ZF-DUOPLAN Two-speed Gearbox 2K250 / 2K300 …Application and Design EN 4161.758.102r – 2018-09 9 3 Application and Design 3.1 Application The DUOPLAN 2-speed gearbox by ZF is mainly

Operating Instructions ZF-DUOPLAN Two-speed Gearbox 2K250 / 2K300 Industrial Drives

Copyright © ZF Friedrichshafen AG

This document is protected by copyright. Complete or partial reproduction or distribution of this document is not permitted without the approval of ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution.

Contents

EN 4161.758.102r – 2018-09 3

1 Preface ................................................................................................................................... 5

1.1 Validity and field of application ..................................................................................................... 5

1.2 Consumables ............................................................................................................................... 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 Radial run-out, axial run-out and linear tolerances of 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 design (with shaft seal) ................................................................................................... 18 4.3.4 Open design with adapter ring ................................................................................................... 19 4.3.5 Closed design with hub bearing, shaft sealing ring and keyless hub ........................................... 20 4.3.6 Mounting the gearbox ................................................................................................................ 21 4.3.7 Version with pulley drive ............................................................................................................ 22 4.3.8 Closed design with hub bearing, shaft sealing ring and clamping hub ........................................ 23

4.4 Output ........................................................................................................................................ 25 4.4.1 Version with belt output ............................................................................................................. 25 4.4.2 Version with coaxial output ........................................................................................................ 25 4.4.3 Version with TSC ........................................................................................................................ 25

4.5 Electrical connection, gearchange .............................................................................................. 25 4.5.1 Shift unit .................................................................................................................................... 25 4.5.2 Shift logic ................................................................................................................................... 28

Contents

4 EN 4161.758.102r – 2018-09

4.6 Lubrication ................................................................................................................................ 29 4.6.1 Splash lubrication ...................................................................................................................... 29 4.6.2 Recirculating lubrication ............................................................................................................ 29 4.6.3 Connections for lubrication ........................................................................................................ 31

5 Initial Operation ................................................................................................................... 34

5.1 Initial inspection ........................................................................................................................ 34

5.2 Checking setting dimension of sun gear .................................................................................... 34

6 Maintenance ........................................................................................................................ 34

6.1 Oil change ................................................................................................................................. 34

7 Repair .................................................................................................................................. 35

7.1 Gearbox fault checklist .............................................................................................................. 35

7.2 Gearbox – disassemble ............................................................................................................. 36

7.3 Input hub with parallel key ........................................................................................................ 36

7.4 Disassembly of gearbox with clamping hub ............................................................................... 37

8 Frequently Asked Questions (FAQ) ...................................................................................... 38

Preface

EN 4161.758.102r – 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:

2K250

2K300

1.2 Consumables

Product Name/Specification Quantity (approx.) [dm3]

Application Comment

Grease

Shell Avania WR2

Fuchs Renolit CXEP2

Esso Beacon EP2

General assembly aid

Gearbox oil

HLP 68 according to ISO VG 68

2K250 B5: 1.5 V1: 1.2 2K300 B5: 2.8 V1: 1.5

Gearbox oil for splash lubrication depending on installation position

Can also be used for recirculating lubrication and recirculating lubrication with heat exchanger

Gearbox oil


Gearbox oil for recirculating lubrication

Can also be used for recirculating lubrication with heat exchanger

Gearbox oil


Gearbox oil for recirculating lubrication with heat exchanger

Gearbox oil HLP 22 according to ISO VG 22

Gearbox oil for recirculating lubrication with heat exchanger and integrated lubricating oil system

Bonding agent (liquid seal)

Loctite 574 Sealing end cover in hub

End washer 40 DIN 470 1 Hub sealing Replace after hub disassembly

Safety

6 EN 4161.758.102r – 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 NOTICE 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 additionally used:

This symbol refers to additional, safety-relevant 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 4161.758.102r – 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 Operating hours 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 devices 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 4161.758.102r – 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 4161.758.102r – 2018-09 9

3 Application and Design

3.1 Application

The DUOPLAN 2-speed gearbox by ZF is mainly used in machine tool drives.

As a result of the different installation positions, the gearbox can be used, for example, for turning machines (horizontal B5) or machining centers (vertical V1). In addition, the gearboxes are used in various equipment in which an increase in torque or a reduction in speed is needed.

The gearboxes have a coaxial output and are suited to the high speeds encountered in machine tool engineering.

3.2 Features

2-speed gearbox for AC and DC main spindle drives in machine tools

Compact thanks to 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

Combined axial and radial force thanks to flexible output bearings

High efficiency

Electromechanical gearchange


10 EN 4161.758.102r – 2018-09

3.3 Design

The gearbox primarily comprises the following assemblies:

Connecting parts: Input hub (1) Where required, adapter plate (2) with radial

shaft seal (3) and hub bearing (4) Housing: Gearbox housing (5) Input: Sun gear (6) Ring gear (7) Ring gear bearing (8)

Output: Bearing housing (9) Output bearing (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 disk (18) Shift unit: Shift unit (19) Selector finger (20)


