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Related Manuals for ZF Duoplan 2K800
Summary of Contents for ZF Duoplan 2K800
- Page 1 OPERATING INSTRUCTIONS ZF-Duoplan Two-speed Gearbox 2K800 / 2K801 / 2K802...
- Page 2 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 and criminal prosecution. This document is a translation of the German original.
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Page 3: Table Of Contents
Operating Instructions 2K800/2K801/2K802 Contents Preface ..............................5 Safety instructions ........................5 ZF instructions ..........................5 Service products .......................... 6 Application and Design ......................... 7 Application ........................... 7 Features ............................7 ... - Page 4 Operating Instructions Contents 2K800/2K801/2K802 Taking into Operation ......................... 25 Initial inspection ........................25 Maintenance ............................25 Oil change ..........................25 Repair ..............................26 Gearbox fault checklist ......................26 Gearbox –...
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Page 5: Preface
Preface Preface Safety instructions This documentation is intended for specialists who All persons repairing ZF units are responsible for have experience to carry out maintenance and their own work safety. repair work. Every applicable safety regulation and legal... -
Page 6: Service Products
Operating Instructions Preface 2K800/2K801/2K802 Service products Product Name/specification Quantity Remarks (approx.) Grease Shell Avania WR2 General purpose Fuchs Renolit CXEP2 Esso Beacon EP2 Gearbox oil Gearbox oil for Can also be used for HLP 46 to ISO VG 46 recirculating recirculating lubrication lubrication with heat exchanger... -
Page 7: Application And Design
2K800/2K801/2K802 Application and Design Application and Design Application The ZF-DUOPLAN two-speed gearbox is mainly used in machine tool drives. By way of example, the gearbox can be used in turning machines (horizontal B5) or machining centers (vertical V1) thanks to its variable installation position. -
Page 8: Design
Operating Instructions Application and Design 2K800/2K801/2K802 Design The gearbox primarily comprises the following Output: assemblies: Bearing housing (9) Output bearings (10, 11) Connecting parts: Output shaft (12) Drive hub (1) Radial shaft seal (13) Adapter plate (2) with radial shaft seal (3) and ... -
Page 9: Technical Data
When using engine brakes/counterflow to brake (affixed to gearbox housing) the spindles (e. g. emergency stop) ensure that the moments of inertia do not exceed the admissible output torques. Braking times must be ZF FRIEDRICHSHAFEN AG adapted accordingly. MADE IN GERMANY TYPE PARTS LIST RATIO SERIAL-NO. -
Page 10: Installation Positions
Operating Instructions Application and Design 2K800/2K801/2K802 Installation positions Horizontal B5 Horizontal B5 (shift unit rotated) Vertical V1 Vertical V3 CAUTION The breather outlet must always be at the top, regardless of the installation position. EN 4161.758.103m – 2015-10... -
Page 11: Initial Installation
Operating Instructions 2K800/2K801/2K802 Initial Installation Initial Installation Axial runout, radial runout and length tolerances – drive motor In order to guarantee fault-free operation, the Take into account the motor shaft elongation motor must not exceed the specified tolerances. caused by heating in motors with fixed bearing on the B-side (opposite the motor output shaft). -
Page 12: Balancing
Operating Instructions Initial Installation 2K800/2K801/2K802 Balancing The hubs (2) come with a keyway (1) for transmitting power from the motor shaft (3) as standard. There are two balancing types for the motor and gearbox: Semi-key and full-key, which are described in more detail in DIN ISO 8821. It must be ensured that the hub is balanced in the same way as the motor. -
Page 13: Adaptation, Motor/Gearbox
Operating Instructions 2K800/2K801/2K802 Initial Installation Adaptation, motor/gearbox CAUTION Risk of motor shaft damage if the hub is not The motors must have a flange-mounting option sufficiently heated. for mounting the gearboxes. Tighten the threaded pin (9) and secure it to The gearbox housing is fitted to the motor by prevent it from turning, see chap. -
Page 14: Close Design (With Shaft Sealing Ring)
Operating Instructions Initial Installation 2K800/2K801/2K802 3.3.2 Close design (with shaft sealing ring) This variant incorporates an adapter plate (5) with shaft seal (7), which means that the gearbox forms a compact, closed unit. The adapter plate (5) and drive hub (1) are separately delivered loose. -
