2K800 & 2K801 & 2K802 Manual - Drive Lines Technologies Ltd
Contents
1. 2K800 2K801 2K802 Initial Installation 3 Initial Installation 3 1 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 A Lei B Lei 5 C a m Axial runout radial runout and length tolerances electric motor mounting flange Gearbox Tolerance HES A B C L 140 2K800 10 030 0 063 o 063 0 200 2K801 A B C L 140 2K802 10 030 10 063 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 shaft length L must be maintained in order to guarantee fault free gearbox operation Undersize shafts must be compensated for by using shims when mounting to the motor Oversize shafts must be machined to the correct length ZF DUOPI AIN Operating Instructions Initial Installation 2K800 2K801 2K802 3 2 Balancing The hubs 2 come2. ooo cc cece cece eccc eee eeeeeeeeeseseeneeeeeeneeeeeees 15 3 3 4 Open design with adapter ring for 2kKO 07 ects sees eeeese sees eetseeeeseeeeaeees 15 323 97 Eege elle 16 3 4 Gearbox TT 16 SEE ENEE 17 3 5 1 Version with belt output titt ettei t tt t re r ru E EELEE EEEEEEEEEEE EEEE EEE EErEE EEEE Ena 17 3 5 2 Version With coaxial OUTPUT EE 17 3 5 3 Version without output tiete it titte terre u e EPLE LE EE EELEE EEEEEEEEEEEEEEEEEEE EEE E EEEE Enn 17 3 6 Electrical connection gearchange etter eed eee ter Err PEP EPES PES S EEEren rres rere enr EES 18 IT ES i Ge 18 ET Oe 20 3 7 Lubrication cece 21 3 7 1 Recirculating Allee indie EN 3 7 2 Recirculating lubrication for V1 B5 operation ecueeeesseeessenessennessnnnsennnnnnnnnnnnenennnnennnnnnsnnnnnn 21 3 7 3 Recirculating lubrication with heat evchanger cess sees eeeseeeseeeeseeeeaeeees 21 3 7 4 Recirculating lubrication with intermediate tank 22 3 7 5 Ports and connections for recirculating lubrication eesseeesseeesseeesennnsennesennnsennnsnnnnsnnn en 23 3 7 6 Connections for recirculating lubrication for direct mounting on the headstock 24 ZF DUOPI AN Operating Instructions Contents 2K800 2K801 2K802 4 Taking into Operation 2u ucnenasca stillen 25 4 1 Initial INSPECTION ueeeeeseeeseesseeasuennensnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnsnnnnnnsnennenennnennnenn 25 5 Maintenance sce scssvcesccds sh ENE
3. E EE EES 25 Bite Oi Meine E 25 6 TT 26 6 1 Gearbox fault checklist ee nnnnsnnnren nenn 26 6 2 Geanbox Oi gassemble A EEEEREEERRNRNKNEKEEEREEEEENENENEEEEEREEEENNENENEEEEEEEEENNENENEEEEEEEEENNNENENEEEREEEEENENENN 27 Do gt U EE 27 7 Frequently Asked Questions FA 28 Operating Instructions 2K800 2K801 2K802 ZF DUOPLAN Preface 1 Preface This documentation is intended for specialists who have experience to carry out maintenance and repair work The ZF product is documented in accordance with the design status as of the issue date The following safety notices are used in these operating instructions NOTE Used to highlight special sequences methods information etc CAUTION Used when incorrect and improper operating procedures can cause damage to the product N DANGER Used when due lack of care and attention can cause injury to personnel and or damage to property A ENVIRONMENTAL HAZARDS Lubricants and cleaning products must not be poured onto the ground into groundwater or down the drain e Obtain and comply with the safety regulations relevant to these products issued by your local environmental authority e Collect used oil in a suitably large container e Dispose of used oil clogged filters lubricants and cleaning products in accordance with local environmental protection regulations e Always follow the instructions issued by the manufacturer when handling lubricant
4. Operating Instructions ZF DUOPLAN Two speed Gearbox 2K800 2K801 2K802 08 2013 Edition 4161 758 103m_en ZF DUOPLAN 2K800 2K801 2K802 NOTE These operating instructions also apply to the predecessor model 2K50 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 2013 08 4161 758 103m Operating Instructions ZF D UOPLAIN 2K800 2K801 2K802 Contents 1 EE Eege Eeer 5 1 1 Safety instructions 00 0 cece cece cece cece ce ecce eee eee cece ceceeeuecceseeesteceseeesecteeeseeeseeteeeseeeseeteeeseetieeteeeaeeens 5 142 ZF INSIUCTIONS aaa na ET 5 Eege UE 6 2 Applieation and WAT NEE H 2 1 Applecaton tittie ir rt ie terre e e e rP E EE EELEE EE E EELEE EE EE EEEEEEEEEE EEEE EEEE Erna 7 2 2 Features 7 2 32 D2 EE 8 24 Technical iaaa AAA A AAEE ATAA EEES 9 2 5 ANStAallAtl OM ele EE 10 3 Jul DC Eet e EE 11 3 1 Axial runout radial runout and length tolerances drive motor cece ceccceeccceeeeeeeeeeeueeeeueeeenees 11 3 2 Balancing ccc 12 321 Semi key DAlANCING ainiin aAA nn an aa een an ansehe 12 3 22 PUII KeYy DalaNGING scssisenssdansiannsssnascaaninannaiannaasnaawaansaanne kann nn a 12 3 3 Adaptation Motor gear DOK eresian nn ana mania 13 3 3 1 Opendesaign ec 13 3 3 2 Close design with shaft sealing ng 14 3 3 3 Open design with adapter ring for 2K800 and 2K801
