ZF-DUOPLAN 2K250 User manual

OPERATING INSTRUCTIONS
Two-speed Gearbox
2K250 / 2K300
08.2007 Edition
4161 758 102i

2K250/2K300
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

Operating Instructions
2K250/2K300 Contents
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 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 Shift logic.....................................................................................................................................23
3.7 Lubrication...................................................................................................................................24
3.7.1 Splash lubrication ........................................................................................................................24
3.7.2 Recirculating lubrication..............................................................................................................24
3.7.3 Ports and connections for lubrication ..........................................................................................26
3.7.4 Gearbox oil pump ........................................................................................................................29
3.7.5 Heat exchanger ............................................................................................................................31
4 Taking into Operation .........................................................................................................................33
4.1 Initial inspection ..........................................................................................................................33
4.2 Sun gear setting - check ...............................................................................................................33

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

Operating Instructions
2K250/2K300 Preface
1Preface
1.1 Safety instructions
This documentation is intended for specialists who
have experience to carry out maintenance and re-
pair work.
•
•
•
•
•
•
•
•
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.
The ZF product is documented in accordance with
the design status as of the issue date.
The following safety notices are used in these op-
erating instructions: Repair staff should familiarize themselves with
these regulations before commencing work.
NOTE Correct and proper repair of these ZF products
can only be assured by appropriately trained
specialists.
Used to highlight special sequences, methods, in-
formation, etc.
CAUTION The organization in charge of repairs is respon-
sible for ensuring that such training is given.
Used when incorrect and improper operating
procedures can cause damage to the product. Read these operating instructions carefully be-
fore commencing any testing or repair work.
DANGER!
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 single illustration or drawing).
!
Lubricants and cleaning products must
not be poured onto the ground, into
groundwater or down the drain.
Work must be performed as described in the
text.
Following the completion of repair work and test-
ing, the specialists must satisfy themselves that the
product will function perfectly again.
• Obtain and comply with the safety
regulations relevant to these products
issued by your local environmental au-
thority.
1.2 ZF instructions
• Collect used oil in a suitably large con-
tainer.
• Dispose of used oil, clogged filters, lu-
bricants and cleaning products in ac-
cordance with local environmental
protection regulations.
Remove any traces of old seals or gaskets from
mating faces. Use an oil stone to carefully re-
move any burrs or similar irregularities.
Carefully cover or shield open gearboxes to
prevent the ingress of foreign matter.
• Always follow the instructions issued
by the manufacturer when handling
lubricants and cleaning products.

Operating Instructions
Preface 2K250/2K300
6
1.3 Service products
Product Name/specification Quantity
(approx.)
[dm3]
Use Remarks
Grease Shell Avania WR2
Fuchs Renolit CXEP2
Esso Beacon EP2
General-purpose
Gearbox oil HLP 68 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 posi-
tion
Can also be used for
recirculating 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 and
integrated lubrica-
tion oil system
Bonding agent
(liquid seal)
Loctite 574 Sealing end cover
in hub
End disc 40 DIN 470 1 Hub sealing Exchange after disas-
sembling the hub

Operating Instructions
2K250/2K300 Application and Design
2Application 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 installa-
tion 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 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
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
Electromagnetic gearchange
7

Operating Instructions
Application and Design 2K250/2K300
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 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

Operating Instructions
2K250/2K300 Application and Design
2.4 Technical data
2K250 2K300
Nominal power max. 39 kW max. 47 kW
Nominal speed 1500 rpm 1500 rpm
Max. speed
in ratio i≠1
in direct drive i=1
(with gearbox oil
cooling and integral
lube oil system).
See section 3.7.3.3
“Ports and connec-
tions for integral
lube oil system and
maximum speed”
(values apply as of
01/2004).
6 300 rpm
10 000 rpm
6 300 rpm
10 000 rpm
9
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
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
e2300 350
a1- -
s218 18
2K250 2K300
Nominal input
torque
max. 250 Nm max. 300 Nm,
at i = 5.50
max. 250 Nm
Max. output
torque for
i = 1.00
i = 3.16
i = 4.00
i = 5.50
250 Nm
792 Nm
1000 Nm
1375 Nm
300 Nm
951 Nm
1200 Nm
1375 Nm
Weight approx. 62 kg approx. 70 kg
Model plate (standard)
(affixed to gearbox housing)

Operating Instructions
Application and Design 2K250/2K300
2.5 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

Operating Instructions
2K250/2K300 Initial Installation
3Initial Installation
3.1 Axial runout, radial runout and length
tolerances – drive motor
In order to guarantee fault-free operation, the mo-
tor must not exceed the specified tolerances.
ABC
L
001064
Axial runout, radial runout and length tolerances –
electric motor mounting flange:
Tolerance
Gearbox
type A B C L
2K250 /
2K300
0.025 0.063 0.063 - 0.200
Tolerances A, B, C to DIN 42955R
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 forces on
the motor shaft. Also see ZF-DUOPLAN cata-
logue (4161 750 102), "Performance data" sec-
tion.
Take into account the motor shaft elongation
caused by heating in motors with fixed bearing on
the B-side (opposite the motor output shaft).
11

