ZF Duoplan 2K800 User manual

OPERATING INSTRUCTIONS
ZF-Duoplan
T
wo-speed Gearbox
2K800 / 2K801 / 2K802

Copyright © ZF Friedrichshafen AG
This document is protected by copyright. Complete or partial reproduction
or dissemination of this document is prohibited without the consent of
ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution.
This document is a translation of the German original.

Operating Instructions
2K800/2K801/2K802 Contents
EN 4161.758.103m – 2015-10 3
1Preface ..................................................................................................................................................5
1.1Safety instructions........................................................................................................................5
1.2ZF instructions .............................................................................................................................5
1.3Service products ..........................................................................................................................6
2Application and Design .........................................................................................................................7
2.1Application...................................................................................................................................7
2.2Features .......................................................................................................................................7
2.3Design..........................................................................................................................................8
2.4Technical data..............................................................................................................................9
2.5Installation positions...................................................................................................................10
3Initial Installation.................................................................................................................................11
3.1Axial runout, radial runout and length tolerances – drive motor..................................................11
3.2Balancing ...................................................................................................................................12
3.2.1Semi-key balancing ....................................................................................................................12
3.2.2Full-key balancing ......................................................................................................................12
3.3Adaptation, motor/gearbox ........................................................................................................13
3.3.1Open design...............................................................................................................................13
3.3.2Close design (with shaft sealing ring).........................................................................................14
3.3.3Open design with adapter ring for 2K800 and 2K801.................................................................15
3.3.4Open design with adapter ring for 2K802...................................................................................15
3.3.5Version with pulley drive ............................................................................................................16
3.4Gearbox – fit ..............................................................................................................................16
3.5Output........................................................................................................................................17
3.5.1Version with belt output .............................................................................................................17
3.5.2Version with coaxial output ........................................................................................................17
3.5.3Version without output ...............................................................................................................17
3.6Electrical connection, gearchange..............................................................................................18
3.6.1Shift unit ....................................................................................................................................18
3.6.2Shift logic...................................................................................................................................20
3.7Lubrication .................................................................................................................................21
3.7.1Recirculating lubrication.............................................................................................................21
3.7.2Recirculating lubrication for V1/B5 operation..............................................................................21
3.7.3Recirculating lubrication with heat exchanger ............................................................................21
3.7.4Recirculating lubrication with intermediate tank ........................................................................22
3.7.5Ports and connections for recirculating lubrication .....................................................................23
3.7.6Connections for recirculating lubrication for direct mounting on the headstock ..........................24

Operating Instructions
Contents 2K800/2K801/2K802
4 EN 4161.758.103m – 2015-10
4Taking into Operation......................................................................................................................... 25
4.1Initial inspection ........................................................................................................................ 25
5Maintenance ...................................................................................................................................... 25
5.1Oil change................................................................................................................................. 25
6Repair ................................................................................................................................................. 26
6.1Gearbox fault checklist .............................................................................................................. 26
6.2Gearbox – disassemble ............................................................................................................. 27
6.3Hub........................................................................................................................................... 27
7Frequently Asked Questions (FAQ) .................................................................................................... 28