EN 4161.758.102r – 2018-09 11

S2

a1 e2

d b

h

l

3.4 Technical data

2K250 2K300

Nominal power max. 39 kW max. 47 kW

Nominal speed 1,500 rpm 1,500 rpm

Max. speed when ratio i1 in direct drive i=1 (with gearbox oil cooling and integrated lubricating oil system). See Chap. 4.6.3.3 "Connections for integrated lubrication oil system and maximum speed"

6,300 rpm 10,000 rpm

6,300 rpm 10,000 rpm

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 installation dimensions (in mm) according to EN 50347: 2001

Two-stage gearboxes

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

Input nominal torque

max. 250 Nm max. 300 Nm, when i = 5.50 max. 250 Nm

Output torque, max. for

i = 1.00

i = 3.07

i = 4.00

i = 5.50

250 Nm

768 Nm

1,000 Nm

1,375 Nm

300 Nm

921 Nm

1,200 Nm

1,375 Nm

Weight approx. 68 kg approx. 86 kg

Model plate (standard) (mounted on gearbox housing)

ZF FRIEDRICHSHAFEN AGMADE IN GERMANY

TYPE PARTS LIST

RATIO SERIAL-NO.

BACKLASHMAX.

INPUT TURN RPMPOWER MAX.AT RPM KW

INPUTTORQUE NM OIL GRADE

OILQUANTITY

SHITING VUNIT W

i , - ,

MIN.


12 EN 4161.758.102r – 2018-09

3.5 Installation positions

Horizontal B5

Horizontal B5

Shift unit on right Gearbox rotated around longitudinal axis (looking at output)

Vertical V1

Vertical V3

Possible damage to gearbox due to oil leaks. Fit breather at top in all installation positions.

Initial Installation

EN 4161.758.102r – 2018-09 13

4 Initial Installation

4.1 Radial run-out, axial run-out and linear tolerances of drive motor

To ensure trouble-free operation, the motor to be connected must comply with the specified tolerances.

Radial run-out, axial run-out and linear tolerances of mounting flange of electric motor:

Gearbox type

Tolerance

A B C L

2K250 / 2K300

0.025 0.063 0.063 -0.200

Tolerances A, B, C according to DIN 42955R Please note the restricted tolerance of the shaft length "L" compared to DIN.

The gearbox function will be impaired by incorrect tolerances. Comply with tolerance of shaft length "L".

Compliance with tolerance, especially of shaft length "L", is important for smooth gearbox functions. If undersized, compensate the insufficient length using shim rings when mounting on the motor. If oversized, the shaft must be machined to the correct length. Note the permissible axial forces on the motor shaft. Also refer to ZF-DUOPLAN catalog (4161.750.102), Chapter Performance data.

Take into account the motor shaft elongation caused by heating in motors with fixed bearing on the B-side (opposite the motor output shaft).

A B C

L001064


14 EN 4161.758.102r – 2018-09

Semi-key balancing Full-key balancing

4.2 Balancing

If using motors with parallel keys, note the balancing type.

The hubs (2) are delivered with a keyway (1) to transmit power from the motor shaft (3) as standard.

There are two balancing types for motor and gearbox: semi-key and full-key. They are described in more detail in DIN ISO 8821.

Note that the hub is balanced using the same balancing type as the motor.

When ordering, it is therefore very important that you state the motor along with the associated dimensions and balancing type.

Motor output shafts with standard parallel key according to EN 50347: 2001

Shaft diameter Parallel key Parallel key length

42 mm A12x8 90 mm

48 mm A14x9 90 mm

55 mm A16x10 90 mm

60 mm A18x11 125 mm

In the case of motor shafts with open keyway ends, glue the parallel key into the groove in order to avoid axial migration of the parallel key and/or the hub.

Clamping hubs are used for motors without parallel keys. A balancing type is not required.

4.2.1 Semi-key balancing

With semi-key balancing, the keyway is filled by balance compensation corresponding to approximately half a parallel key, shape B by default. This is based on the original parallel key, shape, length and position used by the motor manufacturer and is defined as a counterweight. Since in semi-key balancing – in contrast to full-key balancing – the joint passes through a shared component, imbalance can arise after assembly due to tolerance factors.

As a result, it is recommended that rebalancing should be performed after the joined parts have been assembled.

4.2.2 Full-key balancing

With full-key balancing, the motor shaft is balanced with a full parallel key whereas the hub is balanced without one. The parallel key, shape, length and position are not important in this case.

1

2

3


EN 4161.758.102r – 2018-09 15

4.2.3 Motor shafts/Hubs without keyways

Clamping hubs are available for motor shafts with diameters of 42 mm, 48 mm, 55 mm and 60 mm.

1 Hub

2 Motor shaft


16 EN 4161.758.102r – 2018-09

4.3 Adaptation, motor/gearbox

The motors must have a flange-mounting design for mounting the gearbox.

The gearbox housing is fitted to the motor by means of the centering adapter on the bearing housing. This is standard.

A foot fastener is also available on the gearbox housing for 2K250 and 2K300.

Depending on the motor version, different gearbox variants are used. The gearbox mounting differs accordingly.

Reference dimensions for hub position

Gearbox type Dimension D in mm

2K250 125.0-0.2

2K300 125.0-0.2

In the case of motors with fixed bearing on the B-side, the dimension is D = 124.5-0.2.

If using spacer disks, shim rings of various thicknesses are also supplied. These are used to compensate for motor shaft length tolerances and therefore to comply with control dimension "D".

