ITEM KGT 6 60 P20 User manual

KGT 6 60 P20
Assembly guide

2
KGT 6 60 P20 – assembly guide
Contents
Symbols, safety .......................................................................................................................................................................................................2
General safety information ...................................................................................................................................................................................3
Correct use ...............................................................................................................................................................................................................3
Improper use.............................................................................................................................................................................................................4
Product description.................................................................................................................................................................................................4
Technical data .........................................................................................................................................................................................................5
Preparing for assembly ..........................................................................................................................................................................................6
Fitting the spindle support stops..........................................................................................................................................................................7
Fitting the linear guide rail.....................................................................................................................................................................................9
Fitting the magnetic strips.................................................................................................................................................................................. 10
Fitting the carriage ............................................................................................................................................................................................... 10
Number and positioning of spindle supports................................................................................................................................................. 12
Fitting the xed and oating bearings.............................................................................................................................................................. 14
Fitting the steel strip............................................................................................................................................................................................. 15
Fitting Cover Prole LE 6 .................................................................................................................................................................................... 17
Motor connection with Drive Set KGT 6 60.................................................................................................................................................... 18
Motor connection with Parallel Drive Set 6 60..............................................................................................................................................20
Precongured variants ....................................................................................................................................................................................... 21
KGT 6 60 P20 accessories ................................................................................................................................................................................22
Proximity Switch KLE 6........................................................................................................................................................................22
Cover Prole 6 LE .................................................................................................................................................................................22
Dealer conguration and spare parts list........................................................................................................................................................23
Checklist .................................................................................................................................................................................................................26
Repair and maintenance .... ...............................................................................................................................................................................26
Care and cleaning.................................................................................................................................................................................................26
Disposal .................................................................................................................................................................................................................27
Product development and documentation .................................................................................................................................................... 27
Symbols, safety
Important information
Observe directions for disposal
Observe directions for disposal
Maintenance
Note! Failure to observe this safety instruction can result in material damage
Warning! Failure to observe this safety instruction can result in material damage, serious injury or death
Caution! Failure to observe this safety instruction can result in material damage, serious injury or death
Caution! Failure to observe this safety instruction can result in material damage or injury

3
KGT 6 60 P20 – assembly guide
General safety information
The details and information in this assembly guide are provided for the purposes of describing the product and its assembly
only. This information does not discharge users from the obligation to conduct their own assessments and checks. It is also
important to bear in mind that our products are subject to a natural process of wear and ageing.
This guide contains important information that will enable you to use the product safely and appropriately. When sold, rented
out or otherwise passed on to another party, this product must be handed over with the assembly guide. You must therefore
read and follow the safety instructions set out below.
▪ All work on and with the KGT 6 60 P20 must be performed with “safety rst” in mind.
▪ Switch off the power to the KGT 6 60 P20 before carrying out any work on the linear axis.
▪Observe the regulations pertaining to accident prevention and environmental protection that apply in the country and place
of work where the product is being used.
▪Use only item products that are in perfect working order.
▪Failure to use original spare parts will invalidate the product warranty!
▪Check the product for obvious defects.
▪Use the product only within the performance range described in the technical data.
▪ Ensure all the safety equipment associated with the product is present, properly installed and in full working order.
▪ Do not alter the position of safety equipment, circumvent it or render it ineffective.
The KGT 6 60 P20, as described here, corresponds to the state of the art and takes into account the general principles of
safety applicable at the time this assembly guide was published. Nevertheless, failure to observe the safety instructions and
warning notices in this assembly guide may result in personal injury and damage to property. We will assume no liability for
any resulting damage or injury. We reserve the right to make changes that represent technical advances. Keep this guide in
a place where it can be accessed by all users at any time. This general safety information applies to the entire lifecycle of the
KGT 6 60 P20.
Correct use
The KGT 6 60 P20 is a component and must only be used in accordance with the technical data and safety requirements set
out in this document. Combining linear axis KGT 6 60 P20 with a motor and controller creates a partly completed machine as
dened in Machinery Directive 2006/42/EC. The declaration of incorporation for the variants with our Motors and Controllers,
such as the item MotionKit Linear Unit KGT 6 60 P20 as an all-in-one package for automation projects, is included with this
document. Internal company requirements and the regulations that apply in the country where the product is being used must
be observed. You must not make any design modications to the KGT 6 60 P20 yourself. We will assume no liability for any
resulting damage or injury. You may only install, operate and maintain the KGT 6 60 P20 if:
▪The KGT 6 60 P20 has been integrated into its surroundings in a proper and safe manner.
▪You have carefully read and understood the assembly guide.
▪ You are appropriately qualied.
▪You are authorised to do so by your company.
▪ You are using only original equipment from the manufacturer.
The KGT 6 60 P20 is designed for indoor use.

