ZF DUOPLAN 2K121, DUOPLAN 2K120 Operating Instructions
Operating Instructions
ZF-DUOPLAN
Two-speed Gearbox
2K120 / 2K121
Industrial Drives
Copyright © ZF Friedrichshafen AG
This document is protected by copyright.
Complete or partial reproduction or dissemination of this document is
prohibited without the consent of ZF Friedrichshafen AG. Infringements lead
to civil and criminal prosecution.
Contents
EN 4161.758.101m – 2018-09 3
1 Preface ................................................................................................................................... 5
1.1 Validity and field of application ..................................................................................................... 5
1.2 Service products .......................................................................................................................... 5
2 Safety ..................................................................................................................................... 6
2.1 Signal words and symbols ............................................................................................................ 6
2.2 General safety instructions ........................................................................................................... 6
2.3 Product-specific safety instructions .............................................................................................. 8
3 Application and Design .......................................................................................................... 9
3.1 Application ................................................................................................................................... 9
3.2 Features ....................................................................................................................................... 9
3.3 Design ........................................................................................................................................ 10
3.4 Technical data ............................................................................................................................ 11
3.5 Installation positions ................................................................................................................... 12
4 Initial Installation ................................................................................................................. 13
4.1 Axial runout, radial runout and length tolerances – drive motor .................................................. 13
4.2 Balancing ................................................................................................................................... 14
4.2.1 Semi-key balancing .................................................................................................................... 14
4.2.2 Full-key balancing ...................................................................................................................... 14
4.2.3 Motor shafts/hubs without keyways ........................................................................................... 15
4.3 Adaptation, motor/gearbox ........................................................................................................ 16
4.3.1 Open design............................................................................................................................... 16
4.3.2 Closed design with hub bearing and shaft sealing ring ............................................................... 17
4.3.3 Closed version (with shaft seal) .................................................................................................. 18
4.3.4 Open design with adapter ring ................................................................................................... 19
4.3.5 Closed design with hub bearing, shaft seal and keyless hub ....................................................... 20
4.3.6 Gearbox – fit .............................................................................................................................. 21
4.3.7 Closed design with hub bearing, shaft seal and clamping hub ................................................... 22
4.4 Output ........................................................................................................................................ 24
4.4.1 Version with belt output ............................................................................................................. 24
4.4.2 Version with coaxial output ........................................................................................................ 24
4.4.3 Version with TSC ........................................................................................................................ 24
4.5 Electrical connection, gear change ............................................................................................. 24
4.5.1 Shift unit .................................................................................................................................... 24
4.5.2 Control logic ............................................................................................................................... 27
4.6 Lubrication ................................................................................................................................. 28
4.6.1 Splash lubrication ....................................................................................................................... 28
4.6.2 Recirculating lubrication ............................................................................................................. 28
4.6.3 Ports and connections for lubrication ......................................................................................... 30
Contents
4 EN 4161.758.101m – 2018-09
5 Taking into Operation .......................................................................................................... 32
5.1 Initial inspection ........................................................................................................................ 32
6 Maintenance ........................................................................................................................ 32
6.1 Oil change ................................................................................................................................. 32
7 Repair .................................................................................................................................. 33
7.1 Gearbox fault checklist .............................................................................................................. 33
7.2 Gearbox – disassemble ............................................................................................................. 34
7.3 Input hub with fitted key ............................................................................................................ 34
7.4 Disassembly of gearbox with clamping hub ............................................................................... 35
8 Frequently Asked Questions (FAQ) ...................................................................................... 36
Preface
EN 4161.758.101m – 2018-09 5
1 Preface
In addition to the ZF documentation, observe the
provisions of the body manufacturer.
1.1 Validity and field of application
This documentation applies to the following ZF
products:
2K120
2K121
1.2 Service products
Product Name/specification Quantity
(approx.)
