Related Manuals for ZF ZF-DUOPLAN 2K800
Summary of Contents for ZF ZF-DUOPLAN 2K800
- Page 1 Operating Instructions ZF-DUOPLAN Two-speed Gearbox 2K800 / 2K801 / 2K802 2K1000 / 2K1001 / 2K1002 Industrial Drives...
- Page 2 Copyright © ZF Friedrichshafen AG 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.
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Page 3: Table Of Contents
Contents Preface ..............................5 Validity and field of application ..................... 5 Service products .......................... 5 Safety ..............................6 Signal words and symbols ......................6 General safety instructions ......................6 ... - Page 4 Contents 4.7.4 Recirculating lubrication with intermediate tank ............... 26 4.7.5 Ports and connections for recirculating lubrication ..............27 4.7.6 Connections for recirculating lubrication for direct mounting on the headstock ......28 Taking into Operation ......................... 29 ...
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Page 5: Preface
Preface Preface Validity and field of application In addition to the ZF documentation, observe the This documentation applies to the following ZF provisions of the body manufacturer. products: 2K800, 2K801, 2K802 2K1000, 2K1001, 2K1002 Service products Product Name/specification... -
Page 6: Safety
Information as to how the hazard can be malfunctions and damage in operation. prevented. The ZF product is designed and produced in line with state-of-the-art technology. The ZF product is safe to operate in its delivery status. However, the... - Page 7 Close open pipelines and hoses and avoid guarantee. damage. Observe tightening torques. In case of damage, contact ZF and have the Protect cables against mechanical damage. following information on the product to hand: Type Noise ...
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Page 8: Product-Specific Safety Instructions
Safety Product-specific safety instructions Remove any traces of old seals or gaskets from mating faces. Burrs or other similar rough surfaces are to be carefully removed with an oil stone. Carefully cover opened gearboxes to prevent the entry of foreign matter. EN 4161.758.103o –... -
Page 9: Application And Design
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 10: Design
Application and Design 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 11: Technical Data
Application and Design Technical data Type 2K800 2K800 Type 2K800 2K800 2K801/802 2K801/802 2K801/802 2K801/802 Standard with STW Standard with STW version (i = 1.236) version (i = 1.236) Nominal input max. 800 Nm max. 800 Nm Nominal power max. 84 kW max. - Page 12 Standard fixing dimension (in mm) (affixed to gearbox housing) in accordance with EN 50347: 2001 Two-speed 2K800 2K801 2K802 gearbox 2K1000 2K1001 2K1002 ZF FRIEDRICHSHAFEN AG FF350 FF400 FF500 MADE IN GERMANY Motor size TYPE PARTS LIST RATIO SERIAL-NO. BACKLASH INPUT TURN POWER MAX.
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Page 13: Installation Positions
Application and Design Installation positions Horizontal B5 Horizontal B5 (shift unit rotated) Vertical V1 Vertical V3 Possible material damage to gearbox due to oil leaks. The breather outlet must always be at the top, regardless of the installation position. EN 4161.758.103o –... -
Page 14: Initial Installation
Initial Installation Initial Installation Axial runout, radial runout and length tolerances – drive motor The special tolerance for shaft length “L” must be In order to guarantee fault-free operation, the maintained in order to guarantee fault-free motor must not exceed the specified tolerances. gearbox operation. -
Page 15: Balancing
Initial Installation Balancing Motors with parallel keys are used, which is why the balancing type needs to be noted. 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. -
Page 16: Adaptation, Motor/Gearbox
Initial Installation Adaptation, motor/gearbox After cleaning the fitting surfaces, heat the drive The motors must have a flange-mounting option hub to approx. 120 °C from the opening and slide for mounting the gearboxes. it onto the motor shaft until it reaches the stop. The gearbox housing is fitted to the motor by Then check reference dimension “C”. -
Page 17: Closed Design (With Shaft Sealing Ring)
