ZF Duoplan Gearbox Catalogue - Drive Lines Technologies

Power and Dynamics 

Two-Speed Gearbox 

for Machine Tools

ZF-Duoplan 2K120 INLINE 

Direct Mounting to Spindle 

ZF-Duoplan 2K250 Standard 

for Belt Drives 



ZF-Duoplan 2K250 TSC (Through-Spindle-Cooling) 

Allows cutting liquids like emulsions, hydraulic oils and air-oil mixtures to be passed through the gearbox and spindle, directly to the tool



Precision in movement 

The ZF Friedrichshafen division Special 

Driveline Technology is able to offer you 

a wide range of machine drives, brakes and 

clutches for applications in engineering as 

well as customer specific drive solutions. 

Application, Benefits , Design 

Modular Design 

Technical Data 

page 4-5 

page 6-7 

page 8-9 

Our development and production activities 

are focused on servo-assisted drives for 

automation engineering, two-speed drive 

gearboxes for machine tools as well as 

customer-specific drives, such as for printing 

machines, robot applications and elevator 

gearboxes. 

Motor Connection 

Motor Output Shaft 

Adaptions 

Bearing Lifetime 

page 10 

page 11-12 

page 13 

page 14-15 

Our innovative standard products range 

from low backlash servogearboxes 

(ZF-Servoplan), and high precision robust 

two-speed gearboxes (ZF-Duoplan) to hysteresis 

clutches and brakes for non-contact 

web control (ZF-Tiratron). 

Torsional Backlash 

Lubrication 

Connections for 

Recirculation Lubrication 

page 16 

page 17 

page 18-20 

Overview Installation Drawings 

page 21-34 

Ordering Information 

page 35-41 

3

ZF Douplan - Two-speed gearboxes 

Application 

The ZF Duoplan two-speed gearbox is mainly used in machine tool main-spindle drives, test-benches and 

applications where high torque is needed. 

By way of example, the gearbox can be used in turning machines (horizontal B3/B5), machining centers 

(vertical V1/V3) thanks to its variable installation position (see page 10). The gearbox is also suitable for 

use in many systems in which torque increase and/or speed reduction is required. 

Benefits 

Machine tools are designed to be universal so that they can process different materials. This requires both high 

cutting speeds for soft materials as well as high cutting forces for hard materials requirements which a two-speed 

gearbox can fulfill, since it can either retain high motor speeds (i = 1:1) or multiply the motor torque 

(e.g. ratio i = 4.00) and reduce the speeds, both by the same factor. 

Flexible 

The cutting power is therefore constant and remains available across a wide 

speed range. This flexibility can only be economically achieved by using a gearbox. 

ZF-Duoplan Standard 

Wide bearing base for 

high cantilever force 

Direct Mounting to Spindle (INLINE + TSC) 

This gearbox is mounted directly to the spindle. No more belt drives are used. 

The gearbox is dedicated for today’s high speed requirements in machine tools. 

Torque-power curve 

Speed ranges with constant power of up to 1:20 can be achieved for the spindle with 

the gearbox, depending on the controllable range of the motor. This provides high 

torque at low speeds on the one hand and high power at high speeds on the other, 

allowing the cutting power of modern tools to be fully utilized. 

Torque - Power Curve - e.g. ZF-Duoplan 2K250 

Torque 

Power 

Nm 

kW 

rpm 

rpm 

400% increased motor torque. Doubled constant power range. 

1) Motor-gearbox in i 2 = 1.00 

or motor without gearbox 

4 

2) Motor-gearbox in i 2 = 4.00

Machining Center 

ZF-Duoplan - Design 

Design 

ZF developed the ZF-Duoplan gearbox as a single-stage planetary design with a 

shift mechanism, hereby meeting today’s high demands of low noise operation. 

In contrast to conventional spur gearboxes in lay-shaft design, this planetary 

gearbox has the distinct advantage of allowing an extremely compact and 

space-saving design since the power is distributed among 4 or 5 planetary gears. 

In addition, the four resp fire simultaneously meshing planetary gears with 

helical gearing also assure low-noise operation at high speeds. 

Misalignments and concentricity issues are ideally concentrated by the floating 

design of the sun gear. Thus such a planetary gearbox is much less sensitive to 

tolerances. 

The motor-gearbox unit is commonly fixed to the machine frame 

or bed by using the gearbox foot mount. 

(Available for 2K120, 2K250, 2K300, 2K450, 2K600 only). 

Each gearbox also has available an output side pilot for flange mounts. 

ZF-Duoplan INLINE 

For each application there is an ideal choice of output bearings with a 

wide bearing base. 

A range of output housing variants cater to different spindle drive designs: 

e.g. ZF-Duoplan STANDARD with wide bearing base for belt drives with high 

cantilever forces, ZF-Duoplan INLINE with short output housing and angular 

contact bearings for direct drive and ZF-Duoplan TSC (Through-Spindle-Cooling) 

to facilitate the transfer of cutting liquids like emulsions, hydraulic oils and air-oil 

mixtures with up to 140 bars of pressure at a flow rate of 35 l/min through the 

gearbox and spindle, directly to the tool. 

Short output housing 

for direct mounting 

to spindle 

5

ZF-DUOPLAN 2K120 Standard 

19 

2 

4 

5 

20 17 

18 

16 

10 11 

Main components of the gearbox: 

3 

1 

13 

12 

Adapter parts: 

1: Drive hub 

2: Adapter plate 

3: with radial shaft seal 

4: and hub bearing 

033245 

6 

Housing: 

5: Gearbox housing 

Input: 

8 

7 

9 

14 

6: Sun gear 

7: Ring gear 

8: Ring gear bearing 

ZF-DUOPLAN 2K250 INLINE 

Output: 

9: Output housing 

10: Output bearings 

11: Output bearings 

12: Output shaft 

13: Radial shaft seal 

14: Planetary carrier 

15: Axial bearing with cup springs 

15 10 11 

Gear shift mechanism: 

16: Sliding sleeve 

17: Gear shift fork 

18: Brake disc 

12 

Shift unit: 

19: Switch unit 

20: Gear shift finger 

033247 

9 

6

Adapter parts: 

1: Keyless hub 

6: Sun gear 

22: Counter holder 

23: Clampig rings 

24: Pressure piece with bushing 

Output: 

12: Output shaft 

TSC: 

25: Pipe 

26: Rotary union joint 

ZF-Duoplan TSC 

ZF-DUOPLAN 2K250 TSC 

Through-Spindle-Cooling: 

Allows cutting liquids like 

emulsions, hydraulic oils 

and air-oil mixtures with 

up to 140 bars of pressure 

at a flow rate of 35 l/min 

to be passed through the 

gearbox and spindle, 

directly to the tool. 

