Operating Instructions - Drive Lines Technologies Ltd
Contents
1. Operating Instructions ZF D UOPLAIN 2K120 2K121 Initial Installation 3 7 3 Ports and connections for lubrication 3 7 3 1 Ports and connections for initial fill oil change Installation Oil fill Oil drain position B5 G F V1 LK for version with output shaft P for version with output flange V3 F G l e e em R M O O i Be K E ME 6 7 Ge D 9 a N F G y En 25 ZF DUOP AN 6 Operating Instructions Initial Installation Duoplan 2K120 2K121 3 7 3 2 Ports and connections for recirculating lubrication Installation position Oil inlet port Max pressure Oil return port V1 closed variant M 0 5 bar D 0 5 dm min Main rotation direction and counter clockwise K R and or L S 0 5 bar E 1 0 dm3 min Main rotation direction clockwise V1 open variant K R and or L S 0 5 bar 1 5 dm3 min B5 G 1 5 bar 1 5 dm3 min Vi Main rotation direction counter clockwise Or F 1 5 dm 3 min Main rotation direction clockwise V3 P 1 5 dm min 1 5 bar H or K R and or L S 0 5 bar H 1 5 dm min As seen facing gearbox output NOTE The principal factor in determining the oil supply volume is always the volume that flows out of the oil return NOTE2. Gearbox leaking at gearbox input output Gearbox leaking at breather Defective seals Oil has aged e oo much oil added during oil change Renew seals send gearbox to ZF for inspection if necessary e Change the oil 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 Error 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 30 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
3. Port K and or L must be connected to 1 5 dm min at maximum speed 12000 rpm Furthermore recirculating lubrication with gear oil cooling gt 0 3 kW and an oil circulation volume gt 15 litres is necessary 26 Operating Instructions ZF D UOPLAIN 2K120 2K121 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 Fase of movement can be turned by hand Breather vertical position 5 Maintenance 5 1 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 Request safety information for the products concerned from your local environmental protection authority and follow any instructions herein at all times Always collect used oil in a suitably large container Always dispose of used oil clogged filters lubricants and cleaning agents in accordance with environmental protection laws Always observe manufacturer instructions when 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 t
4. been assembled 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 2K120 2K121 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 There is also a foot mounting on the gearbox housing for 2K120 Different gearbox variants are used depending on the motor type Gearbox mounting also differs accordingly Reference dimensions for hub position Gearbox type Dimension C in mm 2K120 33 3 0 2 2K121 53 3 0 2 CAUTION Dimension C 32 8 0 2 2K120 or 52 8 0 2 2K121 in the case of motors with fixed bearing on the B side 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 grease 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 t
5. 14 3 3 3 Closed design with shaft seal ert tee ere vvvee a vn es vane nn YR EE EUER 15 3 3 4 Open design with adapter mg 16 3 3 91 En De ERE A 17 3 4 Gearbox TT 18 S E EEN 19 3 5 1 Version with belt output RII II II II ne re nne nnn enn ee nne en ne nne ne E nnn nean 19 3 5 2 Version with eoaxial OUtDUt EE 19 3 5 3 Version with SC 19 3 6 Electrical connection gearchange eee ene hehe eene hene hene rene rene nnne rennes 19 3 61 5S lE DIEM E eee tee tentare a red tread e RU PURO dre e n d nae E 19 ET Oe 22 3 7 Lubrication ccc 23 EE Mal WOM CAL Le ie EE 23 3 7 2 Recirculatind LUT CAE OM E 23 3 7 3 Ports and connections for Jubrteation ene mene ene nene rennen rene nnn nne 25 ZF DUOP AN 6 Operating Instructions Contents 2K120 2K121 4 Taking into ele Le EE 27 4 1 Initial inspection rrarena II I RII RII n Rn nnn nnn ne nne nne ne n e nne ne n e ne ere nenne 27 5 MaintenanG Mm 27 bo OU GhangQesssencnecutuiiiitce eee e i ea ee 27 6 afecte FEED 28 6 1 Gearbox fault checklet eene hene hnee n rne ne rre n n n rennen 28 6 2 Gearbox disassemble AAA 29 MM Uo nc Em 29 7 Frequently Asked Questions FACH 30 Operating Instructions 2K120 2K121 ZF DUOPLAN Preface 1 Preface This documentation is intended for specialists who have experience to carry out
6. 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 Operating Instructions ZF D UOPLAN e 2K120 2K121 Initial Installation Diagram for shift unit with two positions standard or three positions with neutral position 1st gear gt e g 4 1 2nd gear gt 1 1 3rd gear gt S3 neutral position idling option X8 blue i grey black 3 black The electromotive gearchange is performed by a shift unit on the gearbox which is driven by a DC motor 2
