ZF-DUOPLAN 2K120 Operating Instructions Manual Download Page 1

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Operating Instructions

Two-speed Gearbox

2K120 / 2K121

08.2013 Edition

4161 758 101j_en

Summary of Contents for 2K120

Page 1: ...Operating Instructions Two speed Gearbox 2K120 2K121 08 2013 Edition 4161 758 101j_en...

Page 2: ...120 2K121 2 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 10...

Page 3: ...ncing 12 3 2 2 Full key balancing 12 3 3 Adaptation motor gearbox 13 3 3 1 Open design 13 3 3 2 Enclosed design with hub bearing and oil seal 14 3 3 3 Closed design with shaft seal 15 3 3 4 Open desig...

Page 4: ...ntents 2K120 2K121 4 4 Taking into Operation 27 4 1 Initial inspection 27 5 Maintenance 27 5 1 Oil change 27 6 Repair 28 6 1 Gearbox fault checklist 28 6 2 Gearbox disassemble 29 6 3 Hub 29 7 Frequent...

Page 5: ...ing 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 produ...

Page 6: ...s B5 2K121 Installation pos B5 Can also be used for recirculating lubrication and recirculating lubrication with heat exchanger Gearbox oil HLP 46 to ISO VG 46 Gearbox oil for recirculating lubricatio...

Page 7: ...orque 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...

Page 8: ...s Drive hub 1 Adapter plate 2 with radial shaft seal 3 and hub bearings 4 as necessary Housing Gearbox housing 5 Input Sun gear 6 Ring gear 7 Ring gear bearings 8 Output Bearing housing 9 Output beari...

Page 9: ...e admissible output torques Braking times must be adapted accordingly Standard fixing dimension in mm in accordance with EN 50347 2001 Two speed gearbox 2K120 FF215 2K121 FF265 Motor size 100 112 h 10...

Page 10: ...0 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 al...

Page 11: ...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 ope...

Page 12: ...tor 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 3 2 1 Semi key balancing In semi key balanc...

Page 13: ...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 pr...

Page 14: ...unout 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...

Page 15: ...faces 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 C...

Page 16: ...ive 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 ho...

Page 17: ...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 addi...

Page 18: ...or 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 pla...

Page 19: ...ricant hydraulic oils or air oil mixtures1 through the gearbox to the spindle A rotary transmission lead through is necessary to ensure that the fluid can be conveyed in a ratio operating at different...

Page 20: ...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 energize...

Page 21: ...n 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 u...

Page 22: ...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...

Page 23: ...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 dir...

Page 24: ...ent 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...

Page 25: ...25 3 7 3 Ports and connections for lubrication 3 7 3 1 Ports and connections for initial fill oil change Installation position Oil fill Oil drain B5 I G F V1 L K for version with output shaft P for ve...

Page 26: ...R and or L S 1 5 dm3 min 0 5 bar B5 V1 G 1 5 dm3 min Main rotation direction counter clockwise or F 1 5 dm3 min Main rotation direction clockwise 1 5 bar V3 P 1 5 dm3 min or K R and or L S 1 5 dm3 mi...

Page 27: ...thority 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 wi...

Page 28: ...n the model plate Typ Type St ckliste 4161 Parts list no Serien Nr Serial no Motor data on the model plate Manufacturer Type size Questions for fault diagnosis Is gearbox oil sight glass dark discolor...

Page 29: ...rnatively there are two threads 13 on the end face of the drive hub which can be used to secure the puller brace Press off against a removing aid 12 on the cover 8 Keep turning the puller until the co...

Page 30: ...o machining in ratio 4 1 No gearbox damage Gearbox running noise normalizes after several gear changes Gearbox leaking at gearbox input output Defective seals Renew seals send gearbox to ZF for inspec...

Page 31: ...Industrial Technology Special Driveline Technology Industrial Drives Positioning Systems 88038 Friedrichshafen Germany Phone 49 7541 77 3694 Fax 49 7541 77 2379 E Mail industrial drives zf com www zf...

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