Page 15: Open Design With Adapter Ring For 2K800 And 2K801
Operating Instructions 2K800/2K801/2K802 Initial Installation 3.3.3 Open design with adapter ring for 2K800 and 2K801 The adapter ring allows adaptation to different connection dimensions. A seal is required on the motor output shaft. The adapter ring (5) and drive hub (1) are delivered loose. -
Page 16: Version With Pulley Drive
Operating Instructions Initial Installation 2K800/2K801/2K802 Gearbox – fit CAUTION Risk of motor shaft damage if the hub is not sufficiently heated. NOTE For drive hub (1) assembly, the M12 set screw (9) Tighten the threaded pin (9) and secure it to must be screwed in and tightened at the parallel prevent it from turning, see chap. -
Page 17: Output
3.5.3 Version without output In the case of drive units that are fixed on the The output shaft is not supplied by ZF. It is gearbox flange, support the motor on the B-side manufactured by the customer. Refer to the so that it does not vibrate. -
Page 18: Electrical Connection, Gearchange
Operating Instructions Initial Installation 2K800/2K801/2K802 Electrical connection, gearchange Rotation direction changes The gearbox is electrically connected using the supplied 8-pole Harting connector (HAN 8 U). The plug-in connection is located on the shift unit. 3.6.1 Shift unit Technical data: Power consumption 84 W In average, this means: n = 5°/s = 5°... - Page 19 DC motor must always be switched off using a regenerative motor stop (Quickstop). Under certain operating conditions (e. g. installation orientation V3, higher cable resistance values), it may be necessary to have a variable timing element in the control unit contact ZF. EN 4161.758.103m – 2015-10...
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Page 20: Shift Logic
Operating Instructions Initial Installation 2K800/2K801/2K802 3.6.2 Shift logic Reduce main spindle motor speed from operating speed to zero. Leave controller enable on converter. Apply desired oscillating speed to converter and speed controller without delay. Shift unit energized (pin 2 and 3) Gear ratio change is Number of attempted completed within 2 seconds. -
Page 21: Lubrication
Operating Instructions 2K800/2K801/2K802 Initial Installation Lubrication The diagrams on page 23 show the oil inlet and outlet points on the gearbox. Please refer to the relevant installation drawings for precise details. 3.7.1 Recirculating lubrication The following instances are no cause for concern: NOTE ... -
Page 22: Recirculating Lubrication With Intermediate Tank
NOTE To prevent gearbox damage due to lack of oil, ZF recommends you install an oil level sensor at the intermediate tank. A 60 μm filter must be used at the gearbox oil inlet. -
Page 23: Ports And Connections For Recirculating Lubrication
Operating Instructions 2K800/2K801/2K802 Initial Installation 3.7.5 Ports and connections for recirculating lubrication Installation position Oil inlet port Max. pressure Oil return port G or F 0.5 l/min 3 bar 2.5 l/min 5 bar D or E 0.5 l/min 3 bar 2.5 l/min 5 bar L (with suction) -
Page 24: Connections For Recirculating Lubrication For Direct Mounting On The Headstock
Operating Instructions Initial Installation 2K800/2K801/2K802 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 the installation orientation. Oil supply in all installation orientations 2.5 l/min EN 4161.758.103m –... -
Page 25: Taking Into Operation
Operating Instructions 2K800/2K801/2K802 Taking into Operation/Maintenance Taking into Operation Maintenance Initial inspection Oil change Check that the gearbox is correctly installed Oil change interval: Every 5000 operating hours before taking it into operation. ENVIRONMENTAL HAZARD! Mechanical fastening Lubricants and cleaning agents must not ... -
Page 26: Repair
Gearbox running noise in 1:1 or 4:1 gear ratio, Repairs on the gearbox itself may only be carried or only in one rotation direction or in both out by ZF Friedrichshafen AG or by authorized ZF rotation directions? after-sales points. -
Page 27: Gearbox - Disassemble
Operating Instructions 2K800/2K801/2K802 Repair Gearbox – disassemble (e. g. version with adapter plate and shaft seal) Proceed accordingly in the case of other versions. Switch off the machine Switch off the power supply Disconnect the electrical connections ... -
Page 28: Frequently Asked Questions (Faq)
Error in the shift unit Send gearbox to ZF for inspection Gear disengages Limit position switch defective Send gearbox to ZF Friedrichs- hafen AG for inspection... - 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...
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