Installing the servomotor....................................................................................... 195
10.3 Exchanging the stop.............................................................................................. 196
10.3.1 Removing the stop................................................................................................ 197
10.3.2 Installing the stop.................................................................................................. 198
11 Decommissioning, storage and disposal............................................. 199

11.1 Decommissioning................................................................................................... 199
11.2 Storage.................................................................................................................. 201
11.3 Disposal................................................................................................................. 201
12 Options...................................................................................................... 203
12.1 Cleaning brushes................................................................................................... 204
12.1.1 Removing the cleaning brushes........................................................................... 204
12.1.2 Installing the cleaning brushes............................................................................. 205
12.2 Covers.................................................................................................................... 206
12.2.1 Exchanging the beam cover................................................................................. 207
12.2.1.1 Removing the beam cover.................................................................................... 207
12.2.1.2 Installing the beam cover...................................................................................... 208
12.2.2 Exchanging the track cover.................................................................................. 208
12.2.2.1 Removing the track cover..................................................................................... 209
12.2.2.2 Installing the track cover....................................................................................... 209
12.3 Permanent lubrication unit.................................................................................... 210
12.3.1 Control and signal cable KFL XLUB for "permanent lubrication unit ‘pre-
mium’"XLUB1......................................................................................................... 211
12.3.2 Maintenance table, permanent lubrication unit..................................................... 212
12.3.3 Exchanging the permanent lubrication unit.......................................................... 213
12.3.3.1 Removing the permanent lubrication unit............................................................. 214
12.3.3.2 Installing the permanent lubrication unit............................................................... 215
12.3.4 Exchanging the felt pinion..................................................................................... 217
12.3.4.1 Removing the felt pinion....................................................................................... 217
12.3.4.2 Installing the felt pinion......................................................................................... 218
12.3.5 Exchanging the cartridge...................................................................................... 220
12.3.5.1 Removing the cartridge......................................................................................... 220
12.3.5.2 Installing the cartridge........................................................................................... 221
13 Appendix................................................................................................... 223
13.1 Tightening torques................................................................................................. 223

KL 4000; KL 4000 S
13.2 Auxiliary and operating materials used................................................................ 224

13.3 Applied norms and regulations............................................................................. 224
14 KUKA Service........................................................................................... 227

14.1 Requesting support............................................................................................... 227
14.2 KUKA Customer Support...................................................................................... 227
Index 229

KL 4000; KL 4000 S
Introduction
1 Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and

skills:
• Advanced knowledge of mechanical engineering
• Advanced knowledge of electrical engineering
• Knowledge of the robot controller system
For optimal use of KUKA products, we recommend the training courses

offered by KUKA College. Information about the training program can be
found at www.kuka.com or can be obtained directly from our subsidia-
ries.
1.2 Documentation for the linear unit
The linear unit documentation consists of the following parts:
• Operating instructions for the linear unit

• Operating and programming instructions for the KUKA System Soft-
ware
• Operating instructions for the robot controller
• Instructions for options and accessories
• Parts lists for this linear unit in KUKA.Xpert
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety
These warnings are provided for safety purposes and must be observed.
DANGER
These warnings mean that it is certain or highly probable that death or
severe injuries will occur, if no precautions are taken.
WARNING
These warnings mean that death or severe injuries may occur, if no
precautions are taken.
CAUTION
These warnings mean that minor injuries may occur, if no precautions
are taken.
NOTICE
These warnings mean that damage to property may occur, if no precau-
tions are taken.
These warnings contain references to safety-relevant information or gen-

eral safety measures.
These warnings do not refer to individual hazards or individual precau-
tionary measures.

KL 4000; KL 4000 S
This warning draws attention to procedures which serve to prevent or rem-

Introduction
edy emergencies or malfunctions:

SAFETY INSTRUCTION
The following procedure must be followed exactly!
Procedures marked with this warning must be followed exactly.
Notices
These notices serve to make your work easier or contain references to

further information.
Tip to make your work easier or reference to further information.

KL 4000; KL 4000 S
Product description
2 Product description
2.1 Overview of the linear unit system
The linear unit is generally integrated into the robot system. Such a sys-
tem consists of the following components:
• Linear unit
• Robot
• Robot controller
• KUKA smartPAD teach pendant
• Connecting cables
• Software
• Options, accessories
Fig. 2-1: Example of a robot system with linear unit
1 Robot 4 Robot controller

2 Linear unit 5 KUKA smartPAD
teach pendant
3 Connecting cables
and ground conductor
The linear unit can be integrated as an independent product into other
systems. Only the linear unit with its connecting cables is considered and
described in these instructions.

Product description KL 4000; KL 4000 S
2.2 Description of the linear unit
Overview
The linear unit is a single-axis track system and is used principally as an

external axis of the robot. The robot is mounted on the carriage, allowing
it to be moved along a linear axis. The carriage is moved by a drive of its
own. It is controlled by the robot controller. The movement range of the
carriage is limited by programmable software limit switches. It is addition-
ally safeguarded by means of mechanical stops (buffers) on the rack side.
Up to four independently driven carriages can be operated on the linear
unit. Each of these carriages can additionally be coupled to one or more
tender carriages. The tender carriage does not have a drive of its own
and is moved by the driven carriage. The rated travel of the carriage is
defined specifically for each individual unit. The interval is 500 mm.
The linear unit is fastened to the floor or to a substructure provided by the
customer.
The energy supply chain contains the supply lines for the robot and the
energy and fluid supply.
The linear unit consists of the following components:
• Beam
• Carriage
• Drive
• Energy supply system
• Beam and track covers (optional)
Fig. 2-2: Structure of the linear unit – example
1 Energy supply system 4 Connector plate

2 Carriage 5 Beam
3 Drive

KL 4000; KL 4000 S
Product description
Fig. 2-3: Structure of linear unit with covers
1 Carriage 4 Connector plate

2 Drive 5 Beam, covered
3 Energy supply system 6 Tracks, covered
The illustrated position of the connector plate is an example. The con-

nector plate is located approximately halfway along the axis. It can be
repositioned within the range of the remaining cable play provided the
minimum bending radius is observed.
Installation
The linear unit can be installed as illustrated (>>> Fig. 2-4) with a travel of
up to 8.5 m and a maximum of two carriages. The energy supply system
is attached to the beam of the linear unit. Depending how the energy sup-
ply system is configured, the linear unit is either a standard design or a
mirrored design. In the mirrored design, the foundations are not always
mirrored. The order-specific layout must be observed.
Fig. 2-4: Installation of linear unit, energy supply system on beam

1 Linear unit, mirrored design

2 Rack
3 Linear unit, standard design
The energy supply system can also be installed on the side of the linear
unit, as illustrated in (>>> Fig. 2-5). It can be attached in front of (stand-
ard) or behind (mirrored) the beam. In the mirrored design, the founda-
tions are not always mirrored. The order-specific layout must be observed.
Fig. 2-5: Installation of linear unit, energy supply system on side

2 Rack
Beam
The beam is assembled from beam segments 1.5 m and 2 m in length. At

the joints, the beam segments are fastened together using centering pins.
The length of the beam is dependent on the travel (permitted movement
range) of the carriage. The beam is fastened to the floor or customer
beam by means of a fastening system.
The tracks, racks, stops (buffers) and the mastering notch are fastened to
the beam. Optionally, the tracks and the space between the tracks can be
covered.
Carriage
The robot is fastened to the carriage. For this purpose, the carriage is
provided with a mounting face. Two pins are used for centering.
The drive unit is seated laterally beneath the carriage. The energy supply
system is fastened to the carriage via the driver.
The carriage moves on the tracks on four groups of rollers. The motion
range of the carriage is restricted by programmable software limit
switches. If the permitted travel is exceeded, a stop (buffer) at the end of
the beam stops the carriage.
The carriage is mastered at the zero point. A mount for the measuring de-
vice is provided for this purpose on the carriage.
Detailed information about mastering is contained in the operating and
programming instructions for end users or system integrators.

KL 4000; KL 4000 S
Reference holes are provided on the carriage for use by the customer. By
Product description
means of the reference holes the customer can determine the position of
the carriage in relation to the system.
Drive
The drive assembly consists of a servomotor, a gear unit and fasteners.

The pinion on the gear unit engages with the rack on the beam and
moves the carriage. The rack and pinion have helical toothing. The motor
speed is reduced by the gear unit and transferred by the pinion to the
rack. The gear unit is oil-lubricated. The motor and control cables are con-
nected to the servomotor by means of the connectors.
Energy supply system
The energy supply system is required for power supply to and control of
the linear unit and the robot. The supply lines for the robot and linear unit
and the energy and fluids supply are routed in the energy supply chain.
The energy supply chain is located in a side-mounted guide system or in-
stalled on the beam. It is fastened to the carriage via the driver and thus
moves with it. The other end of the energy supply chain is screwed to the
fixed point module in the guide system or to the beam. Figures
(>>> Fig. 2-6) and (>>> Fig. 2-7) show how the driver can be attached to
the carriage. The fastening variant depends on the permitted travel (H) of
the carriage and on the width of the energy supply chain (BK).
Special variants are possible.
The connector plate constitutes the interface between the linear unit and
the robot controller (connecting cables). All connectors for the supply lines
in the energy supply chain are fastened to the connector plate.
Fig. 2-6: Attachment of energy supply system, short travel
1 Energy supply system attached to the beam

2 Energy supply system installed at the side

Fig. 2-7: Attachment of energy supply system, long travel
1 Energy supply system installed at the side
Guide system
The energy supply chain lies in a guide system. It consists of chain

guides, aluminum profiles and add-on parts. It is installed on the side of
the linear unit. Special variants are possible.
The guide system is fastened to the floor using concrete screw anchors.
The length and width of the guide system depends on the length and
width of the energy supply chain.
Electrical installations
The electrical installations include the motor and control cables for the mo-
tor of the linear unit and the motors of the robot.
Options
The following options are available for the KL 4000:

• Permanent lubrication unit: The rack and pinion can optionally be lubri-
cated via an automatic lubricating unit.
• Cleaning brushes: The wipers on the carriage can optionally be fitted
with cleaning brushes which remove any dirt from the range of motion
of the rollers.
• Covers: The beams and tracks can optionally be fitted with covers.
• Booster frame for KR QUANTEC robot series
Height: 200 mm - 1000 mm
in 200 mm steps
• Booster frame for KR FORTEC robot series
Height: 250 mm, 500 mm
• Tender carriages: Tender carriages can optionally be coupled to the
driven carriages.
• Additional EMD gauge pin: can be purchased subsequently if required.
Art. no.: 0000-272-068
2.3 Intended use
Use
The linear unit is used for linear traversing of a robot or of other equip-
ment. Use is only permitted under the specified environmental conditions.

KL 4000; KL 4000 S
Any use or application deviating from the intended use is deemed to be
Product description
misuse and is not allowed. The manufacturer is not liable for any damage
resulting from such misuse. The risk lies entirely with the user.
Misuse
Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. It will result in the loss of warranty and liability
claims. KUKA is not liable for any damage resulting from such misuse.
This includes e.g.:
• Use as a climbing aid
• Operation outside the specified operating parameters
• Operation without the required safety equipment
• Transportation of persons and animals
• Outdoor operation.
• Use in a potentially explosive area
• Use in radioactive environments
• Operation in underground mining
NOTICE
Changes to the structure of the linear unit, e.g. drill holes can result in
damage to the components. This is considered improper use and leads
to loss of guarantee and liability entitlements.
The linear unit is an integral part of an overall system and may only be
operated in a CE-compliant system.


KL 4000; KL 4000 S
Safety
3 Safety
3.1 General
In addition to this “Safety” chapter, the “Safety” chapter of the operating

instructions or assembly instructions of the KUKA robot controller must
be observed.
3.1.1 Liability
The linear unit described in this document is a component of an industrial

robot.
The linear unit is built using state-of-the-art technology and in accordance
with the recognized safety rules. Nevertheless, misuse may constitute a
risk to life and limb or cause damage to the linear unit and to other mate-
rial property.
The linear unit may only be used in perfect technical condition in accord-
ance with its intended use and only by safety-conscious persons who are
fully aware of the risks involved in its operation. Use of the linear unit is
subject to compliance with this document and with the declaration of incor-
poration supplied together with the linear unit. Any functional disorders,
especially those affecting safety, must be rectified immediately.
Safety information
Information about safety may not be construed against KUKA Deutschland

GmbH. Even if all safety instructions are followed, this is not a guarantee
that the linear unit will not cause personal injuries or material damage.
No modifications may be carried out to the linear unit without the authori-
zation of KUKA Deutschland GmbH. Additional components, not supplied
by KUKA Deutschland GmbH, may be integrated into the linear unit. The
user is liable for any damage these components may cause to the linear
unit or to other material property.
In addition to the Safety chapter, this document contains further safety in-
structions. These must also be observed.
3.1.2 EC declaration of conformity, declaration of incorporation and accept-

ance
The linear unit constitutes partly completed machinery as defined by the

EC Machinery Directive. The linear unit may only be put into operation if
the following preconditions are met:
• The linear unit is integrated into a complete system.
or: The linear unit, together with other machinery, constitutes a com-
plete system.
or: All safety functions and safeguards required for operation in the
complete machine as defined by the EC Machinery Directive have
been added to the linear unit.
• The complete system complies with the EC Machinery Directive. This
has been confirmed by means of an assessment of conformity.
EC declaration of conformity
The system integrator must issue an EC declaration of conformity for the

complete system in accordance with the Machinery Directive. The EC dec-

KL 4000; KL 4000 S
laration of conformity forms the basis for the CE mark for the system. The
Safety
linear unit must be operated in accordance with the applicable national

laws, regulations and standards.
The robot controller has a CE mark in accordance with the EMC Directive
and the Low Voltage Directive.
Declaration of incorporation
The linear unit as partly completed machinery is supplied with a declara-

tion of incorporation in accordance with Annex II B of the EC Machinery
Directive 2006/42/EC. The assembly instructions and a list of essential re-
quirements complied with in accordance with Annex I are integral parts of
this declaration of incorporation.
The declaration of incorporation declares that the start-up of the partly
completed machinery is not allowed until the partly completed machinery
has been incorporated into machinery, or has been assembled with other
parts to form machinery, and this machinery complies with the terms of
the EC Machinery Directive, and the EC declaration of conformity is
present in accordance with Annex II A.
The declaration of incorporation with its annexes remains with the system
integrator as part of the technical documentation of the completed machi-
nery.
Acceptance
If no acceptance of the linear unit is performed at the site of installation

by KUKA Deutschland GmbH, no responsibility for the linear unit will be
accepted by KUKA Deutschland GmbH.
3.1.3 Terms in the “Safety” chapter
Term Description
Axis range Range within which the axis may move The axis range must be de-
fined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance

The stopping distance is part of the danger zone.
Workspace Area within which the robot may move. The workspace is derived
from the individual axis ranges.
User The user of the industrial robot can be the management, employer
or delegated person responsible for use of the industrial robot.
Service life The service life of a safety-relevant component begins at the time
of delivery of the component to the customer.
The service life is not affected by whether the component is used
or not, as safety-relevant components are also subject to aging dur-
ing storage.
Danger zone The danger zone consists of the workspace and the stopping dis-
tances of the manipulator and external axes (optional).
KCP KUKA Control Panel

Teach pendant for the KR C2/KR C2 edition2005
The KCP has all the operator control and display functions required
for operating and programming the industrial robot.

KL 4000; KL 4000 S
Safety
KUKA smartPAD see “smartPAD”
KUKA smartPAD-2 see “smartPAD”
Manipulator The robot arm and the associated electrical installations
Safety zone The safety zone is situated outside the danger zone.
Safety options Generic term for options which make it possible to configure addi-
tional safe monitoring functions in addition to the standard safety
functions.
Example: SafeOperation
smartPAD Teach pendant for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operation and programming. The following models exist:
• KUKA smartPAD
• KUKA smartPAD-2
• KUKA smartPAD pro
For robot controllers of the KR C5 series with KUKA System Soft-
ware or VW System Software, only the model KUKA smartPAD-2
is used.
For robot controllers of the KR C5 series with KUKA iiQKA.OS, on-
ly the model KUKA smartPAD pro is used.
For other robot controllers, the designation “KUKA smartPAD” or
“smartPAD” always refers to all models possible for the respective
controller unless an explicit distinction is made.
Stop category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator and any external axes (optional) perform path-ori-
ented braking.
Note: This stop category is called “STOP 0” in this document.
Stop category 1 The manipulator and any external axes (optional) perform path-
maintaining braking. The drives are only disconnected once the ma-
chine has come to a standstill.
Stop category 1 – The manipulator and any external axes (optional) perform path-ori-
Drive Ramp Stop ented braking. The drives are only disconnected once the machine
has come to a standstill.
Note: This stop category is called “STOP 1 - DRS” in this docu-
ment.
Stop category 2 The drives are not deactivated and the brakes are not applied. The
manipulator and any external axes (optional) are braked with a
path-maintaining braking ramp.
System integrator The system integrator is responsible for safely integrating the indus-
(plant integrator) trial robot into a complete system and commissioning it.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
T2 Test mode, Manual High Velocity (> 250 mm/s permissible)

Safety KL 4000; KL 4000 S
External axis Motion axis which is not part of the manipulator but is controlled by
the robot controller, e.g. KUKA linear unit, turn-tilt table, positioner.
3.2 Personnel
The following persons or groups of persons are defined for the linear unit:
• User
• Personnel
All persons working on the linear unit must have read and understood
the linear unit documentation, including the safety chapter.
User
The user must observe the labor laws and regulations. This includes e.g.:
• The user must comply with his monitoring obligations.

• The user must carry out briefing at defined intervals.
• The user must comply with the regulations relating to personal protec-
tive equipment (PPE).
Personnel
Personnel must be instructed, before any work is commenced, in the type

of work involved and what exactly it entails as well as any hazards which
may exist. Instruction must be carried out regularly. Instruction is also re-
quired after particular incidents or technical modifications.
Personnel includes:
• System integrator
• Operators, subdivided into:
‒ Start-up, maintenance and service personnel
‒ Operating personnel
‒ Cleaning personnel
Installation, exchange, adjustment, operation, maintenance and repair

must be performed only as specified in the operating or assembly in-
structions for the linear unit and only by personnel specially trained for
this purpose.
System integrator
The linear unit is safely integrated into a complete system by the system
integrator.
The system integrator is responsible for the following tasks:
• Installing the linear unit

• Connecting the linear unit
• Performing risk assessment
• Implementing the required safety functions and safeguards
• Issuing the EC declaration of conformity
• Attaching the CE mark
• Creating the operating instructions for the system

KL 4000; KL 4000 S
Safety
Operators
The operator must meet the following preconditions:

• The operator must be trained for the work to be carried out.
• Work on the system must only be carried out by qualified personnel.
These are people who, due to their specialist training, knowledge and
experience, and their familiarization with the relevant standards, are
able to assess the work to be carried out and detect any potential
hazards.
Work on the electrical and mechanical equipment of the linear unit may
only be carried out by specially trained personnel.
3.3 Workspace, safety zone and danger zone
Workspaces are to be restricted to the necessary minimum size. A work-

space must be safeguarded using appropriate safeguards.
The safeguards (e.g. safety gate) must be situated inside the safety zone.
In the case of a stop, the manipulator and external axes (optional) are
braked and come to a stop within the danger zone.
The danger zone consists of the workspace and the stopping distances of
the manipulator and external axes (optional). It must be safeguarded by
means of physical safeguards to prevent danger to persons or the risk of
material damage.
The stopping distances must be taken from the documentation for the ma-
nipulator and the linear unit, or they must be determined by the system in-
tegrator.
3.4 Overview of protective equipment
The protective equipment of the linear unit may include:
• Mechanical end stops

• Mechanical axis limitation (optional)
• Labeling of danger areas
Not all equipment is relevant for every linear unit.
3.4.1 Mechanical end stops
Mechanical end stops can be installed on the external axes.

WARNING
If the manipulator or an external axis hits an obstruction or a mechani-
cal end stop or mechanical axis limitation, the manipulator and the ex-
ternal axis can no longer be operated safely. They must be taken out of
operation and the manufacturer must be consulted before it is put back
into operation.
3.4.2 Labeling on the linear unit
All plates, labels, symbols and marks constitute safety-relevant parts of

the linear unit. They must not be modified or removed.
Labeling on the linear unit:
• Identification plates

• Warning labels
• Safety symbols
• Designation labels
• Cable markings
• Rating plates
3.5 Safety measures
3.5.1 General safety measures
The linear unit may only be used in perfect technical condition in accord-
ance with its designated use and only by safety-conscious persons. Oper-
ator errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the linear unit
even after the controller has been switched off and locked, e.g. due to in-
correct assembly or mechanical defects. The linear unit must therefore be
secured by appropriate means.
DANGER
In the absence of operational safety functions and safeguards, the linear
unit can cause personal injury or material damage. If safety functions or
safeguards are dismantled or deactivated, the linear unit must not be
operated.
CAUTION
Risk of burns from hot motors
The motors reach temperatures during operation which can cause
burns.
• Avoid contact.
• Take appropriate safety precautions, e.g. wear protective gloves.
Modifications
After modifications to the industrial robot, checks must be carried out to

ensure the required safety level. The valid national or regional work safety
regulations must be observed for this check. The correct functioning of all
safety functions must also be tested.
New or modified programs must always be tested first in Manual Reduced
Velocity mode (T1).
After modifications to the industrial robot, existing programs must always
be tested first in Manual Reduced Velocity mode (T1). This applies to all
components of the industrial robot and includes e.g. modifications of the
external axes or to the software and configuration settings.
Faults
The following tasks must be carried out in the case of faults in the linear
unit:
• Switch off the controller and secure it (e.g. with a padlock) to prevent
unauthorized persons from switching it on again.
• Indicate the fault by means of a label with a corresponding warning
(tagout).
• Keep a record of the faults.
• Eliminate the fault and carry out a function test.

KL 4000; KL 4000 S
Safety
3.5.2 Transportation
The regulations for transportation must be observed. Transportation must

be carried out in accordance with the operating instructions or assembly
instructions of the linear unit.
3.5.3 Start-up and recommissioning
Before starting up systems and devices for the first time, a check must be
carried out to ensure that the systems and devices are complete and op-
erational, that they can be operated safely and that any damage is detec-
ted.
The valid national or regional work safety regulations must be observed
for this check. The correct functioning of all safety circuits must also be
tested.
If additional components (e.g. cables), which are not part of the scope
of supply of KUKA Deutschland GmbH, are integrated into the linear
unit, the user is responsible for ensuring that these components do not
adversely affect or disable safety functions.
Function test
The following tests must be carried out before start-up and recommission-
ing:
It must be ensured that:
• The linear unit is correctly installed and fastened in accordance with

the specifications in the documentation.
• There are no foreign bodies or defective or loose parts on the linear
unit.
• All required safety equipment is correctly installed and operational.
• The power supply ratings of the linear unit correspond to the local
supply voltage and mains type.
• The ground conductor and the equipotential bonding cable are suffi-
ciently rated and correctly connected.
• The connecting cables are correctly connected and the connectors are
locked.
• There is no damage on the linear unit or any other component of the
industrial robot that could be attributed to external forces. Example:
Dents or abrasion that could be caused by an impact or collision.
WARNING
Danger to life and limb resulting from external forces
The external application of force, such as an impact or a collision,
can cause non-visible damage. For example, it can lead to a gradu-
al loss of drive power from the motor, resulting in unintended move-
ments of the manipulator.
Death, severe injuries or damage to property may result from non-
visible damage.
‒ Check the robot for damage that could have been caused by ex-
ternal forces, e.g. dents or abrasion of paintwork.
Check the motor and counterbalancing system particularly care-
fully.
(Motor inspection not relevant for robots with internal motors.)
‒ In the case of damage, the affected components must be ex-
changed.