4
KGT 6 60 P20 – assembly guide
Improper use
Improper use is dened as any use of the product for purposes other than those authorised in the assembly guide and under
the denition of correct use. We will assume no liability for any resulting damage or injury.
Product description
Compact, precise and dynamic, Linear Unit KGT 6 60 combines a ball screw drive that has a stroke of up to 2600mm with
a strong carriage, and does so in the smallest of installation spaces. In applications with a long travel distance, travelling
spindle supports keep everything running smoothly and precisely without sacricing dynamics. Mechanical coding on the
inside of the axis provides perfect support for the specially shaped spindle with any stroke length and in any carriage position.
Two Drive Sets are available that suit the performance spectrum of the mechanical axis and are fully prepared for combina-
tion with item Motors and item Controllers to produce customer-specic solutions. The universal Drive Set 6 60 D30/D12
makes it possible to connect to third-party motors.
Three precongured Linear Units complete with Motor and Controller are available for the various stroke lengths. The variants
are based on these basic mechanical components.
Linear Unit KGT 6 60 P20:
0.0.706.00
74
The distances S1and S2are built as follows:
S1: distance to the xed bearing (13mm) + safety distance (Smin = 26mm) + n x
spindle support (16mm)
S2: distance to oating bearing (11mm) + safety distance (Smin = 26mm) + n x
spindle support (16mm)
The safety distance of 26mm is in all variants the free area, in which e.g. during the
reference motion procedure is driven.
Stroke range
[mm] X [mm] S1[mm] S2[mm] Basic mass [kg]
0 - 1000 323 56 53 2.635
1001 - 1560 355 72 69 2.855
1561 - 2120 387 88 85 3.053
2121 - 2600 419 104 101 3.253
Drive Set KGT 6 60 D30/D12 SE 40: Drive Set KGT 6 60 D30/D12 SE 60: Drive Set KGT 6 60 D30/D12:
0.0.692.53 0.0.692.55 0.0.704.53

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KGT 6 60 P20 – assembly guide
Technical data
Maximum stroke: 2600mm
Safety clearance: 26mm
Mass per mm of stroke: 3592g/mm
Repeatability: 0.01mm
Maximum acceleration: 15m/s²
Maximum speed: 1m/s
Feed: 20mm/revolution
Mounting dimension: 60mm x 60mm
Spindle lead: 20mm
Maximum operating load: 1000N
Support
width Lmax
at
Fz max [mm]
Support
width Lmax
at
Fy max [mm]
Fy max [N] Fz max [N] Mx max
[Nm]
My max
[Nm]
Mz max
[Nm]
Operating
load
Fx max [N]
Linear Unit KGT
6 60 P20 600 800 2000 2000 15 120 120 1000
Ambient conditions:
Storage temperature: -20°C to +70°C
Relative humidity: 5% to 85%
Linear Unit KGT 6 60 P20 is intended as a permanent xture to be used in an area that is protected from the weather.
Do not install or use in close proximity to industrial plants that produce chemical emissions.
Do not install or use in an area that is regularly exposed to high-energy surges such as those caused by presses or heavy
machinery, for example.
In case of doubt regarding resistance to certain chemicals such as test oil, alloyed oils, aggressive cleaning substances,
solvents or brake uid, we advise that you consult your specialist representative.
Consult the manufacturer if using in very salty air.
Deection in the KGT 6 60 P20 should not exceed 1mm over an axis of 1000mm. In scenarios where high demands are
placed on the system dynamics, supports should be added every 300mm to 600mm.

