Operating Instructions - Drive Lines Technologies Ltd
Contents
1. L raf P Axial runout radial runout and length tolerances electric motor mounting flange Le i 2 001064 Gearbox Tolerance SES A B C L 2K450 0 025 0 063 0 063 0 200 2K600 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 Operating Instructions ZF DUOPLAN Initial Installation 2K450 2K600 3 2 Balancing The hubs 2 come with a keyway 1 for transmitting power from the motor shaft 3 as standard There are two balancing types for the motor and gearbox 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 impo2. The electromotive gearchange is performed by a shift unit on the gearbox 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 21 Operating Instructions ZF DUOPLAN 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 1 Shift unit energized pin 2 and 3 Gear ratio change is completed within 2 seconds Acknowledgement from limit switch S1 S2 or S3 from the shift unit Shut off desired
3. NOTE Used to highlight special sequences methods information etc CAUTION Used when incorrect and improper operating procedures can cause damage to the product DANGER Used when due lack of care and attention can cause injury to personnel and or damage to property N ENVIRONMENTAL HAZARDSI 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 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 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
4. 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 Preface ZF DUOPLAN Operating Instructions 2K450 2K600 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 HLP 68 to ISO VG 68 2K450 Gearbox oil for Can also be used for B5 5 1 splash lubrication recirculating lubrication HLP 46 to ISO VG 46 and recirculating 2K600 lubrication with heat Bb 5 4 exchanger Gearbox oil HLP 46 to ISO VG 46 Gearbox oil for Can also be used for recirculating recirculating lubrication lubrication with heat exchanger Gearbox oil
5. F 2 0 dm3 min counter clockwise Main rotation direction clockwise 1 5 bar E or Main rotation direction T 2 0 dm min 0 5 bar clockwise B5 M 1 0 dm min and 0 5 bar closed variant T 1 5 dm min 0 5 bar B5 gedreht T 2 0 dm min or 0 5 bar H open variant 2 0 dm3 min or 1 5 bar F 2 0 dm3 min or 1 5 bar G 2 0 dm3 min 1 5 bar Vi M 1 0 dm min and 0 5 bar E closed variant T 1 5 dm min 0 5 bar V1 T 2 0 dm min 0 5 bar E open variant V3 M 1 0 dm min and 0 5 bar D closed variant T 1 5 dm3 min 0 5 bar V3 T 2 0 dm min 0 5 bar D open variant 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 In the case of transmission with belt pulley drive consider the additional lube oil bore T also refer to Chapter 3 3 5 26 Operating Instructions ZF DUOPLAN 2K450 2K600 Initial Installation 3 7 3 3 Connections for recirculating lubrication for direct mounting on the headstock Take account of connection M acc to chapter 3 7 3 2 for the oil supply Implement the oil return according to the installation orientation Oil supply in all installation orientations 2 l min 27 Operating Instructions ZF DUOPLAN Taking into Operation Maintenance 2K450 2K600 4 Taking into Operation 4 1 Initial inspection Check that the gearbo
6. 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 ZF DUOPLAN Initial Installation 2K450 2K600 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 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 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 Reference dimension D is set at the factory 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 motor 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 r
7. 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 Tighten by max 1 turn if necessary 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 1 gear position A Brake disc B Sliding sleeve 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 or housing the motor can be supported on the B side so that it does not vibrate Operating Instructions 2K450 2K600 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 t
8. socket insert and 8 jacks type Harting AWG16 The shift unit can only be obtained as a complete part Operating Instructions ZF DUOPLAN Initial Installation 2K450 2K600 Gearbox shift mechanism Gearchanges are effected when the 24 V voltage is applied to pin 2 and 3 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 rom 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 max