3.5.4 Manual mode
Manual mode is the mode for setup work. Setup work is all the tasks that
have to be carried out on the industrial robot to enable automatic opera-
tion. Setup work includes:
• Jog mode
• Teaching
• Programming
• Program verification
The following must be taken into consideration in manual mode:
• New or modified programs must always be tested first in Manual Re-

duced Velocity mode (T1).
• The manipulator, tooling or external axes (optional) must never touch
or project beyond the safety fence.
• Workpieces, tooling and other objects must not become jammed as a
result of the industrial robot motion, nor must they lead to
short-circuits or be liable to fall off.
• All setup work must be carried out, where possible, from outside the
safeguarded area.
If the setup work has to be carried out inside the safeguarded area, the
following must be taken into consideration:
In Manual Reduced Velocity mode (T1):
• If it can be avoided, there must be no other persons inside the safe-

guarded area.
If it is necessary for there to be several persons inside the safeguar-
ded area, the following must be observed:
‒ Each person must have an enabling device.
‒ All persons must have an unimpeded view of the industrial robot.
‒ Eye-contact between all persons must be possible at all times.
• The operator must be so positioned that he can see into the danger
zone and get out of harm’s way.
In Manual High Velocity (T2) mode:
• This mode may only be used if the application requires a test at a ve-
locity higher than that possible in T1 mode.
• Teaching and programming are not permissible in this operating mode.
• Before commencing the test, the operator must ensure that the ena-
bling devices are operational.
• The operator must be positioned outside the danger zone.
• There must be no other persons inside the safeguarded area. It is the
responsibility of the operator to ensure this.
3.5.5 Automatic mode
Automatic mode is only permissible in compliance with the following safety

measures:
• All safety equipment and safeguards are present and operational.

• There are no persons in the system or the requirements for collabora-
tive operation in accordance with EN ISO 10218 have been met.
• The defined working procedures are adhered to.

KL 4000; KL 4000 S
If the manipulator or an external axis (optional) comes to a standstill for
Safety
no apparent reason, the danger zone must not be entered until an EMER-
GENCY STOP has been triggered.
3.5.6 Maintenance and repair
After maintenance and repair work, checks must be carried out to ensure
the required safety level. The valid national or regional work safety regula-
tions must be observed for this check. The correct functioning of all safety
functions must also be tested.
The purpose of maintenance and repair work is to ensure that the system
is kept operational or, in the event of a fault, to return the system to an
operational state. Repair work includes troubleshooting in addition to the
actual repair itself.
The following safety measures must be carried out when working on the
linear unit:
• Carry out work outside the danger zone. If work inside the danger
zone is necessary, the user must define additional safety measures to
ensure the safe protection of personnel.
• Switch off the controller and secure it (e.g. with a padlock) against be-
ing switched on again. If it is necessary to carry out work with the
controller switched on, the user must define additional safety meas-
ures to ensure the safe protection of personnel.
• If it is necessary to carry out work with the controller switched on, this
may only be done in operating mode T1.
• Label the system with a sign indicating that work is in progress. This
sign must remain in place, even during temporary interruptions to the
work.
• The EMERGENCY STOP devices must remain active. If safety func-
tions or safeguards are deactivated during maintenance or repair work,
they must be reactivated immediately after the work is completed.
DANGER
Before work is commenced on live parts of the system, the main switch
must be turned off and secured against being switched on again. The
system must then be checked to ensure that it is deenergized.
It is not sufficient, before commencing work on live parts, to execute an
EMERGENCY STOP or a safety stop, or to switch off the drives, as this
does not disconnect the system from the mains power supply. Parts re-
main energized. Death or severe injuries may result.
Faulty components must be replaced using new components with the

same article numbers or equivalent components approved by the manu-
facturer for this purpose.
Cleaning and preventive maintenance work is to be carried out in accord-
ance with the operating instructions.
Hazardous substances
The following safety measures must be carried out when handling hazard-
ous substances:
• Avoid prolonged and repeated intensive contact with the skin.
• Avoid breathing in oil spray or vapors.
• Clean skin and apply skin cream.

Use current safety data sheets

Knowledge of the safety data sheets of the substances and mixtures
used is a prerequisite for the safe use of KUKA products. Death,
injuries or damage to property may otherwise result.
• Request up-to-date safety data sheets from the manufacturers of
hazardous substances regularly.
3.5.7 Decommissioning, storage and disposal
The linear unit must be decommissioned, stored and disposed of in ac-

cordance with the applicable national laws, regulations and standards.

KL 4000; KL 4000 S
Technical data
4 Technical data
In addition to the standard variant, special models can also be supplied.
For this, the order-specific layout must be observed.
4.1 Basic data
KL 4000, KL 4000 S
Number of axes 1
Gradation of rated 500 mm
travel
Repeatability ±0.02 mm
(ISO 9283)
Mass of carriage as- m = 516 kg
sembly
Mass of beam assem- m = 210 kg/m, without mounting base
bly
Payload Robot with supplementary loads, see robot
Maximum 4 000 kg
supplementary load
per carriage
Maximum 4 000 kg
supplementary load
(KL 4000: observe permissible total moved
per tender carriage
mass of 6000 kg)
(KL 4000 S: observe permissible total moved
mass of 4000 kg)
Beam fastening See Section: (>>> 5.2 "Beam fastening"
Page 75)
Foundation loads See Section:
(>>> 4.4 "Foundation loads" Page 49)
Foundation dimen- See Section: (>>> 5.2 "Beam fastening"
sions Page 75)
Acceleration in the The calculated acceleration in the event of a
event of a crash crash (hitting the buffer) with the smallest mass
is about 82 m/s2.
Color Carriage: KUKA orange 2567
Beam: RAL 7022
Protection rating Motor and gear unit connected (according to
EN 60529): IP65.
Linear unit ready for operation, with connecting
cables plugged in (according to EN 60529):
IP65.
Sound level < 75 dB (A) outside the working envelope
(moving KL with moving robot)
< 75 dB (A) outside the working envelope
(moving KL without robot)
Permissible angle of 0°
inclination

Technical data KL 4000; KL 4000 S
Installation position of Floor

KL 4000
Number of carriages max. 4 carriages
max. 2 carriages: Energy supply system instal-
led on beam
KL 4000 valid KR CYBERTECH series
for robots
KR IONTEC series
KR QUANTEC series
KR FORTEC-1 series
Booster frames 200 mm - 1000 mm
KR QUANTEC series (in 200 mm steps)
Booster frames 250 mm, 500 mm
KR FORTEC series
Installation position
KL 4000 is approved for operation with the following robots:

• KR CYBERTECH nano series
• KR CYBERTECH series
• KR IONTEC series
• KR QUANTEC series
• KR FORTEC series
The robots from the product series can be installed in various positions,
rotationally offset at 45° intervals. For the 45°, 135°, 225° and 315° instal-
lation positions, an adapter plate is required.
These installation positions apply for all robots of the aforementioned ro-
bot series, with the exception of the KR QUANTEC nano robot family
(>>> Fig. 4-2).
Fig. 4-1: Floor installation positions
An adapter plate is required for installing a robot of the KR QUANTEC

nano robot family. This results in installation positions at 60° intervals.

KL 4000; KL 4000 S
Technical data
Fig. 4-2: Floor installation positions for KR QUANTEC nano
Ambient temperature
Operation 283 K to 328 K (+10 °C to +55 °C)

Storage and transpor- 233 K to 333 K (-40 °C to +60 °C)
tation
Classification of ambi- 3K3
ent conditions
(EN 60721-3-3)
4.2 Dimensions, KL 4000
Energy supply system

on beam
Fig. 4-3: Principal dimensions, cross-section

Fig. 4-4: Arrangement and spatial requirements for the linear unit
1 Effective travel
2 Effective travel + 1100 mm (depends on the number of carriages)
* The required dimension may also be smaller in certain cases.
Energy supply system, side installation
Fig. 4-5: Principal dimensions, cross-section
Value in brackets apply in the case of an energy supply chain width of BK

= 434 mm.

KL 4000; KL 4000 S
Technical data
Fig. 4-6: Arrangement and spatial requirements for the linear unit
1 Effective travel
2 Effective travel + 1100 mm (depends on the number of carriages)
* The required dimension may also be smaller in certain cases.

Example, principal dimensions
Fig. 4-7: Principal dimensions (example)

KL 4000; KL 4000 S
Technical data
Fig. 4-8: Mounting bases, racks, covers (example)
Carriage dimensions, standard
Robots of the KR FORTEC product series as well as the KR QUANTEC

pro, KR QUANTEC extra, KR QUANTEC prime, KR QUANTEC ultra, KR
QUANTEC nano, KR QUANTEC press, and KR QUANTEC PA product
families can be mounted on the carriage.

Fig. 4-9: Mounting surface and hole patterns on the carriage
1 Reference holes Ø12, 4x

(measuring device provided by customer)
2 Gauge cartridge, mastering

KL 4000; KL 4000 S
Technical data
3 Tapped hole M24-38 deep, 16x
4 Dowel pin Ø30 H7
(centering Ø20 H7, fitting length 8 mm, 6x)
Carriage dimensions, standard-2
Robots of the KR QUANTEC and KR FORTEC product series can be

mounted on the carriage.

Fig. 4-10: Mounting surface and hole patterns on the carriage
1 Reference holes Ø12, 4x

(measuring device provided by customer)
2 Gauge cartridge, mastering

KL 4000; KL 4000 S
Technical data
3 Dowel pin Ø30 H7
4 Tapped hole M24-38 deep, 16x
5 Dowel pin Ø30 H7

Adapter plate KR CYBERTECH nano, KR CYBERTECH
Fig. 4-11: Adapter plate for KR CYBERTECH nano series and KR CYBERTECH series

KL 4000; KL 4000 S
Technical data
Eccentricity KR CYBERTECH nano, KR CYBERTECH
Fig. 4-12: Eccentricity for KR CYBERTECH nano series and KR CY-

BERTECH series
1 Adapter plate KR CYBERTECH

2 Eccentricity KR CYBERTECH nano
3 Eccentricity KR CYBERTECH

Adapter plate KR IONTEC
Fig. 4-13: Adapter plate for KR IONTEC series

KL 4000; KL 4000 S
Technical data
Adapter plate
KR QUANTEC 45º
Fig. 4-14: Adapter plate for KR QUANTEC series, 45° position

Adapter plate
KR QUANTEC-2
Fig. 4-15: Adapter plate for KR QUANTEC-2 series

KL 4000; KL 4000 S
Technical data
Adapter plate
KR FORTEC 45º
Fig. 4-16: Adapter plate for KR FORTEC series, 45° position

Example, overlength dimension

connecting cables
Fig. 4-17: Example, overlength dimension for connecting cables, car-

riage 1

KL 4000; KL 4000 S
Technical data
4.3 Axis data
Type KL 4000, KL 4000 S

Axis velocity, axis 1 vmax. = 1.89 m/s, KL 4000
vmax. = 2.35 m/s, KL 4000 S
Effective travel Min. effective travel = 400 mm
Max. effective travel = 30 400 mm
(longer rated travels available on request)
Direction of travel
The direction of travel of the linear unit is the direction in which the car-
riage moves. A distinction is made between the plus and minus direction.
The carriage has a mastering point determined by the mechanical design.
The direction of travel is specified in relation to the software zero point
E1. The sign indicating the two directions (- and +) is attached at a num-
ber of points on the linear unit.
If more than one carriage is used on a single linear unit, all the carriages
have the same direction of travel.
Fig. 4-18: Direction of travel of linear unit, energy supply system on

beam

2 Rack

Fig. 4-19: Direction of travel of carriage, energy supply system on

side

2 Rack
Software zero point
The software zero point is defined identically for all the carriages of a lin-
ear unit. By definition, the center of the slide is located at the software
zero point when the edge of the slide is at a distance of 200 mm from the
positive end of the track.
Mastering
The carriages can be mastered with an EMD mastering set. A mount with
a gauge cartridge is provided on each carriage for this purpose. It is loca-
ted directly on the carriages. There is a single mastering notch on the
beam that is used for mastering all carriages. This means that all carriag-
es are in the same axis-specific coordinate system.
The mastering position depends on the number of carriages. The master-
ing position is offset in the negative direction as the number of carriages
increases in order to be able to address it with all of the carriages.
The $MAMES[7] system variable is used to offset the software zero point
to the defined position.
Number of carriages
$MAMES[7]
(LW)
1 $MAMES[7] = 0 (>>> Fig. 4-20)
2 $MAMES[7] = -1500 (>>> Fig. 4-21)
3 $MAMES[7] = -2500 (>>> Fig. 4-22)
4 $MAMES[7] = -3500 (>>> Fig. 4-23)
The MAMES value applies to all carriages in accordance with the num-
ber of carriages.

KL 4000; KL 4000 S
Technical data
Fig. 4-20: Linear unit with one carriage (LW), mastering position
1 Mastering position at center of carriage

2 Possible travel in plus direction
3 Distance from mastering position to end of track
4 Minimum length of beam
In the case of a linear unit with one carriage, the position of software val-
ue E1 in the mastering position corresponds to the mechanical zero posi-
tion. In all other cases, the mastering position differs from the mechanical
zero position.
Fig. 4-21: Linear unit with two carriages (LW), mastering position


Fig. 4-22: Linear unit with three carriages (LW), mastering position


KL 4000; KL 4000 S
Technical data
Fig. 4-23: Linear unit with four carriages (LW), mastering position

NOTICE
Under certain circumstances, it might not be possible to reach the
standard mastering position on account of the reduced travel range of a
tender carriage or another disruptive contour. In this case, the clearance
(position of the mastering notch) is increased by at least the travel re-
duction due to the tender carriage or the disruptive contour. This is pos-
sible in steps of 500 mm. Offset by a multiple of 500 mm. In order to
relocate the software zero point E1 to 200 mm before the right-hand
end of the beam, the software value E1 in the mastering position must
be increased in accordance with this offset.
4.4 Foundation loads
Description
The foundation loads depend on the robot variant. The specified forces al-
ready include the payload and the inertia force (weight) of the robot.
These are the maximum values acting at the fastening points of the
beam. When a mounting base or machine frame mounting assembly is
used, the effect of the horizontal force Fh is shifted to the mounting sur-
face of the substructure. The force Fh can act in any horizontal direction.

The values specified correspond to the highest generated forces within

the corresponding robot family.
Fig. 4-24: Foundation loads
1 Beam fastening point

2 Mounting surface of substructure
3 Mounting base, end
4 Mounting base, center

KL 4000; KL 4000 S
Technical data
Mounting base loads, KR QUANTEC
Mounting base at Mounting base at

end of beam beam joint
Lateral force 5 366 N 3 016 N
Fh dynamic
(max. load during op-
eration)
Fh dynamic
(max. load during E-
STOP)
Vertical force 25 986 N 26 153 N
FV dynamic
(pull during operation)
FV dynamic
(pull during E-STOP)
Vertical force -48 895 N -56 487 N
FV dynamic
(pressure during oper-
ation)
FV dynamic
(pressure during E-
STOP)
Mounting base loads, KR FORTEC

Fh dynamic
eration)
Fh dynamic
STOP)
FV dynamic
FV dynamic
FV dynamic
ation)
FV dynamic
(pressure during E-
STOP)

4.5 Foundation loads, strengthened foundation
Description
Fig. 4-25: Foundation loads

KL 4000; KL 4000 S
Technical data
1 Beam fastening point
2 Mounting surface of substructure
3 Mounting base, end
4 Mounting base, center
Mounting base loads, KR QUANTEC

Lateral force 5,121 N 3,021 N
Fh dynamic
eration)
Fh dynamic
STOP)
Vertical force 25,986 N 26,153 N
FV dynamic
FV dynamic
Vertical force -48,895 N -56,487 N
FV dynamic
ation)
FV dynamic
(pressure during E-
STOP)
Mounting base loads, KR QUANTEC-2

Fh dynamic
eration)
Fh dynamic
STOP)
FV dynamic
FV dynamic


FV dynamic
ation)
FV dynamic
(pressure during E-
STOP)
Mounting base loads, KR FORTEC

Fh dynamic
eration)
Fh dynamic
STOP)
FV dynamic
FV dynamic
FV dynamic
ation)
FV dynamic
(pressure during E-
STOP)
Mounting base loads KR FORTEC on 500 mm booster frame

Fh dynamic
eration)
Fh dynamic
STOP)
FV dynamic

KL 4000; KL 4000 S
Technical data
FV dynamic
FV dynamic
ation)
FV dynamic
(pressure during E-
STOP)
4.6 Foundation loads for mounting bases with lateral joint, longitudinal
compensation
Description
Fig. 4-26: Foundation loads, mounting base, end

Foundation loads with a KR QUANTEC

Fy dynamic
eration)
Fy dynamic
STOP)
FV dynamic
FV dynamic
FV dynamic
ation)
FV dynamic
(pressure during E-
STOP)

KL 4000; KL 4000 S
Technical data
Foundation loads with a KR FORTEC

Fh dynamic
eration)
Fh dynamic
STOP)
FV dynamic
FV dynamic
FV dynamic
ation)
FV dynamic
(pressure during E-
STOP)
4.7 Foundation loads for mounting bases with lateral joint, longitudinal
compensation, strengthened foundation
Description

Fig. 4-29: Foundation loads, mounting base, center

KL 4000; KL 4000 S
Technical data
Foundation loads with a KR QUANTEC

Fy dynamic
eration)
Fy dynamic
STOP)
FV dynamic
FV dynamic
FV dynamic
ation)
FV dynamic
(pressure during E-
STOP)
Foundation loads with a KR QUANTEC-2

Fy dynamic
eration)
Fy dynamic
STOP)
FV dynamic
FV dynamic
FV dynamic
ation)
FV dynamic
(pressure during E-
STOP)

Foundation loads with a KR FORTEC

Fh dynamic
eration)
Fh dynamic
STOP)
FV dynamic
FV dynamic
FV dynamic
ation)
FV dynamic
(pressure during E-
STOP)
Foundation loads with a KR FORTEC on 500 mm booster frame

Fh dynamic
eration)
Fh dynamic
STOP)
FV dynamic
FV dynamic
FV dynamic
ation)
FV dynamic
(pressure during E-
STOP)

KL 4000; KL 4000 S
Technical data
4.8 Foundation loads for mounting bases with longitudinal joint, lateral
compensation
Description
1 Fixed bearing side (rack side)

2 Floating bearing side


Foundation loads, KR QUANTEC
Mounting base Mounting base

at end of beam at beam joint
Fixed bearing Fh dynamic
side (max. load dur-
ing operation)
Fh dynamic
(max. load dur-
ing E-STOP)
Lateral force 802 N 1 604 N
Floating bearing Fx dynamic
ing operation)
Fx dynamic
(max. load dur-
ing E-STOP)

KL 4000; KL 4000 S
Technical data
FV dynamic
(pull during op-
eration)
FV dynamic
(pull during E-
STOP)
FV dynamic
(pressure during
operation)
FV dynamic
(pressure during
E-STOP)
Foundation loads, KR FORTEC

ing operation)
Fh dynamic
(max. load dur-
ing E-STOP)
ing operation)
Fx dynamic
(max. load dur-
ing E-STOP)


FV dynamic
(pull during op-
eration)
FV dynamic
(pull during E-
STOP)
FV dynamic
(pressure during
operation)
FV dynamic
(pressure during
E-STOP)
4.9 Foundation loads for mounting bases with longitudinal joint, lateral
compensation, reinforced foundation
Description

KL 4000; KL 4000 S
Technical data


Fig. 4-33: Foundation loads, mounting base, center

Foundation loads, KR QUANTEC

ing operation)
Fh dynamic
(max. load dur-
ing E-STOP)
Lateral force 802 N 1 604 N
ing operation)
Fx dynamic
(max. load dur-
ing E-STOP)

KL 4000; KL 4000 S
Technical data
FV dynamic
(pull during op-
eration)
FV dynamic
(pull during E-
STOP)
FV dynamic
(pressure during
operation)
FV dynamic
(pressure during
E-STOP)
Foundation loads, KR QUANTEC-2

ing operation)
Fh dynamic
(max. load dur-
ing E-STOP)
ing operation)
Fx dynamic
(max. load dur-
ing E-STOP)


FV dynamic
(pull during op-
eration)
FV dynamic
(pull during E-
STOP)
FV dynamic
(pressure during
operation)
FV dynamic
(pressure during
E-STOP)
Foundation loads, KR FORTEC

ing operation)
Fh dynamic
(max. load dur-
ing E-STOP)
ing operation)
Fx dynamic
(max. load dur-
ing E-STOP)

KL 4000; KL 4000 S
Technical data
FV dynamic
(pull during op-
eration)
FV dynamic
(pull during E-
STOP)
FV dynamic
(pressure during
operation)
FV dynamic
(pressure during
E-STOP)
Foundation loads, KR FORTEC on 500 mm booster frame

ing operation)
Fh dynamic
(max. load dur-
ing E-STOP)
ing operation)
Fx dynamic
(max. load dur-
ing E-STOP)


FV dynamic
(pull during op-
eration)
FV dynamic
(pull during E-
STOP)
FV dynamic
(pressure during
operation)
FV dynamic
(pressure during
E-STOP)
4.10 Plates and labels
The following plates and labels (>>> Fig. 4-34) are attached to the linear
unit. They must not be removed or rendered illegible. Illegible plates and
labels must be replaced.
Fig. 4-34: Plates and labels

KL 4000; KL 4000 S
Technical data
Item Description
1
Direction of travel
The carriages can be moved in two directions, which are indica-
ted by the plate.
2
Identification plate
Content according to Machinery Directive.
3
Hot surface
During operation of the linear unit, surface temperatures may be
reached that could result in burn injuries. Protective gloves must
be worn!
4
High voltage
Any improper handling can lead to contact with current-carrying
components. Electric shock hazard!
4.11 REACH duty to communicate information acc. to Art. 33
As of June 2007, the Regulation (EC) 1907/2006 of the European Parlia-

ment and of the Council dated 18 December 2006 on the registration,
evaluation and authorization of chemicals (REACH Regulation) is in force.
Detailed REACH information can be found in the product information in
KUKA Xpert.
4.12 Stopping distances and times
4.12.1 General information
Information concerning the data:
• The stopping distance is the distance traveled by the carriage from the
moment the stop signal is triggered until the carriage comes to a com-
plete standstill.
• The stopping time is the time that elapses from the moment the stop
signal is triggered until the carriage comes to a complete standstill.