15 

12 

1 

22 

23 

24 

033246 

25 

26 

6 

7


i 

Gearbox Sizes: 

2K120 

2K 121 

2K250 2K300 2K450 2K600 

8 

Nominal data: 

Motor frame size 100/112 132 160 160/180 180 

Nominal power (kW) 19 39 47 47 63 

Nominal speed (min -1 ) 1 500 1 500 1 500 1 000 1 000 

Nominal input torque (continuous operation S1) (Nm) 120 250 300/250*** 450 600 

Output torque (Nm) 1.00 120 250 300/- 450 600 

(Nm) 3.16 379 - - - - 

(Nm) 3.17 - 792 951/- - - 

(Nm) 4.00 480 1 000 1 200/- 1 800 2 400 

(Nm) 4.91 589 - - / - - - 

(Nm) 5.00 - - - 2 250 3 000 

(Nm) 5.50 - 1 375 - / 1 375 - - 

Maximum data: 

Maximum torque in Nm (intermitted loading 

S6 cycle duration 10 min, ED. max. 60 %) 

Input (Nm) 140 400 400 630 840 

Output 

(max. accelarating torque) 

(Nm) 1.00 140 400 400 630 840 

(Nm) 3.16 442 - - - - 

(Nm) 3.17 - 1 268 1 268 - - 

(Nm) 4.00 560 1 600 1 600 2520 3360 

(Nm) 4.91 687 - - - - 

(Nm) 5.00 - - - 3150 4200 

(Nm) 5.50 - 2 200 2 200 - - 

Maximum permitted input speed (min -1 ) - - - - - 

in reduction ratio i ≠ 1 (min -1 ) ≠ 1 8 000 6 300 6 300 5000 5000 

for direct drive i = 1 2) (min -1 ) 1 2) 12 000 3) 10 000 3)4) 10 000 3)4) 8000 5000 

Maximum vibration value (mm/s) 2.0 1.4 1.4 ≤2.0 ≤2.5 

reduced (mm/s) 1.2 1.0 1.0 

INLINE (mm/s) 1.0 1.0 1.0 

reduced (mm/s) 0.7 0.7 0.7 

at reference speed (min -1 ) 6 000 5 000 5 000 4 000 4 000 

Max. axial force in reduction (N) 3.16 - - - 

ratio in counter clockwise (ccw) operation 

running and max. input torque 

(N) 3.17 - 3 090 3 710 - - 

see permissible 

(N) 4.00 - 3 964 4 756 5 439 7 253 

(N) 4.91 - - - - - 

(N) 5.00 - - - 7 139 9 519 

(N) 5.50 - 5 288 5 288 - - 

Mass moment of inertia 1 ) (J in kgcm 2 ) 1.00 110 270 270 tbd tbd 

Output 4.00 144 570 570 tbd tbd 

Input 9 36 36 tbd tbd 

Operating data: 

Oil fill volume in dm 3 Horizontal (B5) 1.0/1.4 1.5 2.8 5,1 5,4 

Approx. oil fill in dm³. Oil level in middle of oil sight glass 

is most accurate reading 

Vertical (V1/V3) 

recirculation lubrication 

Oil grade for: 

splash lubrication 

recirculating lubrication 

recirculating lubrication with heat exchanger 

recirculating lubrication with DSL** 

HPL 68 as per ISO VG 68 




for V1 and V3 installation positions oil recirculating system is mandatory 

Oil change interval 

Oil temperature 

5 000 hours 

max. 120° C permitted depending on application , installation position, lubrication and cooling 

Weight: 

Standard (approx. kg) 42/52 68 86 155 165 

ElectricalConnection: 

for shift unit: 

power consumption W 120 120 120 120 120 

Supply voltage (at shift unit) V 24±10% 24±10% 24±10% 24±10% 24±10% 

current supply at 24V A 5,0 5,0 5,0 5,0 5,0 

Operator is free to define bearing load and lifetime. See installation drawings or page 14 - 15 for bearing data. 

1) Mass moments of inertia for other ratios on request. 

2) admissible with oil cooler, otherwise n max for reduction ratio. 

3) max. speed only permitted with oil connection at port K+ T (see pages 18/19 for oil recirculation 

systems connections). 

4) max. speed only permitted with integrated oil channel versions 

* on request 

** DSL = Dry Sump Lubrication 

*** i=5,5 = reduced input torque


Nominal data: 

i 

Gearbox Sizes: 

2K800 

2K801/2K802 

standard 

2K800 

2K801/2K802 

mit STW 

2K2100 

standard 

ohne Abtrieb 

2K2100 

mit STW 

Motor frame size 180/200/225 180/200/225 225/280 225/280 

Nominal power (kW) 84 84 120 120 

Nominal speed 

(min -1 ) 

1 000 1 000 500 500 

Nominal input torque (continuous operation S1) (Nm) 800 800 2 100 2 100 

Output torque (Nm) 1.00 800 989 2 100 2 932 

Maximum data: 

Maximum torque in Nm (intermitted loading 

S6 cycle duration 10 min, ED.max. ED. max. 60%) 

(Nm) 3.16 - - - - 

(Nm) 3.17 - - - - 

(Nm) 3.19 2 552 3 154 - - 

(Nm) 4.00 3 200 3 955 8 400 11 726 

(Nm) 4.91 - - - - 

(Nm) 5.50 - - - - 

Input (Nm) 900 900 * * 

Output 

(max. accelerating torque) 

(Nm) 1.00 900 1 112 - - 

(Nm) 3.16 - - - - 

(Nm) 3.17 - - - - 

(Nm) 3.19 2 871 3 549 - - 

(Nm) 4.00 3 600 4 450 - - 

(Nm) 4.91 - - - - 

(Nm) 5.50 - - - - 

Max. permitted input speed (min -1 ) 5 000 5 000 3 500 3 500 

in reduction ratio i ≠ 1 (min -1 ) ≠1 - - - - 

for direct drive i = 1 2) (min -1 ) 1 2) - - 3 000 - 

Max. vibration value (mm/s) 3,0 3,0 5,0 * 

reduced 

INLINE 

reduced 

(mm/s) 

(mm/s) 

(mm/s) 

at refence speed (min -1 ) 4 000 4 000 * * 

Max. axial force in reduction (N) 3.16 - - - - 

ratio in counter clockwise (ccw) operation 

running and max. input torque 

See permisible axial force for motor shaft 

(N) 3.17 - - - - 

(N) 3.19 - - - - 

(N) 4.00 - - - - 

(N) 4.91 - - - - 

(N) 5.50 - - - - 

Mass moments of inertial 1) (J in kgcm 2 ) 1.00 1 956 * * * 

Output 4.00 1 766 * * * 

Input 110 * * * 

Operating data: 

Oil fill volume dm 3 

Approx. oil fill in dm³. Oil level in middle of 

oil sight glass is most accurate reading 

Oil grade for: 

splash lubrication 

recirculating lubricaton 

recirculation lubrication with heat exchanger 

recirculating lubrication with DSL** 

Oil change interval 

Oil temperature 

Weight: 

Horizontal (B5) 

Vertical (V1/V3) 

Standard (approx. kg) 175 325 180 400 

Electrical connection: 

for shift unit: 

HLP 68 as per ISO VG 68 




5 000 hours 



for V1 oder V3 installation positions oil recirculating system is mandatory 

max. 120° C permitted depending on application, installation position, lubrication and cooling 

Power consumption W 120 120 85 85 

Supply voltage (at shift unit) V 24±10% 24±10% 24±10% 24±10% 

Current supply at 24V A 5,0 5,0 5,0 5,0 

Operator is free to define bearing load and lifetime. See installation drawings or page 14 - 15 for bearing data. 

