ZF-DUOPLAN 2K2100, Operating Instructions Manual

Page 1: ...OPERATING INSTRUCTIONS Two speed Gearbox 023636 019928 019927 Pulley Drive 2K2100 with STW 06 2009 Edition 4161 758 104a...

Page 2: ...00 with STW 2 Subject to alterations in design Copyright by ZF Reproduction in whole or in part is only allowed with our written approval and authorization Printed in Germany 06 2009 Edition 4161 758...

Page 3: ...design 15 3 4 2 Closed design on request with shaft seal 16 3 4 3 Open design with adapter ring for 2K2100 on request 17 3 5 Mounting the gearbox 18 3 6 Output as STW spur gear stage gearbox 19 3 6 1...

Page 4: ...tents 2K2100 with STW 4 4 Taking into operation 29 4 1 Initial inspection 29 5 Maintenance 29 5 1 Oil change 29 6 Repair 30 6 1 Gearbox fault checklist 30 6 2 Gearbox removal 31 6 3 Hub 31 7 Frequentl...

Page 5: ...r work DANGER Used when due lack of care and attention can cause injury to personnel or put lives at risk CAUTION Pictures drawings and components do not always represent the original object but are u...

Page 6: ...R2 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 Gear...

Page 7: ...put spur gear being fixed to the machine spindle with clamping elements In this case the machine spindle can be designed as a hollow shaft The 2K2100 variant with input flange ensures a short installa...

Page 8: ...n gear 6 Ring gear 7 Ring gear bearings 8 Planetary gear carrier K Axial bearings with cup springs L Output on request Option shaft flange Bearing housing 9 Output bearings 10 11 Output shaft 12 outpu...

Page 9: ...do not exceed the admissible output torques Braking times must be adapted accordingly Standard fixing dimensions in mm in accordance with EN 50347 Two speed gearbox 2K2100 with 1PH7 224 Motor size FF...

Page 10: ...00 with STW 2 5 Installation positions 2K2100 Horizontal B5 Vertical V1 Vertical V3 Adapter plate or motor with shaft seal CAUTION The breather outlet 1 must always be at the top regardless of the ins...

Page 11: ...IL SERVOMOTOR BREATHER VERSION A VERSION B FOR BOLTS M16 SPINDLE GEARBOX SPECIAL VERSION OIL OUTLET POSSIBLE ON LEFT OR ALTERNATIVE LY RIGHT OIL OUTLET HOLLOW SCREW PORT FOR LUBE OIL GEARBOX OIL OUTLE...

Page 12: ...0 2K2100 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 The special tolerance for sha...

Page 13: ...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 023647 1 2 3 Semi key balancing Full key balancing 3 2 1 Semi key ba...

Page 14: ...44x9H with ring gear onto the shaft with the profile W90x2x30x44x9k Bolt the planetary gear carrier using the pan head screw D with hexagon socket head M24x2x60 with bore Tightening torque 420 Nm 0236...

Page 15: ...thout adapter plate but with seal on the motor output shaft 2 to prevent gearbox oil ingress The drive hub 1 is delivered loose with the gearbox Clean the fitting surfaces of the motor 3 and drive hub...

Page 16: ...7 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 Then check reference dimension C and change using shims if nec...

Page 17: ...described in section 3 Also lightly grease the motor shaft After cleaning the fitting surfaces place the adapter ring onto the motor housing Then heat the drive hub to approx 120 C from the opening a...

Page 18: ...l spline of the hub This can be made easier by turning to the left or right at the gearbox output The gearbox housing adapter ring if applicable and motor are bolted together using four six or eight h...

Page 19: ...e maximum eccentricity is indicated by a marking 0 on the eccentric bolt On the left side 3 place the marking at the 2 4 o clock position On the right side 2 place the marking at the 3 5 o clock posit...

Page 20: ...same way as the clamping elements for the helical gear on the main spindle Eccentric adjustment of the intermediate gear After installing the helical gear on the main spindle adjust the intermediate...

Page 21: ...rrent consumption 5 A max pull in current The required cable lead diameter is 1 5 mm The 24 VDC supply voltage and 5 A current consumption must be assured at the shift unit plug on the gearbox Losses...

Page 22: ...anges In most cases adjust based on the smaller value and then repeat the shift attempt Shifting at low speed without oscillation is not permitted as a perfect change cannot be assured flowchart for g...

Page 23: ...the case check the hexagon nut item 870 for firm attachment and if necessary retighten and secure it 023657 3 7 5 Checking the limit switches 1st gear limit switch setting Use a screwdriver to turn t...

Page 24: ...pleted within 2 seconds acknowledgement from limit switch S1 or S2 from the shift unit Shut off desired oscillating speed Servomotor OFF after 0 5 to 1 0 seconds Gear ratio change complete Number of a...

Page 25: ...r for gear ratio change ON 25 Gear ratio change is completed within 2 seconds acknowledgement from limit switch S1 or S2 from the gearbox shift unit Shut off desired oscillating speed Gear ratio chang...

Page 26: ...concern The oil level in the tank falls due to foaming of the gearbox oil in the gearbox during operation An oil air emulsion is formed in the oil return and in the tank 3 8 1 1 Recirculating lubricat...

Page 27: ...59 Installation position Oil inlet port 2K2100 with STW Max pressure Oil return port B5 M at least 3 0 l min and K at least 2 5 l min 3 bar 5 bar E or F or D V1 M at least 3 0 l min and K at least 2 5...

Page 28: ...position Oil inlet port 2K2100 with STW Max pressure Oil return port B5 M at least 3 0 l min and K at least 2 5 l min 3 bar 5 bar E or F or D V1 M at least 3 0 l min and K at least 2 5 l min 3 bar 5...

Page 29: ...eather vertical position Collect used oil in a suitably large container Dispose of used oil clogged filters lubricants and cleaning products in accordance with local environmental protection regulatio...

Page 30: ...model plate Typ Type St ckliste P L 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 black Smell of...

Page 31: ...l 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 radially secure the fitted key Use a r...

Page 32: ...ing in ratio 4 1 No gearbox damage Gearbox running noise normalizes after several gear changes Gearbox is loud running noise in ratio Motor shaft is too long axial bearing damaged Check bearing instal...

Page 33: ...Operating Instructions 2K2100 with STW Frequently Asked Questions FAQs 33...

Page 34: ...ZF Friedrichshafen AG Group Headquarters D 88038 Friedrichshafen Tel 49 75 41 77 0 Fax 49 75 41 77 90 8000 www zf com...