• Stopping distances and stopping times in accordance with DIN EN

ISO 10218-1, Annex B.
• Stop categories:
‒ Stop category 0 » STOP 0
‒ Stop category 1 » STOP 1
according to IEC 60204-1
• The values specified for Stop 0 are guide values determined by
means of tests and simulation. They are average values which con-
form to the requirements of DIN EN ISO 10218-1. The actual stopping
distances and stopping times may differ due to internal and external
influences on the braking torque. It is therefore advisable to determine
the exact stopping distances and stopping times where necessary un-
der the real conditions of the actual robot application.
• Measuring techniques
The stopping distances were measured using the robot-internal meas-
uring technique.
• The wear on the brakes varies depending on the operating mode, ro-
bot application and the number of STOP 0 stops triggered. It is there-
fore advisable to check the stopping distance at least once a year.
4.12.2 Stopping distances and stopping times, STOP 0
KL 4000
The table shows the stopping distances and stopping times after a STOP
0 (category 0 stop) is triggered. These are the maximum values deter-
mined for the linear unit, with the heaviest robot in a robot series and the
highest booster frame.
Stopping distance
Stopping time (s)
(mm)
KR CYBERTECH ser-
444 0.30
ies
KR CYBERTECH ser-
478 0.33
ies on booster frame
KR IONTEC series 521 0.36
KR IONTEC series on
566 0.39
booster frame
KR QUANTEC series 429 0.37
KR QUANTEC series
438 0.39
on booster frame
KR QUANTEC-2 ser-
383 0.34
ies
KR QUANTEC-2 ser-
411 0.38
KR FORTEC series 670 0.59
KR FORTEC series
684 0.66
on booster frame
KL 4000 S

KL 4000; KL 4000 S
Technical data
Stopping distance
Stopping time (s)
(mm)
KR CYBERTECH ser-
471 0.33
ies
KR CYBERTECH ser-
507 0.35
KR IONTEC series on
597 0.42
booster frame
KR QUANTEC series
813 0.62
on booster frame
KR QUANTEC-2 ser-
676 0.52
ies
KR QUANTEC-2 ser-
715 0.54
KR FORTEC series
780 0.77
on booster frame
4.12.3 Stopping distances and stopping times, STOP 1
KL 4000
Stopping distance
Stopping time (s)
(mm)
KR CYBERTECH ser-
410 0.37
ies
KR CYBERTECH ser-
460 0.45
KR IONTEC series on
570 0.55
booster frame
KR QUANTEC series
520 0.56
on booster frame
KR QUANTEC-2 ser-
470 0.49
ies
KR QUANTEC-2 ser-
530 0.60
KR FORTEC series
770 0.80
on booster frame

KL 4000 S
Stopping distance
Stopping time (s)
(mm)
KR CYBERTECH ser-
560 0.40
ies
KR CYBERTECH ser-
620 0.47
KR IONTEC series on
660 0.59
booster frame
KR QUANTEC series
860 0.69
on booster frame
KR QUANTEC-2 ser-
780 0.58
ies
KR QUANTEC-2 ser-
860 0.72
KR FORTEC series
800 0.85
on booster frame

KL 4000; KL 4000 S
Planning
5 Planning
5.1 Information for planning
In the planning and design phase, care must be taken regarding the func-
tions or applications to be executed by the kinematic system. The follow-
ing conditions can lead to premature wear. They necessitate shorter main-
tenance intervals and/or earlier exchange of components. In addition, the
permissible operating parameters specified in the technical data must be
taken into account and observed during planning.
• Continuous operation near temperature limits or in abrasive environ-
ments
• Continuous operation close to the performance limits, e.g. high rpm of
an axis
• High duty cycle of individual axes
• Monotonous motion profiles, e.g. short, frequently recurring axis mo-
tions
• Static axis positions, e.g. continuous asymmetrical stress on the car-
riage
• External forces (process forces) acting on the robot
If one or more of these conditions are to apply during operation of the kin-
ematic system, KUKA Service must be consulted.
If the robot reaches its corresponding operation limit or if it is operated
near the limit for a period of time, the built-in monitoring functions come
into effect and the robot is automatically switched off.
This protective function can limit the availability of the robot system.
5.2 Beam fastening
Description
The beam is fastened by means of a fastening system to the floor or to a

substructure prepared by the customer. The two assemblies “Mounting
base” and “Anchoring kit” can be used to fasten the linear unit to a con-
crete foundation. The beam is bolted to a substructure provided by the op-
erating company using the “Machine frame mounting” assembly. The inter-
faces are the fastening holes on the beam of the linear unit.
5.2.1 Standard mounting base
Description
The “Mounting base, end” and “Mounting base, center” assemblies are
employed when the linear unit is installed on the floor or a substructure
using bedplates. The number of bedplates depends on the length of the
beam. Please refer to the layout (>>> 4 "Technical data" Page 27).
This mounting variant requires a level and smooth surface on a substruc-
ture (e.g. concrete foundation) with adequate load bearing capacity. The
substructure must be able to accommodate the forces occurring during
operation.

Planning KL 4000; KL 4000 S
Fig. 5-1: “Mounting base, end” assembly
1 Fastening elements
2 Mounting base, end (beam ends)

KL 4000; KL 4000 S
Planning
Fig. 5-2: “Mounting base, center” assembly
2 Mounting base, center (beam joint)
Edge distances for foundations
Edge distances are the minimum distances of the anchor holes from any
edge present on the base plate.

Fig. 5-3: Edge distances
Grade of concrete for foundations
When producing foundations from concrete, observe the load-bearing ca-

pacity of the ground and the country-specific construction regulations.
The quality of the concrete must meet the requirements of the following
standard:
• C20/25 according to DIN EN 206-1:2001/DIN 1045-2:2008
Screed
The screed layer must be in full contact with the concrete subsurface over
its full area so that load application of the transverse forces on the basis
of the anchor approval can be verified. The screed must have a compres-
sive strength of at least 25 N/mm2.
5.2.2 Standard mounting base, reinforced
Description
The “Mounting base, end” and “Mounting base, center” assemblies are
employed when the linear unit is installed on the floor or a substructure
using bedplates. The number of bedplates depends on the length of the
beam. Please refer to the layout (>>> 4 "Technical data" Page 27).
operation.

KL 4000; KL 4000 S
Planning
Fig. 5-4: “Mounting base, end” assembly

Fig. 5-5: “Mounting base, center” assembly

KL 4000; KL 4000 S
Planning

standard:
Screed
5.2.3 Mounting base with lateral or longitudinal joint
Description
The “Mounting base with lateral or longitudinal joint” assemblies are em-
ployed when the linear unit is installed on the floor using bedplates. This
mounting base variant is used if one or two expansion joints in the foun-
dations need to be spanned. The choice of mounting bases depends on
the position and direction of the expansion joints.
The following mounting bases are available for compensation of
expansion joints:
• Mounting base, end, lateral joint, longitudinal compensation
• Mounting base, center, lateral joint, longitudinal compensation
• Mounting base, end, longitudinal joint, lateral compensation
• Mounting base, center, longitudinal joint, lateral compensation
NOTICE
The mounting bases only allow the described compensation directions.
If the expansion joint runs parallel to the beam, a mounting base for the
longitudinal joint with lateral compensation is used. A standard bedplate is
fastened on the fixed bearing side (rack side). The bedplate with the slots
is located on the floating bearing side. The slots are arranged perpendicu-
lar to the beam. If the expansion joint runs perpendicular to the beam, a
mounting base for the lateral joint with longitudinal compensation is used.
In this case, bedplates with slots are fastened on both the fixed bearing
side (rack side) and the floating bearing side. The slots are arranged par-
allel to the direction of motion of the carriage.
The slots in the bedplates are not filled with resin. The maximum range of
motion perpendicular to the beam or in the direction of motion of the car-
riage is ±7.5 mm in each case.
The arrangement and number of mounting bases with lateral or longitudi-
nal compensation depends on the length of the beam. Please refer to the
layout (>>> 4 "Technical data" Page 27).
operation.

Lateral joint, longitudinal compensation
Fig. 5-7: Mounting base, end, lateral joint, longitudinal compensation

KL 4000; KL 4000 S
Planning
Fig. 5-8: Mounting base, center, lateral joint, longitudinal compensa-
tion

Longitudinal joint, lateral compensation
Fig. 5-9: Mounting base, end, longitudinal joint, lateral compensation

KL 4000; KL 4000 S
Fig. 5-10: Mounting base, center, longitudinal joint, lateral compensa- Planning
tion

1 Mounting base with lateral joint, longitudinal compensation

2 Mounting base with longitudinal joint, lateral compensation

standard:
Screed
5.2.4 Mounting base with lateral or longitudinal joint, strengthened
Description
The “Mounting base with lateral or longitudinal joint” assemblies are em-
ployed when the linear unit is installed on the floor using bedplates. This
mounting base variant is used if one or two expansion joints in the foun-
dations need to be spanned. The choice of mounting bases depends on

KL 4000; KL 4000 S
the position and direction of the expansion joints.
Planning
The following mounting bases are available for compensation of
expansion joints:
• Mounting base, end, lateral joint, longitudinal compensation
• Mounting base, center, lateral joint, longitudinal compensation
• Mounting base, end, longitudinal joint, lateral compensation
• Mounting base, center, longitudinal joint, lateral compensation
NOTICE
The mounting bases only allow the described compensation directions.
If the expansion joint runs parallel to the beam, a mounting base for the
longitudinal joint with lateral compensation is used. A standard bedplate is
fastened on the fixed bearing side (rack side). The bedplate with the slots
is located on the floating bearing side. The slots are arranged perpendicu-
lar to the beam. If the expansion joint runs perpendicular to the beam, a
mounting base for the lateral joint with longitudinal compensation is used.
In this case, bedplates with slots are fastened on both the fixed bearing
side (rack side) and the floating bearing side. The slots are arranged par-
allel to the direction of motion of the carriage.
The slots in the bedplates are not filled with resin. The maximum range of
motion perpendicular to the beam or in the direction of motion of the car-
riage is ±7.5 mm in each case.
The arrangement and number of mounting bases with lateral or longitudi-
nal compensation depends on the length of the beam. Please refer to the
operation.

Lateral joint, longitudinal compensation
Fig. 5-12: Mounting base, end, lateral joint, longitudinal compensa-

tion

KL 4000; KL 4000 S
Planning
Fig. 5-13: Mounting base, center, lateral joint, longitudinal compensa-
tion

Longitudinal joint, lateral compensation
Fig. 5-14: Mounting base, end, longitudinal joint, lateral compensa-

tion

KL 4000; KL 4000 S
Planning
Fig. 5-15: Mounting base, center, longitudinal joint, lateral compensa-
tion

1 Mounting base with lateral joint, longitudinal compensation

2 Mounting base with longitudinal joint, lateral compensation

standard:
Screed
5.2.5 Adjusting plates for mounting base
Description
If the height difference between all foundation plates exceeds 20 mm, a

height difference from 20 mm to up to 50 mm can be compensated for us-
ing adjusting plates.

KL 4000; KL 4000 S
The bedplates are fastened to the adjusting plates at the points of adjust-
Planning
ment. The adjusting plates are anchored to the floor using anchor rods.
Adjusting plates with a height of 20 mm, 30 mm, 40 mm and 50 mm are
available.
Fig. 5-17: Adjusting plates
1 Fastening elements for linear unit

2 Mounting base at the ends of the beam or at the beam joint
3 Adjusting plate
4 Concrete foundation
5.2.6 Hilti anchoring kit
Description
The anchoring kit is used when the linear unit is fastened directly to the
floor. The bedplates are anchored by means of chemical anchors with Dy-

KL 4000; KL 4000 S
namic Set. In the case of non-compliance with the specified floor struc-
Planning
ture, it must be checked whether the anchoring kit is still suitable.

The anchoring kit contains the required number of chemical anchors with
Dynamic Set and accessories including injection resin.
The minimum dimensions must be observed.
Fig. 5-18: Anchoring kit
1 Hole depth 3 Concrete foundation

2 Concrete thickness

There must be no layers of insulation between the bedplates and the con-
crete foundation. The chemical anchors used only permit a load-bearing
screed thickness of maximum 11 mm.
standard:
Screed

KL 4000; KL 4000 S
Planning
5.2.7 Hilti anchoring kit, strengthened foundation
Description
floor. The bedplates are anchored to the floor using dynamic anchors. In
the case of non-compliance with the specified floor structure, it must be
checked whether the anchoring kit is still suitable.
The anchoring kit contains the required number of chemical anchors and
accessories including injection resin.
1 Chemical anchor 3 Concrete foundation

with Dynamic Set
2 Bedplate
There are three types of chemical anchors available for selection; they are
listed in the following table. The choice depends on the characteristics of
the mounting surface at the installation site of the linear unit.
Max. Required con-
Type of Drill hole
clamping crete thick-
Variant chemical an- depth Comment
thickness ness
chor in mm
in mm in mm
1 HAS-D 165 30 195 - clamping
M16x200 thickness
M16x220 thickness
M16x245 thickness


KL 4000; KL 4000 S
Planning
standard:
Screed
5.2.8 Fischer anchoring kit
Description

with Dynamic Set
2 Bedplate
There are four types of chemical anchors available for selection; they are

KL 4000; KL 4000 S
Planning
Max. Required con-
Type of Drill hole
clamping crete thick-
Variant chemical an- depth Comment
thickness ness
chor in mm
in mm in mm
1 FHB-A dyn 155 25 185 - clamping
M16x125/25 thickness
3 FHB-A dyn 180 50 210 - clamping Corrosion-re-
M16x125/50C thickness sistant

standard:
Screed
5.2.9 Anchoring kit, strengthened foundation
Description


with Dynamic Set
2 Bedplate
There are four types of chemical anchors available for selection; they are
Max. Required con-
Type of
Hole depth clamping crete thick-
Variant chemical an- Comment
in mm thickness ness
chor
in mm in mm
3 FHB-A dyn 180 50 210 - clamping Corrosion-re-
M16x125/50C thickness sistant

standard:

KL 4000; KL 4000 S
Planning
Screed
5.2.10 Anchoring kit, adjusting plate (strengthened foundation)
Description
Adjusting plates can be used to compensate for the height difference over
20 mm. The adjusting plates are anchored to the floor using dynamic an-
chors. In the case of non-compliance with the specified floor structure, it
must be checked whether the anchoring kit is still suitable.
The “Foundation adjusting plate” assembly contains the required number
of chemical anchors and accessories including injection resin.
Fig. 5-22: Anchoring kit, adjusting plates
1 Adjusting plate height, 20 mm, 30 mm, 40 mm or 50 mm

2 Chemical anchor with Dynamic Set
3 Bedplate
4 Concrete foundation
There are two types of chemical anchors available for selection; they are
listed in the following table. The selection depends on the height of the
adjusting plates.

Max. Required con-

Adjust- Type of
Hole depth clamping crete thick-
ing plate chemical an- Comment
in mm thickness ness
height chor
in mm in mm
20 mm FHB-A dyn 155 25 185 - clamping

standard:
Screed
5.2.11 Machine frame mounting
Description
The machine frame mounting assembly is used when the linear unit is
fastened to a substructure (e.g. steel structure). It must be ensured that
the substructure is able to withstand safely the forces occurring during op-
eration (foundation loads).
The following diagram contains all the necessary information that must be
observed when preparing the mounting surface.
The tapped holes must be created in the substructure in accordance
with the layout by the customer before the linear unit has reached the
installation site. The responsibility for this lies with the user.
The machine frame mounting assembly (>>> Fig. 5-23) consists of:
• Studs
• Fastening elements

KL 4000; KL 4000 S
Planning
Fig. 5-23: Machine frame mounting
1 Machine frame mounting

2 Substructure
3 Minimum thickness of substructure
Bending and
torsional
stiffness
If the linear unit is installed on a substructure, this must have adequate

bending and torsional stiffness. An operating load acting on the foundation
in any possible direction (see “Foundation loads”) must not cause defor-
mations of more than 0.5 mm at any point.
5.3 Connecting cables and interfaces
Connecting cables
The connecting cables comprise all the cables for transferring energy and
signals between the robot controller, the linear unit and the robot. The
contents of the connecting cable set (energy supply chain) of the linear
unit are determined for each individual order. For operating the linear unit
without a robot, the connecting cable set contains:
• Motor cable, linear unit, XM
• Control cable, linear unit, XP
• Ground conductor (order as an option)
The connecting cables are connected to the robot by means of connec-
tors. The ground conductors are screwed to threaded bolts.
The robot motor cable (A1 - A6) and data cable are described in the ro-
bot operating instructions.
A connector plate serving as an interface is located on the linear unit. The

connector plate serves as a common interface for all the connecting ca-
bles. Only control cable XP of the linear unit is routed and connected in
accordance with the specific order. As a rule, control cable XP runs from
the servomotor of the linear unit to the RDC box of the robot.
The connecting cables and ground conductor (optional) are connected to
the robot controller via the connector plate. A connection panel is provided
on the robot controller for motor cable XM of the linear unit. Cable lengths
of 7 m, 15 m, 25 m and 35 m are available.

KL 4000; KL 4000 S
A ground conductor is required to provide a low-resistance connection be-

Planning
tween the linear unit and the control cabinet in accordance with
DIN EN 60204. The ground conductor is connected via ring cable lugs. A
low-resistance connection must be provided between all components of a
system. The ground conductor and threaded bolts can be ordered as an
option.
Wiring diagrams, connector pin allocations and connector designations for
the energy supply chain can be found in the chapter (>>> 7 "Start-up and
recommissioning" Page 105).
The following points must be observed when planning and routing the
connecting cables:
• The bending radius for fixed routing – 150 mm for motor cables and
60 mm for control cables – must not be exceeded.
• For the connecting cables in the energy supply chain, the bending ra-
dius must not exceed 240 mm.
• Protect cables against exposure to mechanical stress.
• Route the cables without mechanical stress – no tensile forces on the
connectors.
• Cables are only to be installed indoors.
• Observe the permissible temperature range (fixed installation) of
263 K (-10 °C) to 343 K (+70 °C).
• Route the motor cables and the control cables separately in metal
ducts; if necessary, additional measures must be taken to ensure elec-
tromagnetic compatibility (EMC).
• The length of the connecting cables between the robot controller and
the robot must not exceed 50 m.
CAUTION
Risk of injury due to tripping hazards
Improper installation of cables can cause tripping hazards. Injuries or
damage to property may result.
• The connecting cables must be installed in such a way (e.g. cable
ducts) as to prevent tripping hazards.
• Potential tripping hazards must be marked accordingly.
Interface for energy supply system
The linear unit can be fitted with an energy supply system (motor and da-
ta cables, hose lines, etc.), which is guided in the energy supply chain.
The energy supply chain forms the moving (translational) connection be-
tween the connector plate (interface) and the driver on the carriage. De-
pending on the application, the connector plate differs in design and
scope.
Detailed information on the connector pin allocation, threaded unions, etc.
can be found in separate documentation that is supplied with the system.

KL 4000; KL 4000 S
Transportation
6 Transportation
Description
The linear unit must be prepared for transportation. For this, all assem-
blies and components that are to be transported separately must be dis-
mantled. A maximum of 3 beam segments may be transported together
per transport unit. The beam must be prepared for transportation accord-
ingly. If a transport unit includes a carriage, this must be positioned in the
middle. It must be ensured that the carriage is secured so that it cannot
move. A maximum of two carriages per transport unit are allowed. At the
joints of the transport units, the tracks result in an overlap. The screws
with conical spring washers and covers must be removed at the overlap if
necessary. The tracks are not removed at these points.
If covers are mounted on the beam segments, these must be removed.
NOTICE
For work on the linear unit, the use of personal protective equipment is
mandatory. Where applicable, additional local or national accident pre-
vention regulations must also be observed.
Assemblies and components
The following measures are to be taken before assemblies and individual

components are transported:
• Protect components against corrosion.
• Pack motors and gear units in wooden cases with protection against
moisture and transport damage.
• Wrap components in PE film or VCI paper (RESY symbol), with desic-
cant if necessary.
• Provide electrical components with shock-resistant and break-proof
packing.
Mark transport cases and packing according to the sensitivity of their con-
tents (e.g. TOP, FRAGILE, DO NOT BEND) and attach labels to ensure
correct transportation (e.g. indication of center of gravity). In addition to
these measures, the regulations and conditions of the company entrusted
with the transportation are to be observed.
Transportation
Each transport unit can be transported by fork lift truck or using lifting
tackle.
WARNING
Risk of injury and damage to property resulting from unsuitable handling
equipment. Only use handling equipment with a sufficient load-bearing
capacity. The components must always be picked up over the center of
gravity.
Transportation by fork lift truck
For transportation by fork lift truck (>>> Fig. 6-1), the transport unit must
be picked up at its center of gravity in order to prevent it from toppling.
The fork lift truck must have a minimum payload capacity of 3.5 t and an
adequate fork length.

Transportation KL 4000; KL 4000 S
Fig. 6-1: Transportation by fork lift truck
Transportation with lifting tackle
Each transport unit can also be transported using lifting tackle. A minimum
payload capacity of 3.5 t must be observed. If the transport unit consists
of the maximum of three beam segments, the ropes must be attached as
shown in the illustration (>>> Fig. 6-2). All ropes must be long enough to
ensure that the linear unit is not damaged and can be transported safely.
An angle of 60° between the rope and the linear unit should be observed.
If covers are mounted on the beam segments, these must be removed.
WARNING
The beam may tip during transportation. Risk of personal injury and
damage to property.
If the beam is being transported using lifting tackle, special care must
be exercised to prevent it from tipping. Additional safeguarding meas-
ures must be taken. It is forbidden to pick up the beam in any other
way using a crane!
Fig. 6-2: Transportation by crane

KL 4000; KL 4000 S
Start-up and recommissioning

7 Start-up and recommissioning
NOTICE
DANGER
Insufficient fastening of the load or failure of the lifting tackle can cause
the load to fall, resulting in injury to persons or material damage:
Check that the Load Lifting Attachment is fastened correctly and only
use lifting tackle with a sufficient load-bearing capacity.
Never work or stand under suspended loads!
WARNING
When work is carried out on the robot system, turn the main switch on
the robot controller to “OFF” and secure it with a padlock to prevent un-
authorized persons from switching it on again.
WARNING
During work on the linear unit, there is a risk of slipping or tripping over
the beam, tracks and energy supply chain guide. Risk of personal injury
and damage to property.
Clean the beam before work is started on the linear unit. Do not walk
on the tracks, energy supply chain or energy supply chain guide! Care-
fully step over the energy supply chain and energy supply chain guide!
WARNING
Persons walking on the beam are at risk of falling into the holes. If the
linear unit is installed in an elevated position, there is an additional risk
of falling from a greater height.
Risk of personal injury and damage to property.
Do not walk on the beam without the beam covers!
If necessary, take measures to guard against falling!
The maximum permissible weight of persons is 150 kg.
CAUTION

Start-up and recommissioning KL 4000; KL 4000 S
CAUTION
For screwed connections, the fastening screws (standard, strength class
8.8) are to be tightened with the tightening torques specified in the ap-
pendix (>>> 13 "Appendix" Page 223). Tightening torques deviating from
these values are specified directly.
The specified screw sizes and strength classes are those valid at the
copy deadline. The specifications contained in the Parts Catalog are,
however, always to be taken as the most up-to-date information.
Screws of strength class 10.9 and higher as well as screws with test
certification may only be tightened once with the rated tightening torque.
When the screws are first slackened they must be replaced with new
ones.
None or false machine data for the linear unit may result in malfunction.
Before programming and start-up of the linear unit, the machine data
(Translation, Motor-/drive module data, controller setting, $ERSYSROOT,
run-up time and ET1) must be configured and entered correctly.
7.1 Installing the mounting base
7.1.1 Installing the standard mounting base
Description
These instructions apply to the floor-mounted variant of the linear unit.