Operating Instructions
Initial Installation 2K250/2K300
3.2 Balancing
The hubs (2) come with a keyway (1) for trans-
mitting power from the motor shaft (3) as stan-
dard. 1
12
Half-key balancing Full-key balancing
There are two balancing types for the motor and
gearbox: Semi-key and full-key, which are de-
scribed in more detail in DIN ISO 8821.
2
It must be ensured that the hub is balanced in the
same way as the motor. 3
This is why it is very important to indicate the
motor data, dimensions and balancing type when
ordering.
Motor output shafts with standard fitted key
in accordance with EN 50347: 2001
Shaft diameter 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 balancing – the joint passes
through a shared component. This means imbal-
ance 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.
3.2.2 Full-key balancing
In full-key balancing, the motor shaft is balanced
with a full key whereas the hub is not. The key,
shape, length and position are not important in
this case.

Operating Instructions
2K250/2K300 Initial Installation
3.3 Adaptation, motor/gearbox
The motors must have a flange-mounting option
for mounting the gearboxes.
The gearbox housing is fitted to the motor by
means of the centering adapter on the bearing
housing. This is standard.
There is also a foot mounting on the gearbox
housing for 2K250 and 2K300.
Different gearbox variants are used depending on
the motor type. Gearbox mounting also differs
accordingly.
Reference dimensions for hub position
Gearbox type Dimension D in mm
2K250 125.0-0.2
2K300 125.0-0.2
13
CAUTION
Dimension D on request in the case of motors
with fixed bearing on the B-side. Motors with
fixed bearing on the B-side are not permitted
for version with hub bearings.
Spacer discs are supplied with shims of varying
thickness. These enable 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, axial runout and length according to sec-
tion 3.1 and correct as necessary. Use shim rings
to compensate undersize. Shorten the motor shaft
in case of oversize. Also lightly grease the motor
shaft.
After cleaning the fitting surfaces, heat the drive
hub to approx 120 °C from the opening and slide
it onto the motor shaft until it reaches the stop.
Then check reference dimension "D". If under-
size, use shims for balancing. If oversize, shorten
the motor shaft.
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, see section 3.4.

Operating Instructions
Initial Installation 2K250/2K300
3.3.2 Closed design with hub bearing and
shaft sealing ring
Variant with ball bearing (4), in which the hub (1)
is also mounted in bearings to prevent axial hub
migration.
When assembling, separate the drive hub (1) with
adapter plate (5) from the gearbox housing (6).
Clean the fitting surfaces of the motor (3) and
drive hub. Check the motor shaft (2) for axial and
radial runout as described in section 3.1. Also
lightly grease the motor shaft.
After cleaning the fitting surfaces, heat the drive
hub to approx 120 °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 the
hub onto the motor shaft.
Check by ensuring that the fitted adapter plate can
be turned freely. This ensures that there is no hub
bearing preload.
Tighten the threaded pin (9) and secure it to pre-
vent it from turning, see section 3.4.
NOTE
The radial shaft sealing ring in the drive motor
must be removed on the output end when the
closed design is used.
14

Operating Instructions
2K250/2K300 Initial Installation
3.3.3 Closed version (with shaft seal)
This variant incorporates an adapter plate (5) with
shaft seal (7), which means that the gearbox forms
a compact, closed unit.
The adapter plate and drive hub (1) are separately
delivered loose. Clean the fitting surfaces of the
motor (3) and drive hub. Check the motor shaft
for axial and radial runout as described in section
3.1. Also lightly grease the motor shaft (2).
After cleaning the fitting surfaces, place the
adapter plate with 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, see section 3.4. Check sliding
sleeve factory setting "Y" as per section 6.5.
Check sun gear factory setting "A" as per section
6.6.
CAUTION
Thoroughly grease the radial shaft seal and the
drive hub before installation. When installing,
make sure that the sealing lip and the radial
shaft seal are in the correct position.
15

Operating Instructions
Initial Installation 2K250/2K300
3.3.4 Open design with adapter ring
The adapter ring allows adaptation to different
connection dimensions. A seal is required on the
motor output shaft.
The adapter ring (5) and drive hub (1) are deliv-
ered loose. Clean the fitting surfaces of the motor
(3) and drive hub. Check the motor shaft (2) for
axial 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
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, see section 3.4.
16