1) Mass moments of inertia for other ratios on request. 

2) admissible with oil cooler, otherwise n max for reduction ratio. 

* on request 

9

Standard Motor Connection Dimensions 

Gearbox sizes: 

2K120 2K121 2K250 2K300 2K450 2K600 2K801 2K802 2K2100 2K2100 

Motor frame size: 100 112 132 160 160/180 180 200 225 225 280 

Standard motormotor 

connection dimension 

h 100 112 132 160 160/180 180 200 225 225 280 

d 38 48 42 55 55/60 65 65 75 75 90 

l 80±0.1 110±0.1 110-0.2 110-0.2 110–0.2 140–0.2 140±0.2 140±0.2 140±0.2 170±0.2 

140–0.2 

b 180 230 250 300 300 300 350 450 450 550 

e 2 215 265 300 350 350 400 400 500 500 600 

a 1 - - - - 400 450 450 550 550 660 

s 2 14 15 18 18 18 18 19 19 19 24 

All measure in mm 

EN 50347: 2001 

2K120 / 2K121 / 2K250 / 2K300 / 2K450 / 2K600 

S 2 

e 2 

b 

d 

h 

I 

2K800 / 2K801 / 2K802 / 2K2100 

S 2 

a 1 

e 2 

I 

d 

b 

10

Motor output shafts with standard fitted key 

Gearbox sizes 

ZF-Duoplan 

Shaft diameter 

[mm] 

See DIN ISO 8821 

For half-key balancing the key type B is standard. 

For a full-key balanced motorshaft both types can be used. 

Application with smooth motorshaft without keyway on request. 

Fitted key 

b x h [mm] 

Fitted key length 

[mm] 

2K120/121 38 10x8 70 

32 10x8 70 

42 12x8 90 

2K250 42 12x8 90 

48 14x9 90 

55 16x10 90 

2K300 55 16x10 90 

48 14x9 90 

42 12x8 90 

60 18x11 125 

2K450 60 18x11 125 

55 16x10 90 

2K600 65 18x11 125 

2K800/801 60/65 18x11 125 

2K802/2K2100 75 20x12 125 

80 22x14 150 

Half-key balancing 

Full-key balancing 

Nabe 

Hub 

Motorwelle 

Motor shaft 

Installation positions 

Horizontal B5 

Vertikal V1 

Vertikal V3 

Horizontal B5 

Shift unit on right side 

(view from output) 

Gearbox rotated along 

longitudinal axis 

(for 2K120/2K250/ 

2K300/2K450/2K600) 

11

Output / Motor interface 

Gearbox sizes: 

ZF Duoplan 2K120 2K121 2K250 2K300 2K450 2K600 2K800 2K801 2K802 2K2100 

Gearbox Output 

Ø 100 + + 

Ø 118 + 0 

Ø 130 0 + 

Ø 140 + 

Ø 150 + 

Ø 38 0 0 

Ø 42 0 0 

Ø 55 0 0 

Ø 60 0 

Ø 65 0 0 0 

Ø 90 0 

Ø 180 + + + 

Ø with STW 0 0 0 + 

Ø without Output 0 0 0 0 

Ø 38 INLINE 0 0 

Ø 42 INLINE 0 0 

Ø 70 TSC * 0 0 0 0 

+ = Standard 

0 = Option 

* 

Version for Through-Spindle-Cooling to facilitate the transfer of cutting liquids like emulsions, hydraulic oils and airoil 

mixtures without dissolving or abrasive additives, with up to 140 bars of pressure at a flow rate of 35 l/min 

through the gearbox and spindle, directly to the tool. 

Output 

There is a choice of two different output variants. The standard long bearing base output flange version is used for belt 

drives, allowing high cantilever forces. For the 2K300 an extended output version is optional for even higher belt forces. 

Further options include short output housings as ZF-Duoplan INLINE for space saving direct drives. 

This version is supplied as a standard with angular contact bearings. ZF-Duoplan TSC (Through-Spindle-Cooling) 

allows cutting liquids like emulsions, hydraulic oils and air-oil mixtures with up to 140 bars of pressure at a flow rate 

of 35 l/min through the gearbox and spindle, directly to the tool.The STW (spur gearbox with fixed ratio as spindle 

drive) option is used for high output torque drives in conjunction with 2K800 and 2K2100. 

There are two output variants to choose from. Output flanges are standard. 

Output shafts or STW (spur gearbox with fixed ratio directly onto spindle) are available as an option. 

Motor connection 

The hubs are generally fitted with a keyway for power transmission. 

It should be noted that the hub must be balanced in the same way as the motor. 

There are two types of balancing: Half-key and full-key. In the case of full-key balancing, the motor shaft is balanced 

with a fitted key, the hub without. The length of the fitted key is unimportant in this instance. In the case of half-key 

balance, however, the keyway is filled out with a balance compensator. The shape, length, and position of the keyway 

must be adapted. For this reason, it is necessary to provide ZF with details of the motor – including the relevant dimensions 

and balancing type – when ordering. 

For straight motor shaft a keyless hub with clamping ring is mandatory. To this end and in accordance with DIN 332-2, 

the motor shaft must feature a centering bore with a thread.If the motor connection dimensions do not permit direct 

mounting to the ZF-Duoplan, an adapter plate or adapter ring is required. These adapter parts can be included in the 

supply on request, depending to motor manufacturer. 

Note 

For motor-gearbox units that are fixed in the machine with the gearbox output housing/flange only, no preload support 

on motor B-side is permitted. 

12 

11

Possible Connections 

Open Design 

(with/without adapter ring) 

Closed Design 

(with hub bearing and shaft seal) 

Closed Design 

(with shaft seal) 

Gearbox interface: 

Open design 

The open version gearbox is without adapter plate. 

Sealing with motor shaft seal. 

Adapter Ring 

The adapter ring allows adaptation to different dimensions. 

A shaft seal is required on the motor shaft. 

Closed design (with hub bearing and shaft seal) 

There is a version with ball bearing available for 

certain motors. The hub in this version is also fixed 

by the bearing to prevent axial hub movement, rsp. 

present axial forces from the helical gearing onto the 

motor shaft (see technical data page 8). Assembly onto 

spindle motor is made easier due to a fixed hub position 

as supplied bythe factory. 

Closed Version (with shaft seal) 

This version incorporates an adapter plate with shaft 

seal, which means that the gearbox forms a compact, 

closed unit. 

Input flange: (2K250 / 2K450 / 2K600 / 2K800 / 2K2100) 

Besides the classic motor - gearbox - adaptation (motor 

shaft, key way, hub) we offer - on request - a gearbox 

with input flange to mount a pulley, clutch or similar 

(as shown on page 33). 

Output bearings 

The output bearings vary depending on the type and level 

of load on the output shaft. Cylindrical roller bearings are 

used to cope with high radial forces, e.g. in belt pulley 

drives. In contrast, angular-contact ball bearings are 

suitable for coaxial drives, low radial backlash or axial 

forces. The flexible design of the output housings and 

shafts allows a range of selections. 