5. ase the motor shaft After cleaning the fitting surfaces 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 If undersize use shims for balancing If oversize shorten the motor shaft CAUTION Risk of motor shaft damage if the hub is not sufficiently heated Tighten the threaded pin 9 and secure it to prevent it from turning see chap 3 4 EE ch ZF DUOPI AN 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 Clean the fitting surfaces of the motor 3 and drive hub Check the motor shaft 2 for axial and radial runout as described in chapter 3 1 Also lightly grease the motor shaft 2 After cleaning the fitting surfaces place the adapter plate with radial shaft seal 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 necessary CAUTION Risk of motor shaft damage if the hub is not sufficiently heated Tighten the threaded pin 9 and s
6. cal gearing Low torsional backlash Easy to install High radial forces permitted on output end SG Combined axial and radial force thanks to flexible output bearings High efficiency Electromotive gear switching ZF DUOPI AIN Operating Instructions Application and Design 2K800 2K801 2K802 2 3 Design The gearbox primarily comprises the following Output assemblies e Bearing housing 9 e Output bearings 10 11 e Output shaft 12 e Radial shaft seal 13 e Planet carrier 14 e Axial bearing 15 Connecting parts e Drive hub 1 e Adapter plate 2 with radial shaft seal 3 and hub bearings 4 as necessary Housing e Gearbox housing 5 Se 16 Input 9 e Shift fork 17 e Brake disc 18 Shift unit e Shift unit 19 e Selector finger 20 e Sun gear 6 e Ring gear 7 e Ring gear bearings 8 INN ra 1 a nun Operating Instructions 2K800 2K801 2K802 2 4 Technical data ZF DUOPLAN Application and Design Type 2K800 2K800 2K801 802 2K801 802 Standard with STW version i 1 236 Nominal power max 84 kW max 84 kW Nominal speed 1000 rpm 1000 rpm Max speed in direct drive i 1 5000 rpm 5000 rom NOTE When using engine brakes counterflow to brake the spindles e g emergency stop ensure that the moments of inertia do not exceed the admissible output torques Braking times mu
7. e it to prevent it from turning see chap 3 4 3 3 4 Open design with adapter ring for 2K802 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 Check the motor shaft 2 for axial and radial runout as described in chapter 3 1 Also lightly grease the motor shaft 2 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 and slide it onto the motor shaft 2 until it reaches the stop Then check reference dimension C and change using shims if necessary ZF DUOPLAN Initial Installation Operating Instructions 2K800 2K801 2K802 CAUTION Risk of motor shaft damage if the hub is not sufficiently heated Tighten the threaded pin 9 and secure it to prevent it from turning see chap 3 4 3 3 5 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 The pulley must have a balance rating of 6 3 as per VDI Directive 2060 in order to ensure low vibration operation It is mandatory to lubricate the bearings fitted in the pulley drive w
8. ecure it to prevent it from turning see chap 3 4 CAUTION Thoroughly grease the radial shaft seal and the drive hub before installation When installing make sure that the sealing lip and the radial shaft seal are in the correct position NOTE The radial shaft sealing ring in the drive motor must be removed on the output end when the closed design is used In the case of motor adaptation and loosely supplied sealing spacing washers the latter must be pasted in by means of a jointing compound e g Loctite 574 prior to assembly Operating Instructions ZF D UOPLAIN 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 Clean the fitting surfaces of the motor 3 and drive hub 1 Check the motor shaft 2 for axial and radial runout as described in chapter 3 1 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 and slide it onto the motor shaft 2 until it reaches the stop Then check reference dimension C and change using shims if necessary CAUTION Risk of motor shaft damage if the hub is not sufficiently heated Tighten the threaded pin 9 and secur