The linear unit is mounted on bedplates on an appropriate support surface
(e.g. concrete foundation) and fastened there.
Preconditions
• The concrete foundation must have the required dimensions and

cross-section.
• The support surface must be smooth and even.
• The mounting base assembly (bedplates and fastening elements) must
be complete.
• Have the leveling compound readily at hand.
• Have the spacer rings readily at hand.
Procedure
1. Insert the M30 hexagon bolts into the bedplates from below. Position
the bedplates on the concrete foundation in accordance with the
2. Check each individual bedplate to ensure that it is in full contact with
the support surface. If necessary, smooth the floor around the bed-
plate using leveling compound.
3. Mark the position of the bedplates on the concrete foundation.
4. Check the height difference between all of the bedplates by means of
a leveling instrument.
• Height difference <10 mm: No further measures required.
• Height difference 10 mm - 20 mm: Use spacer rings. Only one
spacer ring may be inserted for each M30 hexagon bolt.
5. Anchor the bedplates to the floor (>>> 7.2 "Installing the anchoring kit"
Page 115).
6. Insert the pre-assembled adjusting screws onto the M30 hexagon bolts
and level to the same height.

KL 4000; KL 4000 S

7. Push a ball cup (3) onto each adjusting screw.
8. Install the linear unit.
Fig. 7-1: Installing the mounting bases
1 M30 hexagon bolt 5 Mounting base, center

2 M30 hexagon nut 6 Adjusting screw assembly
3 Ball cup D35 7 Ball cup D35
4 Mounting base, end 8 Spherical washer C31
7.1.2 Installing the reinforced mounting base
Description

Preconditions

cross-section.
be complete.
• Have adjusting plates ready to hand.

Procedure
• Height difference 20 mm - 50 mm: Use adjusting plates. Further
information about the adjusting plates can be found in the
(>>> 5.2.5 "Adjusting plates for mounting base" Page 92) section.
5. Anchor the bedplates to the floor (>>> 7.2 "Installing the anchoring kit"
Page 115).
Proceed as follows at points where adjusting plates are used.
• Insert the M30 hexagon bolts into the bedplates from below.
• Place the bedplates on the adjusting plates.
• Put one C21 spherical washer onto each of the M16x45-8.8 hexa-
gon bolts.
• Put one G19 ball cup onto each of the M16x45-8.8 hexagon bolts.
• Screw the bedplates to the adjusting plates using six M16x45-8.8
hexagon bolts for each one.
• Tighten the M16x45-8.8 hexagon bolts with the specified tightening
torque.
• Position the bedplates on the concrete foundation in accordance
with the layout (>>> 4 "Technical data" Page 27).
• Anchor the adjusting plates to the floor (>>> 7.2.4 "Installing the
anchoring kit, adjusting plate (strengthened foundation)"
Page 127).

KL 4000; KL 4000 S

Fig. 7-2: Installing the mounting bases, strengthened foundation

2 M30 hexagon nut 6 Adjusting screw assembly
3 Ball cup D35 7 Ball cup D35
7.1.3 Installing the mounting base with lateral or longitudinal joint
Description

Preconditions

cross-section.
be complete.

Procedure
layout (>>> 4 "Technical data" Page 27). The slots of the bedplates
must be aligned in such a way that they point in the planned compen-
sation direction.
5. Anchor the bedplates to the floor (>>> 7.2.5 "Installing the anchoring
kit with lateral or longitudinal joint" Page 130).
Fig. 7-3: Mounting base, lateral joint, longitudinal compensation,

installing
1 M30 hexagon bolt 6 Mounting base, end

2 M30 hexagon nut 7 Mounting base, center
3 Ball cup D35 8 Adjusting screw assembly

KL 4000; KL 4000 S

4 Guide strip 9 Ball cup D35
5 Sliding plate 10 Spherical washer C31
Fig. 7-4: Mounting base, longitudinal joint, lateral compensation,

installing

2 M30 hexagon nut 7 Sliding plate
7.1.4 Installing the mounting base, reinforced, with lateral or longitudinal

compensation
Description


Preconditions

cross-section.
be complete.
Procedure
layout (>>> 4 "Technical data" Page 27). The slots of the bedplates
must be aligned in such a way that they point in the planned compen-
sation direction.
5. Anchor the bedplates to the floor (>>> 7.2.5 "Installing the anchoring
kit with lateral or longitudinal joint" Page 130).

KL 4000; KL 4000 S

Fig. 7-5: Mounting base, lateral joint, longitudinal compensation,
installing
1 M30 hexagon bolt 6 Mounting base, end

2 M30 hexagon nut 7 Mounting base, center
5 Sliding plate 10 Spherical washer C31

Fig. 7-6: Mounting base, longitudinal joint, lateral compensation,

installing

2 M30 hexagon nut 7 Sliding plate

KL 4000; KL 4000 S

7.2 Installing the anchoring kit
7.2.1 Installing the Hilti anchoring kit
Description

The linear unit is fastened to a suitable concrete foundation using anchor
rods (resin-bonded anchors).
Preconditions

cross-section.
• The anchoring kit assembly must be complete.
• The bedplates are installed and aligned on the support surface.
Special tools
The following special tools are required:

• Hammer drill with a bit of ø 18 mm.
• Suitable applicator gun from the anchor manufacturer
Procedure
1. Using the bushing, spot-drill all holes for the anchors approximately 2
cm into the foundation through the holes in the bedplates.
2. Mark the setting depth on the anchor rod. The setting depth is deter-
mined by the thickness of the bedplate and the borehole depth, as il-
lustrated in Figure (>>> Fig. 7-8).
3. Drill the spot-drilled anchor holes to the required depth. The drill holes
must be vertical.
4. Clean the anchor holes in accordance with the instructions provided
by the anchor manufacturer; blow-clean and brush if required. If a hol-
low drill with extraction system is used, the anchor holes do not need
to be cleaned.
5. Check the setting depth. The anchor rod must fit into the borehole up
to the setting depth marking. If necessary, remove drilling dust or drill
deeper.
6. Prepare injection of the resin in accordance with the manufacturer’s in-
structions.
Check that the film pack and cassette are functioning correctly. Screw
the static mixer firmly onto the film pack. Insert the film pack into the
cassette and fit the cassette into the applicator gun. The film pack
opens automatically when ejection begins.
7. Eject the initial resin discharge onto a suitable surface. It must not be
injected into the drill hole. The initial resin discharge is shown in the
following table. It is dependent on the size of the film pack.
Quantity, initial resin discharge Container size
2 shots for 330 ml film pack
4 shots for 500 ml film pack,
below 5 °C

8. Assemble the mixer nozzle, mixer extension and piston plug and at-
tach marking 1 as shown in the following figure. Set marking 2 on the
mixer extension by measuring 50 mm from marking 1 in the direction
of the piston plug.
Fig. 7-7: Piston plug
1 Piston plug
2 Marking 2
3 Marking 1
9. Insert the piston plug all the way to the bottom of the borehole. Mark-
ing 1 should then be flush with or deeper than the surface of the bed-
plate.
10. Inject resin into the anchor hole. Ensure that no air bubbles form in
the process. The piston plug is moved by means of back-pressure.
11. Inject the resin until marking 2 is flush with the surface of the bed-
plate.
12. Press the release button on the applicator gun to prevent resin from
spilling over. Skip this step if a battery-operated applicator device is
used.
13. Gently screw the anchor rod into the resin until the marking (depth of
engagement) is reached. Ensure that the anchor rod is vertical.
The anchor rod must be set before the maximum permissible process-
ing time of the resin has elapsed. The manufacturer’s specifications
are shown in the following table.
Temperature Maximum processing time
274 K to 278 K (1 °C to 5 °C) 25 minutes
14. If required, inject more resin into the annular gap. The chemical an-
chor rod is set correctly if the resin is completely mixed and the an-
chor hole in the concrete is completely filled to the upper edge.
15. Perform the insertion procedure for the remaining anchors.
16. Allow the resin to cure. The manufacturer’s specifications are shown in
the following table.

KL 4000; KL 4000 S

Temperature Minimum curing time
274 K to 278 K (1 °C to 5 °C) 2 hours
17. At the end of the required curing time, the extra resin must be re-
moved from the bedplates and anchor rods. The foundation plates and
anchor rods must not be damaged in the process.
18. Mount a Dynamic Set on each anchor rod (ball cup, conical washer,
hexagon nut).
19. Tighten the hexagon nuts one after another with a torque wrench in
diagonally opposite sequence. Gradually increase the tightening torque
to a value of 80 Nm.
20. Screw a lock nut onto each anchor rod and tighten it with a torque
wrench (1/4 to 1/2 turn).
21. Retighten the hexagon nuts once after 100 hours of operation.
Fig. 7-8: Installing the anchoring kit
1 Dynamic Set 3 Hole depth

2 Anchor rod
The mounting base is now ready for the linear unit to be installed.
7.2.2 Installing the Hilti anchoring kit, strengthened foundation
Description

rods.

Preconditions

cross-section.
• The surface of the foundation must be smooth and even.
Special tools

• HIT-RB 18 brushes for cleaning the drill holes.
• Suitable applicator gun from the anchor manufacturer
Procedure
1. Using the bushing, spot-drill all holes for the anchors (>>> Fig. 7-10)
approximately 2 cm into the foundation through the holes in the bed-
plates.
2. Drill the spot-drilled anchor holes to the drill hole depth specified in
the following table. The drill holes must be vertical.
Type of Drill hole depth
Variant
chemical anchor in mm
1 HAS-D M16x200 165
2 HAS-D M16x220 185
3 HAS-D M16x245 210
The minimum dimension 30 mm (>>> Fig. 7-9) must be observed. If
the concrete thickness does not meet this condition, it is possible to
insert a washer (article number 00-417-136) with a thickness of
15 mm. The minimum drill hole depth must be observed.
Fig. 7-9: Installing the anchoring kit with washer (schematic)
1 Bedplate
2 Anchor rod
3 Washer

KL 4000; KL 4000 S

3. Clean the anchor holes in accordance with the instructions provided
by the anchor manufacturer; blow-clean and brush if required. If a hol-
low drill with extraction system is used, the anchor holes do not need
to be cleaned.
4. Check the setting depth. The setting depth corresponds to the drill
hole depth. It must be possible to insert the anchor rod into the drill
hole as far as the thread. If necessary, remove drilling dust or drill
deeper.
5. Prepare injection of the resin in accordance with the manufacturer’s in-
structions.
Check that the film pack and cassette are functioning correctly. Screw
the static mixer firmly onto the film pack. Insert the film pack into the
cassette and fit the cassette into the applicator gun. The film pack
opens automatically when ejection begins.
6. Eject the initial resin discharge onto a suitable surface. It must not be
injected into the drill hole. The initial resin discharge is shown in the
following table. It is dependent on the size of the film pack.
Quantity, initial resin discharge Container size
4 shots for 500 ml film pack,
below 5 °C
The processing times must be observed. See the following table.
Temperature Maximum processing time
7. Set the rotary switch on the applicator gun to 3.5 strokes.

8. Fill 2/3 of the drill hole depth with resin. Position the dispensing gun at
the bottom of the drill hole and inject resin stroke by stroke. Ensure
that there are no air bubbles.
9. Press the release button on the applicator gun to prevent resin from
spilling over. Skip this step if a battery-operated applicator device is
used.
10. Lightly screw the anchor rod into the resin. Ensure that the anchor rod
is vertical. The anchor rod must be set before the maximum permissi-
ble processing time of the resin has elapsed.
Furthermore, resin must have emerged. If this is not the case, pull the
anchor rod out immediately, inject additional resin and re-insert the an-
chor rod.
12. Allow the resin to cure. For curing times, see the following table.
274 K to 278 K (1 °C to 5 °C) 2 hours


13. At the end of the required curing time, the extra resin must be re-
moved from the bedplates and anchor rods. The foundation plates and
anchor rods must not be damaged in the process.
14. Mount a Dynamic Set (washer, hexagon nut) on each anchor rod.
16. Screw a lock nut onto each anchor rod and tighten it with a torque
Fig. 7-10: Installing the anchoring kit, strengthened foundation
1 Anchor rod
2 Resin cartridge
43 Hole in the bedplate

KL 4000; KL 4000 S
7.2.2.1 Installing the anchoring kit, strengthened foundation

Description

rods.
Preconditions

cross-section.
Special tools

• BS 16/18 brushes for cleaning the boreholes.
• Static mixer and blow-out pump from Fischerwerke GmbH.
Procedure
plates.
2. Drill the spot-drilled anchor holes to the depth specified in the follow-
ing table. The holes must be vertical.
Type of Hole depth Setting depth
Variant
chemical anchor in mm in mm
1 FHB-A dyn 155 135
M16x125/25
2 FHB-A dyn 180 160
M16x125/50
3 FHB-A dyn 180 160
M16x125/50C
4 FHB-A dyn 205 185
M16x125/80
10 mm. The minimum hole depth must be observed.

1 Bedplate
2 Anchor rod
3 Washer
3. Blow out the anchor holes, brush them out and then blow them out
again.
4. Screw the static mixer onto the dispenser gun. The mixing spiral must
be clearly visible.
5. Insert the resin cartridge into the dispenser gun. Keep squeezing out
resin until the emerging resin has a uniform gray color. The
processing times must be observed. See the following table.
Cartridge temperature Processing time
< 278 K (+5 °C) No processing allowed
278 K (+5 °C) 15 minutes
293 K (+20 °C) 6 minutes
303 K (+30 °C) 4 minutes
318 K (+40 °C) 2 minutes
6. Fill the anchor hole with resin. Position the dispensing gun at the bot-
tom of the drill hole and inject resin stroke by stroke. Ensure that
there are no air bubbles.
Select the resin quantity in accordance with the following table:
Resin
Scale divisions on the
Type of chemical anchor quantity
resin cartridge
in ml
FHB-A dyn M16x125/25 21 10.5
FHB-A dyn M16x125/50 23 11.5
FHB-A dyn M16x125/50C 23 11.5
FHB-A dyn M16x125/80 25 12.5
7. Using a slight twisting motion, insert the pre-assembled anchor rod to

the setting depth. Adjust the setting depth via the hexagon nut and
spacers to the drill hole depth minus 5 mm. The anchor rod is set

KL 4000; KL 4000 S
when the entire surface area of the filling disc is in contact with the

foundation plate. Furthermore, resin must have emerged. If this is not
the case, pull the anchor rod out immediately, inject additional resin
and re-insert the anchor rod.
Foundation temperature Curing time
268 K (-5 °C) 360 minutes
273 K (0 °C) 180 minutes
278 K (+5 °C) 90 minutes
293 K (+20 °C) 35 minutes
303 K (+30 °C) 20 minutes
318 K (+40 °C) 12 minutes
11. Screw on the lock nuts by hand and tighten them with a torque
wrench (1/4 to 1/2 turn). In the case of the corrosion-resistant anchor-
ing kit, the lock nut is a thin nut and must only be tightened with a
tightening torque of 15 Nm.
12. Remove extra resin from the foundation plates and anchor rods. The
foundation plates and anchor rods must not be damaged in the proc-
ess.

Fig. 7-12: Installing the anchoring kit, strengthened foundation
1 Anchor rod
2 Resin cartridge
7.2.3 Fischer anchoring kit, installing
Description

rods.
Preconditions

cross-section.

KL 4000; KL 4000 S

Special tools

Procedure
plates.
Type of Drill hole depth Setting depth
Variant
1 FHB-A dyn 155 135
M16x125/25
2 FHB-A dyn 180 160
M16x125/50
3 FHB-A dyn 180 160
M16x125/50C
4 FHB-A dyn 205 185
M16x125/80
again.
be clearly visible.
278 K (+5 °C) 15 minutes
293 K (+20 °C) 6 minutes
303 K (+30 °C) 4 minutes
318 K (+40 °C) 2 minutes
Resin
resin cartridge
in ml
FHB-A dyn M16x125/25 21 10.5
FHB-A dyn M16x125/50 23 11.5
FHB-A dyn M16x125/50C 23 11.5
FHB-A dyn M16x125/80 25 12.5


268 K (-5 °C) 360 minutes
273 K (0 °C) 180 minutes
278 K (+5 °C) 90 minutes
293 K (+20 °C) 35 minutes
303 K (+30 °C) 20 minutes
318 K (+40 °C) 12 minutes
ess.

KL 4000; KL 4000 S

Fig. 7-13: Installing the anchoring kit
1 Anchor rod 3 Hole in the bedplate

2 Resin cartridge
7.2.4 Installing the anchoring kit, adjusting plate (strengthened foundation)
Description
To compensate for the height difference of the bedplates, adjusting plates

are used at several points. The bedplates are anchored to the floor via
the adjusting plates at these points. These instructions apply to the an-
choring of the adjusting plates on the floor.
Preconditions

cross-section.
• The anchoring kit for the adjusting plates must be complete.
• Bedplates are fastened to the adjusting plates.
• The bedplates with adjusting plates are installed and aligned on the
support surface.

Special tools

Procedure
1. Using the bushing, spot-drill all the anchor holes (>>> Fig. 7-15) ap-
proximately 2 cm through the holes in the adjusting plate.
2. Drill the spot-drilled anchor holes to the depth specified in the follow-
ing table. The holes must be vertical.
Adjust-
ing Type of Hole depth Setting depth
plate chemical anchor in mm in mm
height
20 mm FHB-A dyn 155 135
M16x125/25
30 mm FHB-A dyn 180 160
M16x125/50
40 mm FHB-A dyn 180 160
M16x125/50
50 mm FHB-A dyn 180 160
M16x125/50
10 mm. The minimum hole depth must be observed.
1 Bedplate
2 Anchor rod
3 Washer
again.

KL 4000; KL 4000 S

be clearly visible.
278 K (+5 °C) 15 minutes
293 K (+20 °C) 6 minutes
303 K (+30 °C) 4 minutes
318 K (+40 °C) 2 minutes
Resin
resin cartridge
in ml
FHB-A dyn M16x125/25 21 10.5
FHB-A dyn M16x125/50 23 11.5
FHB-A dyn M16x125/50C 23 11.5
FHB-A dyn M16x125/80 25 12.5

adjusting plate. Furthermore, resin must have emerged. If this is not
268 K (-5 °C) 360 minutes
273 K (0 °C) 180 minutes
278 K (+5 °C) 90 minutes
293 K (+20 °C) 35 minutes
303 K (+30 °C) 20 minutes
318 K (+40 °C) 12 minutes

ess.
Fig. 7-15: Installing the anchoring kit, adjusting plates
1 Adjusting plate height, 20 mm, 30 mm, 40 mm or 50 mm

2 Anchor rod
3 Resin cartridge
4 Hole in the adjusting plate
7.2.5 Installing the anchoring kit with lateral or longitudinal joint
Description

rods.

KL 4000; KL 4000 S

Preconditions

cross-section.
Special tools

Procedure
1. Install the anchoring kit for bedplates without slots (>>> 7.2.2.1 "Instal-
ling the anchoring kit, strengthened foundation" Page 121)
(>>> 7.2.3 "Fischer anchoring kit, installing" Page 124).
2. Drill all anchor holes (>>> Fig. 7-17) through the holes of the bed-
plates with slots into the foundation to a depth of 2 cm. Use bushing
for slots.
Type of Drill hole depth Setting depth
Variant
1 FHB-A dyn 155 135
M16x125/25
2 FHB-A dyn 180 160
M16x125/50
3 FHB-A dyn 180 160
M16x125/50C
4 FHB-A dyn 205 185
M16x125/80
10 mm. The minimum drill hole depth must be observed.

1 Bedplate
2 Anchor rod
3 Washer
4. Remove the bedplates with slots from the drilled holes and set them
down to one side.
again.
be clearly visible.
278 K (+5 °C) 15 minutes
293 K (+20 °C) 6 minutes
303 K (+30 °C) 4 minutes
318 K (+40 °C) 2 minutes
Resin
resin cartridge
in ml
FHB-A dyn M16x125/25 17 8.5
FHB-A dyn M16x125/50 19 9.5
FHB-A dyn M16x125/50C 19 9.5
FHB-A dyn M16x125/80 21 10.5

KL 4000; KL 4000 S

9. Using a slight twisting motion, insert the pre-assembled anchor rod
without fastening elements to the setting depth. For the setting depth,
refer to the table in step 3. The anchor rod is set when resin has
emerged. If this is not the case, pull the anchor rod out immediately,
inject additional resin and re-insert the anchor rod.
268 K (-5 °C) 360 minutes
273 K (0 °C) 180 minutes
278 K (+5 °C) 90 minutes
293 K (+20 °C) 35 minutes
303 K (+30 °C) 20 minutes
318 K (+40 °C) 12 minutes
12. Remove excess resin from the mounting surface of the bedplate on
the concrete foundation. The mounting surface must be clean.
13. Push the sliding plate onto the anchor rods.
14. Place the bedplate on the sliding plate.
15. Align the sliding plate flush with the bedplate.
16. Screw fastening elements onto the anchor rod without the plastic cen-
tering bushing and tighten gently.
17. Check the position of all bedplates and correct if necessary. Anchor
rods must be centered in the slots.
20. Attach guide strips to the bedplate with slots.
21. Drill anchor holes through the holes of the mounting bases with slots
into the foundation to a depth of 2 cm.
22. Remove the guide strips and drill the spot-drilled anchor holes to the
required depth. For the hole depth, refer to the table in step 3. The
drill holes must be vertical.
again.
24. Reposition the guide strips and fill the anchor hole with resin. Position
the dispensing gun at the bottom of the drill hole and inject resin
stroke by stroke. Ensure that there are no air bubbles.
CAUTION
The slots in the bedplates must not be filled with resin.

