Kuka KL 1500-3 Assembly And Operating Instructions Manual
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Kuka KL 1500-3 Assembly And Operating Instructions Manual

Kuka KL 1500-3 Assembly And Operating Instructions Manual

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Linear Units
KUKA Roboter GmbH
KL 1500-3; KL 1500-3 T; KL 1500-3 S
Assembly and Operating Instructions
Serial Number 141215
Issued: 16.06.2010
Version: MA KL 1500-3 T S 141215 V1 en

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  • Page 1 Linear Units KUKA Roboter GmbH KL 1500-3; KL 1500-3 T; KL 1500-3 S Assembly and Operating Instructions Serial Number 141215 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 2 Publication: Pub MA KL 1500-3 T S 141215 en Book structure: MA KL 1500-3 T S 141215 V1.1 Label: MA KL 1500-3 T S 141215 V1 2 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 3: Table Of Contents

    Start-up and recommissioning ................5.5.4 Manual mode ......................5.5.5 Automatic mode ....................5.5.6 Maintenance and repair ..................5.5.7 Decommissioning, storage and disposal .............. Applied norms and regulations .................. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 3 / 151...
  • Page 4 11.4 Exchanging the upper/lower rollers without using the auxiliary device ...... 11.4.1 Removing the upper/lower rollers ................. 11.4.2 Installing the upper/lower rollers ................11.5 Exchanging the side rollers ..................11.5.1 Removing the side rollers ..................4 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 5 15.1.1.11Toxicological information ..................15.1.1.12Ecological information ................... 15.1.1.13Disposal information ..................... 15.1.1.14Transport information .................... 15.1.1.15Regulations ......................15.1.1.16Other information ....................15.1.2 Safety data sheet for Microlube GL 261 lubricating grease ........Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 5 / 151...
  • Page 6 15.1.3.12Ecological information ..................15.1.3.13Disposal information ..................... 15.1.3.14Transport information ................... 15.1.3.15Regulations ......................15.1.3.16Other information ....................KUKA Service ....................16.1 Requesting support ....................16.2 KUKA Customer Support ................... Index ......................6 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 7: Introduction

    Notes marked with this pictogram contain tips to make your work easier or ref- erences to further information. Tips to make your work easier or references to further information. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 7 / 151...
  • Page 8 KL 1500-3; KL 1500-3 T; KL 1500-3 S 8 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 9: Purpose

    Knowledge of the robot controller system For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training pro- gram can be found at www.kuka.com or can be obtained directly from our subsidiaries.
  • Page 10 KL 1500-3; KL 1500-3 T; KL 1500-3 S 10 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 11: Product Description

    KR 150 to KR 270 (Series 2000); with pedestal The linear unit consists of the following components (>>> Fig. 3-1): Beam Carriage Drive assembly Energy supply system Fig. 3-1: Structure of the linear unit Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 11 / 151...

  • Page 12: Description Of The Beam

    The tracks and racks are screwed onto the beam. Fig. 3-2: Beam Cover Buffer Track Connecting assembly Beam Mounting base 12 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 13: Description Of The Carriage

    The drive assembly is fastened to the carriage via the intermediate plate. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 13 / 151...

  • Page 14: Description Of The Energy Supply System

    Fig. 3-5) below shows the two variants for attaching the energy supply system. These depend on the travel (H) of the carriage and on the chain width (BK). 14 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 15 The trough system is fastened via the C-profiles to the floor using chemical anchors. Fig. 3-6: Trough system (example) Carriage C-profiles Driver Trough Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 15 / 151...

  • Page 16: Design Of The Linear Unit

    Options 3.2.1 Working range monitoring The linear unit may optionally be fitted with working range monitoring. 16 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 17: Technical Data

    4 carriages Valid for robots KR 30 to KR 125, KR 150, KR 200, KR 360, KR 500 KR 150 to KR 270 (Series 2000) Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 17 / 151...