[dm
3
]
Use Remarks
Grease
Shell Avania WR2
Fuchs Renolit CXEP2
Esso Beacon EP2
General
assembly aid
Gearbox oil
HLP 68 according to
ISO VG 68
1.0
1.4
Gearbox oil for
splash lubrication
2K120 –
Installation position
B5
2K121 –
Installation position
B5
Can also be used for
recirculating lubrication
and recirculating
lubrication with heat
exchanger
Gearbox oil
HLP 46 according to
ISO VG 46
Gearbox oil for
recirculating
lubrication
Can also be used for
recirculating lubrication
with heat exchanger
Gearbox oil
HLP 32 according to
ISO VG 32
Gearbox oil for
recirculating
lubrication with
heat exchanger
Bonding agent
(liquid seal)
Loctite 574 Sealing end cover
in hub
End disc 28 DIN 470 1 Hub sealing Exchange after
disassembling the hub
Safety
6 EN 4161.758.101m – 2018-09
2 Safety
2.1 Signal words and symbols
This document contains specifically highlighted
safety instructions which are marked with one of
the following signal words depending on the
severity of the danger.
DANGER
The signal word DANGER indicates a dangerous
situation that, if not prevented, will lead to a
severe injury or death.
Information as to how the hazard can be
prevented.
WARNING
The signal word WARNING indicates a
dangerous situation that, if not prevented, can
lead to a severe injury or death.
Information as to how the hazard can be
prevented.
CAUTION
The signal word CAUTION indicates a
dangerous situation that, if not prevented, can
lead to a slight or moderate injury.
Information as to how the hazard can be
prevented.
The signal word NOTE indicates a situation that,
if not prevented, can lead to property damage.
Information as to how the property damage
can be prevented.
The following symbols are also used:
This symbol refers to additional, safetyrelevant information.
This symbol indicates information
concerning special workflows, methods,
application of auxiliary materials, etc.
2.2 General safety instructions
Read all safety instructions and information.
Failure to comply with safety instructions and
information may lead to property damage, serious
injuries or death.
Intended use
The ZF product is exclusively intended for the
application as defined in the contract and as
agreed on at the time of delivery. Any other or
more extensive form of use does not comply with
this definition of intended use. The intended use
includes compliance with this documentation and
other applicable documents, in order to avoid
malfunctions and damage in operation.
The ZF product is designed and produced in line
with state-of-the-art technology. The ZF product is
safe to operate in its delivery status. However, the
ZF product may pose dangers if improperly used
by unauthorized, untrained and uninstructed staff
or if not used according to its intended use.
Figures might deviate from the ZF product and are
not drawn to scale. No conclusions can be drawn
with regard to size and weight.
Assembly, commissioning, maintenance and
repair
Only perform assembly, commissioning,
maintenance and repair work according to this
documentation and other applicable documents.
Safety
EN 4161.758.101m – 2018-09 7
Observe the following points:
Employ authorized, trained and instructed staff.
Observe technical provisions.
Only use genuine ZF spare parts.
Only use genuine ZF accessories.
Only use genuine ZF special tools.
Unauthorized changes and modifications lead to
the expiry of the operator's license, warranty or
guarantee.
In case of damage, contact ZF and have the
following information on the product to hand:
Type
Parts list [BoM] number
Serial number
Kilometer reading
Description of damage
Observe safety instructions, valid safety regulations
and legal requirements to prevent malfunctions
and damage.
The country-specific safety regulations, accident
prevention regulations and environmental
protection provisions also apply.
Wear workwear in accordance with safety
requirements for all work. Depending on the work,
also wear personal protective equipment.
After completing the work, check correct function
and functional security.
Handling of ZF product
Unauthorized changes and modifications may
impair functional security.
Changes, modifications and applications are only
permitted with the written approval of ZF
Friedrichshafen AG.
Observe the following when working on the ZF
product:
Secure workspace.
Only carry out work at the unit when in a
voltage-free state.
Protect unit against being started accidentally.