7. burning oil at oil breather Gearbox running noise in 1 1 or 4 1 gear ratio or only in one rotation direction or in both rotation directions Before the running noise occurred was the machine operated in only one gear ratio 1 1 for an extended period of time Did the running noise occur after changing the machine s cycle or was the machine cycle unchanged Was any maintenance carried out on the machine before the fault occurred and if yes what did this maintenance work involve No gear change or gear loss in the event of a shift problem Does shift logic conform to ZF specifications see page 22 What is the shift unit voltage during the shift sequence Operating Instructions ZF D UOPLAIN 2K120 2K121 Repair 6 2 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 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 1 Drive hub Use a removing device e g three arm puller to 2 Motor shaft pull off the drive hub against the motor shaft 3 Motor without heating the hub A Hub bearing Alternatively there
8. 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 ZF D UOP AN Operating Instructions Initial Installation 2K120 2K121 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 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 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 or shim 13 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 Operating Instructions 2K120 2K121 ZF DUOPLAN 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 There must be a central thread in the motor output shaft The mating surfaces of the motor 3 m
9. 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 Obtain and comply with the safety regulations relevant to these products issued by your local environmental authority Collect used oil in a suitably large container Dispose of used oil clogged filters lubricants and cleaning products in accordance with local environmental protection regulations Always follow the instructions issued by the manufacturer when handling lubricants 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
10. must be blocked in order to prevent twisting of the motor shaft and input hub when tightening This can be done using a special tool ZF 1X46 190 227 CAUTION Do not grease the motor shaft and the hole in the input hub The cone surface of the ring clamp elements also needs to be lightly oiled NOTE The counter holder is supported on the shoulder of the motor shaft It is necessary to have a large contact surface In the closed version without hub bearing grease the seal running surface for the radial oil seal on the input hub before installation Watch out for the position of the sealing lip when pushing on the input hub CAUTION When using the enclosed design with hub bearing 10 and radial oil seal 11 do not push the input hub onto the motor shaft using the adapter plate Once the screw connection has been tightened the adapter plate must be in contact with the motor housing and it must be possible to turn it freely This means the hub bearing is free from tension ZF DUOPLAN Initial Installation Operating Instructions 2K120 2K121 3 4 Gearbox fit The M8 set screw 9 must be screwed in and tightened at the parallel key 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 de
11. thanks to flexible output bearings High efficiency Electromotive gearchange ZF D UOP AN Operating Instructions Application and Design 2K120 2K121 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 Sun gear bearings 15 Connecting parts e Drive hub 1 e Adapter plate 2 with radial shaft seal 3 and hub bearings 4 as necessary Housing i i e Gearbox housing 5 E 16 Input e e Shift fork 17 e Brake disc 18 Shift unit e Shiftunit 19 e Selector finger 20 e Sun gear 6 e Ring gear 7 e Ring gear bearings 8 AX Operating Instructions 2K120 2K121 ZF DUOPLAN Application and Design 2 4 Technical data Nominal power max 19 kW Nominal speed 1500 rpm Input torque continuous operation max 120 Nm Max speed in ratio i 1 8000 rpm in direct drive i71 with gearbox oil cooling 12000 rpm See chap 3 7 3 2 Ports and connections for recirculating lubrication values apply as of 01 2004 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 must be adapted accordingly Standard fixing dimension in mm in accordance with EN 50347 2001 Nominal inp
12. 4 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 Neutral position can only be engaged via the 1 gear As soon as limit switch S3 receives the signal the electric current must be switched off immediately this can be done with short circuit control if necessary 21 ZF D UOP AN Operating Instructions Initial Installation 2K120 2K121 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 1 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 Shut off desired oscillating speed After maximum 0 5 seconds Shift unit OFF Gear ratio change complete Main spindle motor start 1 Alternatively the first switching test can be performed without oscillating or minor output end masses 22 Number of attempted shifts gt 5 each from the starting position polarity reversal Gear ratio change not successful Switch o