4.3.1 Open design

Open design describes the gearbox without adapter plate, but with a seal to prevent gearbox oil ingress on the motor output shaft (2).

The input hub (1) is delivered loose with the gearbox. Clean the fitting surfaces of motor (3) and input hub. Check the motor shaft and, if necessary, correct in terms of concentric running, axial run-out and length according to Chap. 4.1. If undersized, use shim rings to compensate. If oversized, shorten motor shaft. A little grease must also be applied to the motor shaft.

Risk of burns due to contact with hot surfaces. Slight to moderate injury possible. Wear protective gloves.

After cleaning the fitting surfaces, the input hub must be heated to approx. 120 °C from the opening and slid onto the motor shaft until the stop is reached, using shim rings if required.

Then check reference dimension "D".

Risk of motor shaft damage if input hub is not heated sufficiently. Heat input hub to approx. 120 °C.

Tighten the set screw (9) and secure it to prevent it from turning, refer to Chap. 4.3.6.

36

9 1

2

11

D


EN 4161.758.102r – 2018-09 17

4.3.2 Closed design with hub bearing and shaft sealing ring

Variant with ball bearing (4), containing additional bearing mounting for input hub (1), to prevent axial migration of the input hub.

For assembly, separate input hub (1) with adapter plate (5) from gearbox housing (6). Clean the fitting surfaces of motor (3) and input hub. Check the motor shaft (2) for concentric running and axial run-out according to Chap. 4.1. A little grease must also be applied to the motor shaft.


After cleaning the fitting surfaces, the input hub must be heated to approx. 120 °C from the opening and slid onto the motor shaft until the stop is reached.

Control dimension "D" is set ex works.


During assembly, it must be possible to easily slide the input hub onto the motor shaft up to the point where the adapter plate makes contact with the motor flange.

Do not use adapter plate to slide hub onto motor shaft.

Check by ensuring that the adapter plate is making contact but can be freely rotated. This ensures that there is no hub bearing preload.


The radial shaft sealing ring in the drive motor must be removed on the output end when the closed design is used.

310

9 1

2

56

11

D

7

4


18 EN 4161.758.102r – 2018-09

4.3.3 Closed design (with shaft seal)

This variant contains an adapter plate (5) with shaft sealing ring (7), making the gearbox a compact, self-contained unit.

Adapter plate and input hub (1) are delivered separately and loose. Clean the fitting surfaces of motor (3) and input hub. Check the motor shaft for concentric running and axial run-out according to Chap. 4.1. A little grease must also be applied to the motor shaft.


After cleaning the fitting surfaces, position the adapter plate with radial shaft seal on the motor housing. The input hub must be heated to approx. 120 °C from the opening and slid onto the motor shaft until it reaches the stop, i.e. spacer disk (12) with shim rings (13).

Then check control dimension "D" and vary using shim rings if required.



Thoroughly grease the radial shaft seal and input hub before assembly. During assembly, it is essential that the radial shaft seal's sealing lip is positioned correctly and that the direction of sealing is correct.

310

9 1

2

56

11

D

7

12

13


EN 4161.758.102r – 2018-09 19

4.3.4 Open design with adapter ring

The adapter ring allows adaptation to different connecting dimensions. Sealing is required on the motor output shaft.

Adapter ring (5) and input hub (1) are delivered loose. Clean the fitting surfaces of motor (3) and input hub. Check the motor shaft (2) for concentric running and axial run-out according to Chap. 4.1. A little grease must also be applied to the motor shaft.


After cleaning the fitting surfaces, position the adapter ring on the motor housing. The input hub must then be heated to approx. 120 °C from the opening and slid onto the motor shaft (2) until it reaches the stop, i.e. spacer disk (12) with shim rings (13).

Then check control dimension "D" and vary using shim rings if required.



3 510

6

9 1

2

1111

D

12

13


20 EN 4161.758.102r – 2018-09

4.3.5 Closed design with hub bearing, shaft sealing ring and keyless hub

When mounting on motor with smooth motor shaft without parallel key, ring clamping elements and pressure pieces must be used between motor shaft and input hub for torque transmission. A centric screw thread in the motor output shaft is absolutely essential.

Clean the fitting surfaces for motor (1), motor shaft (10) and input hub (9).

Check the motor shaft (10) for concentric running and axial run-out according to Chap. 4.1.

Loosely preassemble the counter-holder (4), ring clamping elements (5+6), bush (12), pressure piece (7) and screw connection with a thread-lock (8). Pay attention to the position of the ring clamping elements. First install the inner (6) and then the outer (5) ring clamping elements in the package on the motor shaft.

Depending on the version, slide input hub onto motor shaft with or without adapter plate (2).

Attach the ring clamping elements by hand with the help of the screw connection. Tightening the screw connection causes the hub (and the adapter plate, if fitted) to move axially towards the motor. Take this into consideration by using a lead dimension of +0.4 mm with 3 ring clamping elements and a lead dimension of +0.6 mm with 4 ring clamping elements respectively.

Tighten screw connection (8) to 300 Nm for M16 and to 510 Nm for M20.

Note maximum permissible tightening torque for thread in motor shaft. In adaptations without coolant flow, use screws of strength class 10.9.