Operating Instructions
2K800/2K801/2K802 Preface
EN 4161.758.103m – 2015-10 5
1Preface
This documentation is intended for specialists who
have experience to carry out maintenance and
repair work.
The ZF product is documented in accordance with
the design status as of the issue date.
The following safety notices are used in these
operating instructions:
NOTE
Used to highlight special sequences, methods,
information, etc.
CAUTION
Used when incorrect and improper operating
procedures can cause damage to the product.
DANGER!
Used when due lack of care and attention
can cause injury to personnel and/or
damage to property.
ENVIRONMENTAL HAZARDS!
Lubricants and cleaning products must not
be poured onto the ground, into ground-
water or down the drain.
• Obtain and comply with the safety
regulations relevant to these products
issued by your local environmental
authority.
• Collect used oil in a suitably large
container.
• Dispose of used oil, clogged filters,
lubricants and cleaning products in
accordance with local environmental
protection regulations.
• Always follow the instructions issued
by the manufacturer when handling
lubricants and cleaning products.
1.1 Safety instructions
All persons repairing ZF units are responsible for
their own work safety.
Every applicable safety regulation and legal
requirement must be complied with in order to
prevent injury to personnel and/or damage to
the product during the course of maintenance
and repair work.
Repair staff should familiarize themselves with
these regulations before commencing work.
Correct and proper repair of these ZF products
can only be assured by appropriately trained
specialists.
The organization in charge of repairs is
responsible for ensuring that such training is
given.
Read these operating instructions carefully
before commencing any testing or repair work.
CAUTION
Pictures, drawings and components do not
always represent the original object but are used
to illustrate working procedures.
The illustrations, diagrams and parts are not
drawn to scale and no assumptions should be
made regarding size and weight (including within
a single illustration or drawing).
Work must be performed as described in the text.
Following the completion of repair work and
testing, the specialists must satisfy themselves
that the product will function perfectly again.
1.2 ZF instructions
Remove any traces of old seals or gaskets
from mating faces. Use an oil stone to carefully
remove any burrs or similar irregularities.
Carefully cover or shield open gearboxes to
prevent the ingress of foreign matter.



Operating Instructions
Preface 2K800/2K801/2K802
6 EN 4161.758.103m – 2015-10
1.3 Service products
Product Name/specification Quantity
(approx.)
[dm3]
Use Remarks
Grease Shell Avania WR2
Fuchs Renolit CXEP2
Esso Beacon EP2
General purpose
Gearbox oil
HLP 46 to ISO VG 46
Gearbox oil for
recirculating
lubrication
Can also be used for
recirculating lubrication
with heat exchanger
Gearbox oil
HLP 32 to ISO VG 32
Gearbox oil for
recirculating
lubrication with
heat exchanger
Jointing
compound (liquid
seal)
Loctite 574 Seal Sealing washer/
spacing washer

Operating Instructions
2K800/2K801/2K802 Application and Design
EN 4161.758.103m – 2015-10 7
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
installation position. The gearbox is also suitable
for use in many systems in which torque increase
or speed reduction is required.
The gearboxes have coaxial output and are 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
Electromotive gear switching

Operating Instructions
Application and Design 2K800/2K801/2K802
8 EN 4161.758.103m – 2015-10
2.3 Design
The gearbox primarily comprises the following
assemblies:
Connecting parts:
Drive hub (1)
Adapter plate (2) with radial shaft seal (3) and
hub bearings (4), as necessary
Housing:
Gearbox housing (5)
Input:
Sun gear (6)
Ring gear (7)
Ring gear bearings (8)
Output:
Bearing housing (9)
Output bearings (10, 11)
Output shaft (12)
Radial shaft seal (13)
Planet carrier (14)
Axial bearing (15)
Shift mechanism:
Sliding sleeve (16)
Shift fork (17)
Brake disc (18)
Shift unit:
Shift unit (19)
Selector finger (20)
141
6
1
8
17
1
5
8
7
6
1
5
10
9
1
1
13
1
2
2
0
19