13. In this instance the type of recirculating lubrication depends on the operating temperature level required 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 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 25 show the oil inlet and outlet points on the gearbox Please refer to the relevant installation drawings for precise details The oil level must remain in the middle of the oil sight glass following operation for the first time top up to this level if necessary CAUTION The pump oil tank and heat exchanger components must be arranged below the gearbox oil level Connecting an oil return as described in chapter 3 7 3 2 assures limp home emergency control characteristics NOTE The following incidences are no cause for concern e The oil level in the tank falls due to
14. K121 3 2 Balancing The hubs 2 come with a keyway 1 for trans mitting 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 motor data dimensions and balancing type when ordering Motor output shafts with standard fitted key in accordance with EN 50347 2001 Shaft diameter Fitted key Fitted key length 28 mm A7x7 45 mm 32 38 mm A10x8 70 mm 42 A12x8 90 mm NOTE In the case of motor shafts with open ends of the keyway the parallel key is to be glued into the groove in order to avoid axial migration of the parallel key and or the hub Half key balancing Full key balancing 3 2 1 Semi key balancing In semi key balancing the keyway is filled with a balance compensation corresponding to approximately half a key shape B by default This is based on the original key shape length and position used by the motor manufacturer and is defined as a counterweight In semi key balancing in contrast to full key balancing the joint passes through a shared component This means imbalance can arise after assembly due to tolerance factors As a result it is recommended that rebalancing should be performed after the joined parts have
15. Operating Instructions ZF DUOPLAN Two speed Gearbox 2K120 2K121 08 2013 Edition 4161 758 101j en ZF DUOPLAN 2K120 2K121 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 101j Operating Instructions ZF D UOPLAIN 2K120 2K121 Contents 1 MISTER LL EIU IIR 5 1 1 Safety instructions ssssssssssssssssssss tear III IR I II nnn nne en nnn ne nnn ne n e nne ne ne nne ne n e nnn neun 5 1 2 ZF INSIUCTIONS aa UE HUE UAE TH EIL THERE Y 5 EE EE 6 2 Application and BR Ce BEE H 2 1 Applecaton e t EEE 7 PEERS 7 e Ee EE 8 2 4 Technical data cce reati tisa duisi ei dad eiie tddadtiei dt diaeta desides da ULT HORE CES Fe IR 9 2 b JnstallatiotiposltlOHs aeren Assesse 10 3 Initial Installati n iae 11 3 1 Axial runout radial runout and length tolerances drive motor cece eeccceececeeeeceeeeeeueeeeneeeenees 11 3 2 Balancing ccc 12 3 21 Semi key belagert deene I UU 12 3 2 2 F ll key balancifig uii RR ERRARE RARO kann nn a a a 12 3 3 Adaptation motor gearbox sssssssssessesesseeheee hehe hehe hene hehe nen rise rein rese tree e eee rene tenens 13 3 3 1 Open design een eene eI Rene nne hne nne nne rene rine rene rene rene tene rene rennen 13 3 3 2 Enclosed design with hub bearing and oil seg
16. The polarity of the applied 24 V DC voltage dictates which gear is engaged gt Pin 2 Pin 3 gt Pin 2 Pin 3 In 1st gear In 2nd and 3rd gear 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 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 20 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 If the number of resistors is rather small also a lower control current can
17. an be turned by hand In the case of drive units that are fixed on the gearbox flange or housing the motor can be supported on the B side so that it does not vibrate Operating Instructions 2K120 2K121 ZF DUOPLAN Initial Installation 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 full key balancing Refer to the installation drawing for the fitted key dimensions Always fix the fitted key using a threaded pin 3 5 3 Version with TSC The version with TSC Through Spindle Coolant is used for carrying cooling lubricant hydraulic oils or air oil mixtures through the gearbox to the spindle A rotary transmissio
18. 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 ingress of foreign matter ZF DUOPLAN Operating Instructions Preface 2K120 2K121 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 68 to ISO VG 68 splash lubrication recirculating lubrication 1 0 2K120 and recirculating Installation pos B5 lubr
19. are two threads 13 on the 5 Adapter plate end face of the drive hub which can be used to 6 Gearbox housing secure the puller brace Press off against a 7 Shafi seal removing aid 12 on the cover 8 Keep turning 8 ever the puller until the cover is at the motor shaft 9 Threaded pin CAUTION 10 O ring When disassembling the hub ensure that the cover 11 Mounting bolt 8 is centred on the motor shaft Otherwise the cover 12 Removing aid cylinder 20x50 mm may cause the hub to jam when being pulled off 13 Thread for removing device Renew the end disc 28 DIN 470 after disassembly Clean before installing and coat the sealing edge with liquid seal Visually check the shaft seal and O ring and fit new ones if necessary 29 Frequently Asked Questions FAQ ZF DUOPLAN Operating Instructions 2K120 2K121 7 Frequently Asked Questions FAQ Error Cause of error Remedy Gearbox is loud knocking noises e oose 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
