ZF Duoplan 2K800, Duoplan 2K801, Duoplan 2K802 Operating Instructions
OPERATING INSTRUCTIONS
ZF-Duoplan
T
wo-speed Gearbox
2K800 / 2K801 / 2K802
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.
This document is a translation of the German original.
Operating Instructions
2K800/2K801/2K802 Contents
EN 4161.758.103m – 2015-10 3
1 Preface .................................................................................................................................................. 5
1.1 Safety instructions ........................................................................................................................ 5
1.2 ZF instructions ............................................................................................................................. 5
1.3 Service products .......................................................................................................................... 6
2 Application and Design ......................................................................................................................... 7
2.1 Application ................................................................................................................................... 7
2.2 Features ....................................................................................................................................... 7
2.3 Design .......................................................................................................................................... 8
2.4 Technical data .............................................................................................................................. 9
2.5 Installation positions ................................................................................................................... 10
3 Initial Installation ................................................................................................................................. 11
3.1 Axial runout, radial runout and length tolerances – drive motor .................................................. 11
3.2 Balancing ................................................................................................................................... 12
3.2.1 Semi-key balancing .................................................................................................................... 12
3.2.2 Full-key balancing ...................................................................................................................... 12
3.3 Adaptation, motor/gearbox ........................................................................................................ 13
3.3.1 Open design............................................................................................................................... 13
3.3.2 Close design (with shaft sealing ring) ......................................................................................... 14
3.3.3 Open design with adapter ring for 2K800 and 2K801 ................................................................. 15
3.3.4 Open design with adapter ring for 2K802 ................................................................................... 15
3.3.5 Version with pulley drive ............................................................................................................ 16
3.4 Gearbox – fit .............................................................................................................................. 16
3.5 Output ........................................................................................................................................ 17
3.5.1 Version with belt output ............................................................................................................. 17
3.5.2 Version with coaxial output ........................................................................................................ 17
3.5.3 Version without output ............................................................................................................... 17
3.6 Electrical connection, gearchange .............................................................................................. 18
3.6.1 Shift unit .................................................................................................................................... 18
3.6.2 Shift logic ................................................................................................................................... 20
3.7 Lubrication ................................................................................................................................. 21
3.7.1 Recirculating lubrication ............................................................................................................. 21
3.7.2 Recirculating lubrication for V1/B5 operation .............................................................................. 21
3.7.3 Recirculating lubrication with heat exchanger ............................................................................ 21
3.7.4 Recirculating lubrication with intermediate tank ........................................................................ 22
3.7.5 Ports and connections for recirculating lubrication ..................................................................... 23
3.7.6 Connections for recirculating lubrication for direct mounting on the headstock .......................... 24
Operating Instructions
Contents 2K800/2K801/2K802
4 EN 4161.758.103m – 2015-10
4 Taking into Operation ......................................................................................................................... 25
4.1 Initial inspection ........................................................................................................................ 25
5 Maintenance ...................................................................................................................................... 25
5.1 Oil change ................................................................................................................................. 25
6 Repair ................................................................................................................................................. 26
6.1 Gearbox fault checklist .............................................................................................................. 26
6.2 Gearbox – disassemble ............................................................................................................. 27
6.3 Hub ........................................................................................................................................... 27
7 Frequently Asked Questions (FAQ) .................................................................................................... 28
Operating Instructions
2K800/2K801/2K802 Preface
EN 4161.758.103m – 2015-10 5
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:
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.
ENVIRONMENTAL HAZARDS!
Lubricants and cleaning products must not
be poured onto the ground, into groundwater or down the drain.
• Obtain and comply with the safety
regulations relevant to these products
issued by your local environmental
authority.
• Collect used oil in a suitably large
container.
• 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.
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.
Operating Instructions
Preface 2K800/2K801/2K802
6 EN 4161.758.103m – 2015-10
1.3 Service products
Product Name/specification Quantity
(approx.)
[dm
3
]
Use Remarks
Grease
Shell Avania WR2
Fuchs Renolit CXEP2
Esso Beacon EP2
General purpose
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
Jointing
compound (liquid
seal)
Loctite 574 Seal Sealing washer/
spacing washer
Operating Instructions
2K800/2K801/2K802 Application and Design
EN 4161.758.103m – 2015-10 7
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
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 switching
Operating Instructions
Application and Design 2K800/2K801/2K802
8 EN 4161.758.103m – 2015-10
2.3 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)
Axial bearing (15)
Shift mechanism:
Sliding sleeve (16)
Shift fork (17)
Brake disc (18)
Shift unit:
Shift unit (19)
Selector finger (20)
141
618
1
1
5
1
1
2
2
0
Operating Instructions
2K800/2K801/2K802 Application and Design
EN 4161.758.103m – 2015-10 9
2.4 Technical data
Type 2K800
2K801/802
Standard
version
2K800
2K801/802
with STW
(i = 1.236)
Nominal power max. 84 kW max. 84 kW
Nominal speed 1000 rpm 1000 rpm
Max. speed
in direct drive i = 1 5000 rpm 5000 rpm
NOTE
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
adapted accordingly.
Standard fixing dimension (in mm)
in accordance with EN 50347: 2001
Two-speed
gearbox
2K800
FF350
2K801
FF400
2K802
FF500
Motor size 180 200 225
h 180 200 225
d 60 65 75
l 140 0.2 140 0.2 140 0.2
b 300 350 450
e2 350 400 500
a1 400 450 550
s2 4x18.5 8x18.5 8x18.5
Type 2K800
2K801/802
Standard
version
2K800
2K801/802
with STW
(i = 1.236)
Nominal input
torque (S1)
max. 800 Nm max. 800 Nm
Max. output
torque (S1), for
i = 1.00
i = 3.19
i = 4.00
800 Nm
2552 Nm
3200 Nm
989 Nm
3154 Nm
3955 Nm
Weight approx.
175 kg
approx.
325 kg
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.
S
2
a
1
d
b
h
l
e
2
Loading...