Operating Instructions
2K800/2K801/2K802 Application and Design
EN 4161.758.103m – 2015-10 9
2.4 Technical data
Type 2K800
2K801/802
Standard
version
2K800
2K801/802
with STW
(i = 1.236)
Nominal powe
r
max. 84 kW max. 84 kW
Nominal speed 1000 rpm 1000 rpm
Max. speed
in direct drive i = 1 5000 rpm 5000 rpm
NOTE
When using engine brakes/counterflow to brake
the spindles (e. g. emergency stop) ensure that
the moments of inertia do not exceed the
admissible output torques. Braking times must be
adapted accordingly.
Standard fixing dimension (in mm)
in accordance with EN 50347: 2001
Two-speed
gearbox
2K800
FF350
2K801
FF400
2K802
FF500
Motor size 180 200 225
h 180 200 225
d 60 65 75
l 1400.2 1400.2 1400.2
b 300 350 450
e2350 400 500
a1400 450 550
s24x18.5 8x18.5 8x18.5
Type 2K800
2K801/802
Standard
version
2K800
2K801/802
with STW
(i = 1.236)
Nominal input
torque (S1)
max. 800 Nm max. 800 Nm
Max. output
torque (S1), for
i = 1.00
i = 3.19
i = 4.00
800 Nm
2552 Nm
3200 Nm
989 Nm
3154 Nm
3955 Nm
Weight approx.
175 kg
approx.
325 kg
Model plate (standard)
(affixed to gearbox housing)
ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY
TYPE PARTS LIST
RATIO SERIAL-NO.
BACKLASH
MAX.
INPUT TURN RPM
POWER MAX.
AT RPM KW
INPUT
TORQUE NM OIL GRADE
OIL
QUANTITY
SHITING V
UNIT W
i , - ,
MIN.
S2
a1
db
h
l
e2

Operating Instructions
Application and Design 2K800/2K801/2K802
10 EN 4161.758.103m – 2015-10
2.5 Installation positions
Horizontal B5
Horizontal B5
(shift unit rotated)
Vertical V1
Vertical V3
CAUTION
The breather outlet must always be at the top,
regardless of the installation position.

Operating Instructions
2K800/2K801/2K802 Initial Installation
EN 4161.758.103m – 2015-10 11
3Initial Installation
3.1 Axial runout, radial runout and length
tolerances – drive motor
In order to guarantee fault-free operation, the
motor must not exceed the specified tolerances.
Axial runout, radial runout and length tolerances –
electric motor mounting flange:
Gearbox
type
Tolerance
A B C L=140
2K800/
2K801
0.030 0.063 0.063 0.200
A B C L=140
2K802 0.030 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 mounting
to the motor. Oversize shafts must be machined
to the correct length.
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

Operating Instructions
Initial Installation 2K800/2K801/2K802
12 EN 4161.758.103m – 2015-10
Semi-key balancing Full-key balancing
3.2 Balancing
The hubs (2) come with a keyway (1) for
transmitting power from the motor shaft (3) as
standard.
There are two balancing types for the motor
and gearbox: Semi-key and full-key, which are
described in more detail in DIN ISO 8821.
It must be ensured that the hub is balanced in the
same way as the motor.
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
Gearbox
type
Shaft diameter Fitted
key
Fitted key
length
2K800
2K801
2K802
60 mm
65 mm
75 mm
80 mm
A18x11
A18x11
A20x12
A22x14
125 mm
125 mm
125 mm
140 mm
NOTE
In the case of motor shafts with open ends of the
keyway, the parallel key is to be glued into the
groove in order to avoid axial migration of the
parallel key and/or the hub.
3.2.1 Semi-key balancing
In semi-key balancing, the keyway is filled with
a balance compensation corresponding to
approximately half a key, shape B by default. This
is based on the original key, shape, length and
position used by the motor manufacturer and is
defined as a counterweight. In semi-key balancing
– in contrast to full-key balancing – the joint
passes through a shared component. This means
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.
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.
1
2
3

Operating Instructions
2K800/2K801/2K802 Initial Installation
EN 4161.758.103m – 2015-10 13
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.
Different gearbox variants are used depending on
the motor type. Gearbox mounting also differs
accordingly.
Reference dimensions for hub position
Gearbox type For output
shaft length
Dimension C in
mm
2K800
2K801
2K802
140 82.3 -0.2
140 148.3 -0.2
170 182.3 -0.2
CAUTION
DimensionCisreducedby0.5mminmotorswith
afixedbearingontheB‐side.
Spacer discs are supplied with shims of varying
thickness. These enable balancing of the motor
shaft length tolerances and, therefore, compliance
with reference dimension “C”.
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
gearbox. Clean the fitting surfaces of the motor (3)
and drive hub. Check the motor shaft for axial and
radial runout as described in chapter 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 stop.
Then check reference dimension “C”. If undersize,
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
prevent it from turning, see chap. 3.4.