Resin
resin cartridge
in ml
FHB-A dyn M16x125/25 18 9
FHB-A dyn M16x125/50 20 10

Resin
resin cartridge
in ml
FHB-A dyn M16x125/50C 20 10
FHB-A dyn M16x125/80 22 11
26. Allow the resin to cure. For the curing times, refer to the table in
step 11.
27. Remove excess resin from the guide strips and anchor rods. The
guide strips and anchor rods must not be damaged in the process.

KL 4000; KL 4000 S

Fig. 7-17: Installing the anchoring kit (schematic)
1 Anchor rod
2 Resin cartridge
7.3 Installing the machine frame mounting assembly
Description
The machine frame mounting assembly is used for installing a linear unit
on a substructure (steel structure) prepared by the customer. The linear
unit is fastened to the substructure with studs.
The tapped holes must be created in the substructure in accordance
with the layout by the customer before the linear unit has reached the
installation site. The responsibility for this lies with the user.

Precondition
• The mounting surface has been prepared as shown in the diagram

(>>> Fig. 7-18). The M30 tapped holes are set.
• The substructure has been checked for sufficient safety.
• The machine frame mounting assembly is complete.
Procedure
1. Insert the M30 studs (>>> Fig. 7-18) into the hole until the depth of
engagement is reached. The minimum depth of engagement is
30 mm. If the linear unit is to be installed on the ceiling, apply a suita-
ble locking agent to the M30 studs.
2. Insert a spacer sleeve onto each of the M30 studs.
3. Fit the pre-assembled adjusting screws and ball cups onto the M30
studs. If the linear unit is installed on the ceiling, secure the adjusting
screws and ball cups against falling with an O-ring. Do not install the
O-ring if the linear unit is fastened to the floor.
WARNING
Personal injury can occur if the adjusting screw falls.
Warn all persons concerned and undertake appropriate safety pre-
cautions, e.g. wear a safety helmet.
4. Level all adjusting screws to the same height.
Fig. 7-18: Installing the machine frame mounting assembly

KL 4000; KL 4000 S

1 Minimum thickness of sub- 6 Ball cup D35
structure
2 Substructure 7 Adjusting screw assembly
3 M30x220 stud 8 Spacer sleeve
4 Hexagon nut 9 O-ring 28x4
5 Spherical washer C31 10 Ball cup D35
The machine frame mounting assembly is now ready for the linear unit to
be installed.
7.4 Installing the linear unit
Preconditions
• The mounting base or machine frame mounting assembly is prepared

and installed.
• The installation site is accessible with a crane or fork lift truck. Ob-
serve the minimum payload capacity.
• Any tools or other system components which would hinder the work
have been removed.
• The connecting cables and energy supply system cables are installed
on the system side.
Procedure
1. Bring the linear unit to the installation site by crane or fork lift truck.
2. Place the linear unit on the ball cups (>>> Fig. 7-19).
Reassemble the beam if it has been disassembled into a number of
transport units. Observe the correct sequence of the transport units in
accordance with the engraved numbering. Take care not to damage
the exposed ends of the tracks when setting down the beam.
Using a taut wire, align and position the linear unit. If possible, roughly
level it.
3. In sequence, place the ball cup, spherical washer and hexagon nut on
M30 bolt.
Fig. 7-19: Installing the linear unit (schematic)
1 M30 bolt 4 Adjusting screw assembly

2 M30 hexagon nut 5 Ball cup D35
3 Ball cup D35 6 Spherical washer C31
4. At the joints where the linear unit has been reassembled, insert the
missing M20x55-10.9 hexagon bolts with conical spring washers in the
tracks and tighten them lightly.

5. Align beams using a leveling instrument. The beam can be aligned us-
ing adjusting screws. The reference surface is the tracks.
Measure the levelness of the tracks:
The mounting base points at the start and end of each individual
beam segment (1.5 m or 2 m) are defined as the measuring points on
the tracks. The measuring points specified at the ends of the beams
are the center points of the M30 bolts, while the center of the bed-
plates is specified for the beam joints.
The following tolerances must be observed:
• For 4 measuring points of a beam segment, a deviation of 0.5 mm
is permissible for the levelness.
Four such measuring points are shown in the following figure as an
example.
Fig. 7-20: Measuring points for the levelness of the tracks (exam-
ple)
1 Measuring points
6. Measure and adjust the straightness of the track on the rack side.
The following tolerances must be observed:
• The permissible deviation in straightness for the entire beam
length is max. 1.0 mm over a measuring range of 10 m.
A number of measuring ranges are shown schematically in the fol-
lowing figure as an example. The measuring points correspond to
the fastening points of the beam. The number of measuring points
depends on the length of the beam and thus the number of fasten-
ing points.

KL 4000; KL 4000 S

Fig. 7-21: Straightness of track (schematic)
1 Measuring point 1 5 Measuring range 1

2 Measuring point 2 6 Measuring range 2
3 Measuring point... 7 Measuring range...
4 Rack side
• The permissible deviation of the straightness over the joint of the

track at the point at which the beam is dismantled for transport is
0.5 mm. At the point at which the beam is dismantled for
transport, this deviation must be adhered to over a range of
±1.5 m.
7. Tighten the adjusting screws and M30 hexagon nuts with a tightening
torque of MA = 750 Nm.
8. On the rack side of the track joint, check lateral offset with a hairline
gauge or flat needle. If necessary, loosen M20x55-10.9 hexagon bolts
again and align the tracks:
• The gap between the ends of the tracks must be between
0.02 mm and max. 0.09 mm in a range of 40 mm from the outer
edge of the track.
The gap can be positively influenced by means of the leveling
screws. Compliance with the specified levelness and the lateral off-
set of the tracks must then be checked again.
9. Check the track joints with a hairline gauge. If necessary, smooth with
a slip-stone or use a copper pin. Place the copper pin against the side
of the track to be aligned and correct the protrusion by lightly tapping
on the copper pin.
10. Tighten the M20x55-10.9 hexagon bolts with the specified tightening
torque.
11. On the opposite side of the track joint, check lateral offset with a hair-
line gauge or flat needle and calibrate the parallelism.
If necessary, loosen M20x55-10.9 hexagon bolts again and align the
tracks:
• The gap between the ends of the tracks must be between
0.02 mm and max. 0.09 mm in a range of 40 mm from the outer
edge of the track.
The gap can be positively influenced by means of the leveling
screws. Compliance with the specified levelness and the lateral off-
set of the tracks must then be checked again.

• The parallelism must be adjusted in the area of the point at which

the beam is dismantled for transport at the track joint.
For the parallelism of the tracks, a maximum deviation of 0.05 mm
is permissible.
12. Check the track joints with a hairline gauge. If necessary, smooth with
a slip-stone or use a copper pin. Place the copper pin against the side
of the track to be aligned and correct the protrusion by lightly tapping
on the copper pin.
13. Tighten the M20x55-10.9 hexagon bolts with the specified tightening
torque.
14. Check the spacing across the rack joint. To do this, measure the dis-
tance between 2 teeth across the rack joint (>>> Fig. 7-22) using 2
Ø9 mm test pins and a micrometer.
Recommended measuring method:
Alternatively, the spacing at the rack joint can be checked using in-
stallation kit 29.01.005 from Atlanta Antriebssysteme GmbH. Pro-
ceed in accordance with the manufacturer’s instructions. The permis-
sible dimensional tolerance for rollers is ±0.07 mm. Measurement is
carried out at the center of the rack height.
Fig. 7-22: Determining the test dimension at the rack joint (dia-
gram)
1 Assembly gauge (left-hand toothing)

2 Rack joint
3 Test pin, diameter 9 mm
4 Micrometer
15. Compare the measured values with the test dimension 40.42 mm
(±0.05 mm). If the measured value deviates from this, the spacing
across the rack joint must be readjusted. To do so, slacken the
M12x70-8.8 hexagon bolts of one of the rack segments at the rack
joint.
16. Position the assembly gauge at the center of the space between the
racks and clamp it to the rack with 2 screw clamps.
17. Tighten the M12x70-8.8 hexagon bolts with the specified tightening tor-
que.
18. Remove the assembly gauge and check the spacing across the rack
joint again.
19. If a rack segment has been offset, the spacing at all adjacent rack
joints must be checked and readjusted if it differs from the test dimen-
sion 40.42 mm (±0.05 mm).

KL 4000; KL 4000 S

20. Remove the screw clamps from the track segment.
21. Remove protective coatings from the tracks and re-oil them. Please re-
fer to the table “Disposal” for the oil used (>>> 11.3 "Disposal"
Page 201).
22. Regrease the racks. Please refer to the table “Disposal” for the grease
used (>>> 11.3 "Disposal" Page 201).
23. Install the energy supply system (>>> 7 "Start-up and recommission-
ing" Page 105).
24. If necessary, install the beam covers (>>> 12.2.1.2 "Installing the
beam cover" Page 208).
25. If necessary, install the track covers (>>> 12.2.2.2 "Installing the track
cover" Page 209).
26. If applicable, switch on the permanent lubrication unit and readjust it if
required (>>> 12.3 "Permanent lubrication unit" Page 210).
27. If necessary, install the (robot) booster frame.
28. Install the robot in accordance with the operating instructions.
29. Put the linear unit into operation in accordance with the “Start-up”
chapter of the operating and programming instructions for the KUKA
System Software (KSS) and the “Start-up” chapter of the operating in-
structions for the robot controller.
7.5 Installing the energy supply system
Description
The energy supply chain is supported in a guide system. The travel

(range of motion) of the carriage determines the length of the energy sup-
ply chain and thus the length of the guide system. The position of the en-
ergy supply chain driver on the carriage depends on the travel of the car-
riage and on the width of the energy supply chain. This section describes
the energy supply system for the shorter travel.
The length of the connecting cables between the robot controller and
Preconditions
• The electrical equipment assembly is present.

• The energy supply chain is assembled and completely filled with con-
necting cables.
Procedure
1. Fasten the driver (>>> Fig. 7-23) to the carriage with two M10x25-8.8
Allen screws and conical spring washers in accordance with the lay-
out. For the layout, see Section (>>> 4.2 "Dimensions, KL 4000"
Page 29). Tighten the Allen screws with the specified torque.
2. Install the chain guides in accordance with the layout and adjust the
gap between them.
3. Insert the aluminum profiles into the chain guides.
4. On both sides, screw aluminum profiles to the chain guides, each with
two M6x12-8.8 Allen screws, conical spring washers and M6 hammer-
head nuts. Tighten the Allen screws with the specified torque.
In the case of a carriage with a longer travel, the second half of the
profile is mounted in the upper holes of the chain guide with a sliding
strip. In the case of two carriages with a longer travel, only the middle
profile piece is mounted in the upper holes with a sliding strip. The

KL 4000; KL 4000 S
chain of the 3rd and 4th carriages is mounted in the same way as for
the 1st and 2nd carriages, but on the opposite side of the linear axis.
5. Fasten each of the two fixed point modules to the aluminum profiles
with an M8x20-8.8 thread-forming hexagon screws and conical spring
washer.
6. Align the guide system with the linear unit in accordance with the lay-
out.
7. Drill two 6x50 mm holes in the floor for each chain guide. The holes
must be positioned diagonally to each other.
8. Fasten each chain guide to the floor with two HUS-H 7.5x45 screw
anchors.
9. Insert the energy supply chain into the guide system. In the case of a
carriage with a longer travel (range of motion), the sliding strips must
first be inserted into the groove of the aluminum profile.
10. Fasten the energy supply chain to the guide system with an
M8x20-8.8 Allen screw and conical spring washer for each fixed point
module. Tighten the Allen screws with the specified torque.
The position of the fixed point module is shown in the layout.
11. Screw the other end of the energy supply chain to the driver with four
M8x20-8.8 thread-forming screws and lock washers. Tighten the
screws with the specified torque.
12. In accordance with the layout, fasten the connector plate to the floor
with HUS-H 7.5x45 screw anchors.
NOTICE
Damage to property due to incorrect positioning
The remaining cable length from the cable carrier exit to the connec-
tor plate varies according to the axis configuration. If the connector
plate is incorrectly positioned, the cables and hoses might not com-
ply with the minimum bending radius. Damage to property may re-
sult.
‒ Take the following aspects into account when positioning the
connector plate:
‒ Remaining cable length from cable carrier exit to connector
plate
‒ Compliance with the minimum bending radius of all cables
and hoses
‒ If necessary, fit a holder or tray for the cables and hoses.
13. Plug in the connectors of the motor and control cables (XM.., XP..) of
the linear unit on the servomotor of the carriage. The pins and coding
elements of the connectors must be taken into consideration.
When inserting the connectors, turn them until they clearly lock into
the coding elements (twist-proof).

KL 4000; KL 4000 S

Fig. 7-23: Energy supply system, short travel
1 Carriage 6 Aluminum profile

2 Driver 7 Connector plate
3 Energy supply chain 8 Chain guide
4 Lower fastening point 9 Upper fastening point
5 Guide system 10 Fixed point module
14. Connect the connecting cables of the energy supply chain in accord-
ance with the connector designation.
15. Connect the equipotential bonding (ground conductor) between the
carriage and the robot.
16. Connect the equipotential bonding (ground conductor) on the connec-
tor plate and on the beam of the linear unit. Tighten the setscrew
(>>> Fig. 7-24) with a tightening torque of MA = 10 Nm.

Fig. 7-24: Ground conductor, beam - connector plate
1 Grounding bolt set M8 3 Setscrew

2 Hexagon nut 4 PE terminal
17. Connect the equipotential bonding (ground conductor) in the energy

supply chain on the connector plate and on the robot.
18. Check the connecting cables in the energy supply chain and adjust if
necessary. There must be at least 1 mm of free space on both sides
between the cables and the web. Furthermore, these must be able to
move freely in the longitudinal direction. This is illustrated in the figure
below.

KL 4000; KL 4000 S

Fig. 7-25: Installing the connecting cables
19. Attach the strain relief to the end of the energy supply chain. Fasten
each connecting cable to the strain relief comb with two cable straps.
If one connecting cable is routed on top of another, the upper cable
must be fastened to the lower one with two cable straps. The cable
straps must be positioned before and after the lower strain relief
comb.
20. Route the connecting cables on the carriage. Fasten the cables with
cable clips and Velcro strips. The specified overlength dimensions for
the connecting cables must be maintained at the ends of the energy
supply chain (>>> 4 "Technical data" Page 27).
21. If required, connect the energy supply lines.
22. Put the robot and linear unit into operation and move the robot over
the entire length of the travel. The energy supply chain must roll prop-
erly in the guide system.
23. Shut down the linear unit and the robot and lock them.

Example, carriage 1
Fig. 7-26: Example, routing of connecting cables on carriage 1

KL 4000; KL 4000 S

7.6 Installing the energy supply system on the beam
Description
The energy supply chain system is mounted on the beam. The travel
(range of motion) of the carriage determines the length of the energy sup-
ply chain. The position of the energy supply chain driver on the carriage
depends on the robot position. This section describes the energy supply
system for robot position A.
Preconditions
• The electrical equipment assembly is present.

• The energy supply chain is assembled and completely filled with con-
necting cables.
• The energy supply system has been removed for transportation.
• For a linear unit with beam covers, the fixed point module, angled
channels and the hood are not removed for transport.
Procedure
1. Fasten the driver (>>> Fig. 7-27) to the carriage with M24x40-8.8
Allen screws and conical spring washers in accordance with the lay-
out. For the layout, see Section (>>> 4.2 "Dimensions, KL 4000"
Page 29). Tighten the Allen screws with the specified torque.
2. Position the fixed point module on the beam and attach the clamping
brackets. The position of the fixed point is dimensioned in the layout.
The position of the clamping brackets is dependent on the tapped
holes on the beam.
3. Insert the M6x16-8.8 Allen screws together with conical spring wash-
ers into the clamping bracket and tighten with the specified tightening
torque.
4. Position the energy supply system on the beam.
5. Fasten the energy supply chain with two M8x20-8.8 thread-forming
screws and lock washers to the fixed point module. Tighten the
screws with the specified torque.

Fig. 7-27: Energy supply system on beam
1 Carriage 4 Lateral rail

2 Driver 5 Clamping bracket
3 Energy supply chain 6 Fixed point module
The next four work steps only have to be carried out if beam covers
are attached.
6. Remove the hexagon nuts including conical spring washers from the
M6x25-8.8 flat head screws and take off the hood (>>> Fig. 7-28).
7. Fasten the energy supply chain with two M8x20-8.8 Allen screws and
lock washers to the fixed point module. Tighten the Allen screws with
the specified torque.
8. Route the connecting cables down through the opening in the beam
and under the beam outwards and to the side.
9. Mount the hood in the position from which it was removed and fasten
it with four M6 hexagon nuts including conical spring washers. Tighten
the hexagon nuts with the specified torque.

KL 4000; KL 4000 S

Fig. 7-28: Beam covers
1 Energy supply chain

2 Hood
3 Fixed point module
10. Screw the other end of the energy supply chain to the driver
(>>> Fig. 7-27) with four M8x20-8.8 thread-forming screws and lock
washers. Tighten the screws with the specified torque.
11. Route the connecting cables down through the opening in the beam
and under the beam outwards and to the side.
12. Fasten the connecting cables to the lateral rail using cable straps.
13. In accordance with the layout, fasten the connector plate to the floor
in the vertical position with HUS-H 7.5x45 screw anchors.
15. Connect the connecting cables of the energy supply chain in accord-
ance with the connector designation.
16. Connect the equipotential bonding (ground conductor) between the
carriage and the robot.
17. Connect the equipotential bonding (ground conductor) on the connec-
tor plate and on the beam of the linear unit. Tighten the setscrew
(>>> Fig. 7-29) with a tightening torque of MA = 10 Nm.

Fig. 7-29: Ground conductor, beam - connector plate
1 Grounding bolt set M8 3 Setscrew

2 Hexagon nut 4 PE terminal
18. Connect the equipotential bonding (ground conductor) in the energy

supply chain on the connector plate and on the robot.
19. Check the connecting cables in the energy supply chain and adjust if
necessary. There must be at least 1 mm of free space on both sides
between the cables and the web. Furthermore, these must be able to
move freely in the longitudinal direction. This is illustrated in the figure
below.

KL 4000; KL 4000 S

Fig. 7-30: Installing the connecting cables
20. Attach the strain relief to the end of the energy supply chain. Fasten
each connecting cable to the strain relief comb with two cable straps.
If one connecting cable is routed on top of another, the upper cable
must be fastened to the lower one with two cable straps. The cable
straps must be positioned before and after the lower strain relief
comb.
21. Route the connecting cables on the carriage. Fasten the cables with
cable clips and Velcro strips. The specified overlength dimensions for
the connecting cables must be maintained at the ends of the energy
supply chain (>>> 4 "Technical data" Page 27).
22. If required, connect the energy supply lines.
23. Put the robot and linear unit into operation and move the robot over
the entire length of the travel. The energy supply chain must roll prop-
erly.

Example, carriage 1
Fig. 7-31: Example, routing of connecting cables on carriage 1

KL 4000; KL 4000 S

7.7 KR C4/KR C5, connecting control cable XP7
Description
Control cable XP7 is connected to the motor of the carriage of the linear
unit and to the RDC board of the KUKA robot. The control cable is plug-
ged into the motor of the linear unit via the plug-in connection XP7. It is
also plugged into the RDC board via board connector X7.
Preconditions
• The following work may be carried out by qualified personnel only.

These are people who, due to their specialist training, knowledge and
experience, and their familiarization with the relevant standards, are
able to assess the work to be carried out and detect any potential
hazards.
• The KUKA robot has been installed.
• Compliance with the safety regulations in accordance with the EMC
Directive and Low Voltage Directive.
• The safety precautions against electrostatic discharge (e.s.d.) must be
observed.
WARNING
Procedure
1. Plug connector XP7 (>>> Fig. 7-32) into the motor of the linear unit.
2. Route the cables to the robot.
3. Remove four screws and take off the cover of the RDC box.
4. Unscrew the blanking plug from the side of the RDC box.
5. Dismantle the cable gland into its component parts: lower part, pinch
ring, sealing insert and lock nut.
The sealing insert contains two holes, through which the two cables
can be threaded separately. If only one hole is used, the second hole
must be sealed with a dummy post.
6. Cut a slit in the sealing insert.
The slit must be made in the hole through which the control cable is
to be routed.
7. Screw the lower part of the cable gland into the side of the RDC box.
8. Feed the board connector through the lock nut.
9. Push the control cable through the slit into the hole in the sealing in-
sert.
10. Feed the board connector through the pinch ring.
11. Press the sealing insert into the pinch ring and position the pinch ring
so that it is flush with the end of the cable jacket.
12. Insert the board connector through the lower part of the gland into the
RDC box.
13. Connect the shield to the pinch ring, ensuring that a large area is in
contact, and press the pinch ring into the lower part of the gland using
gentle rotation. Trim off projecting parts of the shield.

