ZF-DUOPLAN 2K250 User manual

OPERATING INSTRUCTIONS
ZF-DUOPLAN
2-Speed Gearbox
2K250 / 2K300

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 4161.758.102q – 2017-09 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 4161.758.102q – 2017-09
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 4161.758.102q – 2017-09 5
1Preface
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 HLP 46 according to
ISO VG 46
Gearbox oil for
recirculating
lubrication
Can also be used for
recirculating lubrication
with heat exchanger
Gearbox oil HLP 32 according to
ISO VG 32
Gearbox oil for
recirculating
lubrication with
heat exchanger
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 4161.758.102q – 2017-09
2Safety
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
p
r
evented.
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
p
r
evented.
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
p
r
evented.
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 4161.758.102q – 2017-09 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 4161.758.102q – 2017-09
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 4161.758.102q – 2017-09 9
3Application 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

Application and Design
10 EN 4161.758.102q – 2017-09
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)

Application and Design
EN 4161.758.102q – 2017-09 11
S2
a1e2
db
h
l
3.4 Technical data
2K250 2K300
Nominal powe
r
max. 39 kW max. 47 kW
Nominal speed 1,500 rpm 1,500 rpm
Max. speed
when ratio i1
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
e2300 350
a1– –
s218 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 AG
MADE IN GERMANY
TYPE PARTS LIST
RATIO SERIAL-NO.
BACKLASH
MAX.
INPUT TURN RPM
POWER MAX.
AT RPM KW
INPUT
TORQUE NM OIL GRADE
OIL
QUANTITY
SHITING V
UNIT W
i , - ,
MIN.

Application and Design
12 EN 4161.758.102q – 2017-09
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 4161.758.102q – 2017-09 13
4Initial 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).
ABC
L
001064

Initial Installation
14 EN 4161.758.102q – 2017-09
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 ke
y
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

Initial Installation
EN 4161.758.102q – 2017-09 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.
1Hub
2Motor shaft

Initial Installation
16 EN 4161.758.102q – 2017-09
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
91
2
11
D

Initial Installation
EN 4161.758.102q – 2017-09 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.
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.
Control dimension "D" is set ex works.
Risk of motor shaft damage if input hub is not
heated sufficiently.
Heat input hub to approx. 120 °C.
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.
Tighten the set screw (9) and secure it to prevent
it from turning, refer to Chap. 4.3.6.
The radial shaft sealing ring in the drive motor
must be removed on the output end when the
closed design is used.
3
10
91
2
5
6
11
D
7
4

Initial Installation
18 EN 4161.758.102q – 2017-09
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.
Risk of burns due to contact with hot surfaces.
Slight to moderate injury possible.
Wear protective gloves.
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.
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.
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.
3
10
91
2
5
6
11
D
7
12
13

Initial Installation
EN 4161.758.102q – 2017-09 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.
Risk of burns due to contact with hot surfaces.
Slight to moderate injury possible.
Wear protective gloves.
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.
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.
3 5
10
6
91
2
11
11
D
12
13

Initial Installation
20 EN 4161.758.102q – 2017-09
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 8
11 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.