9. essful Switch off main spindle motor After maximum 0 5 seconds Shift unit OFF Check system Gear ratio change complete Main spindle motor start 20 Operating Instructions 2K800 2K801 2K802 ZF DUOPLAN Initial Installation 3 7 Lubrication 3 7 1 Recirculating lubrication NOTE The 2K800 2K801 and 2K802 gearboxes must always be operated with recirculating lubrication In this case the oil level is not visible in the oil sight glass CAUTION Before operation for the first time ensure that the gearbox oil supply is taken into operation first To do this check the oil level in the reservoir and if necessary top up with oil until the oil level is no longer below the minimum mark in the reservoir The pump oil tank and heat exchanger components must be arranged below the gearbox oil level The transmission oil supply flow must be monitored NOTE After switching off the machine check that the oil level in the reservoir does not rise above the maximum mark The centrifugal forces acting on the oil can lead to insufficient lubrication of the gearing during continuous direct drive operation Occasionally changing gear ratio and then starting the motor nmo 1000 rpm supplies oil to the gearing and prevents one sided position specific loading of the gearing Some applications require a very low operating temperature level which can be reached by connecting an adapted gearbox oil supply
10. is rather small also a lower control current can be used The control current for end position monitoring is to be set according to length line and transition resistance and the number of connection points Increased resistance due to corrosion after some time must be taken into consideration Switching of inductive loads by means of the control current requires it to be wired parallel to the load by a diode If the limit switches detect that a gear is no longer securely engaged steps such as emergency shut off etc must be initiated through the control system NOTE Electromagnetic fields can falsify the limit position monitoring currents This can be prevented by re routing or shielding the line The shift sequence must be monitored If necessary a timer should be used to cancel the shift sequence after approx 2 seconds if there is no limit switch signal S1 S2 The main spindle motor can not be operated until this signal is present Circuit diagram for switchgear unit with solenoid unit and two switch positions standard or three switch positions with neutral position 1st gear gt eg 4 1 2nd gear gt 1 1 3rd gear gt Neutral position idling option optional mN grey IL Lie x8 blue H grey black 3 4 black The electromotive gearchange is performed by a shift unit on the gearb
11. ith 0 5 1 0 l min via oil connector S in the drive housing Oil feed for additional connecton in e case of pulley drive 3 4 Gearbox fit NOTE For drive hub 1 assembly the M8 set screw 9 must be screwed in and tightened at the parallel ey with 18 Nm until firmly home 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 The O ring is delivered oose with the gearbox and has to be coated with grease before being inserted into the seal groove in the housing 6 Check the position of the gearbox shift mechanism The sliding sleeve must be in the 1 gear position low gear ratio Take up the gearbox and place it onto the motor flange Carefully bring the sun gear hub connec tion together when doing this NOTE The external spline of the sun gear must be guided into the internal 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 hexagon bolts 11 Operating Instructions 2K800 2K801 2K802 ZF DUOPLAN Initial Installation Fillthe gearbox with oil and connect up the recirculating lubrication system and the power supply The breather outlet must always be at the top regardless of the installation position Tighten by max 1