Check dimension D and concentric running of hub.

Additional internal sealing is no longer needed if using ring clamping elements. The number of ring clamping elements and bushes may vary depending on the motor.

If using screw connections with a hole for the coolant to flow through, be aware of O-rings and grease them before assembly.

To prevent twisting of the motor shaft and input hub when tightening, the input hub must be blocked. This can be done using ZF special tool 1X46.188.387.

D

6

57

9 811 10

3 4

21

Do not grease: motor shaft (10) and input hub bore (9). Apply a little oil: cone-shaped face of ring clamping elements (5+6).

The counter-holder is supported on the shoulder of the motor shaft. Ensure a large contact surface.

In the closed version without hub bearing, the seal running surface for the radial shaft seal on the input hub is to be greased before assembly. Note position of sealing lip when sliding on input hub.

When using the closed design with hub bearing (11) and radial shaft seal (3), do not use adapter plate to slide input hub onto motor shaft. Once the screw connection has been tightened, the adapter plate must make contact with motor housing and still be free to rotate. The hub is then mounted free from pretension.


EN 4161.758.102r – 2018-09 21

4.3.6 Mounting the gearbox

The M8 set screw (9) must be screwed in and tightened to 18 Nm until firmly home on the parallel key. Apply liquid seal to the set screw before installation.

During assembly, ensure that the O-ring (10) is positioned correctly. The O-ring is delivered loose with the gearbox and is inserted in the sealing ring groove in the housing (6) with grease.

Check position of gearbox shift mechanism. The sliding sleeve must be in gear 1 shift position ("slow" stage).

Take the gearbox and place it on the motor flange. Carefully connect the sun gear to the input hub.

The external spline of the sun gear must be fed into the internal spline of the hub.

This process can be simplified by turning the gearbox output slightly to the left/right.

Gearbox housing, adapter plate and motor are secured to one another with four or eight hexagon bolts (11).

Fill the gearbox with oil and/or connect the recirculating lubrication and power supply. The breather outlet must be mounted at the top in all installation positions. The breather is screwed in to position B5 ex works.

The gearbox is now ready for use.

The gearboxes can be operated under the same degrees of protection as those in effect for AC and DC motors.

During installation ensure that the cooling air of the motor can flow freely in and out.

Before initial operation of the electric motor/ gearbox drive assembly, check that the gearbox output can be turned by hand.

For drive assemblies which are fastened to the gearbox flange or gearbox housing, the motor can be supported on the B-side free from distortion.

Gear 1 shift position:

A Brake disk B Sliding sleeve

A B


22 EN 4161.758.102r – 2018-09

4.3.7 Version with pulley drive

The pulley will be centred on the outer diameter of the drive flange (K6 tolerance), friction-locked in place and secured using screws, whereby the permitted torque must be taken into account.

The pulley must have a balance rating 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 0.5 – 1.0 l/min via oil connector ‘S’ in the drive housing.

Note maximum tensile force of belts (refer to Chap. 4.4.1).

The average belt power must lay in between the bearings. During assembly, it must be possible to easily slide the belt pulley onto the input flange, heat the belt pulley if necessary.


EN 4161.758.102r – 2018-09 23

4.3.8 Closed design with hub bearing, shaft sealing ring and clamping hub

The motor is mounted on the gearbox using an adapter flange with clamping hub. The motor shaft is connected to the clamping hub with a force fit.

The gearbox with clamping hub may only be fitted on motors with a smooth motor shaft.

1 Adapter plate

2 Motor shaft

3 Motor flange

4 Mounting screw

5 Clamping hub

6 Sleeve

7 Clamping screw

8 Cover plate

9 Output shaft

Mounting gearbox on motor:

First the motor shaft (2), the bore of the clamping hub (5) and, if present, the sleeve (6) must be degreased. Then insert the sleeve into the clamping hub until the stop is reached. The clamping hub (5) must be positioned so that the clamping screw (7) can be tightened via the access bore. The cover plate (8) is removed for this purpose. The motor shaft (2) is guided (centered) into the clamping hub (5) until the motor flange (3) makes contact with the adapter plate (1). Ensure that the motor shaft does not jam in the clamping hub. The fixing bores on the motor flange and adapter plate must match precisely. The motor is mounted on the gearbox with four appropriate mounting screws (4), with a screw-in depth into the adapter plate of 15 to 25 mm. Tighten clamping screw (7) to 260 Nm with torque wrench, socket wrench extension and hex socket insert (WAF 14). If necessary, block the output shaft (9). Close off the access bore again with cover plate (8).

Dimension A for extension of hexagon socket wrench

Adapter plate 2K250, A = 100 mm

Adapter plate 2K300, A = 125 mm


24 EN 4161.758.102r – 2018-09

4.3.8.1 Spindle cooling (TSC) version, feeding emulsions, hydraulic oils or air-oil mixtures

Mounting gearbox on motor:

Coat thread of connecting piece (1) with sealing compound. Screw connecting piece with pre-assembled and greased O-rings (2) into motor shaft (3) by hand until stop is reached. Use jaw wrench (WAF 27) to tighten connecting piece to 130 Nm, blocking motor shaft in the process. Follow the description provided in Chapter 4.3.8 for the rest of the mounting process.

