ZF DUOPLAN 2K120, Operating Instructions Manual

Page 1: ...Operating Instructions ZF DUOPLAN Two speed Gearbox 2K120 2K121 Industrial Drives...

Page 2: ...fen AG This document is protected by copyright Complete or partial reproduction or dissemination of this document is prohibited without the consent of ZF Friedrichshafen AG Infringements lead to civil...

Page 3: ...14 4 2 3 Motor shafts hubs without keyways 15 4 3 Adaptation motor gearbox 16 4 3 1 Open design 16 4 3 2 Closed design with hub bearing and shaft sealing ring 17 4 3 3 Closed version with shaft seal 1...

Page 4: ...tion 32 5 1 Initial inspection 32 6 Maintenance 32 6 1 Oil change 32 7 Repair 33 7 1 Gearbox fault checklist 33 7 2 Gearbox disassemble 34 7 3 Input hub with fitted key 34 7 4 Disassembly of gearbox w...

Page 5: ...according to ISO VG 68 1 0 1 4 Gearbox oil for splash lubrication 2K120 Installation position B5 2K121 Installation position B5 Can also be used for recirculating lubrication and recirculating lubric...

Page 6: ...concerning special workflows methods application of auxiliary materials etc 2 2 General safety instructions Read all safety instructions and information Failure to comply with safety instructions and...

Page 7: ...ntally Attach information sign in a clearly visible position Perform work when motor is switched off Protect motor against being started accidentally Attach information sign in a clearly visible posit...

Page 8: ...specific safety instructions Remove any traces of old seals or gaskets from mating faces Burrs or other similar rough surfaces are to be carefully removed with an oil stone Carefully cover opened gea...

Page 9: ...increase or speed reduction is required The gearboxes have coaxial output and are suitable for the high speeds generated in machine tool construction 3 2 Features Two speed gearboxes for AC and DC ma...

Page 10: ...with radial shaft seal 3 and hub bearings 4 as necessary Housing Gearbox housing 5 Input Sun gear 6 Ring gear 7 Ring gear bearings 8 Output Bearing housing 9 Output bearings 10 11 Output shaft 12 Rad...

Page 11: ...sible output torques Braking times must be adjusted accordingly Standard fixing dimension in mm in accordance with EN 50347 2001 Two speed gearbox 2K120 FF215 2K121 FF265 Motor size 100 112 h 100 112...

Page 12: ...tions Horizontal B5 Horizontal B5 Shift unit on right side Gearbox turned around longitudinal axis view to output end Vertical V1 Vertical V3 Possible damage to gearbox due to oil leaks The breather o...

Page 13: ...estricted in relation to the DIN standard The gearbox function will be impaired by incorrect tolerances Comply with tolerance of shaft length L The special tolerance for shaft length L must be maintai...

Page 14: ...pen ends of the keyway the parallel key is to be glued into the groove in order to avoid axial migration of the parallel key and or the hub Clamping hubs are used for motors without parallel keys A ba...

Page 15: ...Initial Installation EN 4161 758 101m 2018 09 15 4 2 3 Motor shafts hubs without keyways Clamping hubs are available for motor shafts with diameters of 38 mm 42 mm and 48 mm 1 Hub 2 Motor shaft...

Page 16: ...2 8 0 2 2K121 4 3 1 Open design The open version is the gearbox without adapter plate but with seal on the motor output shaft 2 to prevent gearbox oil ingress The drive hub 1 is delivered loose with t...

Page 17: ...tact with hot surfaces Slight to moderate injury possible Wear protective gloves After cleaning the fitting surfaces heat the drive hub to approx 120 C from the opening and slide it onto the motor sha...

Page 18: ...aces place the adapter plate with radial shaft seal onto the motor housing Heat the drive hub to approx 120 C from the opening and slide it onto the motor shaft until it reaches the stop using shims 1...