12. l key balancing Refer to the installation drawing for the fitted key dimensions Always fix the fitted keys using threaded pins 3 5 3 Version without output The output shaft is not supplied by ZF It is manufactured by the customer Refer to the installation drawing for a proposal of how the connection point for the output shaft should be configured with the DIN 5480 profile Apply a suitable bolt locking compound e g Loctite no 275 or no 243 to the M12 cap screw and tighten to 115 Nm ZF DUOPLAN Initial Installation Operating Instructions 2K800 2K801 2K802 3 6 Electrical connection gearchange 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 Standard and neutral position 120 W Supply voltage 24 VDC 10 Power consumption 5A Index of protection IP64 The required cable lead diameter is 1 5 mm2 The 24 V DC connection voltage and 5 A power consumption must be assured on the shift unit connector Losses due to cable length and transition resistors must be taken into account Scope of supply Sleeve housing screw connection socket insert and 8 jacks type Harting AWG16 The shift unit can only be obtained as a complete part Gearbox shift mechanism Gearchanges are effected when the 24 V voltage is applied to pin 2 and 3 The polarity of the applied 24 VDC vo
13. least ten times the recirculating oil quantity in order to ensure effective oil cooling NOTE To prevent gearbox damage due to lack of oil ZF recommends you install an oil level sensor at the intermediate tank A 60 um filter must be used at the gearbox oil inlet oi ol ra BR 22 Operating Instructions ZF D UOPLAIN 2K800 2K801 2K802 Initial Installation 3 7 5 Ports and connections for recirculating lubrication Installation position Oil inlet port Max pressure Oil return port B5 M GorF 0 5 l min 3 bar or K 2 5 l min 5 bar D V1 M DorE 0 5 I min 3 bar or K 2 5 l min 5 bar L with suction V3 M H and I with suction 0 5 I min 3 bar K 2 5 l min 5 bar or or M 0 5 l min 3 bar GorF P 2 5 l min 5 bar NOTE The stated values of oil circulation quantities are minimum values The maximum value may be 50 higher The principal factor in determining the oil supply volume is always the volume that flows out of the oil return In the case of transmission with belt pulley drive consider the additional lube oil bore S also refer to Chapter 3 3 5 23 ZF DUORP I AN Operating Instructi
14. lel key and or the hub 3 2 2 Full key balancing In full key balancing the motor shaft is balanced with a full key whereas the hub is not The key shape length and position are not important in this case Operating Instructions 2K800 2K801 2K802 ZF DUOPLAN Initial Installation 3 3 Adaptation motor gearbox The motors must have a flange mounting option for mounting the gearboxes The gearbox housing is fitted to the motor by means of the centering adapter on the bearing housing This is standard Different gearbox variants are used depending on the motor type Gearbox mounting also differs accordingly Reference dimensions for hub position Gearbox type For output Dimension C in shaft length mm 2K800 140 82 3 0 2 ren 140 148 3 0 2 2K802 170 182 3 0 2 CAUTION Dimension C is reduced by 0 5 mm in motors with a fixed bearing on the B side Spacer discs are supplied with shims of varying thickness These enable balancing of the motor shaft length tolerances and therefore compliance with reference dimension C 3 3 1 Open design The open version is the gearbox without 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 Check the motor shaft for axial and radial runout as described in chapter 3 1 Also lightly gre
15. ltage dictates which gear is engaged In 1st gear gt Pin 2 Pin 3 In 2nd and 3rd gear gt Pin 2 Pin 3 During the gearchange the main spindle motor should make the shaft oscillate 5 at a rate of 1 to 5 rotation direction changes per second Major pendulum motion may lead to damage at the meshing gears Rotation direction lt changes In average this means nmot 5 s 5 60 min 300 min 300 360 rpm 0 83 rpm Conversion Pendulum speed lt gt pendulum rotary motion Speed Angle Time Angle rpm min sec sec 0 25 90 3 33 5 0 50 180 1 67 5 1 00 360 0 83 5 2 00 720 0 42 5 3 00 1080 0 28 5 4 00 1440 0 21 5 5 00 1800 0 17 5 The machine optimum is to be determined on the basis of shift tests in relation to the different masses and thereto connected drag torques of the spindle The limit switch signals from S1 contact 4 and S2 contact 6 serve to shut off the shift unit once the gearchange is complete CAUTION After the limit switch signals have been reached the shift unit is allowed to be live for a maximum of 0 5 second The limit switch signals must be monitored during the operating time The limit switches must only be energized with the control current 0 1 0 5 A and not with the changeover current 5 A Operating Instructions 2K800 2K801 2K802 ZF DUOPLAN Initial Installation If the number of resistors