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KGT 6 60 P20 – assembly guide
Nmax with support
[rpm]
Nmax without support
[rpm]
D = speed [rpm]
L = length of spindle [mm]
0
0
500
1000
1500
2000
2500
1000
3000
3500
2000 3000 350025001500500
D [1/min]
L [mm]
Maximum spindle speed with and without KGT 6 60 P20 spindle supports
The spindle supports ensure that the maximum length of the spindle that is unsupported remains more or less the same. This
means the critical speed of 3000rpm is constant over the entire possible stroke range.
Preparing for assembly
Switch off the power to the system before carrying out any installation, cleaning or maintenance work on the KGT 6 60 P20.
Preparations for assembly:
▪ Prole 6 60 LE: L = H+X-24
▪ Spindle: 15mm shorter than Prole 6 60 LE
▪ Prole, guide rail: 20mm shorter than Prole 6 60 LE
▪ Magnetic strip: Approx. 5mm longer than Prole 6 60 LE
▪ Steel strip: Approx. 12mm longer than Prole 6 60 LE
The rst step is to countersink the core bores of Support Prole 6 60 LE on both sides and give them an M5x20 thread. The
tap should have a helix to prevent it from canting in the core hole.
Anti-slip aids should be placed underneath the axis during assembly.

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KGT 6 60 P20 – assembly guide
Fitting the spindle support stops
Secure the stops for the spindle supports – a screw-
washer-nut combination for subsequent positioning of
the support – in the relevant positions in the Support
Prole’s T-slot channels.
Tightening torque MT = 1.2Nm
The number of stops required depends on the stroke of the Linear Unit. Consult the drawings to determine
which of the prole channels to use and where in that channel to place the stop. The stops themselves are identical and only
their position and tightening torque are important.
Variation and number of stops
Stroke range [mm] 0 - 1000 1001 - 1560 1561 - 2120 2121 - 2600
Number of stops 1 2 3 4
Prole channel num-
ber (see drawing) 11 + 2 1 + 2 + 3 1 + 2 + 3 + 4
Position of stop 0.5 x prole length Each 0.33 x prole
length
Each 0.25 x prole
length
Each 0.2 x prole
length
Caution: It is important that the stops are positioned precisely for the KGT 6 60 PS to function correctly. Positioning the stops
incorrectly can result in damage to the linear axis and injuries for users.

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KGT 6 60 P20 – assembly guide
1. Number and position of stops in a stroke range of between 0 mm and 1000 mm:
L
1/2 L
1/2 L
4
3
4
2
1
▪ The numbers indicate the coloured prole channels in which the stops are to be installed.
▪ L is the measured length of the prole and not stroke.
The stop required for a stroke range of between 0and 1000mm must therefore be installed in channel 4, half way along the prole.
2. Number and position of stops in a stroke range of between 1001 mm and 1560 mm:
L
1/3 L
1/3 L
1/3 L
3
4
3
4
2
1
▪ The numbers indicate the coloured prole channels in which the stops are to be installed.
▪ L is the measured length of the prole and not stroke.
The stops required for a stroke range of between 1001mm and 1560mm must therefore be installed in channels 3 and 4, at
intervals of 0.33 x the prole length.
3. Number and position of stops in a stroke range of between 1561 mm and 2120 mm:
1/4 L
L
1/4 L
1/4 L
1/4 L
2
3
4
3
4
2
1
▪ The numbers indicate the coloured prole channels in which the stops are to be installed.
▪ L is the measured length of the prole and not stroke.
The stops required for a stroke range of between 1561mm and 1210mm must therefore be installed in channels 2, 3 and 4,
at intervals of 0.25 x the prole length.