  • Page 18: Principal Dimensions

    233 K to 333 K (-40 °C to +60 °C) tation Humidity rating Humidity class EN 60204/4.4.4 F Principal dimensions Linear unit Fig. 4-1: Principal dimensions, cross-section 18 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 19 4. Technical data Fig. 4-2: Principal dimensions Rated travel + 1840 mm Effective travel Spacing of the mounting bases, dependent on the travel Carriage Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 19 / 151...
  • Page 20 KL 1500-3; KL 1500-3 T; KL 1500-3 S Fig. 4-3: Mounting face for KR 30 to KR 500 M24 tapped hole, 24x M8 tapped hole, 8x 20 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 21 4. Technical data Fig. 4-4: Mounting face for KR 30 to KR 500, robot mounted at 45° M24 tapped hole, 24x M8 tapped hole, 8x Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 21 / 151...

  • Page 22: Plates And Labels

    The following plates and labels (>>> Fig. 4-6) are attached to the linear unit. They must not be removed or rendered illegible. Illegible plates and labels must be replaced. 22 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 23 4. Technical data Fig. 4-6: Plates and labels Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 23 / 151...

  • Page 24: Order-Specific Technical Data

    KL 1500-3; KL 1500-3 T; KL 1500-3 S Order-specific technical data 4.4.1 Principal dimensions 24 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 25 4. Technical data Fig. 4-7: Principal dimensions, serial no. 141215 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 25 / 151...
  • Page 26 KL 1500-3; KL 1500-3 T; KL 1500-3 S Fig. 4-8: Mounting bases, racks, covers; serial no. 141215 26 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 27: Safety

    No modifications may be carried out to the industrial robot without the author- ization of KUKA Roboter GmbH. Additional components (tools, software, etc.), not supplied by KUKA Roboter GmbH, may be integrated into the industrial ro- bot. The user is liable for any damage these components may cause to the in- dustrial robot or to other material property.

  • Page 28: Intended Use Of The Industrial Robot

    The declaration of incorporation declares that the start-up of the partly com- pleted machinery remains impermissible until the partly completed machinery has been incorporated into machinery, or has been assembled with other parts 28 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 29: Terms Used

    Danger zone The danger zone consists of the workspace and the stopping distances. The KCP (KUKA Control Panel) teach pendant has all the operator con- trol and display functions required for operating and programming the industrial robot.
  • Page 30 The tasks can be distributed as shown in the following table. System Tasks Operator Programmer integrator Switch robot controller on/off Start program Select program Select operating mode Calibration (tool, base) Master the manipulator Configuration 30 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 31: Workspace, Safety Zone And Danger Zone

    Fig. 5-1: Example of axis range A1 Workspace Stopping distance Manipulator Safety zone Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 31 / 151...

  • Page 32: Overview Of Protective Equipment

    If the manipulator or an external axis hits an obstruction or a buffer on the me- chanical end stop or axis range limitation, this can result in material damage to the industrial robot. KUKA Roboter GmbH must be consulted before the industrial robot is put back into operation (>>>...

  • Page 33: Release Device (Optional)

    If work is to be carried out on a switched-off industrial robot, the manipulator and external axes must first be Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 33 / 151...
  • Page 34 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. 34 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 35: Transportation

    Warning! If additional components (e.g. cables), that are not part of the scope of supply of KUKA Roboter GmbH, are integrated into the industrial robot, the user is responsible for ensuring that these components do not adversely affect or disable safety functions.

  • Page 36: Manual Mode

    If it is necessary for there to be several persons inside the safeguarded ar- ea, the following must be observed: Each person must have an enabling device. All persons must have an unimpeded view of the industrial robot. 36 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 37: Automatic Mode

    The EMERGENCY STOP systems must remain active. If safety functions or safeguards are deactivated during maintenance or repair work, they must be reactivated immediately after the work is completed. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 37 / 151...