Page 19: ...or shaft Risk of burns due to contact with hot surfaces Slight to moderate injury possible Wear protective gloves After cleaning the fitting surfaces place the adapter ring onto the motor housing Then...

Page 20: ...ted for the thread in the motor shaft Screws with a strength category of 10 9 must be used with adaptations without a coolant flow Check dimension C and the concentricity of the hub There is no longer...

Page 21: ...the internal spline of the hub This can be made easier by turning to the left or right at the gearbox output The gearbox housing adapter plate and motor are bolted together using four or eight hexago...

Page 22: ...eached The clamping hub 5 must be positioned so that the clamping screw 7 can be tightened via the access hole The cover plate 8 is removed for this purpose The motor shaft 2 is guided centered into t...

Page 23: ...ng piece 1 with bonding agent Screw connecting piece with pre assembled and greased O rings 2 into motor shaft 3 by hand until stop is reached Use torque wrench WAF 14 to tighten connecting piece to 1...

Page 24: ...smission lead through is necessary to ensure that the fluid can be conveyed in a ratio operating at differential speed This lead through is subject to wear depending on the load and the status of the...

Page 25: ...erve to shut off the shift unit once the gear change is complete After the limit switch signals have been reached the shift unit is allowed to be live for a maximum of 0 5 seconds The limit switch sig...

Page 26: ...4 3 5 2 6 8 1 7 The electromotive gear change is performed by a shift unit on the gearbox which is driven by a DC motor 24 V DC The gearbox shift element is a positively locking axially movable select...

Page 27: ...rter Apply desired oscillating speed to converter and speed controller without delay 1 Shift unit energized pin 2 and 3 Gear ratio change must be completed within 2 seconds Acknowledgement from limit...

Page 28: ...x performance and less heat is introduced into the machine Gearbox failure due to insufficient lubrication Recirculating lubrication is required for gearboxes installed in the vertical V1 and vertical...

Page 29: ...vent oil return blockages in the gearbox Di approx 20 mm 4 6 2 2 Recirculating lubrication with heat exchanger A heat exchanger is installed in the recirculating lubrication system to ensure additiona...

Page 30: ...9 4 6 3 Ports and connections for lubrication 4 6 3 1 Ports and connections for initial fill oil change Installation position Oil fill Oil drain B5 I G F H V1 D E through suction for version with outp...

Page 31: ...in 0 5 bar 0 5 bar B5 open variant G 1 5 l min main rotation direction counter clockwise or F 1 5 l min main rotation direction clockwise 1 5 bar V3 closed variant M 0 5 l min and T and or U 1 0 l min...

Page 32: ...to contact with hot oil Slight to moderate injury possible Wear protective goggles Wear protective gloves Drain used gearbox oil into a suitable container if it is at operating temperature The drain p...

Page 33: ...model plate Typ Type St ckliste 4161 Parts list no Serien Nr Serial no Motor data on the model plate Manufacturer Type Size Questions for fault diagnosis Is gearbox oil sight glass dark discolored bl...

Page 34: ...the hub Alternatively there are two threads 13 at the front of the input hub that can be used to fasten the counter holder of the removing device Press off against a removing aid 12 on the cover 8 Ke...

Page 35: ...Turn motor shaft 2 until clamping screw 7 can be seen through access hole in the adapter plate 1 Loosen clamping screw Loosen mounting screws 4 and pull gearbox off motor 1 Adapter plate 2 Motor shaft...

Page 36: ...chining in ratio 4 1 No gearbox damage Gearbox running noise normalizes after several gear changes Gearbox leaking at gearbox input output Defective seals Replace seals send gearbox to ZF for inspecti...

Page 37: ...EN 4161 758 101m 2018 09 37...

Page 38: ...EN 4161 758 101m 2018 09 39 ZF Friedrichshafen AG 88038 Friedrichshafen Deutschland Germany Telefon Phone 49 7541 77 0 Telefax Fax 49 7541 77 908000 www zf com EN 4161 758 101m 2018 09...