Operating Instructions
Initial Installation 2K800/2K801/2K802
14 EN 4161.758.103m – 2015-10
3.3.2 Close design (with shaft sealing ring)
This variant incorporates an adapter plate (5) with
shaft seal (7), which means that the gearbox forms
a compact, closed unit.
The adapter plate (5) and drive hub (1) are
separately delivered 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 chapter 3.1. Also lightly grease the
motor shaft.
After cleaning the fitting surfaces, place the
adapter plate with radial shaft seal (7) 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.
Then check reference dimension “C” 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
prevent it from turning, see chap. 3.4.
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.
NOTE
The radial shaft sealing ring in the drive motor
must be removed on the output end when the
closed design is used.
In the case of motor adaptation and loosely
supplied sealing/spacing washers, the latter must
be pasted in by means of a jointing compound
(e. g. Loctite 574) prior to assembly.

Operating Instructions
2K800/2K801/2K802 Initial Installation
EN 4161.758.103m – 2015-10 15
3.3.3 Open design with adapter ring for
2K800 and 2K801
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
delivered loose. Clean the fitting surfaces of the
motor (3) and drive hub (1). Check the motor shaft
(2) for axial and radial runout as described in
chapter 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.
Then check reference dimension “C” 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
prevent it from turning, see chap. 3.4.
3.3.4 Open design with adapter ring for
2K802
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
delivered loose. Clean the fitting surfaces of the
motor (3) and drive hub (1). Check the motor shaft
(2) for axial and radial runout as described in
chapter 3.1. Also lightly grease the motor shaft
(2).
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.
Then check reference dimension “C” and change
using shims if necessary.

Operating Instructions
Initial Installation 2K800/2K801/2K802
16 EN 4161.758.103n – 2015-10
CAUTION
Risk of motor shaft damage if the hub is not
sufficiently heated.
Tighten the threaded pin (9) and secure it to
prevent it from turning, see chap. 3.4.
3.3.5 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.
3.4 Gearbox – fit
NOTE
For drive hub (1) assembly, the M12 set screw (9)
must be screwed in and tightened at the parallel
key with 40 Nm until firmly home. 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 delivered
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 mechanism.
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.
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 ring (if applicable)
and motor are bolted together using four, six or
eight hexagon bolts (11).
Schmierölzufuhr
zusätzlicher Anschluss
bei Riemenantrieb
S
Oil feed for
additional
connecton in
case of pulley drive

Operating Instructions
2K800/2K801/2K802 Initial Installation
EN 4161.758.103m – 2015-10 17
Fill the gearbox with oil and connect up the
recirculating 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 gearbox is now ready for use.
1st gear position
ABrake disc
BSliding sleeve
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.
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, support the motor on the B-side
so that it does not vibrate.
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),
fastened with the bolts so that it is frictionally
engaged 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 chap. 3.2). The gearbox is delivered
with full-key balancing.
Refer to the installation drawing for the fitted
key dimensions. Always fix the fitted keys using
threaded pins.
3.5.3 Version without output
The output shaft is not supplied by ZF. It is
manufactured by the customer. Refer to the
installation drawing for a proposal of how the
connection point for the output shaft should be
configured with the DIN 5480 profile. Apply a
suitable bolt locking compound (e. g. Loctite no.
275 or no. 243) to the M12 cap screw and tighten
to 115 Nm.