  • Page 38: Decommissioning, Storage And Disposal

    5.5.7 Decommissioning, storage and disposal The industrial robot must be decommissioned, stored and disposed of in ac- cordance with the applicable national laws, regulations and standards. 38 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 39: Applied Norms And Regulations

    2007 Part 6-4: Generic standards; Emission standard for indus- trial environments EN 60204-1 Safety of machinery: 2006 Electrical equipment of machines - Part 1: General requirements Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 39 / 151...
  • Page 40 KL 1500-3; KL 1500-3 T; KL 1500-3 S 40 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 41: Planning

    B25 according to DIN 1045:1988 C20/25 according to DIN EN 206-1:2001/DIN 1045-2:2001 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 41 / 151...

  • Page 42: Foundation Data

    “Foundation loads 1” and “Foundation loads 2”. These are the maximum values acting on one plate. Fig. 6-2: Loads acting on the foundation 42 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 43 Vertical force dynamic 17,900 N 23,100 N 36,800 N (pressure on concrete) Vertical force dynamic (pressure on 35,600 N 60,390 N 60,390 N concrete during E- STOP) Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 43 / 151...

  • Page 44: Mounting Base Variants

    These depend on the robot type. The number of chemical anchors required per mounting base are spec- ified in the following table. 44 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 45 8x M20, without Dynamic Set (optional) mounting base Number of chemical 12x M16, with Dynamic Set anchors per mounting base 8x M20, without Dynamic Set (optional) at the beam joint Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 45 / 151...
  • Page 46 6x M16 Fig. 6-4: Mounting base, 6x M16 Borehole depth Distance to edge of foundation Thickness of concrete, without Weld seams screed Concrete foundation, free from cracks 46 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 47 The beam joint is the point at which two beams are joined end to end. Special mounting bases are used at this position. beam joint, 8x M16 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 47 / 151...
  • Page 48 Fig. 6-6: Mounting base, beam joint, 8x M16 Borehole depth Distance to edge of foundation Thickness of concrete, without Weld seams screed Concrete foundation, free from cracks 48 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 49 12x M16 Fig. 6-7: Mounting base, beam joint, 12x M16 Borehole depth Distance to edge of foundation Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 49 / 151...

  • Page 50: Connecting Cables And Interfaces

    The length of the connecting cables between the robot controller and the ro- bot must not exceed 50 m. If Safe robots are used, the cable length must not exceed 35 m. 50 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 51 The interfaces are equipped with connections systems for cables and hoses depending on the application. Detailed information on the connector pin allocation, threaded unions, etc. is given in separate documen- tation. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 51 / 151...
  • Page 52 KL 1500-3; KL 1500-3 T; KL 1500-3 S 52 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 53: Transportation

    Fig. 7-1), the beam must be picked up at its center of gravity in order to prevent it from toppling. Fig. 7-1: Transportation by fork lift truck Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 53 / 151...

  • Page 54: Transportation By Crane

    Additional safeguarding measures must be taken. It is forbidden to pick up the beam in any other way using a crane! Fig. 7-2: Transportation by crane 54 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 55: Start-Up And Recommissioning

    8. Allow the resin to cure. See table, or as specified by manufacturer. These values are guide values. Temperature Time ≥293 K (+20 °C) 20 minutes ≥283 K (+10 °C) 30 minutes Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 55 / 151...

  • Page 56: Installing A Linear Unit With A One-Piece Beam

    The site of installation must be accessible with a fork lift truck or with a crane. Observe the minimum payload capacity. Procedure 1. Lower the linear unit with bolted-on strips (>>> Fig. 8-2) (4) onto the plates. 56 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 57: Removing Linear Unit With One-Piece Beam

    Removing linear unit with one-piece beam Preconditions The removal site is accessible with a fork lift truck or with a crane. Observe the minimum payload capacity. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 57 / 151...