14. Tighten the lock nut on the lower part of the gland and plug the board
connector onto the RDC board.
15. Fit the cover and fasten it with four screws.
Fig. 7-32: KR C4, connecting control cable XP7
1 Cover of RDC box 9 Dummy post

2 Screw 10 Slit
3 Blanking plug 11 Shield
4 RDC box 12 Projecting part of shield
5 Lower part 13 Control cable XP7
6 Pinch ring 14 Wall of RDC box
7 Sealing insert 15 Board connector
8 Lock nut

KL 4000; KL 4000 S

7.8 Description of the connecting cables
Configuration
The connecting cables are used to transfer power and signals between
the robot controller and the robot.
Most of the cables have plug-and-socket connections, which enables them
to be quickly and reliably exchanged. The plugs and sockets are provided
with identification labels.
Only ground conductors (PE conductors) are fastened with cable lugs to
threaded bolts.
A low-resistance equipotential bonding connection must be established be-
tween the linear unit and the control cabinet in accordance with DIN EN
60204.
The energy supply chain forms the moving (translational) connection be-
tween the connector plate and the driver on the carriage.
The scope of supply of the linear unit includes:
• Motor cable, KR FORTEC A1 to A6, X30.1
• Motor cable, KR FORTEC A1 to A3, parallel, X30.4
• Motor cable, KR QUANTEC A1 to A6, X30
• Motor cable, KR QUANTEC-2, KR IONTEC A1 to A6, X30
• Motor cable, KR CYBERTECH A1 to A6, X30
• Data cable, X31
• Motor cable, linear unit, XM7
• Control cable, linear unit, XP7
• Control cable, linear unit, XP... (KR QUANTEC)
• Control cable, linear unit, EA, XP... (KR QUANTEC-2, KR CYBER-
TECH, KR IONTEC)
• Applications (optional)
• Ground conductor 16 mm2
• Ground conductor, 10 mm2 (optional)
• Ground conductors (carriage - robot, beam - connector plate)
• Ground conductor (optional, connector plate - controller)
For motor cables, control cables and ground conductors, standard lengths
are available in 7 m, 15 m, 25 m and 35 m.
The robot connecting cables (A1 to A6) are described in the robot oper-
ating instructions.
Interface
For connection of the connecting cables, the following connectors are

available at the interfaces.
Cable designation from to
Motor cable, KR FORTEC Connector Connector X30.1
A1 to A6 X30.1.1 Motor, brake and PE for ro-
bot axes 1 to 6
Motor cable, KR FORTEC Connector Connector X30.4
A1 to A3, parallel X30.4.1 Motor, brake and PE for ro-
bot axes 1 to 3

Cable designation from to

Motor cable, KR QUANTEC Connector Connector X30
A1 to A6 X30.1 Motor, brake and PE for ro-
bot axes 1 to 6
Motor cable, KR QUAN- Connector Connector X30
TEC-2, KR IONTEC X30.1 Motor, brake and PE for ro-
A1 to A6 bot axes 1 to 6
Motor cable, KR CYBER- Connector Connector X30
TECH X30.1 Motor, brake and PE for ro-
A1 to A6 bot axes 1 to 6
Data cable Connector Connector X31
X31.1 Resolver and temperature
monitoring for axes 1 to 8
Motor cable, linear unit Connector Connector XM7
XM7.1 Motor, brake and PE for lin-
ear unit
Control cable, linear unit Connector Connector XP7
X7 Resolver and temperature
monitoring for linear unit
Control cable, linear unit, Connector Connector XP...
KR QUANTEC XP... Resolver and temperature
monitoring for linear unit
Control cable, linear unit, Connector Connector XP...
EA, XP... Resolver and temperature
KR QUANTEC-2, KR CY- monitoring for linear unit
BERTECH, KR IONTEC
Ground conductor PE bolt on PE bolt on carriage
robot
Ground conductor PE bolt on PE bolt on connector plate
beam
Ground conductor (optional) PE bolt on PE bolt on controller
connector
plate
Ground conductor PE bolt on PE bolt on robot
connector
plate
Ground conductor, 10 mm2 PE bolt on PE bolt on robot for energy
(optional) connector supply system
plate

KL 4000; KL 4000 S

Standard connecting cable
Fig. 7-33: Connection diagram for external axes
1 Control cable, linear unit, XP7 7 Applications (optional)

Control cable, linear unit,
XP... (KR QUANTEC)
Control cable, linear unit, EA
XP... (KR QUANTEC-2, KR
CYBERTECH, KR IONTEC)
2 Ground conductor, carriage 8 Ground conductor, controller
(optional)
3 Motor, linear unit 9 Motor cable, linear unit, XM7
4 Ground conductor, 10 mm2 10 Data cable, X31
(optional)
5 Ground conductor 16 mm2 11 Motor cable, KR FORTEC A1
to A3, parallel, X30.4
6 Ground conductor, beam 12 Motor cable, KR FORTEC A1
to A6, X30.1
Motor cable, KR FORTEC A1
to A6, X30
Motor cable, KR QUAN-
TEC-2, KR IONTEC A1 to
A6, X30
Motor cable, KR CYBER-
TECH A1 to A6, X30

Fig. 7-34: Connecting cable, motor cable, X30.1.1 - X30.1

KL 4000; KL 4000 S
Fig. 7-35: Connecting cable, motor cable, X30.4.1 - X30.4

Fig. 7-36: Connecting cable KR QUANTEC, motor cable, X30.1 - X30

KL 4000; KL 4000 S
Fig. 7-37: Connecting cable, KR QUANTEC-2, KR IONTEC, motor ca-

ble X30.1 - X30

Fig. 7-38: Connecting cable KR CYBERTECH, motor cable, X30.1 -

X30

KL 4000; KL 4000 S

Fig. 7-39: Connecting cable, data cable X31.1 - X31
Fig. 7-40: Connecting cable, motor cable XM...

Fig. 7-41: Connecting cable, control cable XP...
Fig. 7-42: Connecting cable KR QUANTEC, control cable XP...

KL 4000; KL 4000 S

Fig. 7-43: Connecting cable, control cable EA XP...
Fig. 7-44: Ground conductor
1 Ring cable lug M8

2 PE bolt
3 M8 nut
4 Cable lug
5 Conical spring washer
6 Conical spring washer
7 M8 tapped hole
8 M8 nut

9 Ground sign
10 Washer 8.4
7.9 Description of the applications
The application cables are used to transfer power and signals between
the robot controller and the robot. The scope of supply of the linear unit
includes the connectors routed in the energy supply chain. They are rout-
ed from the interface on the robot to the connector plate of the linear unit.
They have plug-and-socket connections, which enables it to be quickly
and reliably exchanged. The plugs and sockets are provided with identifi-
cation labels.
The cables installed vary according to the application. A number of ca-

bles are specified below as examples.
7.9.1 Control and signal cable KFL XLUB for "permanent lubrication unit
‘premium’"XLUB1
Description
The control and signal cable is routed in the energy supply chain from the
carriage to the connector plate.
The control and signal cable has plug-and-socket connections, which ena-
bles it to be quickly and reliably exchanged. The plugs and sockets are
provided with identification labels.
If Safe robots are used, the cable length must not exceed 35 m.
Overview
Fig. 7-45: Cabling plan and pin allocation diagram
1 Connector plate 3 Carriage

2 Energy supply chain 4 Control and signal cable

KL 4000; KL 4000 S

Wiring diagram
Fig. 7-46: Control and signal cable KFL XLUB for "permanent lubrica-
tion unit ‘premium’"
7.9.2 Connecting cable, Power supply XD1
Description
The power supply cable is routed in the energy supply chain from the car-
riage to the connector plate.
The power supply cable has plug-and-socket connections, which enables
it to be quickly and reliably exchanged. The plugs and sockets are provi-
ded with identification labels.
Overview

2 Energy supply chain 4 Power supply cable

Wiring diagram
Fig. 7-48: Connecting cable, power supply XD1.1 - XD1
7.9.3 Connecting cable, Profinet XF1
Description
The Profinet cable is routed in the energy supply chain from the carriage
to the connector plate.
The Profinet cable has plug-and-socket connections, which enables it to
be quickly and reliably exchanged. The plugs and sockets are provided
Overview

2 Energy supply chain 4 Profinet cable

KL 4000; KL 4000 S

Wiring diagram
Fig. 7-50: Connecting cable, Profinet XF1.1 - XF1
7.9.4 Connecting cable, welding cable XD73
Description
The welding cable is routed in the energy supply chain from the carriage
to the connector plate.
The welding cable has plug-and-socket connections, which enables it to
be quickly and reliably exchanged. The plugs and sockets are provided
Overview

2 Energy supply chain 4 Welding cable

Wiring diagram
Fig. 7-52: Connecting cable, welding cable, XD73.1 - XD73
7.9.5 Connecting cable, signal cable XG79
Description
The signal cable is routed in the energy supply chain from the carriage to
the connector plate.
The signal cable has plug-and-socket connections, which enables it to be
quickly and reliably exchanged. The plugs and sockets are provided with
identification labels.
Overview

2 Energy supply chain 4 Signal cable

KL 4000; KL 4000 S

Wiring diagram
Fig. 7-54: Connecting cable, signal cable, XG79.1 - XG79
7.10 Moving the linear unit without drive energy
Description
The release device (optional) can be used for moving the carriage without
drive energy after an accident or malfunction.
This option is only for use in exceptional circumstances and emergencies,
e.g. for rescuing people.
Precondition
• The controller of the linear unit is switched off and secured (e.g. with
a padlock) to prevent unauthorized persons from switching it on again.
Procedure
SAFETY INSTRUCTION
The following procedure must be followed exactly!
1. Remove the protective cap from the motor (>>> Fig. 7-55).
2. Push the release device onto the corresponding motor and move the
axis in the desired direction. The direction of rotation corresponds to
the direction of travel of the carriage.
It is necessary to overcome the resistance of the mechanical motor
brake and any other loads acting on the axis.

Fig. 7-55: Motor with release device
1 Motor
2 Protective cap
3 Release device
WARNING
Danger to life and limb due to damaged motor brake
Moving an axis with the release device can damage the motor brake.
Death, severe injuries or damage to property may result.
• After using the release device, the motor must be exchanged.
WARNING
If the carriage has been moved by the release device, the linear unit
must be remastered. Serious injuries or damage to property may other-
wise result.

KL 4000; KL 4000 S
Configuration
8 Configuration
This documentation specifies only the relevant data for the configuration
of the linear unit.
Information about the procedure for configuration can be found in the
“Configuration of Kinematic Systems” assembly and operating instruc-
tions.
8.1 Configuration data
The procedure can be found in the “Configuration of Kinematic Sys-

tems” assembly and operating instructions. Only the relevant data for
the transformation are specified below in accordance with the respective
installation positions.
Installation position
KL 4000 is approved for operation with the following robots:

• KR CYBERTECH nano series
• KR CYBERTECH series
• KR IONTEC series
• KR QUANTEC series
• KR FORTEC series
The robots from the product series can be installed in various positions,
rotationally offset at 45° intervals. For the 45°, 135°, 225° and 315° instal-
lation positions, an adapter plate is required.
These installation positions apply for all robots of the aforementioned ro-
bot series, with the exception of the KR QUANTEC nano robot family
(>>> Fig. 8-2).
Fig. 8-1: Floor installation positions
An adapter plate is required for installing a robot of the KR QUANTEC

nano robot family. This results in installation positions at 60° intervals.

Configuration KL 4000; KL 4000 S
Fig. 8-2: Floor installation positions for KR QUANTEC nano
Installation position (eccentricity) KR CYBERTECH nano, KR CYBERTECH
The installation position of the robot is offset by a certain amount from the
center of the carriage (eccentricity). The eccentricity corresponds to the
distance from the center of the carriage to the center of axis 1 (A1) of the
robot.
• Eccentricity KR CYBERTECH nano series: 270 mm
• Eccentricity KR CYBERTECH series: 255 mm
Fig. 8-3: Eccentricity for KR CYBERTECH nano series and KR CY-

BERTECH series
1 Center of robot axis 1 (A1)

2 Eccentricity
3 Center of carriage

KL 4000; KL 4000 S
Configuration
Z height
On the KL 4000, the robots can be mounted on booster frames of various

heights (depending on the specific requirements). The height from the
floor to the lower edge of the base frame is important for the transforma-
tion of the coordinate system. The height is determined as follows:
Z height = linear unit height + booster frame height + adapter plate height
Linear unit Adapter plate
Booster frame height
height height
689 mm • KR CYBERTECH nano robot 35 mm
series:
‒ 200 mm - 1000 mm
in 200 mm steps
• KR CYBERTECH robot series:
‒ 200 mm - 1000 mm
in 200 mm steps
• KR IONTEC robot series:
‒ 200 mm - 1000 mm
in 200 mm steps
• KR QUANTEC robot series:
‒ 200 mm - 1000 mm
in 200 mm steps
• KR FORTEC robot series:
‒ 250 mm
‒ 500 mm
The two variables “booster frame height” and “adapter plate height” are
optional components. The adapter plate is required in the following ca-
ses:
• Robots of the product family KR CYBERTECH nano: in all installa-
tion positions, with and without booster frame
• Robots of the product family KR CYBERTECH: in all installation po-
sitions, with and without booster frame
• Robots of the product family KR IONTEC: in all installation positions,
with and without booster frame
• Robots of the product family KR QUANTEC nano: in all installation
positions, with and without booster frame
• Robots of the product family KR QUANTEC and KR FORTEC: In-
stallation positions of 45°, 135°, 225° and 315° without a booster
frame

Constant $ERSYSROOT
Fig. 8-4: Transformation
• $WORLD
• $ERSYSROOT
$ERSYSROOT Frame = {X 0.0, Y 0.0, Z 0.0, A 0.0, B 0.0,

C 0.0}
Align the $World frame in the specified direction of the $ERSYSROOT

frame.
• FRAME $ET1_TA1KR
FRAME $ET1_TA1KR = {X 0.0, Y 0.0, <Z height>, A 0.0,

B-90.0, C 0.0}
Move the robot to <z height> and rotate Z in the positive direction of
motion.
• FRAME $ET1_TFLA3
FRAME $ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B

0.0, C -90.0}
Turn the robot in the direction of the target installation position.
Result: installation position 0°
$BASE alignment
• $BASE alignment: positive X direction (red)

KL 4000; KL 4000 S
Configuration
Fig. 8-5: $BASE alignment
• $TOOL alignment: positive X direction (red)
Fig. 8-6: $TOOL alignment

Overview of KR CYBERTECH nano, KR CYBERTECH, KR IONTEC,

KR QUANTEC, KR FORTEC (without product family KR QUANTEC nano)
Fig. 8-7: Overview
$RAT_MOT_AxX[7]={N a, D b} ;N&D positive Werte
• 0°
$ET1_TA1KR = {X 0.0, Y 0.0, Z <Z height>, A 0.0, B

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 0.0, C
-90.0}
• 45°

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 45.0, C
-90.0}
• 90°

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 90.0, C
-90.0}
• 135°

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 135.0, C
-90.0}
• 180°

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 180.0, C
-90.0}
• 225°

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 225.0, C
-90.0}

KL 4000; KL 4000 S
Configuration
• 270°

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 270.0, C
-90.0}
• 315°

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 315.0, C
-90.0}
Overview of KR QUANTEC nano
Fig. 8-8: Overview
$RAT_MOT_AxX[7]={N a, D b} ;N&D positive Werte
• 0°

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 0.0, C
-90.0}
• 60°

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 60.0, C
-90.0}
• 120°

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 120.0, C
-90.0}
• 180°

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 180.0, C
-90.0}

• 240°

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 240.0, C
-90.0}
• 300°

-90.0, C 0.0}
$ET1_TFLA3 = {X 0.0, Y 0.0, Z 0.0, A -90.0, B 300.0, C
-90.0}

KL 4000; KL 4000 S
Maintenance
9 Maintenance
NOTICE
DANGER
WARNING
WARNING
WARNING
CAUTION

Maintenance KL 4000; KL 4000 S
CAUTION
ones.
9.1 Maintenance table
Description
The table provides an overview of the maintenance work (maintenance in-

tervals, activities, lubrication work) and required lubricants applicable to
the linear unit.
The maintenance intervals given in the table are valid for the operating
conditions specified in the technical data. KUKA Deutschland GmbH must
be consulted in the case of discrepancies!
NOTICE
Only auxiliary substances and consumables approved by KUKA
Deutschland GmbH may be used. Non-approved auxiliary substances
and consumables may cause premature wear and failure of assemblies.
NOTICE
WARNING
Unintentional motions of the linear unit, the robot and affected system
components can cause injuries and damage to property. If work is car-
ried out on an operational linear unit, the linear unit, the robot and affec-
ted system components must be secured by activating the EMERGEN-
CY STOP button.
Warn all persons concerned before putting it back into operation.
WARNING
Immediately after the linear unit is switched off, the surface temperature
of the motor is liable to be high and could result in burn injuries. Protect
body parts that could come into contact with the motor with protective
gloves or other suitable protective clothing.
Only activities on a linear unit without options are listed in this section.
Maintenance and repair work on optional assemblies are described in
the chapter “Options”.

KL 4000; KL 4000 S
Maintenance
Preconditions
• The maintenance points must be freely accessible.

• The carriage is secured against unintended motion.
• Remove the tools and any additional items of equipment if they im-
pede maintenance work.
Maintenance symbols
The overview may contain maintenance symbols that are not relevant
for the maintenance work on this product. The maintenance illustrations
provide an overview of the relevant maintenance work.
Oil change
Lubricate with grease gun
Lubricate with brush
Lubricate with spray grease
Tighten screw/nut
Check component, visual inspection
Clean component
Exchange battery
Exchange component
Check toothed belt tension
Fig. 9-1: Maintenance diagram

Interval Item Task Lubricant

100 h after 4 Mounting bases, chemical anchors:
start-up Check tightening torques for bolts
and nuts.
See Section (>>> 7 "Start-up and
recommissioning" Page 105).
100 h 3 Oil the tracks. LAMORA D 220

(only
Art. no.
for a
00-278-829
travel of
≤ 900 mm)
400 h or 5 Re-oil the racks. Klüberplex AG11-462
25 000
Art. no.
strokes**
00-276-589
4 000 h 3 Clean the tracks with cleaning sol- LAMORA D 220
vent and re-oil.
Art. no.
00-278-829
Annually 5 Clean the racks with cleaning sol- Klüberplex AG11-462
vent and re-grease.
Art. no.
00-276-589
Annually 2 Visual inspection of rollers: check
for signs of scoring on the running
surfaces and loss of grease.
Check pre-tension of all rollers:
• Move the robot into its transport

position.
• It must not be possible to rotate
any roller by hand. Contact
KUKA Service if this is not the
case.
Annually 6 Check the gap between the wiper
plate and the track and adjust if
necessary.
Gap: 0.5 mm
Annually 6 Option: Visual inspection of the
cleaning brushes. If necessary, re-
adjust. Exchange damaged cleaning
brushes.
Annually 1 Check the energy supply system
and exchange components if neces-
sary.
*with 3-shift operation
**The number of strokes corresponds to the number of times the most fre-
quently used tooth flank of the rack is passed over.
In the case of unusual applications or ambient conditions, it may be nec-
essary to adjust the intervals.

KL 4000; KL 4000 S
Maintenance
9.2 Adjusting the backlash
Description
Backlash (>>> Fig. 9-2) occurs between the tooth flanks of the drive pin-
ion and rack. It has to be readjusted after the drive, the rack or the drive
pinion has been replaced.
Fig. 9-2: Backlash
1 Pinion
2 Rack
Tooling and additional equipment must be removed before the adjustment
process is started if they are likely to impede the adjustment work.
Preconditions
• The drive assembly must be freely accessible, and it must be possible

to fasten the dial gauge to the beam.
• The robot is installed and is in the home position.
• The carriage must be moved exactly to the mastering position (zero
point).
• In the case of multiple carriages, the measurement and adjustment of
the backlash must be performed alternately for each carriage at the
same zero point.
The following aids are required:
• Dial gauge with magnetic stand.
• Spring balance with measurement range ≥ 400 N.
NOTICE
WARNING
CY STOP button.

WARNING
9.2.1 Measuring the backlash
Procedure
1. Fasten the dial gauge (>>> Fig. 9-3) to the beam so that the probe is
in contact with the carriage.
2. Attach a spring balance at a suitable point on the carriage.
3. Pull the carriage with a force of 400 N (spring balance) in the plus di-
rection.
4. Set the dial gauge to zero while maintaining the force.
5. Pull the carriage with a force of 400 N (spring balance) in the minus
direction.
6. Read the measured value.
7. If the measured value is outside the range from 0.2 mm to 0.24 mm,
the backlash must be adjusted (>>> 9.2.2 "Adjusting the backlash"
Page 186).
8. If the measured value is within the range from 0.2 mm to 0.24 mm,
the backlash is correct.
9. Remove the measuring set-up.
Fig. 9-3: Measuring device (schematic)
1 Carriage
2 Dial gauge
9.2.2 Adjusting the backlash
Procedure
1. Loosen four M16x40-8.8 Allen screws (>>> Fig. 9-4).

2. Adjust the backlash by means of the hexagon bolt.
If the measured value is greater than 0.24 mm, turn the hexagon bolt
clockwise until the backlash is within the range of 0.2 mm to 0.24 mm.
If the measured value is less than 0.2 mm, turn the hexagon bolt
counterclockwise. By means of the hexagon nut, push the gear unit
away from the rack until the backlash is within the range of 0.2 mm to
0.24 mm.

KL 4000; KL 4000 S
Maintenance
3. Tighten the 4 M16x40-8.8 Allen screws with the specified tightening
torque.
4. Measure the backlash (>>> 9.2.1 "Measuring the backlash" Page 186)
again. Re-adjust the backlash if required.
Fig. 9-4: Adjusting the rack backlash
1 Hexagon bolt 3 Allen screw

with hexagon nut
2 Gear unit 4 Servomotor
9.3 Cleaning the linear unit
Description
The linear unit, parts of the system, tools and the robot controller must be
cleaned in compliance with the instructions given here in order to prevent
damage.
The following must be taken into consideration when using cleaning
agents and carrying out cleaning work:
• Only use solvent-free, water-soluble cleaning agents.
• Do not use flammable cleaning agents.
• Do not use aggressive cleaning equipment.
• Do not use steam or refrigerants for cleaning.
• Do not use pressure equipment or compressed fluids for cleaning.
• It must be ensured that no cleaning agent enters electrical or mechan-
ical system components.
• Personnel protection measures must be taken.
WARNING
CY STOP button.
Procedure

2. Stop adjacent system components and lock them.

3. Remove enclosures if this is necessary in order to carry out the clean-
ing work.
4. Clean the linear unit.
5. Completely remove all traces of cleaning agents from the linear unit.
6. Clean any areas of corrosion and reapply corrosion protection.
7. Remove cleaning agents and equipment from the workspace of the lin-
ear unit.
8. Dispose of cleaning agents properly.
9. Install any safety equipment that has been removed and check that it
is functioning correctly.
10. Replace any damaged or illegible plates and covers.
11. Put back in place any enclosures that have been removed.
12. Put only fully functional linear units and systems back into operation.

KL 4000; KL 4000 S
Repair
10 Repair
NOTICE
DANGER
WARNING
WARNING
WARNING
CAUTION

Repair KL 4000; KL 4000 S
CAUTION
ones.
10.1 Exchanging the drive
Description
The drive assembly consists of a servomotor, a gear unit and fasteners.

The drive is seated on the side of carriage. Attention must be paid to the
specifications on the rating plate of the gear unit.
The removal and installation of the drive are described below.
Preconditions
• Remove the tool and any additional items of equipment if these im-
pede repair work.
WARNING
NOTICE
Wear and premature failure due to damage to toothing
Damage to the toothing of the motor and gear unit can lead to in-
creased wear and premature failure of the components.
• During cleaning, ensure that the toothing is not damaged.
• Before installation, check the toothing of the motor and gear unit for
damage.
WARNING
Risk of crushing during removal and installation
The drive unit weighs approx. 100 kg. When removing or installing the
drive, care must be taken to avoid injury by crushing. Injuries or dam-
age to property may result.
• Protective gloves must be worn.