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KGT 6 60 P20 – assembly guide
4. Number and position of stops in a stroke range of between 2121 mm and 2600 mm:
1/5 L 1/5 L
L
1/5 L
1/5 L
1/5 L
2
1
3
4
3
4
2
1
▪ The numbers indicate the coloured prole channels in which the stops are to be installed.
▪ L is the measured length of the prole and not stroke.
The stops required for a stroke range of between 1001mm and 1560mm must therefore be installed in channels 1, 2, 3 and
4, at intervals of 0.2 x the prole length.
Fitting the Linear Guide Rail
The next step is to t the Linear Guide Rail. Start by
checking the sawn ends of the rail are burrless and
rework them if necessary.
Fit the rail with all the necessary
Hexagon Socket Head Cap Screws and T-Slot Nuts.
Make sure the Hexagon Socket Head Cap Screws are
screwed approximately one to a maximum of two full
turns into the T-Slot Nuts. This then makes it easier to
push the rail into the Support Prole.
Push the rail, tted with the
Hexagon Socket Head Cap Screws and T-Slot Nuts, into
the Support Prole. The T-Slot Nuts must be correctly
aligned when sliding into the relevant groove.
The rail is a total of 20mm shorter than the Support
Prole and must be centred, that is to say 10mm from
each edge. Furthermore, manual pressure must be
applied to keep the rail pressed permanently against
the stop edge while the screws are being tightened.
Tightening torque MT = 1.2Nm
When tightening the screws, apply manual pressure to keep the rail permanently pressed against the stop edge.

10
KGT 6 60 P20 – assembly guide
Fitting the magnetic strips
The next step is to t the magnetic strips that have been cut to size. These strips will subsequently hold the KGT’s steel strip in
place. They should be approximately 5mm longer than the Support Prole. Push the magnetic strips into the Support Prole
on the right-hand and left-hand sides.
Use an appropriate tool to remove any burrs from the prole’s insertion edge. Applying soapy water makes it easier to push in
the strips.
Once they have been tted, the magnetic
strips protrude by approximately 2.5mm at
both ends of the prole.
The ne groove in the magnetic strip should be pointing upwards when it is being tted.
Fitting the carriage
A ball screw drive (KGT) is used to move the Linear
Unit’s carriage. The xed combination of ball screw nut
and ball screw spindle makes the drive more precise.
Ball screw spindles are always tted with a ball screw
nut.
Under no circumstances should the ball screw nut be twisted off the spindle.

11
KGT 6 60 P20 – assembly guide
Push the spindle nut holder onto the spindle nut from
the sawn off, unmachined end of the spindle and screw
it in place on one side using the fastening plate and
screws.
Tightening torque MT = 1.2Nm
Now place the body of the carriage over the ball screw
drive and secure it in place.
Tightening torque MT: tighten by hand and then loosen
again by a ¼ turn
Ensure the relevant assembly aid of the Bearing Carriages (recirculating ball guide carriages) does not slip out. If this happens,
balls could be lost.
Place the two Bearing Carriages underneath the
carriage and also screw these in place.
Tightening torque MT: tighten by hand and then loosen
again by a ¼ turn
Next, push the side slide plates onto the spindle and
screw them to the body of the carriage using Counter-
sunk Screws.
Tightening torque MT = 0.6Nm
Now carefully push the body of the carriage along with
the assembled ball screw drive into the Support Prole,
with the Bearing Carriages sliding off their assembly
aid and directly onto the Linear Guide Rail.
Make sure no balls are lost.

12
KGT 6 60 P20 – assembly guide
The assembly aids should be pressed against the
Linear Guide Rail throughout the process.
Important: Balls can be lost, in which case the Bearing Carriage can no longer be used.
Next, screw the intermediate carriage plate securely
onto the body of the carriage using the eight Counter-
sunk Screws M4x10.
Tightening torque MT = 3Nm
Use the installed intermediate carriage plate to
align the moving carriage so that it is parallel with
and centred in relation to the Support Prole.
Then securely tighten the Bearing Carriage’s eight
Hexagon Socket Head Cap Screws.
Tightening torque MT = 1.5Nm
Number and positioning of spindle supports
Caution: The number and arrangement of the spindle supports included in the scope of supply depend on the stroke of
your Linear Unit KGT 6 60 P20. Regardless of how many are being tted, ensure the individual supports are inserted in the
correct order according to their numbering (black dots or numbers). Incorrect positioning can result in damage to the linear
axis and injuries.
Slide the spindle supports carefully into the prole from the right and left. The metal plates should always be facing out, away
from the carriage.