  • Page 58: Installing A Linear Unit With A Beam Made Up Of Several Parts

    The connecting cables and energy supply system cables are installed on the system side. The site of installation must be accessible with a fork lift truck or with a crane. Observe the minimum payload capacity. 58 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 59 9. Fit the removed rack, together with the track cover, and fasten it with M12x80-8.8 hexagon bolts and lock washers. 10. Lightly tighten the M12x80-8.8 hexagon bolts. Fig. 8-4: Installation Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 59 / 151...
  • Page 60 16. Tighten the hexagon nut (10) with a torque of M = 370 Nm. 17. Remove protective coatings from the tracks and re-oil them. 18. Remove protective coatings from the racks and re-grease them. 60 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 61: Removing A Linear Unit With A Beam Made Up Of Several Parts

    10. If the linear unit is not to be reinstalled, it must be protected against corro- sion in accordance with (>>> 13 "Decommissioning, storage and dispos- al" page 103) before being put into storage. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 61 / 151...

  • Page 62: Installing The Energy Supply System

    50 m. If Safe robots are used, the cable length must not exceed 35 m. Procedure 1. Assemble the trough system (>>> Fig. 8-7). 62 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 63 15. Shut down the linear unit and the robot and lock them. Fig. 8-7: Energy supply system, short travel Carriage C-profiles Driver Trough Energy supply chain Fixed point module Screw anchor Connecting cables Trough system Connector plate Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 63 / 151...

  • Page 64: Removing The Energy Supply System

    See the assembly instructions from IGUS. Fig. 8-8: Energy supply system, short travel Carriage C-profiles Driver Trough Energy supply chain Fixed point module Screw anchor Connecting cables Trough system Connector plate 64 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 65: Maintenance

    Caution! Only lubricants approved by KUKA Roboter GmbH may be used. Maintenance Lubricate with brush symbols Tighten screw/nut Check component, visual inspection Fig. 9-1: Maintenance work Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 65 / 151...

  • Page 66: Cleaning The Linear Unit

    Warn all persons concerned before putting it back into operation. Procedure 1. Shut down the linear unit and the robot and lock them. 2. Stop adjacent system components and lock them. 66 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 67 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. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 67 / 151...
  • Page 68 KL 1500-3; KL 1500-3 T; KL 1500-3 S 68 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 69: Adjustment

    If work is carried out immediately after the linear unit has stopped operating, there is liable to be an elevated surface temperature at the motors. The ap- propriate safety measures must be taken. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 69 / 151...

  • Page 70: Measuring The Backlash

    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. 10-3: Measuring device (schematic) Carriage Dial gauge 70 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 71: Adjusting The Backlash

    Fig. 10-5). By turning the eccen- tric with a torque wrench it is possible to position the eccentric roller (E) on the track in a defined manner. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 71 / 151...
  • Page 72 For tightening torques, see the following table. Roller Eccentric Hexagon nut Ø72 22 Nm 150 Nm Ø110 55 Nm 380 Nm 72 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 73: Repair

    6. If the drive assembly is not to be reinstalled, it must be protected against corrosion before being put into storage. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 73 / 151...

  • Page 74: Installing The Drive Assembly

    4. Insert the eccentric and the M16x55-10.9 Allen screw (5) together with lock washer and lightly tighten. 5. Remove the lifting tackle. 6. Adjust the backlash (>>> 10.1.2 "Adjusting the backlash" page 71). 74 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 75: Exchanging The Servomotor

    The servomotor must not be tilted. The orientation of the servomotor is iden- tified from the position of the sockets. When the motor unit is installed, these sockets must be positioned in the same way as before removal. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 75 / 151...

  • Page 76: Removing The Servomotor

    Connector XM7, motor cable Connector XP7, control cable 11.2.2 Installing the servomotor Preconditions The protective coatings and oil have been removed from the new servo- motor. 76 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 77 6. Tighten the four M12x30-8.8 Allen screws (3) with a torque of M = 78 Nm. 7. Remove the lifting tackle. 8. Install the drive assembly as described in Section (>>> 11.1.2 "Installing the drive assembly" page 74). Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 77 / 151...

  • Page 78: Exchanging The Upper/Lower Rollers Using The Auxiliary Device

    The fixed bearing side is the side on which the drive engages with the rack. The type of wheel bearing is indicated on the end face of the square of each roller. 78 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 79 If the carriage is on the auxiliary device, the remaining three rollers are not guided by a track. These three rollers are freely accessible for exchange work. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 79 / 151...