13

Versions and Lifetime Calculation based on XY-method 

16000 

14000 

12000 

10000 

8000 

6000 

4000 

2000 

2K120 

2K120 / 2K121 

nab/out = 375 min- 1 

nab/out = 1 500 min- 1 

nab/out = 3 000 min- 1 

nab/out = 4 500 min- 1 

nab/out = 7 500 min- 1 

nab/out = 10 000 min- 1 

0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 

Bearing B 

Bearing A 

6208 

NU 2208 

25000 

20000 

15000 

10000 

5000 

2K250 

2K250 / 2K 300 / 2K 300 long 


nab/out = 1 500 min- 1 

nab/out = 3 000 min- 1 

nab/out = 4 500 min- 1 

nab/out = 6 300 min- 1 

nab/out = 8 000 min- 1 

0 

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 

Bearing B 

Bearing A 

NUP 209 

NU 2210 

Transverse force [N] 

30000 

25000 

20000 

2K300 

15000 

10000 

5000 

0 

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 

Bearing B 

Bearing A 

NUP 211 

NU 2211 

Pemitted Cantilever Forces 

30000 

25000 

2K300-LA 

For standard bearing 

service life = 36 000 hours 

20000 

15000 

10000 

5000 

Note: 

Take into account the motor 

manufacturer’s permitted 

cantilever forces. 

0 

0 10 20 30 40 50 60 70 80 90 100 110 120 130 

Bearing B 

Bearing A 

NUP 211 

NU 2211 

14 

Position [mm]

Versions and Lifetime Calculation based on XY-method 

35000 

30000 

15000 

20000 

15000 

10000 

5000 

2K450 

2K450 


nab/out = 1 000 min- 1 

nab/out = 2 000 min- 1 

nab/out = 4 000 min- 1 

nab/out = 6 000 min- 1 

nab/out = 8 000 min- 1 15 

0 

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 

Bearing B 

Bearing A 

NUP 211 

NU 2211 

50000 

40000 

30000 

20000 

10000 

2K600 

2K600 / 2K800 / 2K800 long 



nab/out = 1 000 min- 1 

nab/out = 2 000 min- 1 

nab/out = 3 000 min- 1 

nab/out = 5 000 min- 1 

0 

0 10 20 30 40 50 60 70 80 90 100 110 120 

Bearing B 

Bearing A 

NUP 213 

NU 2213 

Transverse force [N] 

100000 

80000 

60000 

2K800 

40000 

20000 

0 

0 10 20 30 40 50 60 70 80 90 100 110 120 

Bearing B 

Bearing A 

NUP 2217 

NU 22218 

100000 

80000 

2K800-LA 

Permitted Cantilever Forces 

For standard bearing 

service life = 36 000 hours 

60000 

40000 

20000 

Note: 

Take into account the motor 

manufacturer’s permitted 

cantilever forces 

0 

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 

Bearing B 

Bearing A 

NUP 2217 

NU 22218 

Postion [mm]

Torsional backlash 

Three backlash classes in 

reduction mode are available: 

Class 3*: 

Normal torsional 

backlash < 30 arcmin 

Class 2: 

Reduced torsional 


Class 1: 

Especially reduced torsional 


*Torsional backlash in 

2K800 / 801 / 802 / 2100 

Class 3: Normal torsional 


Application and Examples 

Workpiece Processing with Constant Cutting Force 

Class 3*: Normal torsional backlash < 30 arcmin 

Only for turning machine drives involving workpiece processing with 

constant cutting force. 

a) For turning machine drives when cutting is uninterrupted while the 

workpiece is being processed or in the case of predominant facing 

involving cutting speed adjustment. 

b) Boring mills 

c) Milling machines and machining centres 

Extreme Milling Work 

Class 2: Reduced torsional backlash < 20 arcmin 

For milling machines and machining centres used to execute extreme milling 

work, e.g. tool side milling cutters with very coarse index/division (interrupted 

cutting), workpieces made from tough material, milling of ribbed workpieces. 

Highly-dynamic Machine Tools 

Class 1: Especially reduced torsional backlash < 15 arcmin 

As class 2; except in lightweight highly-dynamic machine tools incorporating 

components with high internal elasticity; designed to prevent resonance vibration. 

16

Lubrication 

Splash type lubrication 

The standard gearbox version B5 has splash type lubrication. Splash type lubrication 

is suitable for intermittent operation. In this instance, frequent gear changes, varying 

speeds and idle time (e.g. due to retooling) are a prerequisite. 

Recirculating lubrication 

The 2K120/2K121/2K250/2K300/2K450/2K600 gearboxes (vertical V1 and V3 

installation positions) require recirculating lubrication. In this instance, the type 

of recirculating lubrication depends on the operating temperature levels required. 

The 2K800/2K801/2K802 and 2K2100 gearboxes must always be operated with 

recirculating lubrication (refer also to installation drawings). 

Forced recirculating lubrication 

Some applications require a very low operating temperature level. 

Forced recirculating lubrication is recommended in such instances. Figures on page 

18/19 show the possible oil inlet and outlet positions on the gearbox. Please refer to 

the relevant installation drawings for detailed dimensions. 

Standard recirculating lubrication in V1/B5 with oil tank installation 

The oil inlet is attached in place of the oil drain plug. The oil flow rate is approx. 

1.5 l/min. (only for 2K120/2K121/2K250/2K300); approx. 2,0 l/min. (only for 2K450/ 

2K600); approx. 2,5 l/min. (only for 2K800). In the case of V3 vertical installation 

position, the lubrication oil can be supplied in either radial direction or centrally. 

The tank of the pump unit must be ventilated. Oil back pressure in the return pipe 

to the gearbox must be avoided (Ø min. 20 mm). The tank capacity should be at least 

ten times the recirculating oil quantity. A 60 μm filter and a pressure limitation valve 

should also be used as a safeguard. 

Recirculating lubrication with heat exchanger 

A heat exchanger is installed in the recirculating lubrication system to assure 

additional temperature reduction. For best cooling results without any influence on 

lubrication, various connection parts for different installation positions and operating 

modes are provided. 

In order to achieve an optimal temperature development of the gearbox and to enable 

the max. speeds, an integrated oil channel version is offered (oil port connection see 

pages 18/19, ordering code see pages 35 - 39). 

In addition, it is possible to operate the 2K250/300 without oil level (dry sump lubrication). 

Note 

For continuous operation in direct drive one gear change per hour is mandatory with 

a short turn in reduction ratio. If this is impossible please request special solution. 

17

Connections for recirculating lubrication 

2K120 / 2K121 

Installation position: Oil inlet* Max. pressure Oil outlet* 

V1 (closed version) M (0.5 dm³/min) 0.5 bar D/E 

K/R and/or L/S (1.0 dm³/min) 

0.5 bar 

V1 (open version) K/R and/or L/S (1.5 dm³/min) 0.5 bar D/E 

B5 G (1.5 dm³/min) 1.5 bar D/E 

F (1.5 dm³/min) 

1.5 bar 

B5 turned, right* I or F (1.5 dm³/min) 1.5 bar H 

V3 P (1.5 dm³/min) 1.5 bar H 

or K/R and/or L/S (1.5 dm³/min) 

0.5 bar 

*View toward gearbox output: 

D/G = Mainly counter clockwise rotation 

E/F = Mainly clockwise rotation 

Note: 

For applications using max. speeds of 12 000 rpm, it is mandatory to use port K and/or L with 1.5 dm 3 /min. 