1 Connecting piece

2 O-rings

3 Motor shaft (hollow shaft)

Installing the rotary union:

Apply grease to both ends of tube (5) and place in rotary union (4). Carefully guide tube through greased radial shaft seal (1) into gearbox. Coat the four cap screws (3) with hex socket (WAF 3) with sealing compound and tighten to 2.8 Nm with torque wrench.

1 Radial shaft seal

2 Output shaft

3 Cap screw

4 Rotary union

5 Tube


EN 4161.758.102r – 2018-09 25

4.4 Output

Please note the details relating to the resultant force in the installation drawings.

4.4.1 Version with belt output

The belt pulley is centered to the outside diameter of the output flange (tolerance K6), attached and secured with friction engagement using screws, while noting the permissible tightening torques.

For low-vibration operation, the belt pulley should be balanced to quality 6.3 according to VDI directive 2060.

Possible damage due to bearing overload. Note maximum tensile force of belts.

To avoid overloading the bearings, note the maximum tensile force when tensioning the belts.

The average belt power must lay in between the bearings. During assembly it must be possible to easily slide the belt pulley onto the output flange, heat the belt pulley if required.

4.4.2 Version with coaxial output

For the version with coaxial output (stub shaft), the balancing type should also be noted for the output (refer to Chap. 4.2). The gearbox is delivered with full-key balancing.

The parallel key dimensioning can be seen in the installation drawing. Fix the parallel keys using a set screw in any case.

4.4.3 Version with TSC

The version with TSC (Through Spindle Coolant) serves to transmit cooling lubricant, hydraulic oils or air-oil mixtures1) through the gearbox to the spindle. To ensure liquid transfer during gearbox under speed differential, a rotary union is needed, which is subject to wear depending on the load and the status of the medium. Depending on the system used, leakage drips can occur when activating and deactivating. This can be traced back to design measures in the coolant circuit. A transparent coolant return allows the status of the rotary union to be assessed.

The warranty for the rotary union is limited to 12 months.

Information regarding the product, function, operation and installation of the rotary union can be found in the operating instructions

4161.758.030 (German)

4161.758.130 (English) 1) No abrasive or solvent additives are permitted in the fluids.

4.5 Electrical connection, gearchange

The electrical connection may only be performed by a qualified electrician.

Possible damage to shift unit due to incorrect connections. Connect shift unit as described in Chap. 4.5.1

and 4.5.2.

The gearbox is connected electrically with the 8-pole Harting connector supplied (HAN 8 U). The plug connection is located on the shift unit.

4.5.1 Shift unit

Technical data:

Power consumption 84 W Supply voltage 24 V DC ±10% Max. pickup current 5 A Nominal current: 3.5 A Protection class IP64

The required cable lead diameter is 1.5 mm². Ensure the supply voltage of 24 V DC and the current consumption of 5 A on the shift unit plug. Losses due to cable length and transition resistances are to be taken into consideration.

Scope of supply: Sleeve housing, screw connection, socket insert and 8 Harting AWG16 contact bushings. The shift unit is only available as a complete part.


26 EN 4161.758.102r – 2018-09

Gearbox shift mechanism:

During the gear change, the motor shaft and/or gearbox output is without load (unbraked).

Shifting is performed through application of 24 V on pin 2 and 3. The polarity of the applied 24 V DC voltage is decisive for the gear stage.

In gear 1 => Pin 2: + / Pin 3: ‒ In gears 2 and 3 => Pin 2: ‒ / Pin 3: +

During the gear change, the main spindle motor should make the shaft oscillate +5° or -5° at a rate of 1 to 5 rotation direction changes per second. A larger pendulum motion may cause damage to the meshing gears. The gears usually already mesh at the first rotation direction change, so that the switchover time is approx. 300 to 400 ms.

On average, this means: nMot = 5°/s = 5° 60/min = 300°/min = 300/360 rpm = 0.83 rpm.

Conversion Pendulum speed pendulum rotary motion

Speed [rpm]

Angle [°/min]

Time [sec]

Angle [°/sec]

0.25 90 3.33 5

0.50 180 1.67 5

1.00 360 0.83 5

2.00 720 0.42 5

3.00 1,080 0.28 5

4.00 1,440 0.21 5

5.00 1,800 0.17 5

Because of the different masses and associated drag torques of the spindle, the machine optimum is to be determined on the basis of shift tests.

The limit switch signals of S1 – gear 1 (contact 4) and S2 – gear 2 (contact 6) serve to shut off the shift unit once the gear change is complete.

After the limit switch signals have been reached, the shift unit is allowed to be live for a maximum of 0.5 seconds. The limit switch signals must be monitored during operation.

The limit switches must only be energized with the control current (0.1 to 0.5 A), not the changeover current (5 A).

The changeover current must not be present for more than 2 seconds.

If the number of resistors is small, a lower control current may also be used.

The control current for end-position monitoring must be ensured depending on length, line/ transition resistances and number of connection points. Increased resistances caused by corrosion must also be considered after some time. Switching of inductive loads by means of the control current requires it to be wired parallel to the load by a diode.

If the limit switches detect that a gear is no longer reliably engaged, the control system must initiate appropriate measures, such as emergency shutoff etc.

Electromagnetic fields may falsify the signals of limit position monitoring. Do not route control lines in parallel with

cables for the voltage supply or shield control lines.