  • Page 80: Installing The Auxiliary Device

    6. Mount the auxiliary device on the track and fasten it using two M20x80-8.8 hexagon bolts (11) and lock washers. Tighten the hexagon bolts with a torque of M = 370 Nm. 7. Exchange the rollers. 80 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 81: Removing The Auxiliary Device

    The track cover on the fixed bearing side can only be installed once all work is completed and the bar with the crash elements has been installed. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 81 / 151...

  • Page 82: Converting The Auxiliary Device

    5. Mount the auxiliary device on the track and fasten it using two M20x80-8.8 hexagon bolts (11) and lock washers. Tighten the hexagon bolts with a torque of M = 370 Nm. 82 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 83: Removing The Upper/Lower Rollers

    Procedure 1. Remove the drive assembly as described in Section (>>> 11.1.1 "Removing the drive assembly" page 73). Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 83 / 151...

  • Page 84: Installing The Upper/Lower Rollers

    6. Secure the carriage again so that it cannot be moved unintentionally. 7. Remove the auxiliary device as described in Section (>>> 11.3.2 "Removing the auxiliary device" page 81). 84 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 85: Exchanging The Upper/Lower Rollers Without Using The Auxiliary Device

    The fixed bearing side is the side on which the drive engages with the rack. The type of wheel bearing is indicated on the end face of the square of each roller. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 85 / 151...

  • Page 86: Removing The Upper/Lower Rollers

    2. Loosen the hexagon nut of the roller (upper or lower) to be removed, and remove the nut and lock washers. 3. Pull the roller (upper or lower) intended for removal inwards and out of the carriage. 86 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 87: Installing The Upper/Lower Rollers

    Lower eccentric roller (E), floating bearing side fixed bearing side Upper centric roller (Z), float- Track, fixed bearing side ing bearing side Carriage Track, floating bearing side Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 87 / 151...

  • Page 88: Removing The Side Rollers

    No gap should be visible between the centric roller and the track. An eccentric roller (E) is installed as follows: Insert the eccentric roller (E). Fit the lock washer and tighten the hexagon nut by hand. 88 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 89: Exchanging The Carriage

    Fig. 11-15: Upward removal/installation Carriage on the edge of the arrangement Track Carriages within the arrangement Beam Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 89 / 151...

  • Page 90: Lateral Removal Of Carriage

    Procedure 1. Fasten the carriage to the lifting tackle using four M28 DIN580 eyebolts. 2. Move the carriage onto the tracks from the side. 90 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 91: Removing The Carriage From Above

    6. Move all carriages (>>> Fig. 11-16) away from this track. The carriage to be removed must be situated to the side of the track to be removed. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 91 / 151...
  • Page 92 18. Fasten the carriage to the lifting tackle using four M28 DIN 580 eyebolts. 19. Slightly raise the carriage. 20. Remove the motion safeguards from the carriage. 21. Move the carriage into the area of the removed track segments. 92 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 93: Installing The Carriage From Above

    17. Using lifting tackle and lifting magnet, insert the track segment situated op- posite (Floating bearing side) into the correct installation position on the beam. 18. Insert the two outermost M20x55-8.8 hexagon bolts and lock washers by hand. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 93 / 151...
  • Page 94 27. Install the robot in accordance with the operating instructions. 28. Carry out zero adjustment. Further information about mastering is contained in the operating and pro- gramming instructions for the KUKA System Software. 94 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 95: Electrical Installations

    (optional) ground conductor, energy supply chain (optional) The carriage installations comprise: one control cable A7, XP7 ground conductors (carriage - robot, beam - connector plate) Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 95 / 151...
  • Page 96 Connector X31 X31.1 Resolver and temperature monitoring for axes 1 to 8 Motor cable A7 Connector Connector XM7 XM7.1 Motor, brake and PE for axis 7 96 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 97: Cabling Diagrams