Initial Installation 4.3.2 Closed design (with shaft sealing ring) In the case of motor adaptation and loosely This variant incorporates an adapter plate (5) with supplied sealing/spacing washers, the latter must shaft seal (7), which means that the gearbox forms be pasted in by means of a jointing compound a compact, closed unit. -
Page 18: Open Design With Adapter Ring For 2K800, 2K801, 2K1000 And 2K1001
Initial Installation 4.3.3 Open design with adapter ring for 2K800, 2K801, 2K1000 and 2K1001 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 19: Open Design With Adapter Ring For 2K802 And 2K1002
Initial Installation 4.3.4 Open design with adapter ring for 2K802 and 2K1002 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. Clean the fitting surfaces of the motor (3) and drive hub (1). -
Page 20: Version With Pulley Drive
Initial Installation 4.3.5 Version with pulley drive Gearbox – fit The pulley will be centred on the outer diameter of For drive hub (1) assembly, the M12 threaded pin the drive flange (K6 tolerance), friction-locked in (9) must be screwed in and tightened at the place and secured using screws, whereby the parallel key with 40 Nm until firmly home. -
Page 21: Output
In the case of drive units that are fixed on the gearbox flange, support the motor on the B-side The output shaft is not supplied by ZF. It is so that it does not vibrate. manufactured by the customer. Refer to the... -
Page 22: Electrical Connection, Gear Change
Initial Installation Electrical connection, gear change The electrical connection may only be established During the gear change, the main spindle motor by a qualified electrician. should make the shaft oscillate +5° or -5° at a rate of 1 to 5 rotation direction changes per second. A larger pendulum motion may lead to damage at Risk of damage to shift unit due to incorrect the meshing gears. - Page 23 (quick stop) using command is present. a generator. Under certain operating conditions (e.g., V3 installation position, higher line resistances), a variable time module may be needed in the control system consult ZF. EN 4161.758.103o – 2023-08...
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Page 24: Control Logic
Initial Installation 4.6.2 Control logic Reduce main spindle motor speed from operating speed to zero. Leave controller enable signal on converter. Apply desired oscillating speed to converter and speed controller without delay. Shift unit energized (pin 2 and 3) Gear ratio change must be completed within Number of attempted shifts >... -
Page 25: Lubrication
Initial Installation Lubrication The diagrams on page 27 show the oil inlet and outlet points on the gearbox. Please refer to the relevant installation drawings for precise details. 4.7.1 Recirculating lubrication The following instances are no cause for concern: Gearboxes 2K800, 2K801, 2K802, 2K1000, ... -
Page 26: Recirculating Lubrication With Intermediate Tank
The tank volume should be at least ten times the recirculating oil quantity in order to ensure effective oil cooling. To prevent gearbox damage due to lack of oil, ZF recommends you install an oil level sensor at the intermediate tank. -
Page 27: Ports And Connections For Recirculating Lubrication
Initial Installation 4.7.5 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) H and I (with suction) 0.5 l/min... -
Page 28: Connections For Recirculating Lubrication For Direct Mounting On The Headstock
Initial Installation 4.7.6 Connections for recirculating lubrication for direct mounting on the headstock Take account of connection M acc. to chapter 4.7.5 for the oil supply. Implement the oil return according to the installation orientation. Oil supply in all installation orientations 2.5 l/min EN 4161.758.103o –... -
Page 29: Taking Into Operation
Taking into Operation/Wartung 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. Risk of burns due to contact with hot oil. Mechanical fastening Slight to moderate injury possible. -
Page 30: 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 31: Gearbox - Disassemble
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 Disconnect the gearbox oil connections, drain the gearbox oil ... -
Page 32: 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 33 EN 4161.758.103o – 2023-08...
- Page 34 ZF Friedrichshafen AG 88038 Friedrichshafen Deutschland · Germany Telefon/Phone +49 7541 77-0 Telefax/Fax +49 7541 77-908000 www.zf.com DE 4161.758.003o – 2023-08...
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