13
KGT 6 60 P20 – assembly guide
▪The numbers or black dots on the spindle supports identify the supports.
▪ The carriage is shown in the middle of the prole, which ensures the spindle supports can be slid into the prole in the
correct order from the right and left.
▪The stops, which are shown in grey and have already been installed, make it easier to arrange the spindle supports.
▪ The spindle supports are always tted with the metal plate on them facing out. To do this, slide them carefully in from the
relevant side. When inserted in the correct order, each support will slide past stops until it reaches its designated position,
where it will come to a halt against the appropriate stop.
3
4
2
1
1. Number, position and alignment of spindle supports in a stroke range of between 0 mm and 1000 mm:
4
1
4
2. Number, position and alignment of spindle supports in a stroke range of between 1001 mm and 1560 mm:
43
3 4
12
3. Number, position and alignment of spindle supports in a stroke range of between 1561 mm and 2120 mm:
3 4
2
2 3 4
123

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KGT 6 60 P20 – assembly guide
4. Number, position and alignment of spindle supports in a stroke range of between 2121 mm and 2600 mm:
1 2 3 4
1 2
1234
3 4
Fitting the xed and oating bearings
Pull out the tapered part of the spindle slightly from the
prole. Use a cloth to clean the cone of the spindle and
the cone of the xed bearing hub. Screw the xed bear-
ing and the spindle in place via the cone using Hexagon
Socket Head Cap Screw M5x25.
Tightening torque MT = 2.5Nm
Next, screw the xed bearing to the prole using the
four Hexagon Socket Head Cap Screws M5x20.
Tightening torque MT: tighten by hand and then loosen
again by a ¼ turn
Push the basic carriage structure up to the xed
bearing as far as the stop. The xed bearing can now
be aligned laterally so that it is parallel with the Support
Prole. Then tighten the four Hexagon Socket Head
Cap Screws M3x8 on the spindle holder.
Tightening torque MT = 1.2Nm
Now tighten the four screws that are still loose on the
xed bearing.
Tightening torque MT = 2.5Nm

15
KGT 6 60 P20 – assembly guide
Next, press the oating bearing onto
the sawn end of the spindleand screw it
onto the Support Prole using the four
Hexagon Socket Head Cap Screws M5x20.
Tightening torque MT: tighten by hand and then loosen
again by a ¼ turn
Now push the carriage up to the stop at the oating
bearing end and also align the oating bearing laterally
so that it is parallel with the Support Prole. Then
screw the oating bearing securely to the Support
Prole.
Tightening torque MT = 2.5Nm
Once everything has been properly tted and screwed into place, move the carriage over the entire length of the axis by hand,
checking the operation and smooth running of the guide, bearings and spindle supports.
Subsequently use a brush to apply a thin layer of Divinol Lithogrease G 421 over the entire length of the spindle.
Fitting the steel strip
Wear cut-resistant gloves to prevent injuries when installing the steel strip.
Fit the steel strip, which covers the spindle in the pro-
le. This strip should be approximately 12mm longer
than the Support Prole.

16
KGT 6 60 P20 – assembly guide
Start by threading the steel strip from
either end, from below, through the opening in the
intermediate carriage plate and pull it through approxi-
mately 200mm.
Fit the two guides – correctly aligned – onto the steel
strip. The correct alignment of the steel strip guides is
important and must be ensured.
Next, thread the steel strip out through the second
opening in the intermediate carriage plate and pull it as
far as the end of the Support Prole.
Secure the ends of the steel strip in the
bearing housings. The clamping plate screws need to
be loosened by three to four turns for this purpose.
Once the steel strip has been inserted, the clamping
plate’s Countersunk Screws can be tightened again.
MT = 0.6Nm
Ensure the strip is smoothed down over the entire length of the prole. There must be no creases or dents.