    (optional) Ground conductor, carriage Ground conductor, beam Robot A1 to A6 Ground conductor, controller Control cable A7, XP7 Peripheral cables (optional) Motor cable A7, XM7 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 97 / 151...
  • Page 98 KL 1500-3; KL 1500-3 T; KL 1500-3 S Fig. 12-3: Connecting cable, motor cable X30.1 - X30 98 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 99 12. Electrical installations Fig. 12-4: Connecting cable, data cable X31.1 - X31 Fig. 12-5: Connecting cable, motor cable XM7.1 - XM7 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 99 / 151...
  • Page 100 Fig. 12-7: Ground conductor, energy supply chain (optional) M8 ring cable lug Conical spring washer PE bolt M8 tapped hole M8 nut M8 nut Cable lug Ground plate Conical spring washer 8.4 washer 100 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 101: Electrical Installations, Options

    The Multibus cable has plug-and-socket connections, which enables it to be quickly and reliably exchanged. The plugs and sockets are provided with iden- tification labels. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 101 / 151...
  • Page 102 Fig. 12-9: Cabling plan and pin allocation diagram Connector plate Carriage Energy supply chain Multibus cable Wiring diagram Fig. 12-10: Connecting cable, Multibus X71.1 - X71 (optional) 102 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 103: Decommissioning, Storage And Disposal

    9. Lift off the beam and transport it away. In the case of a multi-piece beam, the beam sections must be transported individually. 10. Prepare the beam for storage. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 103 / 151...

  • Page 104: Storage

    Observe and comply with the permissible temperature ranges for storage. See Section (>>> 4 "Technical data" page 17). Select a storage location in which the covers cannot be damaged. Procedure 1. Remove tools and equipment. 104 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 105: Disposal

    123) Lubricating grease Gear teeth See safety data sheet, consumables (>>> 15.1 "Safety data sheets" page 123) Hinged clamps O-rings FKM (fluorocarbon Shaft sealing rings rubber) Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 105 / 151...
  • Page 106 KL 1500-3; KL 1500-3 T; KL 1500-3 S 106 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 107: Options

    For working range monitoring with a per- sonnel protection function, the wiring beyond the interface must be of failsafe design, and is the sole responsibility of the user. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 107 / 151...

  • Page 108: Technical Data

    See (>>> Fig. 14-3) for installation di- mensions. 3. Mount the cams, align them and tack-weld them in place. Observe the cor- rect installation dimensions. 108 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 109 6. Mount the position switches on the holder, and check the installation posi- tion of the actuating levers. Fig. 14-3: Installation dimensions Energy supply chain side Drive side Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 109 / 151...

  • Page 110: Adjusting The Working Range Monitoring

    Warning! Shut down the linear unit and provide a safeguard to prevent it from being switched on again by unauthorized personnel. 110 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 111 The distance between the center of the fastening screws on the switch hous- ing and the upper edge of the cam must not be less than 52 mm. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 111 / 151...
  • Page 112 Fig. 14-6) between the position switch and cam. Warning! The height offset must not exceed ± 2 mm. Otherwise there is a risk of incor- rect actuation. 112 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 113: Maintenance Instructions

    14.1.4 Maintenance instructions Preconditions Under normal ambient conditions, maintenance should be carried out on the working range monitoring with position switches every three months. In partic- Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 113 / 151...

  • Page 114: Electrical Installations

    Check cables for wear. Replace damaged cables; if neces- sary, change routing of cables. 14.1.5 Electrical installations Fig. 14-7: One monitoring range, personnel protection Actuating lever 114 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 115 (>>> Fig. 14-9). The cables enter the surface-mounted housing through a Pg gland. Fig. 14-9: Connection of the position switch cables to the surface-mount- ed housing Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 115 / 151...
  • Page 116 The individual cables and the dummy posts must have a diameter of approx. 7 mm to ensure that the sealing inserts provide a proper seal. The ground conductors are connected to the respective ground conductor connection bracket. 116 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 117 14. Options Connection diagram Fig. 14-10: Wiring diagram for carriage Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 117 / 151...