The shift sequence is to be monitored; if necessary, a timing element must reverse the gear change if no limit switch signal (S1/S2) is received after approximately 2 seconds. Afterwards repeat the gear change command, the main spindle motor must not be released.

Rotation direction changes


EN 4161.758.102r – 2018-09 27

Diagram for shift unit with two shifting positions (standard) or three shifting positions (with neutral position):

Gear 1 ==> e.g. 4:1

Gear 2 ==> 1:1

Gear 3 ==> S3 neutral position, idling (option)

S3

S1 S2

optional

M

3 4

4

2

1

3 4

blue

blue

grey

grey

black

blue

black black

green

X8

4

3

5

2

6

8

17

The electromechanical gear change is undertaken by a shift unit on the gearbox, which is driven by a direct current motor (24 V DC). The gear shift element is a positively locking, axially movable shift selector that acts on a sliding sleeve. The limit positions are monitored by limit position switches in the shift unit. Monitoring of timing is provided in the control unit. When shifting from gear 1 to gear 2 or vice versa, the motor is to be energized. The rotation direction is changed by means of pole reversal.

Gearbox with neutral position

The neutral position can only be approached from gear 1.

As soon as the S3 limit position switch receives the signal, the direct current motor is to be shut down by means of a dynamic motor stop (quick stop).

Under certain operating conditions (e.g. V3 installation position, higher line resistances), a variable timing element may be needed in the gearbox control consult ZF.


28 EN 4161.758.102r – 2018-09

4.5.2 Shift logic

1) Alternatively, the first switching test can be performed without oscillating, but this requires a de-energized main spindle motor or

minor output-end masses.

Decelerate main spindle motor from operating speed to zero.

Keep controller release (signal) connected with power converter.

Apply desired oscillating speed to converter and speed controller

without delay. 1)

Shift unit energized (pin 2 and 3)

Gear change must be completed within 2

seconds. (Feedback signal from limit switch S1, S2 or S3 from the shift

unit)

Shut off desired oscillating speed.

After 200 ms to max. 500 ms shift unit OFF.

Gear change complete.

Number of gear change attempts > 5

all from the respective starting position (pole reversal)

Gear change not accomplished: switch off

main spindle motor.

Check system.

N

N

Y Y

Start main spindle motor


EN 4161.758.102r – 2018-09 29

4.6 Lubrication

4.6.1 Splash lubrication

The B5 standard version of the gearbox has splash lubrication.

Splash lubrication is suitable for intermittent operation. Frequent gear shifts, different speeds and downtimes, such as those encountered when changing tools, are assumed.

Possible damage to gearbox due to insufficient oil quantity and/or running dry. Fill gearbox oil up to center of oil level gage

glass.

The actual oil level is binding for the amount of oil to add. The number of liters stated on the model plate for the relevant gearbox is a reference value.

If the gearbox is installed at an angle, which may be the case with certain belt tensioning equip-ment, an oil level tube with calibration mark must be fitted in place of the oil level gage glass.

Ensure the same oil level as that obtained when the gearbox is installed horizontally (also refer to installation drawing).

An oil sensor can occasionally be used to check the oil level before starting the machine. The oil sensor can be screwed into connections D or E (figure, page 31) of the gearbox housing. (Oil sensor order no. 4161.298.045, Balluff data sheet available on request)

4.6.2 Recirculating lubrication

Two connecting pieces (hose fittings) with M42x1.5 and M22x1.5 thread are optional accessories, order no. 4161.106.016.

Recirculating lubrication enables efficient gearbox lubrication and cooling. This improves the gearboxes performance and less heat is introduced into the machine.

Gearbox failure due to insufficient lubrication. Gearboxes in the V1 vertical and V3 vertical

installation positions must be operated with recirculating lubrication.

In the 2K250/2K300 gearboxes, the V1 vertical and V3 vertical installation positions require recirculating lubrication. The type of recirculating lubrication depends on the operating temperature level required.

Because of the centrifugal forces acting on the oil, there may be insufficient lubrication at the gearing if operated continually in direct drive.

Occasionally changing gear (ratio) and then starting the motor (nMot=1,000 rpm) feeds oil to the gearing and prevents the gearing from being loaded on the one side linked to the selected position.

Some applications require a very low operating temperature level which can be obtained by connecting a gearbox oil supply with oil cooling specifically designed for this purpose. The relevant gearbox versions are prepared accordingly.

To achieve ideal gearbox cooling without influencing lubrication, various connectors are available for recirculating lubrication on the gearbox depending on the installation position and mode of operation. The figures on page 31 show the oil inlet and outlet points on the gearbox. The precise measurements can be found on the respective installation drawings.

After initial operation, the oil level must be in the center of the oil level gage glass, top up oil if required.

The pump, oil tank and heat exchanger components must be positioned below the gearbox oil level. If the oil return is connected according to Chap. 4.6.3.2, limp-home (emergency control) characteristics are assured.


30 EN 4161.758.102r – 2018-09

The following scenarios are unproblematic:

The oil level in the tank falls during operation as a result of the gearbox oil in the gearbox foaming.

The formation of an oil-air emulsion in the oil return and in the tank.

