ITEM KLE 5 40x40 LR Operating instructions

Linear Unit KLE 5 40x40 LR
Notes on Use and Installation

2
Linear Unit KLE 5 40x40 LR – installation guide
Contents
Symbols, safety .......................................................................................................................................................................................................3
General safety information ...................................................................................................................................................................................3
Correct use ...............................................................................................................................................................................................................4
Improper use.............................................................................................................................................................................................................4
Product description.................................................................................................................................................................................................4
Technical data .........................................................................................................................................................................................................5
Preparing for installation........................................................................................................................................................................................6
Press-tting the Shafts ...........................................................................................................................................................................................7
Installing the carriage.............................................................................................................................................................................................7
Installing the Timing Belt .......................................................................................................................................................................................8
Installing the Timing-Belt Reverse Unit and drive assembly .........................................................................................................................9
Installing the carriage plate................................................................................................................................................................................ 10
Tensioning the Timing Belt................................................................................................................................................................................. 12
Drive Set ................................................................................................................................................................................................................. 13
Installing Drive Set KLE 5 40x40 AP/WP 40 ................................................................................................................................................ 14
Synchronisation..................................................................................................................................................................................................... 17
Accessories Linear Unit KLE 5 40x40 LR ...................................................................................................................................................... 18
Proximity Switch KLE 6 60x60 - 1NC.............................................................................................................................................. 18
Proximity Switch KLE 6 60x60 - 1NO ............................................................................................................................................. 18
Cover Prole 6 LE, grey similar to RAL 7042 ............................................................................................................................... 18
Prole Fastening Set 5 5/8 60x60 (0.0.718.36)......................................................................................................................... 19
Hand-Wheel D60 D12......................................................................................................................................................................... 19
Dealer conguration and spare parts list........................................................................................................................................................20
Checklist ................................................................................................................................................................................................................. 21
Repair and maintenance .................................................................................................................................................................................... 21
Care and cleaning.................................................................................................................................................................................................22
Disposal .................................................................................................................................................................................................................22
Product development and documentation ....................................................................................................................................................23

3
Linear Unit KLE 5 40x40 LR – installation guide
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 is likely to 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
General safety information
The details and information in this guide are provided for the purposes of describing the product and its installation 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 the product is
sold, rented out or otherwise passed on to another party, this guide must be handed over with it. You must therefore read and
follow the safety instructions set out below.
▪ All work on and with Linear Unit KLE 5 40x40 LR must be performed with “safety rst” in mind.
▪Switch off the power to Linear Unit KLE 5 40x40 LR 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.
Linear Unit KLE 5 40x40 LR, as described here, corresponds to the state of the art and takes into account the general
principles of safety applicable at the time this guide was published. Nevertheless, failure to observe the safety instructions and
warning notices in this 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 Linear Unit KLE 5
40x40 LR.

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Linear Unit KLE 5 40x40 LR – installation guide
Correct use
Linear Unit KLE 5 40x40 LR is a component and must only be used in accordance with the technical data and safety
requirements set out in this document. Combining Linear Unit KLE 5 40x40 LR with a motor and controller creates a partly
completed machine as dened in Machinery Directive 2006/42/EC. 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 Linear
Unit KLE 5 40x40 LR yourself. We will assume no liability for any resulting damage or injury. You may only install, operate and
maintain Linear Unit KLE 5 40x40 LR if:
▪Linear Unit KLE 5 40x40 LR has been integrated into its surroundings in a proper and safe manner.
▪You have carefully read and understood the guide.
▪ You are appropriately qualied.
▪You are authorised to do so by your company.
▪You are using only original equipment from the manufacturer.
Linear Unit KLE 5 40x40 LR is designed for indoor use.
Improper use
Improper use is dened as any use of the product for purposes other than those authorised in this guide and under the deni-
tion of correct use. We will assume no liability for any resulting damage or injury.
Product description
Linear Unit KLE 5 40x40 LR with roller guide and dynamic timing-belt drive is designed for operating loads of up to 150N. The
roller elements run from the Timing Belt and are concealed within the prole.
Linear Unit KLE 5 40x40 LR:
LS
L
B
B
SHS
A
Article A [mm] B [mm] s [mm] LS[mm] L [mm] Mass
0.0.710.86
(base unit) 50 60 23.5 140 H+320 1.289 kg
0.0.719.96 1.999 kg/m
H: Stroke

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Linear Unit KLE 5 40x40 LR – installation guide
Technical data
Maximum stroke: 2800mm
Mass per mm of stroke: 1.999kg/m
Repeatability: 0.1mm
Maximum acceleration: 10m/s²
Maximum speed: 5m/s
Feed: 90mm/revolution
Mounting dimension: 50mm x 40mm
Maximum operating load: 150N
L
x
y
z
Fz
Mz
Fx
Mx
Fy
My
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 KLE
5 40x40 LR 1050 1200 250 200 4 8 15 150
Ambient conditions:
Storage temperature: -20°C to +70°C
Relative humidity: 5% to 85%
Linear Unit KLE 5 40x40 LR is intended as a permanent xture to be used in an area that is protected from the weather.
Do not set up 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 Linear Unit KLE 5 40x40 LR should not exceed 1mm over an axis of 1000mm.