  • Page 118: Connecting Cables For Working Range Monitoring

    A1 (optional) X37.1 Control cable for working range Connector Connector X39 monitoring A7 (optional) X39.1 Control cable for working range Connector Connector X40 monitoring A7 (optional) X40.1 118 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 119: Cabling Diagrams

    Energy supply chain Carriage Multi-position proximity switch Control cable, range monitoring A1, X37 (optional) Control cable, range monitoring A7, X39 (optional) Control cable, range monitoring A7, X40 (optional) Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 119 / 151...
  • Page 120 KL 1500-3; KL 1500-3 T; KL 1500-3 S Fig. 14-12: Cabling plan for control cable, working range monitoring A1, X37 (optional) Not assigned 120 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 121 14. Options Fig. 14-13: Cabling plan for control cable, working range monitoring A7, X39 (optional) Energy supply chain Carriage Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 121 / 151...
  • Page 122 KL 1500-3; KL 1500-3 T; KL 1500-3 S Fig. 14-14: Cabling plan for control cable, working range monitoring A7, X40 (optional) Energy supply chain Carriage 122 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 123: Appendix

    May cause mild eye irritation. Eyes: Can dry out the skin and lead to irritation and/or dermatitis. Skin: Allergic reactions are possible in the worst case. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 123 / 151...

  • Page 124: First Aid Measures

    Hazardous decomposition oxides). products: Unusual fire/explosion hazards: Special fire-fighting measures: Fire-fighters must wear self-contained positive pressure breath- Protection of fire-fighters: ing apparatus (SCBA) and full protective gear. 124 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 125: Measures After Unintended Release

    Wear appropriate clothing to avoid prolonged skin contact. Skin and body: 15.1.1.9 Physical and chemical properties Grease Physical state: Black Color: Oily Odor: Density: <1000 kg/m (<1 g/cm ) at 20 °C Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 125 / 151...

  • Page 126: 10Stability And Reactivity

    Unused product Waste code 12 01 12*: Used waxes and greases European Waste Catalog (EWC): 126 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 127: 14Transport Information

    Technical Guideline on Air: 1, Annex no. 3 Classification acc. to the German Administrative Regulation on the Classification of Substances Hazardous to Water into Water Hazard Classes (VwVwS): Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 127 / 151...

  • Page 128: 16Other Information

    The product may only be used for the scope of work specified above; any other use requires prior consultation with KUKA. Using the product for any purpose other than for its designated use could lead to risks which are not described in this document.

  • Page 129: First Aid Measures

    Decomposition products include various oxides (e.g. carbon Hazardous decomposition oxides). products: This product is not inherently explosive in accordance with the Unusual fire/explosion applicable rules. hazards: Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 129 / 151...

  • Page 130: Measures After Unintended Release

    Sufficient ventilation is recommended in industry. If ventilation is Respiratory protection: insufficient, respiratory protection is useful. Wear chemical-resistant gloves (recommended: nitrile gloves) if Hand protection: prolonged or repeated contact is likely. 130 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 131: Physical And Chemical Properties

    The product can be separated by mechanical means. Persistence / degradability: The product is insoluble in water. Mobility: Prevent from entering wastewater and soil. Environmental hazards: Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 131 / 151...

  • Page 132: 13Disposal Information

    The product may only be used for the scope of work specified above; any other use requires prior consultation with KUKA. Using the product for any purpose other than for its designated use could lead to risks which are not described in this document.

  • Page 133: Composition / Information About The Components

    Change clothing and shoes if they become Skin contact: contaminated with product. Wash clothing before reuse. Clean shoes thoroughly before reuse. If irritation occurs consult a doc- tor. Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 133 / 151...

  • Page 134: Fire-Fighting Measures

    Use suitable protective equipment. Prevent the product from entering the drainage system, surface Environmental protection waters and soil. Notify the competent authorities, if required. measures: 134 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 135: Handling And Storage

    Eye protection: Wear appropriate clothing to avoid prolonged skin contact. Skin and body: 15.1.3.9 Physical and chemical properties Liquid Physical state: Dark brown (amber) Color: Specific Odor: Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 135 / 151...