9. 19 3 5 2 Version with COAXIAL output en ee 19 3 5 3 Version without output cece cece ceccc ccc eeee cece ceseceueceeeeseceueceeeeseetuecseeeeeeteeeseeeseeteceseeteeeneeneeens 19 3 6 Electrical connection oearchange trt iteris EE EEEE ENE E EErEE EEE rE eenn e rnea 19 3 6 1 Shift UNE nn anne 19 EE lee 22 Se SE Eelere EE ER e ae tele ele EE 23 3 7 2 Recirculating ubrteation cece cece cece cece cece ceca neces eee UE EEE t rE EEEE ESEEs a SEEGESEEGEEEtGESEEGEEEEEE EEEn EEEn 23 3 7 3 Ports and connections for Iubrteanon irei ii r a EOE 25 Operating Instructions ZF DUOPLAN Contents 2K450 2K600 4 Taking into Operation rien 28 4 1 Torgral inspectHOn a nn nn an SES a ha pm EEN 28 4 2 Sun gear setting check 28 5 E E Ee EE 28 Bet Oillehang EE 28 6 TS ET 29 6 1 Gearbox fault checklist oe ccc cece c cece ccc a ceeeeeeecee eee eeeeeeeeeseceueceeseseetueeeeeeseetseeeeeseetseeneeeaeeens 29 6 2 Gearbox dsassemble ccc ccc ccc ccc c cece ccc e cece eeeeceeceseeeueceeeeseceueeseeeseeeeeeteeseetseeteeeseeteereeeaeeees 30 EC NEE 30 7 Frequently Asked Questions FACH 31 Operating Instructions ZF DUOPLAN 2K450 2K600 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
10. 2K600 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 H 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 ii and slide it onto the motor shaft 2 until it reaches the stop i e spacer disc 12 with shims 13 Then check reference dimension D 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 secure it to prevent it from turning see chap 3 4 Operating Instructions ZF DUOPLAN 2K450 2K600 Initial Installation 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 with 0 5 1 0 l min via
11. DUOPLAN Application and Design Operating Instructions 2K450 2K600 2 3 Design The gearbox primarily comprises the following assemblies 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 Input e Sun gear 6 e Ring gear 7 e Ring gear bearings 8 Output 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 with cup springs 15 Shift mechanism e Sliding sleeve 16 e Shift fork 17 e Brake disc 18 Shift unit e Shift unit 19 e Selector finger 20 1 mm Cl eg Operating Instructions ZF DUOPLAN 2K450 2K600 Application and Design 2 4 Technical data 2K450 2K600 2K450 2K600 Nominal power max 47 kW max 63 kW Nominal 450 Nm 600 Nm input torque ominal speed 1000 rpm 1000 rpm S1 Max Spaey Max output n ratio Li 5000 rpm 5000 rpm ne Be torque S1 n direct drive i 1 8000 rpm 5000 rpm N i 1 00 450 Nm 600 Nm NOTE i 4 00 1800 Nm 2400 Nm When using engine brakes counterflow to brake i 5 00 2250 Nm 3000 Nm the spindles e g emergency stop ensure that Weight BEER Angler 16 the moments of inertia do not exceed the admissible output torques Braking times must be adapted accordingly Model
12. HLP 32 to ISO VG 32 Gearbox oil for recirculating lubrication with heat exchanger Gearbox oil HLP 22 to ISO VG 22 Gearbox oil for recirculating lubrication with heat exchanger and integrated lubrication oil system Bonding agent Loctite 574 Sealing end cover liquid seal in hub End disc 40 DIN 470 1 Hub sealing Exchange after disassembling the hub Operating Instructions ZF DUOPLAN 2K450 2K600 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 suitable 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 helical 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 gearchange ZF
13. Operating Instructions ZF DUOPLAN Two speed Gearbox 2K450 2K600 08 2013 Edition 4161 758 106c_en ZF DUOPLAN 2K450 2K600 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 106c Operating Instructions ZF DUOPLAN 2K450 2K600 Contents 1 Pr face u giess ee ee geess 5 1 1 Safety instructions ueceeeseueseessnsnsusnnnennnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnsnnennsnnnsnnennnnnnennnn 5 CN leg Oe E 5 dr EIERE 6 2 Application and Design 7 eelere E H 22 EAU Ee EE ENEE ENEE 7 23 Design 8 ENEE E 9 E ENEE UE e Tele le EE 10 3 Initial Ee EE 11 3 1 Axial runout radial runout and length tolerances drive MOTOS 0 cece ceccccecccseeceeueeeeueeceueeeenees 11 BZ BAl NEING EE 12 3 2 1 Semi Key EE EE 12 3 2 2 Full key balancing 0 cc cece cece cece cece cece eee nee EU EEE EU EE EU EEE DEE GE SEEGE SEED EEEEGESEEG a SEEGESEtGEEEEEEEEEEE EEE 12 3 3 Adaptation motor gearbox cece 13 He re Joule 751 Ne Ee e ME 13 3 3 2 Closed design with hub bearing and shaft sealing ring eeseeeeseenessenessnesseneesenensnensnenn nen 14 3 3 3 Closed version with shaft seg 15 3 3 4 Open design with adapter mg 16 3 3 5 Version with Goller drives dese 17 3 4 Gearbox TT 18 SE e EE 19 3 5 1 Version with Pelkes eessen au nie
14. ating 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 2K450 2K600 gearboxes installed in the vertical V1 output downwards and vertical V3 output upwards positions 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 Following the initial startup
15. ensioning 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 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 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 24V DC 10 Power consumption 5A Index of protection IP64 The required cable lead diameter is 1 5 mm The 24 VDC 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