Attach information sign in a clearly visible
position.
Perform work when motor is switched off.
Protect motor against being started accidentally.
Attach information sign in a clearly visible
position.
Do not stand beneath a suspended load.
Do not work on a suspended load.
Only use permitted means of transport and
lifting appliances with sufficient load-bearing
capacity.
Close open pipelines and hoses and avoid
damage.
Observe tightening torques.
Protect cables against mechanical damage.
Noise
Noise may cause irreversible damage to hearing.
The perception of acoustic signals, warning calls
or sounds warning of impending danger is
impaired by noise.
Observe the following when working on the ZF
product:
Avoid noise.
Wear ear protection.
Operating supplies and auxiliary materials
Operating supplies and auxiliary materials may
cause permanent damage to health and
environmental damage.
Observe the following when selecting operating
supplies and auxiliary materials:
Health risks
Environmental compatibility
Material safety data sheets
Observe the following when handling operating
supplies and auxiliary materials:
Store operating supplies and auxiliary materials
in suitable and correctly labeled containers.
Seek medical help in case of injuries due to hot,
cold or caustic operating supplies or auxiliary
materials.
Observe the following to protect the environment:
Collect leaking operating supplies and auxiliary
materials in containers of a sufficient size.
Observe disposal regulations.
Observe material safety data sheets.
Safety
8 EN 4161.758.101m – 2018-09
2.3 Product-specific safety instructions
Remove any traces of old seals or gaskets from
mating faces. Burrs or other similar rough
surfaces are to be carefully removed with an oil
stone.
Carefully cover opened gearboxes to prevent
the entry of foreign matter.
Application and Design
EN 4161.758.101m – 2018-09 9
3 Application and Design
3.1 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.
3.2 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 thanks to
flexible output bearings
High efficiency
Electromotive gear change
Application and Design
10 EN 4161.758.101m – 2018-09
3.3 Design
The gearbox primarily comprises the following
assemblies:
Connecting parts:
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 bearings (10, 11)
Output shaft (12)
Radial shaft seal (13)
Planet carrier (14)
Sun gear bearings (15)
Shift mechanism:
Sliding sleeve (16)
Shift fork (17)
Brake disc (18)
Shift unit:
Shift unit (19)
Selector finger (20)
Application and Design
EN 4161.758.101m – 2018-09 11
3.4 Technical data
Nominal power max. 19 kW
Nominal speed 1,500 rpm
Input torque
(continuous operation): max. 120 Nm
Max. speed
in ratio i1 8,000 rpm
in direct drive i=1
(with gearbox oil cooling) 12,000 rpm
See chap. 4.6.3.2 “Connections for circulating
lubrication” (Values apply as of 01/2004).
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 adjusted
accordingly.
Standard fixing dimension (in mm)
in accordance with EN 50347:2001
Two-speed
gearbox
2K120
FF215
2K121
FF265
Motor size 100 112
h 100 112
d 28/32/38 28/32/38
l 80±0.1 80±0.1
b 180 230
e2 215 265
a1 – –
s2 14 14
Nominal input torque
(continuous operation) max. 120 Nm
Max. output torque for
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)
approx. 52 kg (2K121)
Model plate (standard)
(affixed to gearbox housing)
ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY
TYPE PARTS LIST
RATIO SERIAL-NO.
BACKLASH
MAX.
INPUT TURN RPM
POWER MAX.
AT RPM KW
INPUT
TORQUE NM
OIL GRADE
OIL
QUANTITY
SHITING V
UNIT W
i , - ,
MIN.
Application and Design
12 EN 4161.758.101m – 2018-09
3.5 Installation positions
Horizontal B5
Horizontal B5
Shift unit on right side
Gearbox turned around longitudinal axis
(view to output end)
Vertical V1
Vertical V3
Possible damage to gearbox due to oil
leaks.
The breather outlet must always be at the
top, regardless of the installation position.
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