4.6.2.1 Recirculating lubrication during V1/B5 operation

For the position of the oil inlets and outlets, refer to Chap. 4.6.3.2.

The oil inlet is connected in place of the oil drain plug.

Oil inlet quantity 1.5 to 2 l/min.

One oil level gage glass is removed and replaced with a screw-in drain pipe (M42x1.5).

In the V3 vertical installation position, the gearbox oil can be supplied both radially and centrally.

The outlet line should be dimensioned so as to prevent oil return blockages in the gearbox (Di approx. 20 mm).

4.6.2.2 Recirculating lubrication with heat exchanger

A heat exchanger is installed in the recirculating lubrication to achieve an additional reduction in temperature.

4.6.2.3 Recirculating lubrication with intermediate tank

For effective oil cooling, the tank volume should be at least ten times the amount of oil circulated.

To avoid gearbox damage from running dry, ZF recommends installing an oil level sensor on the intermediate tank.

Use a 60 μm filter and a safety non-return valve (1) at the gearbox oil inlet.

This arrangement permits continued operation using splash lubrication, refer to Chap. 4.6.1.

Downstream of the gearbox, the oil return line must always be below the oil outlet so that the oil level in the gearbox cannot rise.

Installation example B5

1


EN 4161.758.102r – 2018-09 31

4.6.3 Connections for lubrication

4.6.3.1 Connections for initial fill/ oil change

Installation position

Oil fill Oil drain

B5

I

G, F, H

B5 rotated D

V1 D, E by drawing off

(for version with output shaft)

P (for version with output flange)

V3 H


32 EN 4161.758.102r – 2018-09

4.6.3.2 Connections for recirculating lubrication in standard applications

Installation position

Oil inlet connection Max. pressure

Oil return port

V1 (closed variant)

M (0.5 l/min) and T (1.0 l/min)

0.5 bar

0.5 bar

D Main direction of rotation counterclockwise *

E Main direction of rotation clockwise *

V1 (open variant)

T (1.5 l/min) 0.5 bar

B5 (closed variant)


0.5 bar

0.5 bar

B5 (open variant)

G (1.5 l/min) main direction of rotation counterclockwise* or F (1.5 l/min) main direction of rotation clockwise*

1.5 bar

B5 rotated (open on right)

I or F (1.5 l/min) 1.5 bar H

V3 (closed variant)


0.5 bar

0.5 bar

H

V3 (open variant)

T or P (1.5 l/min) 1.5 bar H

* As seen facing gearbox output The principal factor in determining the oil supply volume is always the volume that flows out of the

oil return. In the case of gearboxes with a belt pulley drive, consider the additional lube oil bore "S" (refer to Chapter 4.3.7).


EN 4161.758.102r – 2018-09 33

4.6.3.3 Connections for integrated lubrication oil system and maximum speed

For applications with a maximum speed of 10,000 rpm and/or a dry sump, the T connection with integrated lubrication oil system is mandatory. Furthermore, gearbox oil cooling >0.3 kW and a circulating oil volume >15 liters is required.

All versions include T connection with integrated lubrication oil bore.

When ordering, note the corresponding Machine-Readable Product Designation (MLFB) number for the integrated lubrication oil system.

The integrated lubrication oil system is only available with the closed variant.

The recommended oil viscosity for integrated lubrication oil system is HLP 22 according to ISO VG 22.

With dry-sump lubrication, HLP 10 according to ISO VG 10 can be used if it can be ensured that the gearbox oil outlet temperature is below 65 °C at all times.

Installation position Oil inlet connection Max. pressure Oil return connection

V1 (closed variant)

T (1.5 l/min) and M (approx. 0.5 l/min)

0.5 bar 0.5 bar

D or E

V3 (closed variant)

T (1.5 l/min) and M (0.5 l/min)

0.5 bar 0.5 bar

H

B5 (dry sump)


0.5 bar 0.5 bar

H

B5 (rotated, dry sump)


0.5 bar 0.5 bar

D

The principal factor in determining the oil supply volume is always the volume that flows out of the oil return.

Initial Operation/Maintenance

34 EN 4161.758.102r – 2018-09

5 Initial Operation

5.1 Initial inspection

Before initial operation, the correct installation condition of the gearbox must be checked.

Mechanical fastening

Motor flange-mounting

Gearbox oil connections

Oil supply/oil fill ensured

Electrical connections

Ease of movement (can be turned by hand)

Vertical breather position

5.2 Checking setting dimension of sun gear

Control dimension "A": 125.1 mm, tolerance +0.2 mm, measured between housing connection surface and front side of sun gear. When measur-ing, press the sun gear towards the output until it reaches the stop.

The dimension is set correctly ex works.

Check the dimension after inserting the sun gear, e. g. following disassembly. Dimension "A" is correct if the spring assembly (2) and shims (1) are correctly installed in their entirety (see detailed figure below).

6 Maintenance

6.1 Oil change

Oil change interval: every 5,000 hours of operation

Risk of burns due to contact with hot oil. Slight to moderate injury possible. Wear protective goggles. Wear protective gloves.

Allow used oil to drain at operating temperature into a suitable container.

The drain connections differ depending on the installation position and gearbox version (refer to Chap. 4.6.3.1).

Fill new gearbox oil at connection I.