16. imum 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 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 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 DUOPLAN 2K450 2K600 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 blue grey black 3 4 black 52 ya
17. ing in the drive motor must be removed on the output end when the closed design is used 3 5 1 Ne haber iT Ve La 11 Operating Instructions ZF DUOPLAN 2K450 2K600 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 4 delivered loose 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 2 l we After cleaning the fitting surfaces place the F S Sege plate with EES shaft seal onto en ZB g Heat the drive hub to approx 120 C from Te SC the opening and slide it onto the motor shaft until 7 it reaches the stop i e spacer disc 12 with shims 13 Then check reference dimension D 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 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 lip and the radial shaft seal are in the correct position Operating Instructions ZF DUOPLAN Initial Installation 2K450
18. nd 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 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 Operating Instructions 2K450 2K600 ZF DUOPLAN Repair 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 4161 Parts list no Serien Nr 000000 Serial no Motor data
19. oil connector S in the drive housing CAUTION The stipulated maximum tensioning strength must not be exceeded when the belt is tensioned in order to prevent the bearings from being overloaded The average belt power must lay in between the bearings The pulley must be just touching the drive flange when fitted heat up the pulley if necessary Operating Instructions ZF DUOPLAN Initial Installation 2K450 2K600 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 delivered 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 turning to the left or right at the gearbox output
20. on the model plate Manufacturer Type size Questions for fault diagnosis e Is gearbox oil sight glass dark discolored black e Smell of burning oil at oil breather e Gearbox running noise in 1 1 or 4 5 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 22 e What is the shift unit voltage during the shift sequence 29 Operating Instructions ZF DUOPLAN Repair 2K450 2K600 6 2 Gearbox disassemble e g version with adapter plate shaft seal and hub bearings 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 1 Drive hub Motor
21. 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 minor output end masses 22 2K450 2K600 Number of attempted shifts gt 5 each from the starting position polarity reversal Gear ratio change not successful Switch off main spindle motor Check system but this requires a de energized main spindle motor or Operating Instructions ZF DUOPLAN 2K450 2K600 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 Recircul
22. plate affixed to gearbox housing Standard fixing dimension in mm ZF FRIEDRICHSHAFEN AG in accordance with EN 50347 2001 MADE IN GERMANY Two speed 2K450 2K600 PARTS LIST _ gearbox FF300 FF350 A SERIAL NO Motor size 160 180 180 BACKLASH INPUT TURN AX _ POWER MAX h 160 180 180 AT RPM NPUT d 55 60 60 65 TORQUE OIL GRADE SHITING OIL 110 0 2 140 0 2 UNIT QUANTITY 140 0 2 b 250 300 e2 350 400 S2 18 18 Operating Instructions ZF DUOPLAN Application and Design 2K450 2K600 2 5 Installation positions Horizontal B5 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 DUOPLAN 2K450 2K600 Initial Installation 3 Initial Installation 3 1 Axial runout radial runout and length tolerances drive motor In order to guarantee fault free operation the motor must not exceed the specified tolerances Take into account the motor shaft elongation caused by heating in motors with fixed bearing on the B side opposite the motor output shaft
23. rbox running noise normalizes after several gear changes Axial bearing incorrectly installed Check installation Shims spring washers on sun gear incorrectly installed Measure reference dimension A Gearbox is loud running noise in ratio Gearbox leaking at gearbox input output Motor shaft is too long axial bearing damaged Defective seals Check reference dimension AT correct and install new bearing if necessary Renew seals send gearbox to ZF for inspection if necessary Gearbox leaking at breather e Oil has aged e Too much oil added during oil change 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 e Error in the shift unit e Check the plug connection and clean if necessary secure connectors using clips e Send gearbox to ZF for inspection Gear disengages e Limit position switch defective e Send gearbox to ZF Fried richshafen AG for inspection 31 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
