Related Manuals for ZF-DUOPLAN 2K2100
Summary of Contents for ZF-DUOPLAN 2K2100
- Page 1 OPERATING INSTRUCTIONS Two-speed Gearbox 023636 019928 019927 Pulley Drive 2K2100 with STW 06.2009 Edition 4161 758 104a...
- Page 2 2K2100 with STW 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 104a...
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Page 3: Table Of Contents
Electrical connection, gearchange ....................21 3.7.1 Shift unit ............................21 3.7.2 Checking, adjusting and exchanging the shift unit on the 2K2100 gearbox........22 3.7.3 The cover (item 082) is removed from the shift unit for checking all functions ......23 3.7.4 Checking the slip clutch for the correct friction torque ...............23 3.7.5 Checking the limit switches......................23... - Page 4 Operating Instructions Contents 2K2100 with STW Taking into operation...........................29 Initial inspection...........................29 Maintenance............................29 Oil change ............................29 Repair ..............................30 Gearbox fault checklist ........................30 Gearbox removal..........................31 Hub...............................31 Frequently Asked Questions (FAQs) ....................32...
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Page 5: Preface
Operating Instructions 2K2100 with STW Preface Preface Safety instructions • This documentation is intended for specialists who All persons repairing ZF units are responsible have experience to carry out maintenance and for their own work safety. repair work. • Every applicable safety regulation and legal... -
Page 6: Service Products
Operating Instructions Preface 2K2100 with STW 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... -
Page 7: Application And Design
In this case the machine spindle can be designed as a hollow shaft. The 2K2100 variant with input flange ensures a short installation length thanks to the parallel arrangement of the gearbox and motor. Features •... -
Page 8: Design
Option: STW (spur gear stage) Housing (P) Input spur gear with shaft and bearings (Q) Intermediate gear with bearings (R) 023719 Oil lines (S), lubrication for 2K2100 Output spur gear with labyrinth seal (T) Cover (U) • Tensioning ring as necessary (V) •... -
Page 9: Technical Data
Operating Instructions 2K2100 with STW Application and design Technical data Type 2K2100 2K2100 Type 2K2100 2K2100 version version version version without output with STW without with STW (i=1.396) output (i=1.396) Nominal power max. 120 kW max. 120 kW Nominal input max. -
Page 10: Installation Positions, 2K2100
Operating Instructions Application and design 2K2100 with STW Installation positions, 2K2100 Horizontal B5 023640 Vertical V1 023641 Vertical V3 Adapter plate or motor with shaft seal 023642 CAUTION The breather outlet (1) must always be at the top, regardless of the installation position. -
Page 11: Installation Positions, 2K2100 With Stw (Spur Gear Stage)
Operating Instructions 2K2100 with STW Application and design 2.5.1 Installation positions, 2K2100 with STW (spur gear stage) Horizontal B5 VERSION A VERSION A SPINDLE VERSION B SERVOMOTOR PORT FOR LUBE OIL BREATHER PORT FOR GEARBOX LUBE OIL HOLLOW SPECIAL VERSION... -
Page 12: Initial Installation
Operating Instructions Initial installation 2K2100 with STW Initial installation Axial runout, radial runout and length tolerances – drive motor In order to guarantee fault-free operation, the motor must not exceed the specified tolerances. 023646 Axial runout, radial runout and length tolerances –... -
Page 13: Balancing
Operating Instructions 2K2100 with STW Initial installation 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, irrespective of the balancing quality: semi-key and full-key. -
Page 14: Mounting Of 2K2100 Without Stw (Spur Gear Stage) On Motor/Gearbox
First gear stage) on motor/gearbox position the gearbox housing with the pan head If the 2K2100 without output (without spur gear screws (13xM16x*) "F" and then tighten the stage) is supplied, mount the gearbox as follows. -
Page 15: Adaptation, Motor/Gearbox
NOTE: Option: in the case of the version with output NOTE shaft, the 2K2100 gearbox housing is adapted to the machine by means of centering on the bearing If the gearbox does not have an output, the gearbox must first be mounted onto the machine. -
Page 16: Closed Design, On Request (With Shaft Seal)
Operating Instructions Initial installation 2K2100 with STW 3.4.2 Closed design, on request (with shaft seal) 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 17: Open Design With Adapter Ring For 2K2100, On Request
Operating Instructions 2K2100 with STW Initial installation 3.4.3 Open design with adapter ring for 2K2100, on request 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 18: Mounting The Gearbox