In addition an oil recirculating system using an oil chiller with > 0.3 kW capacity and oil volume >15 litres 

is necessary. 

I 

R 

M 

K 

E 

G 

S 

L 

D 

F 

P 

H 

033244 

18

Connections for recirculating lubrication 

2K250 / 2K300 

2K450 / 2K600 

Installation position: Oil inlet* Max. 

pressure 

Oil outlet* Oil inlet* Max. 

pressure 

Oil Outlet* 

V1, V3 M (0.5 dm³/min) 0.5 bar D/E M (0.5 dm³/min) 0.5 bar D/E 

(closed version) K or R (1.0 dm³/min) 0.5 bar T (1.5 dm³/min) 0.5 bar 

L additional possible 1.5 bar L additional possible 1.5 bar 

V1, V3 K or R (1.5 dm³/min) 0.5 bar D/E T (2.0 dm³/min) 0.5 bar D/E 

(open version) L additional possible 1.5 bar 1.5 bar 

B5 G (1.5 dm³/min) 1.5 bar D/E G (2.0 dm³/min) 1.5 bar D/E 

F (1.5 dm³/min) 1.5 bar or F (2.0 dm³/min) 1.5 bar 

B5 turned right* I or F 1.5 bar H I or F 1,5 bar H 

V3 

P (1.5 dm³/min) 

1.5 bar 

H T (2.0 dm³/min) 1.5 bar H 

K or R (1.5 dm³/min) 

0.5 bar 

L additional possible 

1.5 bar 

*View toward gearbox output: 

D/G = Mainly anti-clockwise rotation 

E/F = Mainly clockwise rotation 

In V1/V3 recirculation lubrication necessary for 2K250/300. 

Note: 

For applications using max. speeds of 10 000 rpm port K or R is mandatory. 

In addition an oil recirculating system using an oil chiller > 0.3 kW and oil volume >15 litres is necessary. 

The integrate oil channe version is available for 2K250/300/450/600 (see note page 36/37). 

This permits a gearbox operation without oil level, however a safety check of oil supply needs to be included 

in the oil system. 

I 

R 

K 

M 

T 

E 

G 

L 

D 

F 

P 

N 

H 

033243 

19

Installation Drawings 

2K120 

2K121 

2K120/121 INLINE TSC 

2K250 

2K300 

2K250/300 INLINE TSC 

2K450 

2K600 

2K800 

2K801 

2K802 

Options 2K800/801/802 

2K2100 

page 22 

page 23 

page 24 

page 25 

page 26 

page 27 

page 28 

page 29 

page 30 

page 31 

page 32 

page 33 

page 34 

21

17 

ø32 

Installation Drawing: 

2K120 

5.1 

10 

4.1 

25 

18 

35 

38 

35 

OELSTANDSSCHAUGLAS 

OIL LEVEL SIGHT GLASS 

(LINKS UND RECHTS) 

(LEFT AND RIGHT) 

83 

65.5 

ø14 

55 

131 

3 

18 

10 

273 

163 

80 

70 

42 

15 

7208 BE 

C=36 KN 

13.5 

39.5 

124.5 

116 

117 

207.5 

17.5 

2K120 

10 

45° 

8x45° 

4 

215 

M8 

80 

108 

98.5 

209 

197 

Ø MA* 

30 

180 H7 

M 12x1.5 

ø14 

ø100 

ø14 

ø100k6 

ø188 

ø190g6 

3 

250 

17 

M42x1.5 

63 63 

87.5-0.5 

87.5 -0.5 

92 

92 

208 

Ø MA* MOTORANSCHLUSSMASS 

MOTOR DIMENSION 

MAX 

MIN 

6208 

C=31 KN 

STANDARD 

12 

BEI GESCHLOSSENER 

VARIANTE 

FOR CLOSED VERSION 

2K120 INLINE 

15 - 25 FQ*) 

