ZF-Duoplan Two-speed Gearbox 2K450 / 2K600

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ZF-DUOPLAN Contents

ZF-DUOPLAN Operating Instructions 2K450/2K600

ZF-DUOPLAN Preface 1 Preface This documentation is intended for specialists who have experience to carry out maintenance and repair work. The ZF product is documented in accordance with the design status as of the issue date. The following safety notices are used in these operating instructions: Used to highlight special sequences, methods, information, etc. Used when incorrect and improper operating procedures can cause damage to the product. Used when due lack of care and attention can cause injury to personnel and/or damage to property. Lubricants and cleaning products must not be poured onto...

ZF-DUOPLAN Operating Instructions 2K450/2K600 1.3 Service products Product

ZF-DUOPLAN Application and Design 2 Application and Design 2.1 Application The ZF-DUOPLAN two-speed gearbox is mainly used in machine tool drives. By way of example, the gearbox can be used in turning machines (horizontal B5) or machining centers (vertical V1) thanks to its variable installation position. The gearbox is also suitable for use in many systems in which torque increase or speed reduction is required. The gearboxes have coaxial output and are suitable for the high speeds generated in machine tool construction. • Two-speed gearboxes for AC and DC main spindle drives in machine tools...

ZF-DUOPLAN Operating Instructions 2K450/2K600 2.3 Design The gearbox primarily comprises the following assemblies: Connecting parts: • Adapter plate (2) with radial shaft seal (3) and hub bearings (4), as necessary • Ring gear bearings (8) • Radial shaft seal (13) • Axial bearing with cup springs (15) Shift mechanism: Shift unit:

ZF-DUOPLAN Application and Design 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 Model plate (affixed to gearbox housing) TYPE _ PARTS LIST___ BACKLASH INPUT TURN _ RPM

Operating Instructions Application and Design Installation positions Horizontal B5 Shift unit on right side, gearbox turned around longitudinal axis (view to output end) CAUTION The breather outlet must always be at the top, regardless of the installation position.

ZF-DUOPLAN Initial Installation 3 Initial Installation3.1 Axial runout, radial runout and length tolerances - drive motor In order to guarantee fault-free operation, the motor must not exceed the specified tolerances. Take into account the motor shaft elongation caused by heating in motors with fixed bearing on the B-side (opposite the motor output shaft). Axial runout, radial runout and length tolerances -electric motor mounting flange: Please note that the tolerance of the shaft length “L" is restricted in relation to the DIN standard The special tolerance for shaft length "L" must be maintained...

Initial Installation ZF-DUOPLAN Operating Instructions 2K450/2K600 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 Shaft diameter In the case of...

ZF-DUOPLAN 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 2K450 and 2K600. Different gearbox variants are used depending on the motor type. Gearbox mounting also differs accordingly. Reference dimensions for hub position After cleaning the fitting surfaces, heat the drive hub to approx 120 °C from the opening and slide it onto the motor shaft...

Operating Instructions Initial Installation 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 chap. 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...

Initial Installation 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 chap. 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...

Operating Instructions Initial Installation 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 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 chap. 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...