Operating Instructions Initial installation 2K2100 with STW 10 11 Mounting the gearbox NOTE When fitting the drive hub (1), screw in and tighten the threaded pin (9) onto the fitted key. Coat the threaded pin with liquid seal before installing it. -
Page 19: Output As Stw (Spur Gear Stage) Gearbox
Mounting Fix the gearbox (2K2100 + spur gear stage) on the motor frame with the centering ring (4) and attach using the pan head screws (M16x80; 15 pcs.) (5). Tighten to 195 Nm in 4 or more stages (50, 100, 150, 195 Nm). -
Page 20: Option: Version With Belt Drive
Operating Instructions Initial installation 2K2100 with STW Clean the main spindle (page 19/7) in the area of Procedure: the helical gear (page 19/8) and remove any oil. First turn the right eccentric bolt (2) clockwise The bore (Ø 250 mm) in the helical gear must be until a slight resistance can be felt. -
Page 21: Option: Version With Coaxial Output, Only On Request
Operating Instructions 2K2100 with STW Initial installation The pulley should be balanced to quality 6.3 as Scope of supply: per VDI Directive 2060 and DIN ISO 1940 Part 1 Sleeve housing, screw connection, socket insert + Part 2 in order to ensure low-vibration and 8 jacks, type Harting AWG16, (ZF order no. -
Page 22: Checking, Adjusting And Exchanging The Shift Unit On The 2K2100 Gearbox
3.7.2 Checking, adjusting and exchanging switches in the shift unit. A time relay must be the shift unit on the 2K2100 gearbox provided to monitor the time lapse, i.e. if a shift is not performed within 2 seconds from the beginning of the shift, it is cancelled (if no signal is received from the limit switch S1 or S2). -
Page 23: The Cover (Item 082) Is Removed From The Shift Unit For Checking All Functions
Operating Instructions 2K2100 with STW Initial installation 023657 023656 3.7.5 Checking the limit switches 3.7.3 The cover (item 082) is removed from the shift unit for checking all functions 1st gear limit switch setting: Check the motor function by changing from 1st to Use a screwdriver to turn the worm shaft to the 2nd gear and back several times. -
Page 24: Shift Logic For 1St And 2Nd Gear
Operating Instructions Initial installation 2K2100 with STW 3.7.6 Shift logic for 1st and 2nd gear d gear 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. -
Page 25: Shift Logic For Centre Position
Operating Instructions 2K2100 with STW Initial installation 3.7.7 Shift logic for centre position e position 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. -
Page 26: Lubrication
Operating Instructions Initial installation 2K2100 with STW Oil inlet quantity: Lubrication Inlet for 2K2100: (M) at least 3.0 l/min at 3 bar, thread M16x1.5 (hollow screw). 3.8.1 Recirculating lubrication Inlet for spur gear stage: (K) approx. 3.5 l/min, NOTE at 3 bar, on eccentric bolt (3), thread M12x1.5. -
Page 27: Ports And Connections For Lubrication
Operating Instructions 2K2100 with STW Initial installation/Maintenance 3.8.2 Ports and connections for lubrication 3.8.2.1 2K2100 with STW (spur gear stage) 023659 Installation position Oil inlet port Max. pressure Oil return port 2K2100 with STW E or F at least 3.0 l/min 3 bar at least 2.5 l/min... - Page 28 Operating Instructions Initial installation 2K2100 with STW 3.8.2.2 2K2100 – direct mounting on headstock or version with output 024878 Installation position Oil inlet port Max. pressure Oil return port 2K2100 with STW E or F at least 3.0 l/min 3 bar at least 2.5 l/min...
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Page 29: Taking Into Operation
Operating Instructions 2K2100 with STW Taking into operation/Maintenance Taking into operation Maintenance Initial inspection Oil change Check that the gearbox is correctly installed before taking it into operation. Oil change interval: every 5000 operating hours • Mechanical fastening • Motor flange-mounting ENVIRONMENTAL HAZARDS! •... -
Page 30: Repair
Operating Instructions Repair 2K2100 with STW Repair In the event of gearbox malfunctions, first check Questions for fault diagnosis: the connected components and their ports and • Is gearbox oil sight glass dark/discolored connections. black? Carefully describe the type of fault so as to assist •... -
Page 31: Gearbox Removal
Operating Instructions 2K2100 with STW Repair Gearbox removal (based on the example of the version with adapter plate and shaft seal) Proceed accordingly in the case of other versions. • Switch off the machine • Switch off the power supply •... -
Page 32: Frequently Asked Questions (Faqs)
Operating Instructions Frequently Asked Questions (FAQs) 2K2100 with STW Frequently Asked Questions (FAQs) Fault Cause of fault Remedy • Loose contact on motor speed Gearbox is loud, knocking Check speed sensor and electrical noises sensor, which causes permanent lines to motor, clean/exchange motor governing speed sensor as necessary. - Page 33 Operating Instructions 2K2100 with STW Frequently Asked Questions (FAQs)
- 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...