Related Manuals for ZF-DUOPLAN 2K250
Summary of Contents for ZF-DUOPLAN 2K250
- Page 1 OPERATING INSTRUCTIONS Two-speed Gearbox 2K250 / 2K300 08.2007 Edition 4161 758 102i...
- Page 2 2K250/2K300 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 Edition: 08.2007 4161 758 102i...
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Page 3: Table Of Contents
Operating Instructions 2K250/2K300 Contents Preface..............................5 Safety instructions .........................5 ZF instructions ..........................5 Service products..........................6 Application and Design..........................7 Application ............................7 Features............................7 Design ............................8 Technical data ..........................9 Installation positions ........................10 Initial Installation..........................11 Axial runout, radial runout and length tolerances – drive motor ..........11 Balancing .............................12... - Page 4 Operating Instructions Contents 2K250/2K300 Maintenance............................33 Oil change ............................33 Repair ..............................34 Gearbox fault checklist ........................34 Gearbox - disassemble .........................35 Hub...............................35 Frequently Asked Questions (FAQ) ....................36...
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Page 5: Preface
Operating Instructions 2K250/2K300 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 re- for their own work safety. pair work. • Every applicable safety regulation and legal... -
Page 6: Service Products
Operating Instructions Preface 2K250/2K300 Service products Product Name/specification Quantity Remarks (approx.) Grease Shell Avania WR2 General-purpose Fuchs Renolit CXEP2 Esso Beacon EP2 Gearbox oil HLP 68 to ISO VG 68 2K250 Gearbox oil for Can also be used for B5: 1.5... -
Page 7: Application And Design
2K250/2K300 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 installa- tion position. -
Page 8: Design
Operating Instructions Application and Design 2K250/2K300 Design Output The gearbox primarily comprises the following • Bearing housing (9) assemblies: • 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
Operating Instructions 2K250/2K300 Application and Design Technical data 2K250 2K300 2K250 2K300 Nominal power max. 39 kW max. 47 kW Nominal input max. 250 Nm max. 300 Nm, torque at i = 5.50 Nominal speed 1500 rpm 1500 rpm max. 250 Nm Max. -
Page 10: Installation Positions
Operating Instructions Application and Design 2K250/2K300 Installation positions Horizontal B5 Horizontal B5 Shift unit on right side, gearbox turned around longitudinal axis (view to output end) Vertical V1 Vertical V3 013765 CAUTION The breather outlet must always be at the top,... -
Page 11: Initial Installation
Oversize shafts must be ma- chined to the correct length. Take into account the permitted axial forces on the motor shaft. Also see ZF-DUOPLAN cata- logue (4161 750 102), "Performance data" sec- tion. Take into account the motor shaft elongation caused by heating in motors with fixed bearing on the B-side (opposite the motor output shaft). -
Page 12: Balancing
Operating Instructions Initial Installation 2K250/2K300 Balancing The hubs (2) come with a keyway (1) for trans- mitting power from the motor shaft (3) as stan- dard. There are two balancing types for the motor and gearbox: Semi-key and full-key, which are de- scribed in more detail in DIN ISO 8821. -
Page 13: Adaptation, Motor/Gearbox
CAUTION There is also a foot mounting on the gearbox Risk of motor shaft damage if the hub is not housing for 2K250 and 2K300. sufficiently heated. Different gearbox variants are used depending on Tighten the threaded pin (9) and secure it to pre- the motor type. -
Page 14: Closed Design With Hub Bearing And Shaft Sealing Ring
Operating Instructions Initial Installation 2K250/2K300 3.3.2 Closed design with hub bearing and shaft sealing ring Variant with ball bearing (4), in which the hub (1) is also mounted in bearings to prevent axial hub migration. When assembling, separate the drive hub (1) with adapter plate (5) from the gearbox housing (6). -
Page 15: Closed Version (With Shaft Seal)
Operating Instructions 2K250/2K300 Initial Installation 3.3.3 Closed version (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 and drive hub (1) are separately delivered loose. -
Page 16: Open Design With Adapter Ring
Operating Instructions Initial Installation 2K250/2K300 3.3.4 Open design with adapter ring 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 deliv- ered loose. Clean the fitting surfaces of the motor (3) and drive hub. -
Page 17: Keyless Hub
Operating Instructions 2K250/2K300 Initial Installation 3.3.5 Keyless hub When mounting on motors with a smooth motor shaft without a keyway, it is necessary to use ring clamping elements and pressure pieces between the motor shaft and the input hub in order to transmit the torque. -
Page 18: Version With Pulley Drive
Operating Instructions Initial Installation 2K250/2K300 3.3.6 Version with pulley drive The pulley will be centred on the outer diameter of the drive flange (K6 tolerance), friction-locked in place and secured using screws, whereby the permitted torque must be taken into account. -
Page 19: Gearbox - Fit
Operating Instructions 2K250/2K300 Initial Installation Gearbox - fit Screw in and tighten the threaded pin (9) onto the fitted key. 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 installation. -
Page 20: Output
Operating Instructions Initial Installation 2K250/2K300 Output warranty rotary transmission leadthrough is limited to 12 months. 3.5.1 Version with belt output Information about the product, function, operation and installation of the rotary transmission The belt pulley must be centered on the outer... - Page 21 Operating Instructions 2K250/2K300 Initial Installation Gearbox shift mechanism: Gearchanges are effected when the 24 V voltage is applied to pin 2 and 3. The polarity of the ap- plied voltage dictates which gear is engaged. Solenoid L3 is always energized when the voltage is applied, regardless of the polarity.
