ZF Duoplan 2K800, Operating Instructions Manual

Page 1: ...OPERATING INSTRUCTIONS ZF Duoplan Two speed Gearbox 2K800 2K801 2K802...

Page 2: ...tected by copyright Complete or partial reproduction or dissemination of this document is prohibited without the consent of ZF Friedrichshafen AG Infringements lead to civil and criminal prosecution T...

Page 3: ...g ring 14 3 3 3 Open design with adapter ring for 2K800 and 2K801 15 3 3 4 Open design with adapter ring for 2K802 15 3 3 5 Version with pulley drive 16 3 4 Gearbox fit 16 3 5 Output 17 3 5 1 Version...

Page 4: ...01 2K802 4 EN 4161 758 103m 2015 10 4 Taking into Operation 25 4 1 Initial inspection 25 5 Maintenance 25 5 1 Oil change 25 6 Repair 26 6 1 Gearbox fault checklist 26 6 2 Gearbox disassemble 27 6 3 Hu...

Page 5: ...l persons repairing ZF units are responsible for their own work safety Every applicable safety regulation and legal requirement must be complied with in order to prevent injury to personnel and or dam...

Page 6: ...nia WR2 Fuchs Renolit CXEP2 Esso Beacon EP2 General purpose Gearbox oil HLP 46 to ISO VG 46 Gearbox oil for recirculating lubrication Can also be used for recirculating lubrication with heat exchanger...

Page 7: ...ms in which torque increase or speed reduction is required The gearboxes have coaxial output and are suit able for the high speeds generated in machine tool construction 2 2 Features Two speed gearbox...

Page 8: ...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 9: ...in mm in accordance with EN 50347 2001 Two speed gearbox 2K800 FF350 2K801 FF400 2K802 FF500 Motor size 180 200 225 h 180 200 225 d 60 65 75 l 140 0 2 140 0 2 140 0 2 b 300 350 450 e2 350 400 500 a1...

Page 10: ...ign 2K800 2K801 2K802 10 EN 4161 758 103m 2015 10 2 5 Installation positions Horizontal B5 Horizontal B5 shift unit rotated Vertical V1 Vertical V3 CAUTION The breather outlet must always be at the to...

Page 11: ...30 0 063 0 063 0 200 A B C L 140 2K802 0 030 0 063 0 063 0 200 Tolerances A B C to DIN 42955R Please note that the tolerance of the shaft length L is restricted in relation to the DIN standard CAUTION...

Page 12: ...125 mm 125 mm 140 mm NOTE In the case of motor shafts with open 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...

Page 13: ...g thickness These enable balancing of the motor shaft length tolerances and therefore compliance with reference dimension C 3 3 1 Open design The open version is the gearbox without adapter plate but...

Page 14: ...he drive hub to approx 120 C from the opening and slide it onto the motor shaft until it reaches the stop Then check reference dimension C and change using shims if necessary CAUTION Risk of motor sha...

Page 15: ...op Then check reference dimension C and change using shims if necessary CAUTION Risk of motor shaft damage if the hub is not sufficiently heated Tighten the threaded pin 9 and secure it to prevent it...

Page 16: ...tightened at the parallel key with 40 Nm until firmly home Make sure you coat the threaded pin with liquid seal before installing it Make sure that the O ring 10 is in the correct position during inst...

Page 17: ...the bolts so that it is frictionally engaged and secured Comply with the specified tightening torques The belt pulley should be balanced to quality 6 3 as per VDI Directive 2060 in order to ensure low...

Page 18: ...ring the gearchange the main spindle motor should make the shaft oscillate 5 or 5 at a rate of 1 to 5 rotation direction changes per second Major pendulum motion may lead to damage at the meshing gear...

Page 19: ...d until this signal is present Circuit diagram for switchgear unit with solenoid unit and two switch positions standard or three switch positions with neutral position 1st gear e g 4 1 2nd gear 1 1 3r...

Page 20: ...controller without delay Shift unit energized pin 2 and 3 Gear ratio change is completed within 2 seconds Acknowledgement from limit switch S1 or S2 from the shift unit Shut off desired oscillating sp...

Page 21: ...plications require a very low operating temperature level which can be reached by connecting an adapted gearbox oil supply with oil cooling The respective gearbox versions are prepared accordingly The...

Page 22: ...termediate tank The tank volume should be at least ten times the recirculating oil quantity in order to ensure effective oil cooling NOTE To prevent gearbox damage due to lack of oil ZF recommends you...

Page 23: ...min K 2 5 l min 3 bar 5 bar D or E or L with suction V3 M 0 5 l min K 2 5 l min or M 0 5 l min P 2 5 l min 3 bar 5 bar 3 bar 5 bar H and I with suction or G or F NOTE The stated values of oil circulat...

Page 24: ...2015 10 3 7 6 Connections for recirculating lubrication for direct mounting on the headstock Take account of connection M acc to chapter 3 7 5 for the oil supply Implement the oil return according to...

Page 25: ...for the products concerned from your local environmental protection authority and follow any instructions herein at all times Always collect used oil in a suitably large container Always dispose of us...

Page 26: ...int Gearbox data on the model plate Typ Type St ckliste 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...

Page 27: ...nnections Disconnect the gearbox oil connections drain the gearbox oil Undo the mounting bolts 11 Pull the gearbox 6 off the adapter plate 5 and drive hub 1 6 3 Hub Undo the threaded pin 9 used to rad...

Page 28: ...running noise normalizes after several gear changes Gearbox is loud running noise in ratio Motor shaft is too long axial bearing damaged Check bearing install new bearing if necessary Gearbox leaking...

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Page 30: ...ZF Friedrichshafen AG 88038 Friedrichshafen Deutschland Germany Telefon Phone 49 7541 77 0 Telefax Fax 49 7541 77 908 000 www zf com EN 4161 758 103n 2015 10...