ZF-DUOPLAN 2K250 Operating Instructions Manual Download

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OPERATING INSTRUCTIONS

Two-speed Gearbox

2K250 / 2K300

08.2007 Edition

4161 758 102i

Summary of Contents for 2K250

Page 1: ...OPERATING INSTRUCTIONS Two speed Gearbox 2K250 2K300 08 2007 Edition 4161 758 102i ...

Page 2: ...K250 2K300 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 08 2007 4161 758 102i ...

Page 3: ...3 3 3 2 Closed design with hub bearing and shaft sealing ring 14 3 3 3 Closed version with shaft seal 15 3 3 4 Open design with adapter ring 16 3 3 5 Keyless hub 17 3 3 6 Version with pulley drive 18 3 4 Gearbox fit 19 3 5 Output 20 3 5 1 Version with belt output 20 3 5 2 Version with coaxial output 20 3 5 3 Version with TSC 20 3 6 Electrical connection gearchange 20 3 6 1 Shift unit 20 3 6 2 Shif...

Page 4: ...Operating Instructions Contents 2K250 2K300 4 5 Maintenance 33 5 1 Oil change 33 6 Repair 34 6 1 Gearbox fault checklist 34 6 2 Gearbox disassemble 35 6 3 Hub 35 7 Frequently Asked Questions FAQ 36 ...

Page 5: ...ER 5 Used when due lack of care and attention can cause injury to personnel and or damage to property ENVIRONMENTAL HAZARDS CAUTION Pictures drawings and components do not al ways 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 singl...

Page 6: ...ulating lubrication and recirculating lubrication with heat exchanger Gearbox oil HLP 46 to ISO VG 46 Gearbox oil for recirculating lubrication Can also be used for recirculating lubrication with heat exchanger Gearbox oil 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 lubri cation with heat exchanger ...

Page 7: ...que 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 Lo...

Page 8: ...al 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 bearings 10 11 Output shaft 12 Radial shaft seal 13 Planet carrier 14 Axial bearing with cup springs 15 Shift mechanism Sliding sleeve 16 Shift fork 17 Brake disc 18 Shift unit Solenoid 19 Selector shaft 20 Adapter plate 21 8 ...

Page 9: ...ounterflow 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 Two speed gearbox 2K250 FF300 2K300 FF350 Motor size 132 160 h 132 160 d 42 48 55 48 55 60 l 110 0 2 110 0 2 b 250 300 e2 300 350 a1 s2 18 18 2K250 2K300 Nominal ...

Page 10: ... Installation positions 013765 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 10 ...

Page 11: ... 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 mount ing to the motor Oversize shafts must be ma chined to the correct length Take into account the permitted axial for...

Page 12: ...Fitted key Fitted key length 48 mm A14x9 90 mm 55 mm A16x10 90 mm 3 2 1 Semi key balancing In semi key balancing the keyway is filled with a balance compensation corresponding to approxi mately half a key shape B by default This is based on the original key shape length and posi tion used by the motor manufacturer and is de fined as a counterweight In semi key balancing in contrast to full key bal...

Page 13: ...e 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 concen tricity axia...

Page 14: ... 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 t...

Page 15: ...h 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 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 pre vent it from turning s...

Page 16: ...xial and radial runout as described in section 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 i e spacer disc 12 with shims 13 Then check reference dimension D and change using shims if necessary CAUTION Ri...

Page 17: ... connection 8 to 300 Nm for M16 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 D and the concentricity of the hub There is no longer any need for an additional in ternal seal in conjunction with ring clamping ele ments In screw connections with a hole for the co...

Page 18: ...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 1 1 5 l min via oil connec tor S in the drive housing BEWARE The stipulated maximum tensioning strength must not be exceeded when the belt is ten sioned in order to prevent the bearings from being overloaded The average belt power must lay inbetween ...

Page 19: ...easier by turning to the left or right at the gearbox output 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 recir culating 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 scre...

Page 20: ...through is subject to wear depending on the load and the status of the medium System condi tions can cause leakage drips to occur when switching on and off and the relative design measures must be implemented in the coolant circuit to retrieve them A transparent coolant return enables an evaluation of the rotary feedthrough status to be made The warranty for the rotary transmission leadthrough is ...

Page 21: ...y be energized with the control current 0 1 0 5 A and not with the changeover current 6 A If the number of resisters rather small also a lower control current can be used The control current for end position monitor ing is to be set according to length line and transition resistance and the number of con nection points Increased resistance due to cor rosion after some time must be taken into con s...

Page 22: ...to 1st gear Solenoid L2 Shift to 2nd gear Solenoid L3 Release of lock out device before gearchange Solenoid L4 Shift to neutral position option Solenoid L4 must be energized for shifts from 1st gear to 2nd gear and vice versa Solenoid L4 is de energized in the case of shifts to neutral NOTE Neutral position can only be engaged via the 1st gear Immediately shut off the power at L1 or L2 as soon as ...