Operating Instructions
Initial Installation 2K800/2K801/2K802
18 EN 4161.758.103n – 2015-10
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 84 W
Supply voltage 24 V DC ± 10 %
Max. pickup current 5 A
Nominal current 3.5 A
Index of protection IP64
The required cable lead diameter is 1.5 mm².
The 24 V DC connection voltage and 5 A power
consumption must be assured on the shift unit
connector.
Losses due to cable length and transition resistors
must be taken into account.
Scope of supply:
Sleeve housing, screw connection, socket insert
and 8 jacks, type Harting AWG16. The shift unit
can only be obtained as a complete part.
Gearbox shift mechanism:
Gearchanges are effected when the 24 V voltage
is applied to pin 2 and 3. The polarity of the
applied 24 VDC voltage dictates which gear is
engaged.
In 1st gear => Pin 2: + / Pin 3: ‒
In 2nd and 3rd gear => Pin 2: ‒/ Pin 3: +
During the gearchange, the main spindle motor
should make the shaft oscillate +5° or -5° at a rate
of 1 to 5 rotation direction changes per second.
Major pendulum motion may lead to damage at
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.
In 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 1080 0.28 5
4.00 1440 0.21 5
5.00 1800 0.17 5
The machine optimum is to be determined on
the basis of shift tests in relation to the different
masses and thereto connected drag torques of
the spindle.
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 gearchange is complete.
CAUTION
After the limit switch signals have been reached,
the shift unit is allowed to be live for a maximum
of 0.5 second. The limit switch signals must be
monitored during the operating time.
The limit switches must only be energized with
the control current (0.1 – 0.5 A) and not with the
changeover current (5 A).
Rotation direction
changes

Operating Instructions
2K800/2K801/2K802 Initial Installation
EN 4161.758.103m – 2015-10 19
If the number of resistors is rather small, also
a lower control current can be used.
The control current for end-position monitoring
is to be set according to length, line and
transition resistance and the number of
connection points. Increased resistance due to
corrosion after some time must be taken into
consideration. 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 securely engaged, steps such as
emergency shut-off etc. must be initiated
through the control system.
NOTE
Electromagnetic fields can falsify the limit position
monitoring currents. This can be prevented by
re-routing or shielding the line.
The shift sequence must be monitored. If
necessary, a timer should be used to cancel the
shift sequence after approx. 2 seconds if there is
no limit switch signal (S1/S2). The main spindle
motor can not be operated until this signal is
present.
Circuit diagram for switchgear unit with solenoid
unit and two switch positions (standard) or three
switch positions (with neutral position):
1st gear ==> e. g. 4:1
2nd gear ==> 1:1
3rd gear ==> Neutral position, idling
(option)
X8
S3
S1 S2
optional
M
34
4
3
5
2
6
8
1
4
2
1
7
34
blue
blue
grey
grey
black
blue
black black
green
The electromotive gearchange is performed by
a shift unit on the gearbox which is driven by a
DC motor (24 V DC). The gearbox shift element is
a positively locking, axially movable selector fork
that acts on a sliding sleeve.
The limit positions are monitored by limit switches
in the shift unit. The time sequence is monitored in
the control unit.
The motor must be energized when shifting from
gear 1 to 2 or vice versa. The direction of rotation
is changed over by reversing the polarity.
NOTE
Gearbox with neutral position
The neutral position can only be reached via
gear 1.
As soon as limit switch S3 receives the signal, the
DC motor must always be switched off using a
regenerative motor stop (Quickstop).
Under certain operating conditions (e. g.
installation orientation V3, higher cable resistance
values), it may be necessary to have a variable
timing element in the control unit contact ZF.

Operating Instructions
Initial Installation 2K800/2K801/2K802
20 EN 4161.758.103n – 2015-10
3.6.2 Shift logic
Reduce main spindle motor speed
from operating speed to zero.
Leave controller enable on
converter.
Apply desired oscillating speed to
converter and speed controller
without delay.
Shift unit energized
(pin 2 and 3)
Gear ratio change is
completed within 2 seconds.
(Acknowledgement from limit switch
S1 or S2 from the
shift unit)
Shut off desired
oscillating speed.
After 200 ms to max. 500 ms
shift unit OFF.
Gear ratio change complete.
Number of attempted
shifts > 5 each from the
starting position
(polarity reversal)
Gear ratio change not
successful:
Switch off main spindle motor.
Check system.
N
N
Y
Y
Main spindle motor start.