KL 4000; KL 4000 S
Repair
10.1.1 Removing the drive unit
Procedure
1. Release and unplug the connectors (>>> Fig. 10-1) of the motor and
control cables (XM.., XP..) on the servomotor of the carriage.
2. If applicable, remove the permanent lubrication unit.
3. Unscrew and remove 2 M6x10-8.8 Allen screws with conical spring
washers and remove the pinion cover.
4. Unscrew the hexagon bolt until the gear unit is free.
5. Pick up the drive at its center of gravity using suitable handling equip-
ment.
6. Remove four M16x50-10.9 Allen screws together with conical spring
washers and Schnorr lock washers.
7. Take the drive unit out of the side of the carriage and set it down.
8. Remove the servomotor (>>> 10.2.1 "Removing the servomotor"
Page 194).
9. If the gear unit is not to be reinstalled, it must be protected against
corrosion before being put into storage.
NOTICE
Replace the vent valve on the gear unit with a plug.
Fig. 10-1: Removing the drive
1 Hexagon bolt 5 M12x30-8.8

Allen screw
3 Vent valve 7 M6x10-8.8
Allen screw
4 M16x50-10.9 8 Pinion cover
Allen screw

10.1.2 Installing the drive unit
Procedure
1. Remove corrosion protection from the new gear unit (>>> Fig. 10-2), if
applicable.
2. Check the designation and transmission ratio of the old and new gear
units. These must match. See identification plate on gear unit.
3. Clean the mounting surfaces on the gear unit and carriage.
4. Install the servomotor (>>> 10.2.2 "Installing the servomotor"
Page 195).
5. Apply a thin but continuous coat of Microlube GL 261 grease to the
mounting surface on the carriage and the centering pins.
6. Pick up the drive at its center of gravity using suitable handling equip-
ment.
7. Mount the drive unit onto the centering pins on the carriage.
8. Insert 4 M16x50-10.9 Allen screws together with conical spring wash-
ers and Schnorr lock washers and tighten until the drive unit can still
just be shifted.
9. Remove the handling equipment.
10. Depending on the installation position, insert the vent valve into the
upper cover of the gear unit.
11. Shift the gear unit until the toothing of the pinion engages with the
rack.
If it is not possible to insert the pinion into the rack, move the carriage
slightly until the drive unit can be engaged.
12. Insert the hexagon bolt into the corresponding tapped hole on the
gear unit.
13. Adjust the backlash (>>> 9.2 "Adjusting the backlash" Page 185).
torque.
15. Fit the pinion cover. Insert 2 M6x10-8.8 Allen screws together with
conical spring washers and tighten with the specified tightening torque.
17. If applicable, install the permanent lubrication unit.
18. Remove elements securing the carriage.
19. Carry out mastering of the linear unit.
Detailed information about mastering is contained in the operating
and programming instructions for end users or system integrators.

KL 4000; KL 4000 S
Repair
Fig. 10-2: Installing the drive
1 Hexagon bolt 5 M12x30-8.8

Allen screw
3 Vent valve 7 M6x10-8.8
Allen screw
4 M16x50-10.9 8 Pinion cover
Allen screw
10.2 Exchanging the servomotor
Description
The servomotor belongs to the drive assembly and is fastened to the gear
unit. The removal and installation of the servomotor are described below.
Preconditions
pede repair work.
WARNING
The servomotor must not be tilted. The orientation of the servomotor is

identified from the position of the sockets. When the motor unit is instal-
led, these sockets must be positioned in the same way as before re-
moval.

WARNING
Risk of crushing during removal and installation
The servomotor weighs approx. 30 kg. When removing or installing the
servomotor, care must be taken to avoid injury by crushing. Injuries or
• Protective gloves must be worn.
NOTICE
Wear and premature failure due to damage to toothing
Damage to the toothing of the motor and gear unit can lead to in-
creased wear and premature failure of the components.
• During cleaning, ensure that the toothing is not damaged.
• Before installation, check the toothing of the motor and gear unit for
damage.
NOTICE
When installing the motor, it must be ensured that the motor shaft and
gear unit centering ring are not damaged. Push the motor manually onto
the gear unit until the motor shaft is up against the stop (motor/gear unit
centering hole). The motor must not be forced into the centering ring
when the fastening screws are tightened.
10.2.1 Removing the servomotor
Procedure
1. Release and unplug the connectors (>>> Fig. 10-1) for the motor and
control cables (XM..., XP...) of the linear unit from the servomotor.
2. If necessary, remove track covers at the removal position of the servo-
motor.
3. Pick up the servomotor at its center of gravity using suitable handling
equipment.
4. Remove the 4 Allen screws together with lock washers.
5. Pull the servomotor off the gear unit and remove from the carriage.
6. If the servomotor is not to be reinstalled, it must be protected against
corrosion before being put into storage.
7. Cover the gear unit and protect it against fouling.

KL 4000; KL 4000 S
Repair
Fig. 10-3: Removing the servomotor
1 Servomotor 4 M12x30-8.8
Allen screw
2 Connector XP7, control cable 5 Gear unit
3 Connector XM7, motor cable
10.2.2 Installing the servomotor
Procedure
1. Remove corrosion protection from new servomotor, if applicable

(>>> Fig. 10-4).
2. Clean the toothing of the motor and the gear unit before installation
and apply a thin but continuous coat of Microlube GL 261 grease.
3. Clean the mounting surface for the servomotor on the gear unit and
apply a thin but continuous coat of Microlube GL 261 grease.
4. Pick up the servomotor at its center of gravity using suitable handling
equipment.
5. Mount the servomotor onto the gear unit on the carriage. For installa-
tion position, see figure (>>> Fig. 10-4).
The motor shaft must not be subjected to any axial loads during instal-
lation.
When inserting the servomotor, it must be ensured that the spline
shaft connection of the servomotor and gear unit meshes properly.
This can be facilitated by gently turning the servomotor during inser-
tion.
6. Fasten the servomotor with 4 M12x30-8.8 Allen screws and lock wash-
ers.
7. Remove the handling equipment.
torque.

9. Plug in the connectors for the motor and control cables (XM..., XP...)
of the linear unit on the servomotor. The pins and coding elements of
the connectors must be taken into consideration.
10. If applicable, install the track covers.
11. Carry out mastering of the linear unit.
Detailed information about mastering is contained in the operating
and programming instructions for end users or system integrators.
Fig. 10-4: Installing the servomotor
1 Servomotor 4 M12x30-8.8
Allen screw
2 Connector XP7, control cable 5 Gear unit
3 Connector XM7, motor cable
10.3 Exchanging the stop
Description
If the permitted range of motion of the carriage is exceeded, the stops on

the beam bring the carriage to a stop. At each end of the linear unit, a
stop is installed on the rack side. The assembly consists of stop, dowel
pin, pin and other attachments. The stops must not be defective or dam-
aged. Damaged stops must be exchanged.
Preconditions
pede repair work.

KL 4000; KL 4000 S
Repair
DANGER
KUKA Deutschland GmbH must be contacted before the mechanical
stops are exchanged. This course of action is necessary in all cases,
e.g. even if a carriage hit the stop at low velocity.
Failure to observe this safety precaution may result in death to persons,
severe injuries or considerable damage to property.
WARNING
Unintentional motion of the robot and the linear unit can result in danger
to persons and materials. If the robot and the linear unit have reached
their disassembly position, shut down the system and take measures to
prevent it from being switched on again unintentionally. If several robots
or linear units are in a system, these must also be switched off and se-
cured against being switched on again unintentionally.
10.3.1 Removing the stop
Procedure
1. If applicable, remove the track cover.

2. Drive out the dowel pin (>>> Fig. 10-5) and bolt. In the event of a
crash, the dowel pin and bolt must be sawn off.
3. Unscrew two hexagon bolts together with conical spring washers.
4. Remove the stop.
Fig. 10-5: Removing the stop (buffer)
1 Stop 3 Dowel pin

2 Hexagon bolt
with conical spring washer

10.3.2 Installing the stop
Procedure
1. Mount the stop (>>> Fig. 10-6) on the track at the installation position.
The hole for the dowel pin must point towards the center of the linear
unit.
2. Insert two M20x75-10.9 hexagon bolts together with conical spring
washers and tighten with the specified tightening torque.
3. Grease the stop hole and bolt with Microlube GL 261.
4. Insert bolt into the hole of the stop.
5. Insert new dowel pin into the hole of the stop. The rounded side of
the dowel pin must be on the outside.
6. Drive the dowel pin in until it contacts the bolt.
7. If applicable, install the track cover.
Fig. 10-6: Installing the stop (buffer)
1 Stop 3 Dowel pin

2 Hexagon bolt
with conical spring washer

KL 4000; KL 4000 S
Decommissioning, storage and disposal

11 Decommissioning, storage and disposal
11.1 Decommissioning
Description
This section describes all the work required for decommissioning the
linear unit if the linear unit is to be removed from the system. After de-
commissioning, it is prepared for storage or for transportation to a different
location.
Following its removal, the linear unit can be transported by means of
transport tackle and crane or by fork lift truck. For transportation, the
beam must be picked up over its center of gravity in order to prevent tilt-
ing. For transportation, the beam may consist of a maximum of three
beam segments. Longer beams must be split up.
NOTICE
DANGER
WARNING
WARNING
WARNING
Preconditions
• The beams are divided into the prescribed transport units as shown in
the layout (>>> 4 "Technical data" Page 27).
• The removal site must be accessible with a crane or with a fork lift
truck for transportation.

Decommissioning, storage and disposal KL 4000; KL 4000 S
• There is no hazard posed by system components.

• If the energy supply system is mounted on the beam, it is removed to-
gether with the linear unit.
Procedure
1. Secure the linear unit.

WARNING
Unintentional motion of the robot and the linear unit can result in
danger to persons and materials. If the robot and the linear unit
have reached their disassembly position, shut down the system and
take measures to prevent it from being switched on again uninten-
tionally. If several robots or linear units are in a system, these must
also be switched off and secured against being switched on again
unintentionally.
2. Move the carriage to the middle of the beam and secure it so that it
cannot move.
3. Remove the robot in accordance with the operating instructions.
4. If applicable, remove the (robot) booster frame.
5. If applicable, remove the permanent lubrication unit (>>> 12.3.3.1 "Re-
moving the permanent lubrication unit" Page 214).
6. Release and unplug the equipotential bonding (ground conductor) on
the carriage.
7. Release and unplug the connectors of the motor and control cables
(XM.., XP..) on the servomotor of the carriage.
8. Remove the Allen screws and conical spring washers of the energy
supply chain from the driver and set down the energy supply chain.
9. Unscrew screw anchors or Allen screws from the connector plate.
10. Unscrew the energy supply chain from the fixed point module.
11. Take the energy supply chain out of the guide system and put it into
storage.
12. Remove the Allen screws and take the driver off the carriage.
13. Unscrew the screw anchors from the chain guides, and remove the
guide system.
14. If necessary, dismantle the guide system.
15. If applicable, remove the beam cover and covers from the overlapping
track segments at the points where the beam is disassembled.
16. Remove Allen screws and lock washers from the overlapping areas of
the track segments.
17. Attach lifting tackle at four places on the transport unit (>>> 6 "Trans-
portation" Page 103) if no fork lift truck is used.
18. Lift the first transport unit to be removed with a crane or fork lift truck.
Start with the end of the linear unit that has exposed ends of tracks
on the beam segment.
19. Unscrew the hexagon nut with spherical washer and ball cup from the
M30 bolts and remove the transport unit.
20. Remove and take away all transportation units one after the other.
21. Prepare the linear unit (>>> 11.2 "Storage" Page 201) for storage.

KL 4000; KL 4000 S
Decommissioning, storage and disposal

11.2 Storage
Description
If the linear unit is to be put into long-term storage, the following points
must be observed:
• The place of storage must be as dry and dust-free as possible.
• Avoid temperature fluctuations.
• Avoid wind and drafts.
• Avoid condensation.
• Use appropriate coverings that cannot detach themselves and which
can withstand the expected environmental conditions.
• Do not leave any loose parts on the linear unit, especially ones that
might knock against other parts.
• Do not leave the linear unit exposed to direct sunlight while in storage.
• Observe and comply with the permissible temperature ranges for stor-
age.
• Select a storage location in which the covers cannot be damaged.
Procedure
1. Remove tools and equipment.

2. Remove the linear unit.
3. Clean and dry the linear unit. No dirt or cleaning agents may remain
on or in the linear unit.
4. Inspect the linear unit, both internally and externally.
5. Remove any foreign bodies.
6. Remove any corrosion.
7. Clean the tracks and racks and protect them against corrosion.
8. Seal off electrical connections with suitable covers.
9. Seal hose connections by suitable means.
10. Cover the linear unit with VCI paper (RESY symbol) and seal it
against dust.
If necessary, add a desiccant beneath the sheeting.
11.3 Disposal
When the linear unit reaches the end of its useful life, it can be removed
from the system and dismantled, and the materials can be disposed of
properly by type.
The following table provides an overview of the materials used in the line-
ar unit. All plastic components are marked with a material designation and
must be disposed of accordingly.
Material Subassembly, component Note
Metal
Copper Cables, wires
Light metals Guide system, gear unit
housing, beam covers,
track cover, stop (buffer),
gear unit
Ductile cast Carriage, beam, bedplate
iron

Decommissioning, storage and disposal KL 4000; KL 4000 S
Material Subassembly, component Note

Steel Screws and washers,
tracks, rack, driver, stop
Electrical components
Motors Dispose of motors without
dismantling.
Electrical components Dispose of as electrical
scrap without disassem-
bling.
Plastics
FKM (fluoro- Shaft sealing rings
carbon rub-
ber)
GRP Energy supply chain
NBR O-rings
PA Hinged clamps
PE-HD Buffers
PU Hoses, energy supply chain
PUR Cable sheaths
Auxiliary substances and consumables
Gear oil Gear units Optigear EP 150
Observe the manufacturer’s
safety data sheet!
Anti-corro- Tracks Rustilo 637
sive
agent
safety data sheet!
Lubricating Rack Klüberplex AG11-462
grease
safety data sheet!
Lubricating If a permanent lubrication Klüberplex AG11-462
grease unit is being used:
pinion and rack
safety data sheet!
Lubricating If a permanent lubrication Klüberplex AG11-461
grease unit is being used:
LC cartridge
safety data sheet!
Lubricating Gear teeth Microlube GL 261
grease
safety data sheet!
Lubricating Tracks LAMORA D 220
oil
safety data sheet!
Up-to-date safety data sheets must be requested from the manufacturers
of auxiliary and operating materials (>>> 13.2 "Auxiliary and operating ma-
terials used" Page 224).

KL 4000; KL 4000 S
Options
12 Options
NOTICE
DANGER
WARNING
WARNING
WARNING
CAUTION

Options KL 4000; KL 4000 S
CAUTION
ones.
12.1 Cleaning brushes
Description
The wipers on the carriage can optionally be fitted with cleaning brushes.
Two cleaning brushes are attached to each wiper. They rest on the track
and can thus remove any dirt from the range of motion of the rollers.
Preconditions
pede repair work.
NOTICE
WARNING
CY STOP button.
12.1.1 Removing the cleaning brushes
Procedure
1. Unscrew two M6x12-8.8 Allen screws (>>> Fig. 12-1) together with
conical spring washers from the wiper to be removed.
2. Remove the wiper from the carriage.
3. Remove the cleaning brushes. To do so, remove the hexagon nuts in-
cluding conical spring washers from the M6x16-8.8 flat head screws
and take off the cleaning brushes.

KL 4000; KL 4000 S
Options
Fig. 12-1: Cleaning brushes
1 Wiper, mirrored 4 Wiper with cleaning brushes

(optional)
2 Wiper, standard 5 M6x12-8.8
Allen screw
3 Cleaning brush, top 6 Cleaning brush, side
12.1.2 Installing the cleaning brushes
Procedure
1. Install new cleaning brushes (>>> Fig. 12-2). To do so, fasten each
cleaning brush to the wiper with two hexagon nuts including conical
spring washers and two M6x16-8.8 flat head screws. Lightly tighten
the hexagon nuts so that it is still possible to shift the cleaning brush-
es easily.
2. Attach the wiper to the carriage. They must be installed in such a way
that the upper side of the tracks is always cleaned.
3. Insert two M6x12-8.8 Allen screws with conical spring washers and
lightly tighten.
4. Move the cleaning brushes far enough to allow the gap between the
wiper and the track to be adjusted.
5. Set a gap of 0.5 mm between the wiper and the track.
6. Check the gap using a feeler gauge plate (0.5 mm). If necessary, set
the gap again.
7. Tighten the 2 M6x12-8.8 Allen screws with the specified tightening tor-
que.
8. Press the cleaning brushes lightly against the track and tighten the M6
hexagon nuts with the specified tightening torque. The cleaning brush-
es must contact the track lightly.

Fig. 12-2: Cleaning brushes
1 Wiper, mirrored 4 Wiper with cleaning brushes

(optional)
2 Wiper, standard 5 M6x12-8.8
Allen screw
3 Cleaning brush, top 6 Cleaning brush, side
12.2 Covers
The linear unit can optionally be fitted with beam and track covers. The
covers are attached to the beam and the tracks.
Fig. 12-3: Structure of linear unit with covers
1 Carriage 4 Connector plate

2 Drive 5 Beam, covered
3 Energy supply system 6 Tracks, covered

KL 4000; KL 4000 S
Options
12.2.1 Exchanging the beam cover
Description
The removal and installation of the beam cover are described below.
Preconditions
pede repair work.
NOTICE
WARNING
CY STOP button.
12.2.1.1 Removing the beam cover
Procedure
1. Unscrew the flat head screws (>>> Fig. 12-4) from the beam cover.
2. Remove the beam cover from the beam and place it on a suitable
support.
3. Put the beam cover into storage if it is not to be reinstalled.
Fig. 12-4: Removing the beam cover
1 Flat head screw

2 Beam segment

3 Beam cover
12.2.1.2 Installing the beam cover
Procedure
1. Move the beam cover (>>> Fig. 12-5) into the correct position and
place carefully onto the beam.
2. Insert the M6x16-8.8 flat head screws into the beam cover and tighten
with the specified tightening torque.
Fig. 12-5: Installing the beam cover
1 Flat head screw

2 Beam segment
3 Beam cover
12.2.2 Exchanging the track cover
Description
The removal and installation of the track cover are described below.
Preconditions
pede repair work.
NOTICE

KL 4000; KL 4000 S
Options
WARNING
CY STOP button.
12.2.2.1 Removing the track cover
Procedure
1. Unscrew Allen screws (>>> Fig. 12-6)from the track cover.

2. Remove the track cover from the track.
3. Remove the clamping plates from the track cover.
4. Set the track cover down on a suitable support surface.
5. If the track cover is not to be reinstalled, insert the M20x55-10.9 hex-
agon bolts with conical spring washers into the empty boreholes of the
track. Tighten the M20x55-10.9 hexagon bolts with the specified tight-
ening torque.
6. Put the track cover and clamping plates into storage if they are not to
be reinstalled.
Fig. 12-6: Removing the track cover
1 Allen screw
2 Track cover
3 Clamping plate
12.2.2.2 Installing the track cover
Procedure
1. Remove the hexagon bolts on the fastening points on the track cover
from the track.
2. Insert the clamping plates (>>> Fig. 12-7) into the track cover and fas-
ten with the M20x60-8.8 Allen screws.

3. Place the conical spring washers on the track.

4. Move the track cover with the clamping plates into the correct position
and carefully place on the track.
5. Insert the M20x60-8.8 Allen screws into the track.
6. Tighten the M20x60-8.8 Allen screws with the specified tightening tor-
que.
Fig. 12-7: Installing the track cover
1 Allen screw
2 Track cover
3 Clamping plate
12.3 Permanent lubrication unit
The linear unit can be equipped with a comfort or premium permanent

lubrication unit. The permanent lubrication unit supplies grease to the pin-
ion and rack.
Permanent lubrication unit “comfort”
The permanent lubrication unit comfort consists of an electromechanical

drive, a cartridge with 120 cm3 or 250 cm3 of lubricant and a battery set.
A cartridge with 120 cm3 (cartridge LC 120) of lubricant is used as stand-
ard for the KL 4000. The desired dispensing time and size of the cartridge
are set by means of the Set key. The current operating state is displayed
with LED signals (red/green) that are visible from all angles as well as on
the LCD display.
Permanent lubrication unit “premium”
The permanent lubrication unit premium consists of an electromechanical

drive, a cartridge with 120 cm3 or 250 cm3 of lubricant and a connecting
cable for voltage supply. A cartridge with 120 cm3 (cartridge LC 120) of
lubricant is used as standard for the KL 4000. The operating state can be
transmitted via the connecting cable to a PLC. The lubrication system dis-
penses as a function of the operating hours in TIME mode. In IMPULSE

KL 4000; KL 4000 S
mode, a precisely set quantity is dispensed as soon as a voltage is
Options
present.
12.3.1 Control and signal cable KFL XLUB for "permanent lubrication unit
‘premium’"XLUB1
Description
The control and signal cable is routed in the energy supply chain from the
carriage to the connector plate.
The control and signal cable has plug-and-socket connections, which ena-
bles it to be quickly and reliably exchanged. The plugs and sockets are
provided with identification labels.
Overview

2 Energy supply chain 4 Control and signal cable
Wiring diagram
Fig. 12-9: Control and signal cable KFL XLUB for "permanent lubrica-
tion unit ‘premium’"

12.3.2 Maintenance table, permanent lubrication unit
Description
The table provides an overview of the maintenance work (maintenance in-

tervals, activities, lubrication work) and required lubricants.
The maintenance intervals given in the table are valid for the operating
conditions specified in the technical data. KUKA Deutschland GmbH must
be consulted in the case of discrepancies!
NOTICE
NOTICE
WARNING
CY STOP button.
WARNING
Preconditions
• The maintenance points must be freely accessible.

• Remove the tools and any additional items of equipment if they im-
pede maintenance work.
Maintenance symbols
Lubricate with brush
Check component, visual inspection

KL 4000; KL 4000 S
Options
Fig. 12-10: Maintenance diagram
Interval Item Activity Lubricant

400 h 1 Check the grease on the rack. If
necessary, check the permanent lu-
brication system. Exchange compo-
nents or adapt the amount of lubri-
cant.
9 months* 2 Exchange the cartridge.
(max. 12 (>>> 12.3.5 "Exchanging the car-
months) tridge" Page 220)
1 year Clean the racks with cleaning sol- Klüberplex AG11-462
vent and re-grease.
Art. no.
00-276-589
1 year Check the lubrication system for
correct operation.
Check the state of the felt pinion.
*with 3-shift operation
In the case of unusual applications or ambient conditions, it may be nec-
essary to adjust the intervals.
12.3.3 Exchanging the permanent lubrication unit
Description
The removal and installation of the permanent lubrication unit are descri-
bed below.
Preconditions

NOTICE
NOTICE
WARNING
CY STOP button.
12.3.3.1 Removing the permanent lubrication unit
Procedure
1. Switch off the permanent lubrication unit (>>> Fig. 12-11) in accord-
ance with the manufacturer’s instructions. In the case of the premium
permanent lubrication unit, unplug the cable connection from the drive
system.
2. Unscrew the Allen screw together with the conical spring washer from
the felt pinion holder.
3. Pull the felt pinion holder with the mounted parts off the roll pin and
remove.
4. If the permanent lubrication unit is not to be reinstalled, it must be
packaged and put into storage.

KL 4000; KL 4000 S
Options
Fig. 12-11: Removing the permanent lubrication unit
1 Pinion cover 7 Cover

2 Gear unit 8 Felt pinion holder
3 Servomotor 9 M8x16-8.8 Allen screw
4 Cartridge with 10 Roll pin ISO8752-6x10
drive system
5 Holder 11 Elbow
6 M6x12-8.8 Allen screw 12 Felt pinion
12.3.3.2 Installing the permanent lubrication unit
Procedure
1. If necessary, knock out the window in the pinion cover

(>>> Fig. 12-12).
2. If necessary, tap a new ISO8752-6x10 roll pin into the gear unit.
3. Soak the felt pinion in oil.
4. Fasten the felt pinion holder with the mounted parts to the gear unit.
Screw in M8x16-8.8 Allen screw with conical spring washer, but do not
tighten.
5. Remove 2 Allen screws together with conical spring washers. Remove
the cover and holder.