17
KGT 6 60 P20 – assembly guide
After that, screw on the carriage plate. Start by using
a mallet to t the Caps X 6 60x12. The carriage plate
must be aligned by hand so that it is centred on and
parallel with the carriage.
Tightening torque MT = 1.5Nm
Alternatively, a Transverse Carriage Plate can also be used to build a Linear Guide 6 60 PS Transverse Carriage.
First, use a mallet to t the Caps X 6 60x12. Centre the
Transverse Carriage Plate on the intermediate carriage
plate, ensuring both are parallel.
Tightening torque MT = 1.5Nm
Fitting Cover Prole LE 6
Lastly, install Cover Prole LE 6.
Cut the plastic prole to the appropriate length and slide it under the carriage to cover the special groove accommodating
Proximity Switches and their wiring.
Now move the carriage over the entire length of the prole. Listen/look out for any noises, rubbing or constrictions to check
whether the carriage is running and being guided on the axis free from any play.

18
KGT 6 60 P20 – assembly guide
Motor connection with Drive Set KGT 6 60
Servomotors from item can be connected directly to the linear axis with the help of the relevant Drive Sets. Motors from other
manufacturers can be adapted using the universal Drive Set 6 60 D30/D12. The ange plate must be adapted accordingly for
this purpose.
This example describes how to t Motor SE 60 using
Drive Set KGT 6 60 D30/D12 SE 60.
Start by inserting the expanding hub coupling half
into bore D12 of the Linear Unit and tightening the
expanding hub screw. The coupling half can be se-
cured in place using a second Allen key.
Tightening torque MT = 2.8Nm
Fit the Coupling Insert followed by Coupling Half
D30/D12 so that they are mounted ush on the
expanding hub coupling half. The clamping screw of
Coupling Half D30/D14 should be aligned as shown.

19
KGT 6 60 P20 – assembly guide
Now t the Coupling Housing and tighten it using the
four Hexagon Socket Head Cap Screws M4x40 so that
it is mounted ush with the xed bearing.
Tightening torque MT = 3Nm
Next, use the four Hexagon Socket Head Cap
Screws M4x12 to screw down the adapter plate for
Motor SE 60 so that it, too, is ush with the Coupling
Housing.
Tightening torque MT = 3Nm
Insert Motor SE 60 (the motor shown here) into the
Drive Set and secure it in place using the four Screws
M4x18.
Tightening torque MT = 3Nm
Four Hexagon Socket Head Cap Screws M4x10 are
used to secure Motor SE 40 (also available but not
shown here).
Tightening torque MT = 1.2Nm
Finally, tighten the clamping hub screw of Coupling Half
D30/D12 through the maintenance hole. Use a Cap to
seal the hole.
Tightening torque MT = 2Nm
If using a third-party motor, t this with the help of Drive Set KGT 6 60 - universal (0.0.704.53).
The installation process is as described above, except that the universal adapter plate must be machined to match the
third-party motor’s connection dimensions.

20
KGT 6 60 P20 – assembly guide
Motor connection with Parallel Drive Set 6 60
35
150
60
57.5
3
149.5
90
∅12
∅14
This example describes how to t Motor SE 60 with the help of Parallel Drive Set 6 60 D12-1 SE 60.
Parallel Drive Set 6 60 D12-1 SE 60 combines Linear Unit KGT 6 60 P20 with a Motor at an angle of 180°. The fact the drive
is positioned parallel to the Linear Unit means exceptionally space-saving applications can be realised.
A timing-belt drive ensures non-slip power transmission. As a plug-and-play solution, it requires no machining when using size
60 item Motors.
Maximum permissible torque of coupling – drive side: Mmax = 3.7Nm
E󹟠ciency: η = 1
The housing of the parallel drive set is screwed onto the xed bearing of the
linear unit KGT 6 60, only the smaller opening in the housing is designed to t
the xed bearing exactly.
Fastening elements are four ISO 7380-M4x16 half-round screws, tightening
torque MA=1,2Nm.
The expansion hub shaft is screwed into the xed bearing of the KGT, for this
purpose it is countered with the help of an open-end wrench when tightening.
Tightening torque of the expansion hub clamping screw MA=2,8 Nm.
Caution!
The clamping ring is now clamped onto the shaft of the 60‘s series motor.
Push the clamping ring onto the motor shaft and ensure a distance of 1mm
between the motor housing and the clamping ring.
Tightening torque of the clamping ring screw, MA=1,2Nm.