24. rtant 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 55 mm A16x10 90 mm 60 mm A18x11 125 mm 65 mm A18x11 125 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 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 ZF DUOPLAN 2K450 2K600 Initial Installation 3 3 Adaptation motor gearbox The motors must have a flange mounting op
25. shaft Motor Hub bearing Use a removing device e g three arm puller to 2 pull off the drive hub against the motor shaft 3 without heating the hub 4 Press off against a removing aid 12 on the cover 5 Adapter plate 8 Keep turning the puller until the cover is at the 6 Gearbox housing 7 8 spacer disc motor shaft Shaft seal CAUTION SE D When disassembling the hub ensure that the cover S dee SEHR 10 O ring 8 is centred on the motor shaft Otherwise the cover may cause the hub to jam when being pulled off 11 Mounting bolt 12 Removing aid cylinder 25x100 mm Renew the end disc 40 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 30 Operating Instructions 2K450 2K600 ZF DUOPLAN Frequently Asked Questions FAQ 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 Gea
26. sure 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 An oil level sensor on the intermediate tank is recommended in order to prevent damage to the gearbox due to dry running 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 The oil return line must always lie below the oil outlet downstream of the gearbox to ensure that the oil level in the gearbox does not rise 24 Installation example B5 Operating Instructions ZF DUOPLAN 2K450 2K600 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 F G H B5 rotated D Vi P for version with output flange V3 D 25 ZF DUOPLAN Initial Installation Maintenance 3 7 3 2 Connections for circulating lubrication in standard applications Operating Instructions 2K450 2K600 Installation Oil inlet port Max Oil return port position pressure B5 G 2 0 dm min 1 5 bar D open variant Main rotation direction counter clockwise Main rotation direction
27. the oil level must be in the middle of the oil sight glass when the gearbox is at standstill Top up the oil 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 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 Operating Instructions ZF DUOPLAN Initial Installation 2K450 2K600 3 7 2 1 Recirculating lubrication for V1 B5 operation Refer to chapter 3 7 2 for the position of the oil inlets and outlets The oil supply is mounted on the central connection point T M12x1 5 and in case of hub bearings connection point M M10x1 The total oil supply rate should be between 2 0 and 2 5 dm3 min For the oil return flow an oil sight glass is removed and an outlet pipe M42x1 5 is screwed in instead In the V3 vertical installation orientation the gear oil can also be supplied centrally via the output shaft connection P 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 en
28. tion 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 2K450 and 2K600 Different gearbox variants are used depending on the motor type Gearbox mounting also differs accordingly Reference dimensions for hub position Gearbox type Dimension D in mm 2K450 175 5 0 2 2K600 175 5 0 2 CAUTION In the case of motors with fixed bearing on the B side the dimension is D 175 0 0 2 Spacer discs are supplied with shims of varying thickness These enable balancing of the motor shaft length tolerances and therefore compliance with reference dimension D 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 gear box Clean the fitting surfaces of the motor 3 and drive hub Check the motor shaft for concentricity axial runout and length according to chapter 3 1 and correct as necessary Use shim rings to compensate undersize Shorten the motor shaft in case of oversize 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 stop Then check reference dimension D CAUTION
29. x is correctly installed before taking it into operation Mechanical fastening Motor flange mounting Gearbox oil ports and connections Oil supply oil fill assured Electrical connections Ease of movement can be turned by hand Breather vertical position 4 2 Sun gear setting check Check dimension A 175 7 mm tolerance 0 2 mm measured between the housing connection surface and the front end of the sun gear When measuring press the sun gear towards the output until it reaches the stop The sun gear is correctly set before leaving the factory Check the dimension after inserting the sun gear e g following disassembly Dimension A is correct if the spring pack 2 and shims 1 are fully and correctly installed see detail illustration opposite 28 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 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 when dealing with lubricants a
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