6. Set the backlash between the pinion and the felt pinion to approxi-
mately 1 mm. The backlash can be set by turning the holder.
7. Tighten the M8x16-8.8 Allen screw with the specified tightening torque.
8. Fill with lubricating grease (cartridge with Klüberplex AG11-461, article
no. 00-282-142) via the elbow until it emerges from all lubricating
channels of the felt pinion.
9. Apply Klüberplex AG11-461 to the toothing of the new felt pinion.
10. Fasten the cover and holder to the felt pinion holder with two
M6x12-8.8 Allen screws with conical spring washers. Tighten the
M6x12-8.8 Allen screws with the specified tightening torque.
11. Assemble and adjust the lubrication system in accordance with the
manufacturer’s instructions.
12. Remove the plug and push the cartridge with the drive system through
the holder and onto the elbow and screw it in.
13. For the lubrication system premium, the four-pole power supply cable
must be connected. Remove the white sealing cap above the display
and attach the power supply cable. When inserting the connector, turn
it until it clearly locks into the coding elements (twist-proof). The icon
for the supply voltage appears on the display and the drive LEDs flash
green.
Fig. 12-12: Installing the permanent lubrication unit
1 Pinion cover 7 Cover

2 Gear unit 8 Felt pinion holder

KL 4000; KL 4000 S
Options
3 Servomotor 9 M8x16-8.8 Allen screw
4 Cartridge with 10 Roll pin ISO8752-6x10
drive system
5 Holder 11 Elbow
12.3.4 Exchanging the felt pinion
Description
The removal and installation of the felt pinion are described below.
Preconditions
NOTICE
NOTICE
WARNING
CY STOP button.
12.3.4.1 Removing the felt pinion
Procedure
1. Switch off the permanent lubrication unit in accordance with the manu-
facturer’s instructions. In the case of a premium permanent lubrication
unit, additionally unplug the cable connection from the drive system.
2. Unscrew the cartridge with the drive system (>>> Fig. 12-13) from the
elbow and pull them through the holder.
3. Fit the plug on the cartridge.
4. Unscrew the Allen screw together with the conical spring washer from
the felt pinion holder.
5. Pull the felt pinion holder with the mounted parts off the roll pin and
remove.
6. Unscrew two Allen screws together with conical spring washers. Re-
move the cover and holder.
7. Unscrew the M6x10-8.8 flat head screw from the mounting shaft.
8. Pull the clamping disk and felt pinion with washer off the mounting
shaft.
9. Dispose of the felt pinion in accordance with the pertinent regulations.

Fig. 12-13: Removing the felt pinion
1 Pinion cover 9 M8x16-8.8 Allen screw

2 Gear unit 10 Roll pin ISO8752-6x10
3 Servomotor 11 M6x10-8.8 flat head screw
4 Cartridge with 12 Clamping disk
drive system
5 Holder 13 Elbow
7 Cover 15 Washer
8 Felt pinion holder
12.3.4.2 Installing the felt pinion
Procedure
1. Soak the felt pinion (>>> Fig. 12-14) in oil.

2. Push the disk and new felt pinion onto the mounting shaft.
3. Place the clamping disk on the felt pinion and insert an M6x10-8.8 flat
head screw into the mounting shaft. Tighten the M6x10-8.8 flat head
screw with the specified tightening torque.
4. Fasten the felt pinion holder with the mounted parts to the gear unit.
Screw in M8x16-8.8 Allen screw with conical spring washer, but do not
tighten.

KL 4000; KL 4000 S
Options
5. Set the backlash between the pinion and the felt pinion to approxi-
mately 1 mm. The backlash can be set by turning the holder.
6. Tighten the M8x16-8.8 Allen screw with the specified tightening torque.
7. Fill with lubricating grease (cartridge with Klüberplex AG11-461, article
no. 00-282-142) via the elbow until it emerges from all lubricating
channels of the felt pinion.
8. Fasten the cover and holder to the felt pinion holder with 2 M6x12-8.8
Allen screws with conical spring washers. Tighten the M6x12-8.8 Allen
screws with the specified tightening torque.
10. With the lubrication system premium, attach the cable connection to
the drive system. When inserting the connector, turn it until it clearly
locks into the coding elements (twist-proof).
11. Switch on the permanent lubrication unit in accordance with the manu-
facturer’s instructions.
Fig. 12-14: Installing the felt pinion
1 Pinion cover 9 M8x16-8.8 Allen screw

2 Gear unit 10 Roll pin ISO8752-6x10
3 Servomotor 11 M6x10-8.8 flat head screw
4 Cartridge with 12 Clamping disk
drive system
5 Holder 13 Elbow


7 Cover 15 Washer
8 Felt pinion holder
12.3.5 Exchanging the cartridge
Description
The removal and installation of the LC cartridge are described below.

If a battery set was used, this must be exchanged as well. Once the per-
manent lubrication unit has been started, the battery set must not be re-
moved as this will result in a malfunction.
Preconditions
NOTICE
NOTICE
WARNING
CY STOP button.
12.3.5.1 Removing the cartridge
Procedure
1. Switch off the permanent lubrication unit in accordance with the manu-
facturer’s instructions. In the case of the premium permanent lubrica-
tion unit, unplug the cable connection from the drive system.
2. Unscrew the cartridge with the drive system (>>> Fig. 12-15) from the
elbow and pull them through the holder.
3. Unscrew the drive system from the cartridge and dispose of it.
4. With the lubrication system comfort, remove the battery set from the
drive system. Observe the manufacturer’s instructions.

KL 4000; KL 4000 S
Options
Fig. 12-15: Removing the cartridge
1 Drive system 3 Holder

2 Cartridge 4 Elbow
12.3.5.2 Installing the cartridge
Procedure
1. With the lubrication system comfort, insert a new battery set into the
drive system (>>> Fig. 12-16). Observe the manufacturer’s instruc-
tions.
Once the permanent lubrication unit has been started, the battery set
must not be removed as this will result in a malfunction.
2. Screw the drive system and cartridge together in accordance with the
4. With the lubrication system premium, attach the cable connection to
the drive system. When inserting the connector, turn it until it clearly
locks into the coding elements (twist-proof).
5. If necessary, re-adjust the lubrication system in accordance with the
Fig. 12-16: Installing the cartridge

1 Drive system 3 Holder

2 Cartridge 4 Elbow

KL 4000; KL 4000 S
Appendix
13 Appendix
13.1 Tightening torques
Tightening torques
The following tightening torques (Nm) are valid for screws and nuts where
no other specifications are given.
The specified values apply to lightly oiled black (e.g. phosphated) and
coated (e.g. mech. galv., zinc flake plating, screw locking elements)
screws and nuts.
Strength class
Thread 8.8 10.9 12.9
M1.6 0.17 Nm 0.24 Nm 0.28 Nm
M2 0.35 Nm 0.48 Nm 0.56 Nm
M2.5 0.68 Nm 0.93 Nm 1.10 Nm
M3 1.2 Nm 1.6 Nm 2.0 Nm
M4 2.8 Nm 3.8 Nm 4.4 Nm
M5 5.6 Nm 7.5 Nm 9.0 Nm
M6 9.5 Nm 12.5 Nm 15.0 Nm
M8 23.0 Nm 31.0 Nm 36.0 Nm
M10 45.0 Nm 60.0 Nm 70.0 Nm
M12 78.0 Nm 104.0 Nm 125.0 Nm
M14 125.0 Nm 165.0 Nm 195.0 Nm
M16 195.0 Nm 250.0 Nm 305.0 Nm
M20 370.0 Nm 500.0 Nm 600.0 Nm
M24 640.0 Nm 860.0 Nm 1030.0 Nm
M30 1330.0 Nm 1700.0 Nm 2000.0 Nm
Strength class
Thread 8.8 10.9
ISO7991 ISO7380, ISO07381
Allen screw Fillister head
screw
M3 0.8 Nm 0.8 Nm
M4 1.9 Nm 1.9 Nm
M5 3.8 Nm 3.8 Nm
Strength class
Thread 10.9
DIN7984
Pan head screws
M4 2.8 Nm
Tighten M5 domed cap nuts with a torque of 4.2 Nm.

Appendix KL 4000; KL 4000 S
13.2 Auxiliary and operating materials used
Product designation / Use Manufacturer designation /

Article number Address
Optigear EP 150 Gear oil Deutsche BP Aktiengesellschaft - In-

dustrial Lubricants & Services
Erkelenzer Strasse 20
D-41179
Mönchengladbach
Germany
Rustilo 637 Anticorrosive agent Deutsche BP Aktiengesellschaft - In-

dustrial Lubricants & Services
0883-236-745
Erkelenzer Strasse 20
D-41179
Mönchengladbach
Germany
Klüberplex AG11-462 Lubricating grease Klüber Lubrication München KG

Geisenhausenerstr. 7
0000-276-589
D-81379
Munich
Germany
Klüberplex AG11-461 Lubricating grease Klüber Lubrication München KG

0000-282-142
D-81379
Munich
Germany
Microlube GL 261 Lubricating grease Klüber Lubrication München KG

0000-135-463
D-81379
Munich
Germany
LAMORA D 220 Lubricating oil Klüber Lubrication München KG

0000-278-829
D-81379
Munich
Germany
To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.
13.3 Applied norms and regulations
Name/Edition Definition
2006/42/EC Machinery Directive:

Directive 2006/42/EC of the European Parliament and of the Coun-
cil of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast)
EN ISO 13850:2015 Safety of machinery:

Emergency stop - Principles for design

KL 4000; KL 4000 S
Appendix
EN ISO 13849-1:2015 Safety of machinery:
Safety-related parts of control systems - Part 1: General principles
of design
EN ISO 13849-2:2012 Safety of machinery:

Safety-related parts of control systems - Part 2: Validation
EN ISO 12100:2010 Safety of machinery:

General principles of design, risk assessment and risk reduction
EN ISO 10218-1:2011 Robots and robotic devices – Safety requirements for industri-
al robots:
Part 1: Robots
Note: Content equivalent to ANSI/RIA R15.06-2012, Part 1
EN 614-1:2006+A1:2009 Safety of machinery:

Ergonomic design principles - Part 1: Terms and general principles
EN Safety of machinery:
60204-1:2006+A1:2009
Electrical equipment of machines – Part 1: General requirements

Appendix KL 4000; KL 4000 S

KL 4000; KL 4000 S
KUKA Service
14 KUKA Service
14.1 Requesting support
Introduction
This documentation provides information on operation and operator con-

trol, and provides assistance with troubleshooting. For further assistance,
please contact your local KUKA subsidiary.
Information
The following information is required for processing a support re-

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• The greatest possible amount of information about the hardware and
software components of the overall system
The following list gives an indication of the information which is rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ Model and serial number of the controller
‒ Model and serial number of the energy supply system
‒ Designation and version of the system software
‒ Designations and versions of other software components or modifi-
cations
‒ System Software diagnosis package
Additionally for KUKA Sunrise: Existing projects including applica-
tions
For versions of KUKA System Software older than V8: Archive of
the software (Diagnosis package is not yet available here.)
‒ Application used
‒ External axes used
14.2 KUKA Customer Support
The contact details of the local subsidiaries can be found at:

www.kuka.com/customer-service-contacts

KUKA Service KL 4000; KL 4000 S

KL 4000; KL 4000 S
Index Cartridge, installing.......................................221

Cartridge, removing...................................... 220
2006/42/EC................................................... 224
CE mark..........................................................18
95/16/EC....................................................... 224
Cleaning brushes..........................................204
Cleaning brushes, installing......................... 205
Cleaning brushes, removing........................ 204
A Cleaning the linear unit................................187
Acceptance..................................................... 18 Cleaning work.................................................25
Acceptance, linear unit...................................17 Configuration.................................................173
Accessories.......................................................9 Connecting cable, Power Supply XD1........ 167
Adapter plate KR CYBERTECH nano, Connecting cable, Profinet XF1...................168
KR CYBERTECH........................................... 38 Connecting cable, signal cable XG79......... 170
Adapter plate KR FORTEC 45º.....................43 Connecting cable, standard......................... 157
Adapter plate KR IONTEC.............................40 Connecting cable, welding cable XD73.......169
Adapter plate KR QUANTEC-2..................... 42 Connecting cables....................................9, 101
Adapter plate KR QUANTEC 45º.................. 41 Connecting cables interface.........................155
Ambient conditions......................................... 29 Control and signal cable KFL XLUB for
Ambient temperature, operation.................... 29 "permanent lubrication unit
Ambient temperature, storage........................29 ‘premium’"XLUB1................................. 166, 211
Ambient temperature, transportation............. 29 Covers...........................................................206
Anchoring kit...................................... 93, 95–97
Anchoring kit with lateral or longitudinal joint,
installing........................................................130
Anchoring kit, adjusting plate (strengthened
D
Danger zone................................................... 18
foundation)......................................................99
Declaration of conformity............................... 17
Anchoring kit, Fischer.....................................96
Declaration of incorporation.....................17, 18
Anchoring kit, Fischer, installing.................. 124
Decommissioning................................... 26, 199
Anchoring kit, Hilti.......................................... 93
Diagnosis package....................................... 227
Anchoring kit, Hilti, installing........................ 115
Dimensions, KL 4000..................................... 29
Anchoring kit, installing.................................115
Disposal......................................... 26, 199, 201
Anchoring kit, installing, strengthened
Documentation, linear unit............................... 7
foundation..................................................... 121
Drive......................................................... 10, 13
Anchoring kit, strengthened foundation......... 97
Drive unit, installing...................................... 192
ANSI/RIA R15.06-2012................................ 225
Drive unit, removing..................................... 191
Appendix....................................................... 223
Drive, exchange............................................190
Applied norms and regulations.................... 224
Assemblies and components....................... 103
Automatic mode..............................................24
Auxiliary materials used............................... 224 E
Axis range.......................................................18 EC declaration of conformity......................... 17
Eccentricity KR CYBERTECH nano,
KR CYBERTECH........................................... 39
B Edge distances for foundations.. 77, 80, 85, 91
EMC Directive.................................................18
Backlash....................................................... 185
EN 60204-1:2006+A1:2009..........................225
Backlash, adjusting.......................................186
EN 60721-3-3................................................. 29
Backlash, adjustment................................... 185
EN 614-1:2006+A1:2009..............................225
Backlash, measuring.................................... 186
EN ISO 10218-1:2011.................................. 225
Basic data.......................................................27
EN ISO 12100:2010..................................... 225
Beam........................................................ 10, 12
EN ISO 13849-1:2015..................................225
Beam cover, exchange.................................207
EN ISO 13849-2:2012..................................225
Beam cover, installing.................................. 208
EN ISO 13850:2015..................................... 224
Beam cover, removing................................. 207
Energy supply system............................. 10, 13
Beam fastening...............................................75
Energy supply system on beam, installing..147
Brake defect................................................... 22
Energy supply system, installing................. 141
Braking distance............................................. 18
External axis................................................... 20
C F
Carriage....................................................10, 12
Faults.............................................................. 22
Cartridge, exchanging.................................. 220
Felt pinion, exchanging................................ 217

KL 4000; KL 4000 S
Felt pinion, installing.....................................218 Linear unit.................................................. 9, 10

Felt pinion, removing....................................217 Linear unit, installing.................................... 137
Fork lift truck.................................................103 Linear unit, moving without drive energy.... 171
Foundation loads.................. 49, 55, 57, 61, 64 Low Voltage Directive.....................................18
Foundation loads for mounting bases with Lubricants............................................. 182, 212
lateral joint, longitudinal compensation..........55 Lubrication work................................... 182, 212
Foundation loads for mounting bases with
lateral joint, longitudinal compensation,
strengthened foundation.................................57 M
Foundation loads for mounting bases with Machine frame mounting..............................100
longitudinal joint, lateral compensation..........61 Machine frame mounting, installing............. 135
Foundation loads for mounting bases with Machinery Directive................................18, 224
longitudinal joint, lateral compensation, Maintenance........................................... 25, 181
reinforced foundation......................................64 Maintenance intervals.......................... 182, 212
Foundation loads, strengthened foundation.. 52 Maintenance symbols.......................... 183, 212
Function test................................................... 23 Maintenance table........................................ 182
Maintenance table, permanent lubrication
unit................................................................ 212
G Manipulator..................................................... 19
General information........................................ 71 Manual mode..................................................24
General safety measures............................... 22 Material designation..................................... 201
Guide system..................................................14 Mechanical end stops.................................... 21
Microlube GL 261.........................................224
Misuse.............................................................15
H Mounting base.............................75, 78, 81, 86
Handling equipment......................................103 Mounting base with lateral or longitudinal
Hazardous substances................................... 25 joint................................................................. 81
Hilti anchoring kit, strengthened foundation.. 95 Mounting base with lateral or longitudinal joint,
Hilti anchoring kit, strengthened foundation, installing........................................................ 109
installing........................................................ 117 Mounting base with lateral or longitudinal joint,
strengthened................................................... 86
Mounting base, installation.......................... 106
Mounting base, reinforced, installing........... 107
I Mounting base, reinforced, with lateral or
Installation, cleaning brushes.......................205
longitudinal compensation, installing............ 111
Installation, linear unit.....................................11
Mounting base, standard............................... 75
Installing the anchoring kit, adjusting plate
Mounting base, standard, installing............. 106
(strengthened foundation)............................ 127
Mounting base, standard, reinforced............. 78
Interface, energy supply system..................102
Interfaces...................................................... 101
Introduction....................................................... 7
O
Operating materials used............................. 224
Operators........................................................ 21
K Optigear EP 150...........................................224
KCP.................................................................18
Options...............................................9, 14, 203
Klüberplex AG11-461................................... 224
Overload......................................................... 22
Klüberplex AG11-462................................... 224
KR C4/KR C5, control cable XP7,
connecting.................................................... 153
KUKA Customer Support............................. 227 P
KUKA Service...............................................227 Permanent lubrication...................................210
KUKA smartPAD........................................ 9, 19 Permanent lubrication unit........................... 210
KUKA smartPAD-2......................................... 19 Permanent lubrication unit, exchanging...... 213
Permanent lubrication unit, installing...........215
Permanent lubrication unit, removing.......... 214
Personal protective equipment...................... 20
L Personnel........................................................20
Labeling.......................................................... 21
Planning.......................................................... 75
LAMORA D 220........................................... 224
Plant integrator............................................... 19
Liability............................................................ 17
Plates and labels............................................70
Lifting tackle......................................... 103, 104
PPE.................................................................20

KL 4000; KL 4000 S
Preventive maintenance work........................ 25 Track cover, installing...................................209

Product description...........................................9 Track cover, removing..................................209
Protective equipment, overview..................... 21 Training............................................................. 7
Transportation........................................ 23, 103
Transportation by fork lift truck.................... 103
R Transportation with lifting tackle.................. 104
Reaction distance........................................... 18 Travel.............................................................. 12
Recommissioning................................... 23, 105
Removal, cleaning brushes..........................204
Repair..................................................... 25, 189 U
Robot................................................................ 9 User.......................................................... 18, 20
Robot controller................................................ 9 Users.................................................................7
Rustilo 637....................................................224
W
S Warnings........................................................... 7
Safety..............................................................17 Workspace................................................18, 21
Safety instructions............................................ 7
Safety of machinery.............................224, 225
Safety options.................................................19
Safety zone.............................................. 19, 21
Safety, general................................................17
Service life...................................................... 18
Servomotor, exchanging...............................193
Servomotor, installing................................... 195
Servomotor, removing.................................. 194
smartPAD........................................................19
Software............................................................9
Start-up...................................................23, 105
Stop (buffer)....................................................10
STOP 0.................................................... 19, 72
STOP 1.................................................... 19, 72
STOP 2...........................................................19
Stop category 0.............................................. 19
Stop category 1.............................................. 19
Stop category 2.............................................. 19
Stop category 1, Drive Ramp Stop............... 19
Stop signal......................................................71
STOP 1 - DRS............................................... 19
Stop, exchanging..........................................196
Stop, installing.............................................. 198
Stop, removing............................................. 197
Stopping distance.................................... 18, 71
Stopping distances......................................... 71
Stopping time..................................................71
Stopping times................................................71
Storage................................................... 26, 199
Support request............................................ 227
System integrator..................................... 18–20
T
T1 (operating mode).......................................19
T2 (operating mode).......................................19
Teach pendant.................................................. 9
Technical data.................................................27
tender carriage............................................... 10
Terms, safety.................................................. 18
Tightening torques........................................ 223
Track cover, exchanging.............................. 208

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Publication: Pub BA KL 4000 (PDF) en

Book structure: BA KL 4000 V10.1

Version: BA KL 4000 V10

2/231 | www.kuka.com BA KL 4000 V10 | Issued: 31.10.2022

BA KL 4000 V10 | Issued: 31.10.2022 www.kuka.com | 3/231

4.12.3 Stopping distances and stopping times, STOP 1................................................ 73

7 Start-up and recommissioning............................................................... 105

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11 Decommissioning, storage and disposal............................................. 199

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13.2 Auxiliary and operating materials used................................................................ 224

14 KUKA Service........................................................................................... 227

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1.1 Target group

This documentation is aimed at users with the following knowledge and

For optimal use of KUKA products, we recommend the training courses

1.2 Documentation for the linear unit

The linear unit documentation consists of the following parts:

• Operating instructions for the linear unit

1.3 Representation of warnings and notes

These warnings contain references to safety-relevant information or gen-

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This warning draws attention to procedures which serve to prevent or rem-

edy emergencies or malfunctions:

Procedures marked with this warning must be followed exactly.

These notices serve to make your work easier or contain references to

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2.1 Overview of the linear unit system

Fig. 2-1: Example of a robot system with linear unit

1 Robot 4 Robot controller

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2.2 Description of the linear unit

The linear unit is a single-axis track system and is used principally as an

Fig. 2-2: Structure of the linear unit – example

1 Energy supply system 4 Connector plate

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1 Carriage 4 Connector plate

The illustrated position of the connector plate is an example. The con-

Fig. 2-4: Installation of linear unit, energy supply system on beam

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1 Linear unit, mirrored design

Fig. 2-5: Installation of linear unit, energy supply system on side

1 Linear unit, mirrored design

The beam is assembled from beam segments 1.5 m and 2 m in length. At

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The drive assembly consists of a servomotor, a gear unit and fasteners.

Energy supply system

Fig. 2-6: Attachment of energy supply system, short travel

1 Energy supply system attached to the beam

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Fig. 2-7: Attachment of energy supply system, long travel

1 Energy supply system installed at the side

The energy supply chain lies in a guide system. It consists of chain

The following options are available for the KL 4000:

2.3 Intended use

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Any use or application deviating from the intended use is deemed to be

Any use or application deviating from the intended use is deemed to be