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Linear Unit KLE 5 40x40 LR – installation guide
Preparing for installation
Switch off the power to the system before carrying out any installation, cleaning or maintenance work on Linear Unit KLE 5
40x40 LR.
Preparations for installation:
▪ Total length of Linear Unit KLE 5 40x40 LR [mm]: L = H + 320mm
▪ Length of prole [mm]: LP = H + 200mm
▪ Length of Cover Prole [mm]: LA= LP
▪Shaft D6 [mm]: LW= LP - 2mm
▪Timing Belt [mm]: LZ= 2 x LP +140 mm
▪Stroke [mm]: H
LS
L
B
B
SHS
A
NOTE! Anti-slip aids should be placed underneath the axis during installation.
Safety gloves should be worn when installing the axis.
The rst step is to countersink the core bores on the
end face of Prole 5 40x40 KLE on both sides and give
them an M4x12 thread. The tap should have a helix to
prevent it from canting in the core hole.
The holes and the prole must then be thoroughly
cleaned of shavings.

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Linear Unit KLE 5 40x40 LR – installation guide
Press-tting the Shafts
The Shafts D6 (0.0.356.01) are pressed into the Support Prole. We recommend using a tool set (0.0.720.58).
Installing the carriage
The carriage is pre-assembled.
There is an extension spring on the bottom of the
carriage, and this must be tensioned.
The safety label is designed to prevent the Hexagon
Socket Head Cap Screws being loosened before instal-
lation, which would release the tension in the spring.
CAUTION! The safety label that covers three Hexagon Socket Head Cap Screws must only be removed after the carriage has
been installed in the prole.
The felt inserts of the End Cap and Lubricating System
are su󹟠ciently wetted with oil before installation
The felt inserts of the End Cap and Lubricating System
are pressed together carefully when the carriage is in-
serted into the support prole so they are not damaged
by the sharp cut edges of the prole.
CAUTION! Damaging the felt inserts will have a signicant impact on the service life of the Linear Unit.

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Linear Unit KLE 5 40x40 LR – installation guide
Once the carriage has been pushed into the prole,
remove the safety label. Signicant play can still be felt
on the carriage within the prole.
Loosen the Hexagon Socket Head Cap Screws, which
are now accessible. The tension in the pre-tensioned
spring will start to release, adjusting the two internal
rollers in the prole to eliminate play. Gently moving the
carriage will help this play-free setting up process.
Move the carriage along the entire length of the prole
to check how free of play it is.
Finally, undo the Hexagon Socket Head Cap Screws
fully and remove the carriage plate.
There are two other plates beneath the carriage plate.
These must both also be removed. Only the Dowel Pins
remain in the carriage body.
Installing the Timing Belt
The Timing Belt, which has already been cut to the
calculated length, is pushed into the lower section of
the prole designed for this purpose.
The back of the Timing Belt should face downwards,
with the teeth of the belt facing inwards.

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Linear Unit KLE 5 40x40 LR – installation guide
Position the Timing Belt so it protrudes evenly to the left and right.
Installing the Timing-Belt Reverse Unit and drive assembly
The Timing-Belt Reverse Unit and drive assembly are installed in the same way.
First screw the prole connecting plate onto the prole
using 2 Button-Head Screws M4x12.
MT=4Nm
Attention must be paid to the alignment of the mount-
ing plate, otherwise the further installation and function
of the Linear Unit will be impacted.
First push the Timing Belt into the bottom of the
Reverse Unit with the teeth pointing inwards, until it
comes out at the top of the Reverse Unit.

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Linear Unit KLE 5 40x40 LR – installation guide
Then pull the Reverse Unit towards the prole and
attach it to the prole from the inside using Hexagon
Socket Head Cap Screw M5x12.
MT=6Nm
Finally, press the enclosed black cap onto the head
of the screw. This cap serves as an impact buffer and
carriage bumper as required.
TIP! Push the carriage gently against the cap to push it
into place.
Installing the carriage plate
To connect the carriage with the Timing Belt, rst set
back the tension pulley of the Reverse Unit.
Do this by alternately screwing out the two tensioning
screws (M3) until the axis of the Return Pulley is in the
front section of the window.