  • Page 136: 10Stability And Reactivity

    Use only approved transporters, recy- clers, treatment, storage or disposal facilities. If necessary, dis- waste specifications: posal should be entrusted to a recognized waste disposal company. 136 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 137: 14Transport Information

    R66 - Repeated exposure may cause skin dryness or cracking. Miscellaneous provisions 2 (S) Classification acc. to the German Administrative Regulation on the Classification of Substances Hazardous to Water into Water Hazard Classes (VwVwS): Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 137 / 151...

  • Page 138: 16Other Information

    The product may only be used for the scope of work specified above; any other use requires prior consultation with KUKA. Using the product for any purpose other than for its designated use could lead to risks which are not described in this document.

  • Page 139: Kuka Service

    The KUKA Roboter GmbH documentation offers information on operation and provides assistance with troubleshooting. For further assistance, please con- tact your local KUKA subsidiary. Faults leading to production downtime should be reported to the local KUKA subsidiary within one hour of their occurrence. Information...
  • Page 140 Tel. +86 21 5922-8652 Fax +86 21 5922-8538 Franz.Poeckl@kuka-sha.com.cn www.kuka.cn Germany KUKA Roboter GmbH Zugspitzstr. 140 86165 Augsburg Germany Tel. +49 821 797-4000 Fax +49 821 797-1616 info@kuka-roboter.de www.kuka-roboter.de 140 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 141 KUKA Robot Automation Korea Co. Ltd. 4 Ba 806 Sihwa Ind. Complex Sung-Gok Dong, Ansan City Kyunggi Do 425-110 Korea Tel. +82 31 496-9937 or -9938 Fax +82 31 496-9939 info@kukakorea.com Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 141 / 151...
  • Page 142 Spólka z ograniczona odpowiedzialnoscia Oddzial w Polsce Ul. Porcelanowa 10 40-246 Katowice Poland Tel. +48 327 30 32 13 or -14 Fax +48 327 30 32 26 ServicePL@kuka-roboter.de 142 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 143 Pol. Industrial Torrent de la Pastera Carrer del Bages s/n 08800 Vilanova i la Geltrú (Barcelona) Spain Tel. +34 93 8142-353 Fax +34 93 8142-950 Comercial@kuka-e.com www.kuka-e.com Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 143 / 151...
  • Page 144 Fax +420 22 62 12 27 0 support@kuka.cz Hungary KUKA Robotics Hungaria Kft. Fö út 140 2335 Taksony Hungary Tel. +36 24 501609 Fax +36 24 477031 info@kuka-robotics.hu 144 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 145 Tel. +1 866 8735852 Fax +1 586 5692087 info@kukarobotics.com www.kukarobotics.com KUKA Automation + Robotics Hereward Rise Halesowen B62 8AN Tel. +44 121 585-0800 Fax +44 121 585-0900 sales@kuka.co.uk Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 145 / 151...
  • Page 146 KL 1500-3; KL 1500-3 T; KL 1500-3 S 146 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...

  • Page 147: Index

    Crash elements 12 General safety measures 33 Danger zone 29 Handling equipment 53 Declaration of conformity 28 Hazardous substances 38 Declaration of incorporation 27, 28 Humidity rating 18 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 147 / 151...
  • Page 148 Technical data, order-specific 24 Principal dimensions 18, 24 tender carriage 12 Principal dimensions linear unit 18 Terms used, safety 29 Principal dimensions of the carriage 19 Training 9 148 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 149 User 29, 30 Users 9 Warnings 7 Working range limitation 32 Working range monitoring 16 Working range monitoring, adjustment 110 Working range monitoring, welded 107 Workspace 29, 31 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 149 / 151...
  • Page 150 KL 1500-3; KL 1500-3 T; KL 1500-3 S 150 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en...
  • Page 151 KL 1500-3; KL 1500-3 T; KL 1500-3 S Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en 151 / 151...

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