20. ff main spindle motor Check system but this requires a de energized main spindle motor Operating Instructions 2K120 2K121 ZF DUOPLAN Initial Installation 3 7 Lubrication 3 7 1 Splash lubrication The standard B5 version of the gearbox has splash lubrication CAUTION Splash lubrication is suitable for intermittent operation In this instance frequent gearchanges varying speeds and idle time e g due to retooling are the order of the day The gearbox oil must be filled up to the middle of the oil sight glass in such applications The actual oil level is all important when it comes to filling up with oil The quantity in liters indicated on the gearbox model plate is intended as a guide only NOTE If the gearbox is installed at an angle as is the case in certain belt tensioners an oil level tube with calibration mark must be fitted in place of the oil sight glass The oil level in the gearbox must be the same as for a gearbox installed in horizontal position also see installation drawing 3 7 2 Recirculating lubrication CAUTION Recirculating lubrication is required for continuous operation for operation in one gear ratio over an extended period of time for high speeds and for intermittent operation with shorter idle times regardless of the installation position Recirculating lubrication is required for 2K120 2K121 gearboxes installed in the vertical V1 and vertical V3 positions
21. 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 23 ZF DUOPLAN Initial Installation Operating Instructions 2K120 2K121 3 7 2 1 Recirculating lubrication for V1 B5 operation Refer to chapter 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 One oil sight glass is removed and replaced with a screw in drain pipe M42x1 5 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 Di approx 20 mm 3 7 2 2 Recirculating lubrication with heat exchanger A heat exchanger is installed in the recirculating lubrication system to ensure additional temperature reduction 3 7 2 3 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 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 and a safety non return valve 1 must be used at the gearbox oil inlet This arrangement ensures continued operation based on the splash lubrication see chap 3 7 1 24 Installation example B5
22. he installation position and gearbox version see chap 3 7 3 1 Pour new gearbox oil through port I The oil level is deemed correct when it reaches the middle of the oil sight glass when the gearbox is idle 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 27 ZF DUOPLAN Repair Operating Instructions 2K120 2K121 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 St ckliste 2161 es Parts list no Serien Nr Serial no Motor data on the model plate Manufacturer Type size 28 Questions for fault diagnosis Is gearbox oil sight glass dark discolored black Smell of
23. he stop or shim 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 9 3 Z 4 us EA Ki Iz ZA NIT LS RU 11 LE j ZF D UOP AN Operating Instructions Initial Installation 2K120 2K121 3 3 2 Enclosed design with hub bearing and oil seal Variant with ball bearing 4 in which the hub 1 is additionally mounted in order to ensure more straightforward installation There is no longer any need to measure the parts or to use shims because the hub is delivered with an adapter plate and hub bearing in exactly the right position There are no internal axial forces in the 2K120 2K121 that could act on the hub When assembling separate the drive hub 1 with adapter plate 5 from the gearbox housing 6 Clean the fitting surfaces of the motor and drive hub Check the motor shaft for axial and radial runout as described in chapter 3 1 Also lightly grease 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 motor flange stop CAUTION Risk of motor shaft damage if the hub is not sufficiently heated NOTE When assembling it must be possible to easily slide the hub onto the motor shaft until the adapter plate is against the moto
24. ication with heat 1 4 2K121 exchanger Installation pos B5 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 Bonding agent Loctite 574 Sealing end cover liquid seal in hub End disc 28 DIN 470 1 Hub sealing Exchange after disassembling the hub Operating Instructions ZF D UOPLAIN 2K120 2K121 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 High running smoothness and low noise operation thanks to helical gearing Low torsional backlash Easy to install High radial forces permitted on output end Combined axial and radial force
25. ion 3 Initial Installation 3 1 Axial runout radial runout and length tolerances drive motor Take into account the motor shaft elongation caused by heating in motors with fixed bearing on the B side opposite the motor output shaft In order to guarantee fault free operation the motor must not exceed the specified tolerances bh C o L lt 001064 Axial runout radial runout and length tolerances electric motor mounting flange Gearbox Tolerance WR A B C L 2K120 0 025 0 050 0 050 0 100 2K121 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 Take into account the permitted axial forces on the motor shaft Also see ZF DUOPLAN catalogue 4161 750 102 Performance data chapter ZF DUOPLAN Initial Installation Operating Instructions 2K120 2