Page 23: ...nds Acknowledgement from limit switch S1 or S2 from the shift unit Shut off desired oscillating speed Solenoid OFF after 0 5 to 1 0 seconds Gear ratio change complete Number of attempted shifts 5 each from the starting position polarity reversal Gear ratio change not successful Switch off main spindle motor Check system N N Y Y Main spindle motor start after min 0 5 seconds 1 Alternatively the fir...

Page 24: ...ype 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 con tinuous direct drive operation Occasionally changing gear ratio and then start ing the motor nMot 1000 rpm supplies oil to the gearing and prevents one sided position specific loading of the gearing Some applica...

Page 25: ... exchanger A heat exchanger is installed in the recirculating lubrication system to ensure additional tempera ture 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 effec tive oil cooling 25 NOTE To prevent gearbox damage due to lack of oil ZF recommends you install an oil level sensor a...

Page 26: ...7 3 Ports and connections for lubrication 3 7 3 1 Ports and connections for initial fill oil change see fig on page 27 Installation position Oil fill Oil drain B5 G F H B5 rotated D V1 N for version with output shaft P for version with output flange V3 I H 26 ...

Page 27: ...turn port V1 V3 closed variant M 0 5 dm3 min K or R 1 0 dm3 min L possible in addition 0 5 bar 0 5 bar V1 V3 open variant K or R 1 5 dm3 min L possible in addition 1 5 bar B5 G 1 5 dm3 min Main rotation direction counter clockwise F 1 5 dm3 min Main rotation direction clockwise 1 5 bar D Main rotation direction counter clockwise E Main rotation direction clockwise B5 rotated open I or F 1 5 bar H ...

Page 28: ...e in conjunction with the closed version The recommended oil viscosity for the integral lube oil system is HLP 22 as per ISO VG 22 HLP 10 to ISO VG 10 can be used with dry sump lubrication if it can be guaranteed that the gearbox oil outlet temperature will remain under 65 C at all times Installation position Oil inlet connection Max pressure Oil return connection V1 B5 closed variant K or R appro...

Page 29: ...ngth Approx 1000 mm 9 pole Running capacitor CB 25 µF not included in scope of supply Hydraulic Delivery rate 0 61 cm rev Nominal pressure 2 bar Intake filter Fineness 100 µm Option Tank with larger volume 19 l The plastic reservoir on the pump must be removed when the tank is used The pump is then inserted in the appropriate opening using the O ring provided and is secured with M8x35 cylindrical ...

Page 30: ...erature monitoring PE Protective conductor Connections 11 and 12 are for monitoring the temperature of the pump motor 3 7 4 3 Connection for nominal voltage 200 240 V AC Terminal diagram 200 240 V AC Circuit diagram for 200 240 V AC High voltage Low voltage Termi nal L N PE Jumpers Capacitor CB U1 U2 U5 U6 Z1 Z2 11 12 Temperature monitoring PE Protective conductor Connections 11 and 12 are for mon...

Page 31: ... the marking on the housing note suction direction Rotation direction 31 The air oil heat exchanger can be supplied in two rat ing classes TL 1 and TL 4 Technical data Nominal voltage 24 V DC Power consumption TL 1 41 W TL 4 113 W Blower drive brushless NOTE The oil coming out of the heat exchanger must always be above the oil coming in The oil through flow direction can be as required Air Oil Oil...

Page 32: ...Operating Instructions Taking into Operation Maintenance 2K250 2K300 Type TL 4 Rotation direction Oil Oil Air Circuit diagram Customer side Blower side interface 32 ...

Page 33: ...ours 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 fil ters lubricants and ...

Page 34: ...t Gearbox data on the model plate Typ Type Stückliste 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 discolored black Smell of burning oil at oil breather Gearbox running noise in 1 1 or 4 1 gear ra tio or only in one rotation direction or in both rotation directions Before the running noise ...

Page 35: ...r to pull off the drive hub against the motor shaft without heating the hub Press off against a removing aid 12 on the cover 8 Keep turning the puller until the cover is at the spacer disc motor shaft CAUTION When disassembling the hub ensure that the cover 8 is centred on the motor shaft Otherwise the cover may cause the hub to jam when being pulled off Renew the end disc 40 DIN 470 after disasse...

Page 36: ...ng noise Shims spring washers on sun gear incorrectly installed Measure reference dimension A Gearbox is loud running noise in ratio Motor shaft is too long axial bearing damaged Check reference dimension A correct and install new bearing if necessary Gearbox leaking at gearbox input output Defective seals Renew seals send gearbox to ZF for inspection if necessary Gearbox leaking at breather Oil h...

Page 37: ...ZF Friedrichshafen AG Special Driveline Technology Ehlersstraße 50 D 88046 Friedrichshafen Phone 49 75 41 77 0 Fax 49 75 41 77 34 70 E mail ZFM Sales zf com Internet www zf com ...

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