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Linear Unit KLE 5 40x40 LR – installation guide
NOTE! Before you attach the Timing Belt, fold an ordinary piece of note paper over the belt to the right and left of the carriage.
This will anchor the belt in place and stop the Timing Belt from tilting or sliding during installation, while also ensuring
the Timing Belt is connected to the carriage centrally.
Now place the Timing Belt fully on the teeth of the
carriage.
If the Timing Belt is too long, it can be shortened.
Once the Timing Belt is in place on top of the carriage, use the pins to position the spacer plate, and then place the sensor
plate – the cruciform plate – on top of the spacer plate.

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Linear Unit KLE 5 40x40 LR – installation guide
Screw in the three Hexagon Socket Head Cap Screws M4x25 with the carriage plate on the plates.
Tightening torque: MT=5Nm
CAUTION! Before tensioning the Timing Belt, remove the paper that served as an installation aid.
Timing belt tension
CAUTION! The Timing Belt must be tensioned. Tensioning the Timing Belt has a signicant impact on the function and service
life of the Linear Unit.
NOTE! Thanks to a spring-mounted tensioning mechanism, the Timing Belt will be su󹟠ciently tensioned at its operating load
(150N) when the clamping screws on the Timing-Belt Reverse Unit are ush with the outer surface of the reverse
unit housing. If the Timing Belt is not su󹟠ciently tensioned, this will lead to skipping in the belt. If the Timing Belt is
tensioned too far, this will damage the Linear Unit.
Tension the Timing Belt by alternately tightening the
tensioning screws M3x30 in the housing of the Tim-
ing-Belt Reverse Unit.

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Linear Unit KLE 5 40x40 LR – installation guide
The Timing Belt is su󹟠ciently tensioned when the head
of the Hexagon Socket Head Cap Screws is ush with
the outer surface of the reverse unit housing.
The straight running of the Timing Belt should then
be checked. If necessary, the straight running can be
corrected by ne adjustment of the tensioning screws
M3x30.
CAUTION! Once you have tensioned the belt, run the carriage along the entire linear axis and check the system for smooth
operation, straight running and indications of collision.
Drive Set
There are several possible options for connecting a motor to Linear Unit KLE 5 40x40 LR.
Universal Connection Sets make it possible to connect a third-party motor.
Drive Set KLE 5 40x40 AP/WP 40 – 0.0.713.46
26
44
10
Ø10
60
50
10 34
Drive Set KLE 5 40x40 – 0.0.718.24 (universal)
20-26
44
10
Ø6-16
10 34
50
60
60

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Linear Unit KLE 5 40x40 LR – installation guide
Drive Set ZU 5 40x40 NEMA 24 – 0.0.717.14
10 34
50
60
60
□47.14 M4
20-26
44
10
Ø8
Installing Drive Set KLE 5 40x40 AP/WP 40
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. The ange plate must be adapted accordingly for this purpose.
In this example, Motor SE 40 and a Gearbox WP 40 are installed using Drive Set KLE 5 40x40 AP/WP 40.
First remove the four screws and nuts from the drive assembly. These will later be replaced by longer Hexagon Socket Head
Cap Screws that will secure the drive set housing. This does not affect the structure of the ready-for-use axis.

15
Linear Unit KLE 5 40x40 LR – installation guide
Insert the expanding hub coupling half into the
D12 bore of the Linear Unit and tighten the
expanding hub screw.
Tightening torque MT= 2.8Nm
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/D12 should be aligned as shown
and accessible from above.
Now put the Coupling Housing in position and screw it
into place through the casing of the Drive Unit and into
the coupling housing of the drive set using the Hexagon
Socket Head Cap Screws M4x45 supplied with the
Drive Set.
Tightening torque:MT= 3 Nm

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Linear Unit KLE 5 40x40 LR – installation guide
Next, use the four Hexagon Socket Head Cap
Screws M4x12 to screw down the adapter plate for
Motor SE 40 so that it, too, is ush with the Coupling
Housing.
Tightening torque MT= 3 Nm
In addition, screw the Connecting Plate onto the motor,
paying attention to the alignment of the centring
elements on both sides.
Place Motor SE 40 (the motor shown here) with
Gearbox WP 40 into the Drive Set and secure it in place
using the four Screws M4x10.
Tightening torque MT= 1.2 Nm
Before tightening the screws, ensure the Coupling
Housing, Adapter Plate, Reverse Unit motor and linear
axis are all aligned ush with each other.
Finally, tighten the clamping hub screw M3 of Coupling
Half D30/D12 through the maintenance hole. Use a
cap to seal the hole.
Tightening torque MT= 1.5 Nm