NU 2208 

C=75 KN 

OPTION 

7208 BE 

C=36 KN 

STANDARD 

M12 

70 

ø38k6 

28 

80 

83 

ø100 

10 N9 

M 10x1 

28 

5 

OELSORTE: HLP 68 NACH ISO VG 68 BEI TAUCHSCHMIERUNG 

HLP 46 NACH ISO VG 46 BEI UMLAUFSCHMIERUNG 

HLP 32 NACH ISO VG 32 BEI UMLAUFSCHMIERUNG MIT WAERMETAUSCHER 

OIL GRADE: HLP 68 ACC. TO ISO VG 68 WITH SPLASH LUBRICATION 

HLP 46 ACC. TO ISO VG 46 WITH RECIRCULATING LUBRICATION 

HLP 32 ACC. TO ISO VG 32 WITH RECIRCULATING LUBRICAT ION AND HEAT EXCHANGER 

STANDARD OPTION 

UEBERSETZUNG: i 1 = 4.00 i 1 = 3.16 

i 2 = 1.0 i 2 = 1.0 

TRANSMISSION RATIO: i 1 = 1.0 i 1 = 3.16 

i 2 = 1.0 i 2 = 1.0 

GEWICHT: ca. 42 kg 

WEIGHT: ca. 42 kg 

5 

WUCHTUNG MIT PASSFEDER 

BALANCE WITH KEY 

PASSFEDER/KEY A10 x 8 x 70 

M22x1.5 

M 12x1.5 

M16x1.5 

116 

STANDARD 

SCHALTUNGSEINHEIT OHNE NEUTRALSTELLUNG 

SHIFT UNIT WITHOUT NEUTRAL POSITION 

OPTION 

SCHALTUNGSEINHEIT MIT NEUTRALSTELLUNG 

SHIFT UNIT WITH NEUTRAL POSITION 

BEI VERTIKALEINBAU V1 

IN VERTICAL INSTALLATION V1 



*) BEI DER LAGERAUSLEGUNG 

ANGENOMMENE WIRKUNGSLINIE 

DER RESULTIERENDEN RIEMENKRAFT 

ASSUMED LINE OF RESULTING 

PULLEY FORCE FOR 

BEARING CALCULATION 

130 

OPTION ABTRIEBSWELLE 

OPTION OUT PUT SHAFT 

4 ø38k6 

83 

22

ø100 

ø100k6 

ø188 

ø190g6 

48 

8x45° 

300 

45° 

M8 

ø80 

265 

R 20 

103 

82.5 

87.5 

240 

82.5 

87.5 

4.1 

151 

10 

293 

75 

42 

15 - 25 

116 

117 

15 

39.5 

17.5 

ø32 





MAX 

3 

124.5 

ø230 H7 ø14 

17 

MIN 

25 

20 

35 

6208 

C=31 KN 

7208 BE 

C=36 KN 

FQ *) NU 2208 

C=75 KN 

STANDARD 

OPTION 

7208 BE 

C=36 KN 

2K121 

ø14 

20 

243 

120 

M 12x1.5 

M 12x1.5 





HLP 68 ACC. TO ISO VG 68 WITH SPLASH LUBRICATION 

OIL GRADE: HLP 46 ACC. TO ISO VG 46 WITH RECIRCULATING LUBRICATION 


UEBERSETZUNG: STANDARD OPTION 

i 1 = 4.00 i 1 = 3.16 

i 2 = 1.0 i 1 = 3.16 

i 2 = 1.0 i 2 = 1.0 


i 2 = 1.0 i 2 = 1.0 









4 

M22x1.5 

M16x1.5 

55 

70 

17 

M42x1.5 





STANDARD 

70 

M12 

ø38k6 

116 130 

10 N9 

13.5 


OPTION OUT PUT SHAFT 


BALANCE WITH KEY 


80 

83 

28 

83 

3 

2K121 INLINE 

163 

80 

10 

70 

207.5 

4 ø38k6 


2K121 

STANDARD 



OPTION 



5 

23


2K120/121 INLINE + TSC 

Dimensions of basic gearbox see 

installation drawing p. 22/23 

STANDARD 



OPTION 



116 130 

83 

3 

24

M12 


2K250 

75 

106 

5.1 

20 20 

35 

46 58 ±0.2 

150 

25 - 35 

30° 

12x30° 

15° 

118.5 118.5 

135 

R58.3 

100 

15° 

ø300 

ø350 

M22x1.5 

135 

270 

5.1 

25 

129.5 

72.1 

83.5 

M10x1 

149 

73.6 

10 

133 

142.5 

171.5 

20 

45.4 

221 

12 

136 

128.5 

108 

268 

258.5 

ø MA* 

30 

35 

ø18 

ø18 

R 68.5 

ø116 

ø118 k6 

ø127.3 

ø249 

ø250 g6 

30 

87 

87 

117 117 

46.9 

M10 

55 

4 

5 

20° 

M22x1.5 

9.5 

2 

2 

MAX 

MIN 

ø14 

(FQ*) 

NUP 209E 

C=60500N 

7209 BE 

C=37700N 

STANDARD 

OPTION 

NU 2210 ECP 

C=78100N 

7210 BE 

C=39000N 

12 h9 

42 k6 

72 

70 

60 

5 

6.5 

23.5 

5 

20 

10 

20 

135 


BALANCING WITH KEY 


4 


OPTION OUTPUT SHAFT 

ø250 H7 

ø116 






VARIANTE 


Ø MA* 

MOTORANSCHLUSSMASS 









UEBERSETZUNG: i 1 = 4.00 i 1 = 3.17 BZW. 5.50 

i 2 = 1.0 i 2 = 1.0 

TRANSMISSION RATIO: i 1 = 4.00 i 1 = 3.17 OR. 5.50 

i 2 = 1.0 i 2 = 1.0 









2K250 INLINE 

181 

STANDARD 

2K250 

M 10x1 

M16x1.5 

M 12x1.5 

M12x1.5 

M42x1.5 





70 

60 

5 

12 

ø42k6 

Dimensions of basic gearbox see 

installation drawing p. 25/26 

STANDARD 



OPTION 



116 130 

83 

3 

25

M12 


2K300 

236 

135 

(FQ*) 

47.5 

55 - 65 

OPTION 

LANGER ABTRIEB 

OPTIONNALLY, 

LONG OUTPUT 

VERSION 

55 

5.1 

75 

106 

142.5 

69.8 

140.5 

48.2 

83.5 

25 - 35 

17 

164 

156.5 

135 

324 

315 

Ø MA* 

+1 35 

ø300 H7 

R73 

30 

ø140 

ø130 k6 

ø249 

ø250g6 

ø18 

ø18 

10 

23 

23 

MAX 

MIN 

20 

M10x1 

NUP 211E 

C=84200N 

7211 BE 

C=48800N 

(FQ*) 

12x30° 

30° 

4 

STANDARD 

OPTION 

NU 2211E 

C=99000N 

ø152 

7211 BE 

C=48800N 

M 22x1.5 

15° 

5 

5 

3 

118.5 118.5 





5 

STANDARD 

15° 

20° 

R70.3 

100 

M16x1.5 

ø350 

9.5 

400 

M42x1.5 

5 102.5 102.5 

5 

290 ±0.2 

163 

326 

30 

25 

5.1 

35 

ø14 

46 58 

150 

20 

10 

149 

M22x1.5 

M 10x1 

M 12x1.5 

M 12x1.5 








UEBERSETZUNG: i 1 = 4.00 i 1 = 3.17 BZW. 5.50 

i 2 = 1.0 i 2 = 1.0 

TRANSMISSION RATIO: i 1 = 4.00 i 1 = 3.17 OR. 5.50 

i 2 = 1.0 i 2 = 1.0 




VARIANTE 


Ø MA* 

MOTORANSCHLUSSMASS 








16 P9 

55 m6 

72 46 

137.5 

171.5 

261 


BALANCING WITH KEY 


20 

112 

110 

90 


OPTION OUTPUT SHAFT 

10 

2K300 

M12 

ø140 

6 

ø130 k6 

ø140 

STANDARD 



OPTION 



116 130 

NUP 211E 

C=84200N 

NUP 2211E 

C=99000N 

130 

20 

23 

83 

83 

2K300 INLINE ABTRIEB WIE BEI 2K250 INLINE 

2K300 INLINE OUTPUT AS IN 2K250 INLINE 





24.5 

26


2K250/300 INLINE, 2K250/300 TSC 

83 

STANDARD 



OPTION 



116 

55 

3 

130 

27

18 


2K450 

55 

M12 

C 

C 

20 

35 

33 

28 

64.4 +0.2 M22x1.5 

M12 x1.5 

11 

14.7 

M12 x1.5 

3.7 

5.7 

60G7 

18P9 

30 

34 

16 

22 

25 

32 

40 

M22x1.5 

16x 22 30'(=360°) 

M22x1.5 

M22x1.5 

M42x1.5 

M16x1.5 

M42x1.5 

175 

102.5 102.5 

350 

129.5 

173.1 

28 

90.1 

165 

28.5 28.5 

100 

14 

50 

100 

155 

200 

Motoranschluss 

Motor connection 

Siehe Blatt 3 

Refer to sheet 3 

35 

300 H7 

86.5 30.5 

5 

155 

370 

375 

22 30' 

9 

215 

83.5 

M42x1.5 

16 16 

160 160 

30 bis/to 40 

65.5 

65 G7 

69.4 +0.2 

18 P9 

80 G7 

85.4 +0.2 

22 P9 

55 G7 

59.3 +0.2 

320g6 

319.5 

16 P9 

45 

10 

197 

193 

140 k6 

142 

230 

1:5 

Harting-Stecker 

HAN 8U 

(Tuellengehaeuse, 

Verschraubung, 

Steckdoseneinsatz und 

Kontaktbuchsen werden 

lose mitgeliefert) 

Harting plug 

HAN 8U 

(Sleeve housing, 

screw union, 

socket insert and 

contact bushings 

are supplied loose) 