16. n dealing with lubricants and cleaning agents Drain used gearbox oil into a suitable container if it is at operating temperature The drain ports differ depending on the installation position and gearbox version see chap 3 7 5 Pour new gearbox oil through port E The oil level itself is all important The oil quantity in liters indicated on the model plate is a reference value only If available let the oil pump operate briefly after filling with oil to remove any air and top up with oil again if necessary 25 ZF DUOPLAN Repair Operating Instructions 2K800 2K801 2K802 6 Repair In the event of gearbox malfunctions first check the connected components and their ports and connections Carefully document the type of fault so as to assist manufacturer diagnosis see chap 6 1 Repairs on the gearbox itself may only be carried out by ZF Friedrichshafen AG or by authorized ZF after sales points 6 1 Gearbox fault checklist If you encounter drive unit faults please refer to the remedies in chapter 7 first of all for help If this does not solve the problem you will need to provide the following information for diagnosis at ZF Friedrichshafen AG or an authorized ZF after sales point Gearbox data on the model plate Typ Type Stuckliste Parts list no Serien Nr 00000 Serial no Motor data on the model plate Manufacturer Type size 26 Questions for fault diagno
17. ngress of foreign matter ZF DUOPLAN Operating Instructions compound liquid seal Preface 2K800 2K801 2K802 1 3 Service products Product Name specification Quantity Use Remarks approx dm 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 Gearbox oil Gearbox oil for HLP 32 to ISO VG 32 recirculating lubrication with heat exchanger Jointing Loctite 574 Seal Sealing washer spacing washer Operating Instructions ZF D UOPLAN e 2K800 2K801 2K802 Application and Design 2 Application and Design 2 1 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 The gearbox is also suitable for use in many systems in which torque increase or speed reduction is required The gearboxes have coaxial output and are suit able for the high speeds generated in machine tool construction 2 2 Features Two speed gearboxes for AC and DC main spindle drives in machine tools Compact thanks to planetary design Flange mountable to all AC DC and standard motors e High running smoothness and low noise operation thanks to heli
18. ons 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 ol 24 Operating Instructions ZF D UOPLAIN 2K800 2K801 2K802 Taking into Operation Maintenance 4 Taking into Operation 4 1 Initial inspection Check that the gearbox is correctly installed before taking it into operation Mechanical fastening Motor flange mounting Gearbox oil ports and connections e Oil supply oil fill assured Electrical connections Ease of movement can be turned by hand Breather vertical position 5 5 1 Maintenance Oil change Oil change interval Every 5000 operating hours A ENVIRONMENTAL HAZARD Lubricants and cleaning agents must not be allowed to enter the ground the water table or the sewage system e Request safety information for the products concerned from your local environmental protection authority and follow any instructions herein at all times e Always collect used oil in a suitably large container e Always dispose of used oil clogged filters lubricants and cleaning agents in accordance with environmental protection laws e Always observe manufacturer instructions whe
19. ox which is driven by a DC motor 24 V DC The gearbox shift element is a positively locking axially movable selector fork that acts on a sliding sleeve The limit positions are monitored by limit switches in the shift unit The time sequence is monitored in the control unit The motor must be energized when shifting from gear 1 to 2 or vice versa The direction of rotation is changed over by reversing the polarity NOTE Gearbox with neutral position The neutral position can only be reached via gear 1 As soon as limit switch S3 receives the signal the 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 gt contact ZF 19 ZF DUOPI AIN 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 completed within 2 seconds Acknowledgement from limit switch S1 or S2 from the shift unit Number of attempted shifts gt 5 each from the starting position polarity reversal Shut off desired Gear ratio change not oscillating speed succ
