ZF-DUOPLAN 2K2100, Operating Instructions Manual, Page: 26 / 34

Operating Instructions
Initial installation 2K2100 with STW
3.8 Lubrication
3.8.1 Recirculating lubrication
NOTE
The 2K2100 gearbox must always be operated
with recirculating lubrication. In this case, the oil
level is not visible in the oil sight glass (max. oil
spray).
CAUTION
Before operation for the first time, always
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 and oil tank components must be
arranged below the gearbox oil level (outlet
bore).
NOTE
After switching off the machine, check that the oil
level in the reservoir does not rise above the
maximum mark.
The diagrams on page 27 show the oil inlet and
outlet points on the gearbox. Please refer to the
relevant installation drawings for precise details.
The following instances are no cause for concern:
•
The oil level in the tank falls due to foaming of
the gearbox oil in the gearbox during
operation.
•
An oil-air emulsion is formed in the oil return
and in the tank.
3.8.1.1 Recirculating lubrication for V1/B5
operation
Refer to section 3.8.2 for the position of the oil
inlets and outlets.
Oil inlet quantity:
Inlet for 2K2100
: (M) at least 3.0 l/min at 3 bar,
thread M16x1.5 (hollow screw).
Inlet for spur gear stage
: (K) approx. 3.5 l/min,
at 3 bar, on eccentric bolt (3), thread M12x1.5.
The outlet line (D) (thread M42x2) should be
dimensioned so as to prevent oil return blockages
in the gearbox. (D
i
approx. 20 mm)
3.8.1.2 Recirculating lubrication with heat
exchanger and intermediate tank
A heat exchanger is installed in the recirculating
lubrication system to ensure additional
temperature reduction.
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
Maschinenantriebe GmbH recommends you
install an oil level sensor at the intermediate tank.
A 60 µm filter must be used at the gearbox oil
inlet.
Cooler
Filter
Pump
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