Operating Instructions
2K250/2K300 Initial Installation
3.3.5 Keyless hub
When mounting on motors with a smooth motor
shaft without a keyway, it is necessary to use ring
clamping elements and pressure pieces between
the motor shaft and the input hub in order to
transmit the torque.
The mating surfaces of the motor (3), motor shaft
(2) and input hub (1) must be cleaned.
The motor shaft (2) must be checked for concen-
tricity and axial run-out in accordance with chap-
ter 3.1.
Loosely mount the counter-holder (4), ring clamp-
ing elements (5+6), pressure piece (7) and screw
connection with thread lock (8) in advance. Watch
out for the position of the ring clamping elements
when doing this. First install the inner (5) then
the outer (6) ring clamping elements in the pack
on the motor shaft.
Push the input hub onto the motor shaft with or
without adapter plate (9), depending on the ver-
sion.
By hand, move the ring clamping elements into
contact using 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 with a lead
dimension of +0.4 mm.
Tighten the screw 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 coolant to
flow through, watch out for the O-rings and
grease them before installation.
The input hub must be blocked in order to prevent
twisting of the motor shaft and input hub when
tightening. This can be done using a special tool
ZF 1X46 188 387.
CAUTION
Do not grease the motor shaft and the hole in
the input hub! The cone surface’s ring clamp
also needs to be lightly oiled!
In the closed version without hub bearing, grease
the seal running surface for the radial oil seal on
the input hub before installation. Watch out for
the position of the sealing lip when pushing on the
input hub.
CAUTION
When using the enclosed design with hub bear-
ing (10) and radial oil seal (11), do not push the
input hub onto the motor shaft using the
adapter plate. Once the screw connection has
been tightened, the adapter plate must be in
contact with the motor housing and it must be
possible to turn it freely. This means the hub
bearing is free from tension.
17

Operating Instructions
Initial Installation 2K250/2K300
3.3.6 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 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 the
bearings. The pulley must be just touching the
drive flange when fitted; heat up the pulley if
necessary.
028946
18

Operating Instructions
2K250/2K300 Initial Installation
3.4 Gearbox - fit
Screw in and tighten the threaded pin (9) onto the
fitted key. Make sure you coat the threaded pin
with liquid seal before installing it.
Make sure that the O-ring (10) is in the correct
position during installation. The O-ring is deliv-
ered loose with the gearbox and has to be coated
with grease before being inserted into the seal
groove in the housing (6).
Check the position of the gearbox shift mecha-
nism. The sliding sleeve must be in the 1st gear
position ("low" gear ratio).
Take up the gearbox and place it onto the motor
flange. Carefully bring the sun gear/hub connec-
tion together when doing this.
19
NOTE
The external spline of the sun gear must be guided
into the internal spline of the hub.
This can be made 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 screwed
in to the B5 position ex-works.
The gearbox is now ready for use.
CAUTION
The gearboxes can be operated under the same
degrees of protection as those defined for AC
and DC motors.
When setting up, make sure that the motor cooling
air can flow in and out unhindered.
1
B
st gear position:
A Brake disc
Slidin
g
sleeve
NOTE
Before taking the electric motor/gearbox assembly
into operation, check that the gearbox output can
be turned by hand.
In the case of drive units that are fixed on the
gearbox flange or housing, the motor can be sup-
ported on the B-side so that it does not vibrate.

Operating Instructions
Initial Installation 2K250/2K300
20
3.5 Output
3.5.1 Version with belt output
The belt pulley must be centered on the outer
diameter of the output flange (tolerance K6), fas-
tened with the bolts so that it is frictionally en-
gaged and secured. Comply with the specified
tightening torques.
The belt pulley should be balanced to quality 6.3
as per VDI Directive 2060 in order to ensure low-
vibration operation.
CAUTION
Note the maximum specified tensioning force
when tightening the belts in order to prevent
bearing overload. The average belt force must
be between the bearings. When assembling, it
must be possible to easily slide the belt pulley
onto the output shaft. Heat the belt pulley if
necessary.
3.5.2 Version with coaxial output
In the case of the version with coaxial output
(shaft stub), also note the balancing type for the
output (see section 3.2). The gearbox is delivered
with full-key balancing.
Refer to the installation drawing for the fitted key
dimensions. Always fix the fitted key using a
threaded pin.
3.5.3 Version with TSC
The version with TSC (Through Spindle Coolant)
is used for carrying cooling lubricant, hydraulic
oils or air/oil mixtures1) through the gearbox to the
spindle. A rotary transmission leadthrough is nec-
essary to ensure that the fluid can be conveyed in
a ratio operating at differential speed. This
leadthrough 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 limited to 12 months.
Information about the product, function, operation
and installation of the rotary transmission
leadthrough can be found in the operating instruc-
tions
4161 758 030 (German)
4161 758 130 (English)
CAUTION
1)
No abrasive or solvent additives are
permitted in the fluids.
3.6 Electrical connection, gearchange
The gearbox is electrically connected using the
supplied 8-pole Harting connector (HAN 8 U).
The plug-in connection is located on the shift unit.
3.6.1 Shift unit
Technical data:
Power consumption 120 W
with neutral position 144 W
Supply voltage 24 V DC ± 10%
Current consumption 5 A
with neutral position 6 A
The required cable lead diameter is 1.5 mm².
The 24 VDC connection voltage and 5 A power
consumption must be assured at the solenoid plug.
Losses due to cable length and transition resistors
must be taken into account.
If switching the solenoid by relay, we recommend
you use a varistor, e.g. Siemens type S14-30
(30 V), to connect to the 24 V voltage, pin 2 and
pin 3.
Scope of supply:
Sleeve housing, screw connection, socket insert
and 8 jacks, type Harting AWG16,
(ZF order no. 4161 298 004). The shift unit can
only be obtained as a complete part.