20. ror in the shift unit Check the plug connection and clean if necessary secure connectors using clips e Send gearbox to ZF for inspection Gear disengages Limit position switch defective e Send gearbox to ZF Friedrichs hafen AG for inspection 28 ZF Friedrichshafen AG Industrial Technology Special Driveline Technology Industrial Drives amp Positioning Systems 88038 Friedrichshafen Germany Phone 49 7541 77 3694 Fax 49 7541 77 2379 E Mail industrial drives zf com www zf com industrial drives
21. s and cleaning products 1 1 Safety instructions All persons repairing ZF units are responsible for their own work safety Every applicable safety regulation and legal requirement must be complied with in order to prevent injury to personnel and or damage to the product during the course of maintenance and repair work Repair staff should familiarize themselves with these regulations before commencing work Correct and proper repair of these ZF products can only be assured by appropriately trained specialists The organization in charge of repairs is responsible for ensuring that such training is given Read these operating instructions carefully before commencing any testing or repair work CAUTION Pictures drawings and components do not always represent the original object but are used to illustrate working procedures The illustrations diagrams and parts are not drawn to scale and no assumptions should be made regarding size and weight including within a single illustration or drawing Work must be performed as described in the text Following the completion of repair work and testing the specialists must satisfy themselves that the product will function perfectly again 1 2 ZF instructions Remove any traces of old seals or gaskets from mating faces Use an oil stone to carefully remove any burrs or similar irregularities Carefully cover or shield open gearboxes to prevent the i
22. sis e s gearbox oil sight glass dark discolored black e Smell of burning oil at oil breather e Gearbox running noise in 1 1 or 4 1 gear ratio or only in one rotation direction or in both rotation directions e Before the running noise occurred was the machine operated in only one gear ratio 1 1 for an extended period of time e Did the running noise occur after changing the machine s cycle or was the machine cycle unchanged e Was any maintenance carried out on the machine before the fault occurred and if yes what did this maintenance work involve e No gear change or gear loss in the event of a shift problem e Does shift logic conform to ZF specifications see page 20 e What is the shift unit voltage during the shift sequence Operating Instructions ZF D UOPLAIN 2K800 2K801 2K802 Repair 6 2 Gearbox disassemble e g version with adapter plate and shaft seal Proceed accordingly in the case of other versions e Switch off the machine e Switch off the power supply e Disconnect the electrical connections e Disconnect the gearbox oil 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 removing device e g three arm puller to pull off the drive hub against the motor shaft without heating the hub 1 Drive h
23. st be adapted accordingly Standard fixing dimension in mm in accordance with EN 50347 2001 Type 2K800 2K800 2K801 802 2K801 802 Standard with STW version i 1 236 ominal input max 800 Nm max 800 Nm torque S1 Max output torque S1 for i 1 00 800 Nm 989 Nm i 3 19 2552 Nm 3154 Nm i 4 00 3200 Nm 3955 Nm Weight approx approx 175 kg 325 kg Two speed 2K800 2K801 2K802 gearbox FF350 FF400 FF500 Motor size 180 200 225 h 180 200 225 d 60 65 75 140 0 2 140 0 2 1404 0 2 b 300 350 450 e2 350 400 500 a1 400 450 550 2 4x18 5 8x18 5 8x18 5 Model plate standard affixed to gearbox housing BACKLASH AX NPUT TORQUE SHITING UNIT ZF FRIEDRICHSHAFEN AG MADE IN GERMANY PARTS LIST SERIAL NO INPUT TURN POWER MAX AL OIL GRADE OIL QUANTITY RPM ZF DUOPLAN Application and Design Operating Instructions 2K800 2K801 2K802 2 5 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 Operating Instructions ZF D UOPLAIN