Anschluss I 

Connection I 

Erstbefuellung 

Initial fill 

Y 

Anschluss E 

Connection E 

Anschluss D 

Connection D 

Anschluss H 

Connection H 

Anschluss G 

Connection G 

Anschluss F 

Connection F 






Oelablass bei Einbaulage B5 

und Tauchschmierung 

Oil drain at installation position B5 

and splash lubrication 




i 2 = 1.0 i 2 = 1.0 


i 2 = 1.0 i 2 = 1.0 



STANDARD 



OPTION 



Motorwelle: Folgende Naben sind lieferbar 

Motor shaft: Following hubs are available 

Y 

Stutzen fuer Oelruecklauf 

Tube for oil return 

Bei Vertikaleinbau V1 

In vertical installation V1 



X 

X 

Entluefter 

Breather 

Bei Horizontaleinbau B5 

In horizontal installation B5 

Anschluss M 

Connection M 

Anschluss T 

Connection T 

Oelstandsschauglas 

Oil level sight glass 

Links und rechts 

Left and right 

C-C 

Betriebsanleitung 

Operating manual 

2K450/2K600 

Nach aktuellem Aenderungsindex siehe: 

For the current modification index see: 

Internet:http://industrial-drives.zf.com 

Beachten 

Pay attention to 

SW14 

WAF 

Stutzen fuer Oelzufuhr 

Tube for oil feeding 

nur zur Info 

nicht im Lieferumfang enthalten 

only for information 

not included in delivery 

SW24 

WAF 

Standard 

NU2211 E/TN 

NUP211 ECP 

Anschluss P 

Connection P 

F Q * 

80.5 

197.5 

230 

F Q * Bei der Lagerauslegung optimale Wirkungslinie 

der resultierenden Riemenkraefte 

Optimum line of action of resulting pulley 

forces at the bearing calculation 

186 +1 

112 

28

Ø18 

C 

C 


2K600 

M12 x1.5 

Ø 11 

Ø 14.7 

Ø 3.7 

M12 x1.5 

Ø 5.7 

20 

16 

22 

25 

32 

236.5 

232 

40 

Ø 320g6 

Ø 319.5 

Ø 150 k6 

Ø 155 

Ø 230 

28 

165 

155 

28.5 28.5 

100 

10 

Ø14 

50 

100 

155 

200 

45 bis/to 55 

120 

64.5 

241 

269.5 

186 +1 

Ø300H7 

35 

M16 x1.5 



X 

178 

130 

89 

45 

Links und rechts 

Left and right 

Betriebsanleitung 

Operating manual 

2K450/2K600 

Nach aktuellem Aenderungsindex siehe: 

For the current modification index see: 

Internet:http://industrial-drives.zf.com 

Stutzen fuer Oelzufuh 

Tube for oil feeding 

Nur zur Information 

Nicht im Lieferumfang enthalten 

Only for information 

Not included in delivery 

116 



Entluefter 

Breather 

Bei Horizontaleinbau B5 

In horizontal installation B5 

Anschluss M 

Connection M 

Anschluss T 

Connection T 

Oelstandsschauglas 

Oil level sight glass 

SW14 

WAF 

SW24 

WAF 

Standard 

NUP213E/J NU2213E/TN 

F Q * 

93 

Harting Buchse 

Han 8D 

Harting bush 

Han 8D 

C-C 

1:5 

X 

STANDARD 



OPTION 



Anschluss P 

Connection P 

Anschluss I 

Connection I 

Motorwelle: Folgende Naben sind lieferbar 

Motorshaft: Following hubs are available 

Erstbefuellung 

Initial fill 

F Q * Bei der Lagerauslegung optimale Wirkungslinie 

der resultierenden Riemenkraefte 

Optimum line of action of resulting pulley 

forces at the bearing calculation 

84 

59 

64.4 +0.2 M22x1.5 

Ø60G7 

Ø370 

M22x1.5 

55 

16x22~30'(=360°) 

18P9 

M12 

22~30' 

69.4 +0.2 

Ø Motoranschluss 

Ø Motor connection 

Siehe Blatt 2 

Refer to sheet 2 

Ø65 G7 

Ø120 

Y 

18 P9 

375 

M42 x1.5 

M42x1.5 

Anschluss D 

Connection D 

Anschluss E 

Connection E 

Ø80 G7 

85.4 +0.2 

215 

22 P9 

M 22x1.5 

M 42 x1.5 

Anschluss H 

Connection H 

Ø55 G7 

M 22x1.5 

9 

59.3 +0.2 

16 16 

Anschluss F 

Connection F 

102.5 102.5 

Anschluss G 

Connection G 

160 160 

16 P9 

175 

350 

Y 

Stutzen fuer Oelruecklauf 

Tube for oil return 

Oelablass bei Einbaulage B5 

und Tauchschmierung 

Oil drain at installation position B5 

and splash lubrication 







Ø 28 

Ø 33 

Ø 35 



i 2 = 1.0 i 2 = 1.0 

30 

34 


i 2 = 1.0 i 2 = 1.0 



29


2K800 

40° 

16x22°30« 

40° 

25 

5.1 

490 

21 

Ø30 

M12x1.5 

215 

177 

138 

Ø350j7 

Ø410 

Ø400 

Ø300 H7 

Ø272 

Ø180k6 

Ø190 

Ø200 

180 

45° 

22° 30ʼ 

32° 30ʼ 

40° 

45° 

4x90° 

90° 

M48x1.5 

80 

157 

314 

324 

M16 

M12 

150 

40° 

Ø370 

45° 

50-60 

39 

FQ*) 23 X 

10 

14 

M20x1.5 

45° 

Ø350 

SCHMIEROELZUFUHR B5/V1 

ca.2.5dm 3 /min BEI 5 bar DRUCK 

LUBE OIL SUPPLY B5/V1 

ca.2.5dm 3 /min 

AND 5 bar PRESSURE 

R 30 

M48x1.5 

B A 

118 

72 

OELAUSTRITT BEI EINBAULAGE B5 

WAHLW. LINKS ODER RECHTS 

OIL OUTLET 

IN VERTICAL INSTALLATION, 

EITHER LEFT OR RIGHT 

67 


OIL LEVEL SIGHT GLAS 

GETRIEBEBEFESTIGUNG 

AN DER MASCHINE 

TRANSMISSION 

MOUNTING AT 

MACHINE 

LAGER A 

22218J/290kN 

SCHMIEROEL- 

ZUFUHR B5/V1 


BEI 3 bar DRUCK 

LUBE OIL 

SUPPLY B5/V1 



LAGER B 

NU2217TN/216kN 

OELAUSTRITT 

BEI EINBAULAGE V1 

OIL OUTLET 


BEARING A 

22218J/290kN 

BEARING B 


**HAN 8U **HAN 8U 

HARTING-STECKER HARTING PLUG 

(TUELLENGEHAEUSE, 

VERSCHRAUBUNG, 

STECKDOSENEINSATZ UND 

KONTAKTBUCHSEN WERDEN 

LOSE MITGELIEFERT) 

(SLEEVE HOUSING, 

SCREW UNION, 

SOCKET INSERT AND 

CONTACT BUSHINGES 

ARE SUPPLIED LOOSE) 

*) BEI DER LAGERAUSLEGUNG ANGENOMMENE 

WIRKUNGSLINIE DER RESULTIERENDEN 

RIEMENKRAFT 

*) ASSUMMED LINE OF RESULTING PULLEY 

FORCE FOR BEARING CALCULATION 

70 

STANDARD 



OPTION 



ANSICHT X 

VIEW 

18 

240 

2K800 

OELSORTE: 