- Page 22 Operating Instructions Initial Installation 2K250/2K300 Diagram for shift unit with two positions (stan- dard) or three positions (with neutral position): 1st gear ==> e.g. 4:1 2nd gear ==> 1:1 3rd gear ==> Neutral position, idling (option) Solenoid L1 Shift to 1st gear...
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Page 23: Shift Logic
Operating Instructions 2K250/2K300 Initial Installation 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. Solenoid energized (pin 2 and 3) Gear ratio change is completed within 2 seconds. -
Page 24: Lubrication
Recirculating lubrication is required for 2K250 / 2K300 gearboxes installed in the vertical V1 and vertical V3 positions. In this instance, the type of recirculating lubrication depends on the operating temperature level required. - Page 25 Operating Instructions 2K250/2K300 Initial Installation 3.7.2.1 Recirculating lubrication for V1/B5 operation Refer to section 3.7.3.2 for the position of the oil inlets and outlets. The oil inlet is connected in place of the oil drain plug. Oil inlet quantity 1.5 to 2 l/min.
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Page 26: Ports And Connections For Lubrication
Operating Instructions Initial Installation 2K250/2K300 3.7.3 Ports and connections for lubrication 3.7.3.1 Ports and connections for initial fill/oil change (see fig. on page 27) Installation Oil fill Oil drain position G, F, H B5 rotated (for version with output shaft) - Page 27 Operating Instructions 2K250/2K300 Initial Installation 3.7.3.2 Connections for circulating lubrication in standard applications NOTE Internal lubrication hole with oil inlet port K and R is only existing in V1/V3 - part lists. In B5 - part lists only oil inlet port K without internal lubrication hole is available.
- Page 28 Operating Instructions Initial Installation 2K250/2K300 3.7.3.3 Connections for integral lube oil system and maximum speed NOTE Connecting K or R to an integral lube oil system is mandatory in applications with maximum speeds of 10000 rpm and/or dry sumps. Furthermore, a gearbox oil cooler >0.3 kW and a circulating oil volume of >15 liters is required.
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Page 29: Gearbox Oil Pump
Operating Instructions 2K250/2K300 Initial Installation 3.7.4 Gearbox oil pump 3.7.4.1 Technical data Electrical: Nominal voltage: 200-240 V AC 50/60 Hz 100-120 V AC 50/60 Hz Nominal power: 100 W Operating mode: S1 = 100% ED Degree of protection: IP 44... - Page 30 Operating Instructions Initial Installation 2K250/2K300 3.7.4.2 Connection for nominal voltage 100-120 V AC Terminal diagram 100 – 120 V AC: Circuit diagram for 100 – 120 V AC: Termi- Jumpers Capacitor C • voltage • • • Temperature monitoring •...
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Page 31: Heat Exchanger
Operating Instructions 2K250/2K300 Initial Installation 3.7.5 Heat exchanger Type TL 1 The heat exchanger cooler fan is driven by a 24 V D.C. motor. The rotation direction of the cooler fan must match the Rotation direction marking on the housing (note suction direction). - Page 32 Operating Instructions Taking into Operation/Maintenance 2K250/2K300 Type TL 4 Rotation direction Circuit diagram: Customer side Blower-side interface...
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Page 33: Taking Into Operation
Operating Instructions 2K250/2K300 Taking into Operation Taking into Operation Maintenance Initial inspection Oil change Check that the gearbox is correctly installed Oil change interval: Every 5000 operating before taking it into operation. hours • Mechanical fastening • Motor flange-mounting ENVIRONMENTAL HAZARD! Lubricants and cleaning agents must not •... -
Page 34: Repair
Operating Instructions Taking into Operation/Maintenance 2K250/2K300 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 document the type of fault so as to assist Smell of burning oil at oil breather? •... -
Page 35: Gearbox - Disassemble
Operating Instructions 2K250/2K300 Repair Gearbox - disassemble (e.g. version with adapter plate, shaft seal and hub bearings) Proceed accordingly in the case of other versions. • Switch off the machine • Switch off the power supply • Disconnect the electrical connections •... -
Page 36: Frequently Asked Questions (Faq)
Operating Instructions Frequently Asked Questions (FAQ) 2K250/2K300 Frequently Asked Questions (FAQ) Error Cause of error Remedy Gearbox is loud, knocking • Loose contact on motor speed Check speed sensor and electrical noises sensor, which causes permanent lines to motor, clean speed sensor if motor governing. - Page 37 ZF Friedrichshafen AG Special Driveline Technology Ehlersstraße 50 • D-88046 Friedrichshafen Phone: ++49 (75 41) 77-0 • Fax: ++49 (75 41) 77-34 70 E-mail: ZFM.Sales@zf.com • Internet: www.zf.com...