17
Linear Unit KLE 5 40x40 LR – installation guide
Synchronisation
Two Linear Units KL 5 40x40 LR can be connected to form a functional unit using Synchronising Set GSF 8 40 R10
(0.0.662.95). The synchroniser shaft (Tube D16x1.5 St, stainless – 0.0.664.14) transfers the motor’s torque to the second
drive unit.
The Tube St (sawn to length) turns the Synchronising
Set into complete synchronisation.
The permissible speed of a Synchroniser Shaft de-
pends on its length.
n = Rotary speed of the Synchroniser Shaft
a = Distance between Linear Units
CAUTION! The rotating synchronisation elements must be safely covered if they pose any kind of potential risk.
Synchroniser Shaft Cover Set KLE 5 40x40
(0.0.717.72) is a fastening for a protective housing
made from Conduit Proles U to safely cover a synchro-
niser shaft between two Linear Units KLE 5 40x40 LR
(0.0.710.86).
The Cover Set contains the Adapter Plates and the
fastening materials required. Conduit Prole U 40x40
E (7.0.001.44) and Cover Prole D40 E (7.0.001.46)
must be ordered separately
The required length of Conduit Prole U 40x40 E and
Cover Prole D40E is calculated based on the distance
a between the reverse units:
Prole length = a - 20

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Linear Unit KLE 5 40x40 LR – installation guide
Accessories Linear Unit KLE 5 40x40 LR
Proximity Switch KLE 6 60x60 - 1NC (0.0.604.41)
Proximity Switch KLE 6 60x60 - 1NO (0.0.609.31)
Inductive proximity switch, positive switching
Housing Al, anodized, natural
Fixing mechanism, xing screws
Voltage = 10…30 VDC
Maximum switching current = 150 mA
Sensing range = 2 mm
Cable, grey, l = 10 m; d = 3 mm
Cover Pro󰺔le 6 LE, grey similar to RAL 7042 (0.0.603.88)
The support prole of Linear Unit KLE 5 40x40 LR features two indentations running
along the top to accommodate Proximity Switch KLE and cables. These grooves are to
be sealed with cover proles to ensure a smooth, easy-to-clean surface.
To install, pass the Cover Prole, which has already been cut to the correct length, under the carriage then press it into the
groove. When doing so, the carriage should be close to a Reverse Unit so the Cover Prole does not have to be pushed too far.

19
Linear Unit KLE 5 40x40 LR – installation guide
Pro󰺔le Fastening Set 5 5/8 60x60 (0.0.718.36)
60
40
12
22
60
Prole Fastening Set 5 5/8 60x60 enables a friction-based connection between a
Linear Unit KLE 5 40x40 LR (0.0.710.86) and proles with a Line 5 or Line 8 groove.
Secure the Fastening Set in the groove. Then release the clamping jaws on the side,
push in the Linear Unit and retighten the screws.
Hand-Wheel D60 D12 (0.0.714.12)
Hand-Wheel D60 D12 can be used to operate linear axes with a D12 hollow shaft by hand.
This means adjustments can easily be made at a low torque.
Easy to install, the Hand-Wheel can be used both as an alternative to a motor in develop-
ment applications and for making manual adjustments in production applications. Featur-
ing a rotating cylindrical knob, the Hand-Wheel can transmit a torque of up to 3.7Nm.

20
Linear Unit KLE 5 40x40 LR – installation guide
Dealer conguration and spare parts list
5
2
4
3
66 7 7
1
The construction of a Linear Unit KLE 5 40x40 LR, the individual parts to be used and precongured sets of articles depend
largely on the stroke lengths selected.
Basic con󰺔guration and spare parts list for constructing Linear Unit KLE 5 40x40 LR
Ref. No. Article num-
ber Product name Comments
DA 10.0.711.36 Drive Unit KLE 5 40x40 1 set -
DA 20.0.717.82 Timing-Belt Reverse Unit KLE 5
40x40 1 set -
DA 30.0.710.87 Prole X 5 40x40 D6 1 pce., 6m cut-off: 0.0.710.95
DA 40.0.710.88 Carriage Set KLE 5 40x40 1 set with
safety closure
DA 50.0.711.41 Timing Belt R16 AT3 1 roll, 50m cut-off: 0.0.711.42
CA 60.0.453.75 Shaft D6, bare 1 pce., 3m cut-off: 0.0.356.01
CA 70.0.603.88 Cover Prole 6 LE, grey 1 pce., 2m cut-off: 0.0.605.10
Key:
▪CA: Catalogue article
▪DA: Dealer article