24. turn if necessary The gearbox is now ready for use 1 gear position A Brake disc B Sliding sleeve CAUTION The gearboxes can be operated under the same degrees of protection as those defined for AC and DC motors When setting up make sure that the motor cooling air can flow in and out unhindered NOTE Before taking the electric motor gearbox assembly into operation check that the gearbox output can be turned by hand In the case of drive units that are fixed on the gearbox flange support the motor on the B side so that it does not vibrate 3 5 Output 3 5 1 Version with belt output The belt pulley must be centered on the outer diameter of the output flange tolerance K6 fastened with the bolts so that it is frictionally engaged and secured Comply with the specified tightening torques The belt pulley should be balanced to quality 6 3 as per VDI Directive 2060 in order to ensure low vibration operation CAUTION Note the maximum specified tensioning force when tightening the belts in order to prevent bearing overload The average belt force must be between the bearings When assembling it must be possible to easily slide the belt pulley onto the output shaft Heat the belt pulley if necessary 3 5 2 Version with coaxial output In the case of the version with coaxial output shaft stub also note the balancing type for the output see chap 3 2 The gearbox is delivered with ful
25. ub 2 3 4 5 6 7 Shaft seal Motor shaft Motor Cover Adapter plate Gearbox housing 9 Threaded pin 10 O ring 11 Mounting bolt 27 Frequently Asked Questions FAQ ZF DUOPLAN Operating Instructions 2K800 2K801 2K802 7 Frequently Asked Questions FAQ Error Cause of error Remedy Gearbox is loud knocking noises e Loose contact on motor speed sensor which causes permanent motor governing e Speed sensor dirty no clear signals sent Check speed sensor and electrical lines to motor clean speed sensor if necessary Check engine management system adjust speed control accordingly softer setting Gearbox is loud running noise Long periods at high cutting speed in ratio 1 1 followed by change to machining 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 install new bearing if necessary Gearbox leaking at gearbox Defective seals Renew seals send gearbox to ZF input output for inspection if necessary Gearbox leaking at breather e Oil has aged e Change the oil e Too much oil added during oil change e Check the oil level and correct if necessary Machine control receives no shift position signals from the gearbox shift unit e Loose contact in the plug connection on the gearbox shift unit Er
26. with oil cooling The respective gearbox versions are prepared accordingly The gearbox has different ports and connections for recirculating lubrication depending on the installation position and the operating type in order to ensure optimum gearbox cooling without affecting 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 The following instances are no cause for concern e The oil level in the tank falls due to foaming of the gearbox oil in the gearbox during operation e An oil air emulsion is formed in the oil return and in the tank 3 7 2 Recirculating lubrication for V1 B5 operation Refer to chapter 3 7 5 for the position of the oil inlets and outlets Oil inlet quantity Inlet 1 2 5 l min Inlet 2 0 5 l min If the gearbox is installed in vertical position V3 the gearbox oil can be supplied both radially and centrally The outlet line should be dimensioned so as to prevent oil return blockages in the gearbox Diapprox 20 mm 3 7 3 Recirculating lubrication with heat exchanger A heat exchanger is installed in the recirculating lubrication system to ensure additional tempera ture reduction 21 ZF DUOPI AIN Operating Instructions Initial Installation 2K800 2K801 2K802 3 7 4 Recirculating lubrication with Installation example B5 intermediate tank The tank volume should be at
27. 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 This is why it is very important to indicate the Semi key balancing Full key balancing motor data dimensions and balancing type when ordering Motor output shafts with standard fitted key 3 2 1 Semi key balancing in accordance with EN 50347 2001 In semi key balancing the keyway is filled with Gearbox Shaft diameter Fitted key Fitted key a balance compensation corresponding to type length approximately half a key shape B by default This is based on the original key shape length and 2K800 60 mm A18x11 125 mm position used by the motor manufacturer and is 2K801 65 mm A18x11 125 mm defined as a counterweight In semi key balancing 2K802 75 mm A20x12 125 mm in contrast to full key balancing the joint 80 mm A22x14 140 mm passes through a shared component This means imbalance can arise after assembly due to tolerance factors NOTE In the case of motor shafts with open ends of the As a result it is recommended that rebalancing should be performed after the joined parts have been assembled keyway the parallel key is to be glued into the groove in order to avoid axial migration of the paral
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