The oil level is correct when it reaches the center of the oil level gage glass with a stationary gearbox.

The oil level is binding. The number of liters stated on the model plate is a reference value.

If available, briefly allow oil pump to run after filling with oil in order to vent, top up oil if required.

1

2

A

Repair

EN 4161.758.102r – 2018-09 35

7 Repair

In the event of gearbox malfunctions, first check the connected components and their connections.

Carefully document the type of fault so as to assist manufacturer diagnosis (refer to Chap. 7.1).

Repairs to the gearbox itself may only be performed by ZF Friedrichshafen AG or by authorized ZF after-sales points.

7.1 Gearbox fault checklist

If you encounter drive unit faults, please first check the solutions listed in Chapter 8.

If this does not solve the problem, you will need to provide the following information for diagnosis at ZF Friedrichshafen AG or an authorized ZF aftersales point:

Gearbox data on the model plate:

Typ: . . . (Type)

Parts list [BoM]: 4161 . . . . . (Parts list no.)

Serien-Nr.: . . . . . (Serial no.)

Motor data on the model plate:

Manufacturer: . . .

Type/Size: . . .

Questions for fault diagnosis:

Is oil level gage glass on gearbox dark/black?

Is there a smell of burning oil at the oil breather?

Gearbox running noise in 1:1 or 4:1 gear ratio, or only in one rotation direction or in both rotation directions?

Before the running noise occurred, was the machine operated in only one gear ratio (1:1) for an extended period of time?

Did the running noise occur after changing the machine's cycle or was the machine cycle unchanged?

Was any maintenance carried out on the machine before the fault occurred and, if yes, what did this maintenance work involve?

No gear change or gear loss in the event of a shift problem?

Does the shift logic conform to ZF specifications? (Refer to page 28)

What is the shift unit voltage during the shift sequence?

Repair

36 EN 4161.758.102r – 2018-09

7.2 Gearbox – disassemble

(e. g. version with adapter plate, shaft seal and hub bearings)

Proceed accordingly in the case of other versions.

Switch off the machine

Switch off the power supply

Disconnect the electrical connections

Disconnect the gearbox oil connections, drain the gearbox oil

Undo the mounting bolts (11)

Pull gearbox (6) off adapter plate (5) and input hub (1)

7.3 Input hub with parallel key

Undo the set screw (9) used to radially secure the parallel key.

Use a removing device, e.g. three-arm puller, to pull off input 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.

The cover plate may cause the input hub to jam when being pulled off. Position cover plate (8) centrally on motor

shaft.

Replace end washer 40 DIN 470 after disassembly. Clean before installing and coat the sealing edge with liquid seal. Visually check the shaft seal and O-ring and fit new ones if necessary.

3

10

91

212

85

6

11

7

4

1 Input hub 2 Motor shaft 3 Motor 4 Hub bearing 5 Adapter plate 6 Gearbox 7 Shaft sealing ring 8 Cover plate 9 Set screw 10 O-ring 11 Mounting bolt 12 Removing aid

(cylinder 25x100 mm)

Repair

EN 4161.758.102r – 2018-09 37

7.4 Disassembly of gearbox with clamping hub

Note Chapter 7.2.

Turn motor shaft (2) until clamping screw (7) can be seen through access bore in adapter plate (1). Loosen clamping screw.

Loosen mounting screws (4) and pull gearbox off motor.

1 Adapter plate

2 Motor shaft

3 Motor flange

4 Mounting screw

5 Clamping hub

6 Sleeve

7 Clamping screw

8 Cover plate

9 Output shaft

Frequently Asked Questions (FAQ)

38 EN 4161.758.102r – 2018-09

8 Frequently Asked Questions (FAQ)

Error Cause of error Remedy

Gearbox is loud, knocking noises

Loose contact on motor speed sensor. This causes permanent motor governing.

Speed sensor dirty, no clear signals sent

Check speed sensor and electrical lines to motor, clean speed sensor if necessary. Check engine management system, adjust speed control accordingly (softer setting).

Gearbox is loud, running noise

Long periods at high cutting speed in ratio 1:1 followed by change to machining in ratio 4:1

No gearbox damage

Gearbox running noise normalizes after several gear changes

Axial bearing incorrectly installed Check installation.

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

Measure 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 has aged

Too much oil added during oil change

Change the oil

Check oil level, adjust to correct oil volume if required

Machine control does not receive signals for the shift position from the shift unit on the gearbox

Loose contact in plug connection on gearbox shift unit

Error in the shift unit

Check plug connection and clean if necessary, secure connectors using clips.

Send gearbox to ZF for inspection

Gear disengages Limit position switch defective Send gearbox to ZF Friedrichshafen AG for inspection

Frequently Asked Questions (FAQ)

40 EN 4161.758.102r – 2018-09

ZF Friedrichshafen AG 88038 Friedrichshafen Deutschland · Germany Telefon/Phone +49 7541 77-0 Telefax/Fax +49 7541 77-908000 www.zf.com

EN

416

1.75

8.1

02r

– 20

18-0

9

Documents

ZF-DUOPLAN Two-speed Gearbox 2K250 / 2K300 …Application and Design EN 4161.758.102r – 2018-09 9 3 Application and Design 3.1 Application The DUOPLAN 2-speed gearbox by ZF is mainly