26. livered loose 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 connection 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 slightly turning the motor shaft or the gearbox output to the left or right Hold the electric motor by the eye bolts Then carefully guide the motor shaft with fitted drive hub into the gearbox The gearbox housing adapter plate and motor are bolted together using four eight hexagon bolts 11 Fill the 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 The breather is screwed in to the B5 position ex works The gearbox is now ready for use 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 1st gear position A Brake disc B Sliding sleeve NOTE Before taking the electric motor gearbox assembly into operation check that the gearbox output c
27. n lead through is necessary to ensure that the fluid can be conveyed in a ratio operating at differential speed This lead through is subject to wear depending on the load and the status of the medium The warranty for the rotary transmission lead through is limited to 12 months Information about the product function operation and installation of the rotary transmission lead through can be found in the operating instructions 4161 758 030 German 4161 758 130 English CAUTION 1 No abrasive or solvent additives are permitted in the fluids 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 24VDC 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 is only available as a complete part ZF DUOPLAN Initial Installation Operating Instructions 2K120 2K121 Gearbox shift mechanism Gearchanges are effected when the 24 V voltage is applied to pin 2 and 3
28. otor shaft 2 and input hub 1 must be cleaned The motor shaft 2 must be checked for concen tricity and axial run out in accordance with chapter 3 1 Loosely mount the counter holder 4 ring clamping elements 5 6 bush 12 pressure piece 7 and screw connection with thread lock 8 in advance Watch out for the position of the ring clamping elements when doing this First install the inner 5 then the outer 6 ring clamping elements in the pack on the motor shaft Push the input hub onto the motor shaft with or without adapter plate 9 depending on the version By hand move the ring clamping elements into contact using the screw connection Tightening the screw connection causes the hub and the adapter plate if fitted to move axially towards the motor Take this into consideration with a lead dimension of 0 4 mm Tighten screw connection 8 to 90 Nm for M12 Take note of the maximum torque permitted for the thread in the motor shaft Screws with a strength category of 10 9 must be used with adaptations without a coolant flow Check dimension C and the concentricity of the hub There is no longer any need for an additional internal seal in conjunction with ring clamping elements The number of ring clamping elements and bushes can vary depending on the motor In screw connections with a hole for the coolant to flow through watch out for the O rings and grease them before installation The input hub
29. r flange CAUTION Do not use the adapter plate to help slide the hub onto the motor shaft Check by ensuring that the fitted adapter plate can be turned freely This ensures that there is no hub bearing preload Tighten the threaded pin 9 and secure it to prevent it from turning see chap 3 4 NOTE The radial shaft sealing ring in the drive motor must be removed on the output end when the closed design is used Operating Instructions ZF D UOPLAIN 2K120 2K121 Initial Installation 3 3 3 Closed design 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 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 After cleaning the fitting surfaces place the adapter plate with radial shaft seal 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 or shim 13 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 CAUTION Thoroughly grease the radial shaft seal and the drive hub before installation When installing make sure that the sealing
30. ut torque continuous operation max 120 Nm Max output torque i 1 00 120 Nm i 3 16 379 Nm i 4 00 480 Nm i 4 91 589 Nm Weight approx 42 kg 2K120 Standard type plate approx 52 kg 2K121 affixed to gearbox housing ZF FRIEDRICHSHAFEN AG BACKLASH MAX INPUT TORQUE SHITING UNIT MADE IN GERMANY PARTS LIST SERIAL NO INPUT TURN POWER MAX AT RPM OIL GRADE OIL QUANTITY Two speed 2K120 2K121 gearbox FF215 FF265 Motor size 100 112 h 100 112 d 28 32 38 28 32 38 l 800 1 80 0 1 b 180 230 e2 215 265 E E s2 14 14 ZF D UOP AN Operating Instructions Application and Design 2K120 2K121 2 5 Installation positions STR o N Horizontal B5 gt Horizontal B5 Shift unit on right side gearbox turned around longitudinal axis view to output end Vertical V1 Vertical V3 CAUTION The breather outlet must always be at the top regardless of the installation position Operating Instructions ZF D UOPLAIN 2K120 2K121 Initial Installat
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