MIT WAERMETAUSCHER 



AND HEAT EXCHANGER 


UEBERSETZUNG: 

i 1 

= 4.00 

i 1 

= 3.19 

i 2 

= 1.0 

i 2 

= 1.0 

TRANSMISSION RATIO: 

i 1 

= 4.00 

i 1 

= 3.19 

i 2 

= 1.0 

i 2 

= 1.0 

GEWICHT: ca 

WEIGHT: ca 

110 kg 

110 kg 

30


2K801 

40° 

16x22°30’ 

40° 

25 

5.1 

490 

21 

Ø30 

M12x1.5 

215 

177 

138 

Ø450 

Ø350 H7 

Ø272 

Ø180k6 

Ø190 

Ø200 

Ø350j7 

Ø410 

180 

45° 

22° 30’ 

32° 30’ 

22° 30ʼ 

40¡ 

150 

M48x1.5 

80 

M12 

70 

40° 

Ø400 

Ø370 

45° 

50-60 

FQ*) 

39 

23 






X 

M16 

10 

14 

M20x1.5 

157 240 

314 

324 

45° 

8x45° 

R 30 

B A 

M48x1.5 

118 

72 

67 





OIL OUTLET 



OELAUSTRITT 


OIL OUTLET 




TRANSMISSION 

MOUNTING AT 

MACHINE 

LAGER A 

22218J/290kN 

BEARING A 

22218J/290kN 

SCHMIEROEL- 

ZUFUHR B5/V1 



LUBE OIL 

SUPPLY B5/V1 



LAGER B 


BEARING B 










SCREW UNION, 






RIEMENKRAFT 



STANDARD 



OPTION 



ANSICHT X 

VIEW 

18 

2K801 

OELSORTE: 








UEBERSETZUNG: 

i 1 

= 4.00 

i 1 

= 3.19 

i 2 

= 1.0 

i 2 

= 1.0 


i 1 

= 4.00 

i 1 

= 3.19 

i 2 

= 1.0 

i 2 

= 1.0 

GEWICHT: ca 

WEIGHT: ca 

110 kg 

110 kg 

31


2K802 

40° 

16x22° 

30´ 

22° 30´ 

32° 30´ 

40° 

40° 

25 

556 

490 

21 

ø30 

M12x1.5 

215 

177 

138 

80 

M48x1.5 

M12 

ø550 

ø450 H7 

ø350 H7 

ø180k6 

ø190 

ø200 

ø350j7 

ø410 

180 

150 

40° 

ø370 

45° 

45° 

50-60 

39 

FQ*) 23 

X 

10 

M20x1.5 

157 

45° 

314 

324 

R 30 

B A 

M48x1.5 

118 

72 

67 

14 

70 

ANSICHT X 

VIEW 

M16 

240 

22° 30´ 






8x45° 

ø19 

36.5 

83.5 



OIL OUTLET 



OELAUSTRITT 


OIL OUTLET 






TRANSMISSION 

MOUNTING AT 

MACHINE 

LAGER A 

22218J/290kN 

BEARING A 

22218J/290kN 

SCHMIEROEL- 

ZUFUHR B5/V1 



LUBE OIL 

SUPPLY B5/V1 



LAGER B 


BEARING B 










SCREW UNION, 






RIEMENKRAFT 



STANDARD 



OPTION 



18 

2K802 

OELSORTE: 








UEBERSETZUNG: 

i 1 

= 4.00 

i 1 

= 3.19 

i 2 

= 1.0 

i 2 

= 1.0 


i 1 

= 4.00 

i 1 

= 3.19 

i 2 

= 1.0 

i 2 

= 1.0 

GEWICHT: ca 

WEIGHT: ca 

110 kg 

110 kg 

32


Options for 2K800, 2K801, 2K802 

ANTRIEB GRUNDGETRIEBE 

ABTRIEB 

INPUT BASIC GEARBOX 

OUTPUT 

4.00:1/1:1 

3.19:1/1:1 

112 

150 

ø65 

160 

ø180k6 

66 

275 

293 

268 

140 

ø450 

ø350 

ø300 

ø180k6 

ø350 

E-MOTOR 

ADAPTERRINGE ZUR 

HALTEBREMSE 

EB-ER 16 

PARKING BRAKE 

ANGLEICHUNG AN VERSCH. 

MOTOREN 

ADAPTERRING FOR DIFF. 


2K800 

275 

2K801 

2K802 

ANSCHLUSSVERZAHNUNG 

NACH ZF ANGABEN 

CONNECTING PARTS 

ACC. ZF SPECIFICATION 









B A 

WELLE 

SHAFT 

125 

7.5 

FLANSCH 

FLANGE 

ø350 

177 

215 

275 

33


2K2100 

Technical Support on request 

ANTRIEB 

INPUT 

285 

225 

ENTLÜFTER 

BREATHER 

ÖLEINAUSTRITT M 42 x 2 

OIL OUTLET M 42 x 2 

GRUNDGETRIEBE 

BASIC GEARBOX 

HARTING-STECKER 

HARTING PLUG 

HAN 8U 






HAN 8U 


SCREW UNION, 




ÖLEINTRITT 2 K 2100: 2 dm 3 /min BEI ca. 3 bar 

OILINLET 2 K 2100: 2 dm 3 /min AND ca. 3 bar 

DIN 5480 N90 x 2 x 30 x44 x 9H 

2K 2100 

OELSORTE: HLP 46 NACH ISO VG 46 BEI UMLAUFSCHMIERUNG 






STANDARD 

UEBERSETZUNG: i 1 = 4.00 

i 2 = 1.0 

TRANSMISSION RATIO: i 1 = 4.00 

i 2 = 1.0 

GEWICHT: JE NACH UMFANG 

WEIGHT ACC. TO SCOPE OF DELIVERY 

ø550 

ø190k6 

ø300 

ø200 

210 

210 

ø400j7 

OPTION 

E-MOTOR 

STANDARD 



LEISTUNGSAUFNAHME 85 W BEI 24 VDC 

SHIFTING UNITWATTAGE 85 W AT 24 VDC 

OPTION 



LEISTUNGSAUFNAHME 85 W BEI 24 VDC 

SHIFTING UNITWATTAGE 85 W AT 24 VDC 

145 

2K2100 

39 

41 

45.3 

355 

134 

OPTION 

AUF ANFRAGE 

ON INQUIRY 

34

ZF-Duoplan Standard, INLINE, TSC 

Ordering numbers for gearbox types 2K120/2K121 

Note: 

Standard = Bold type 

Option = Normal type 

1) RWDR= Radial shaft seal 

* motor-specific, on request 

2 L G 

Special 

versions 

1 2 3 4 5 6 7 – 8 9 10 11 12 – 13 14 15 

Two-speed gearbox 

Motor balancing: 

without keyway* central thread mandatory 1 

Full-key 4 

Half-key* 5 

Gearbox interface (see page 13): 

Open without hub 0 

Open with hub 2 

Closed with hub and hub bearing and RWDR 1 ) * 3 

Closed with hub and RWDR 1 ) * 4 

Open with hub and adapter ring * 5 

Gearbox type: 

for motor frame size/ratio 

100/i 1 = 4.00 12 

100/i 1 = 3.16 13 

100/i 1 = 4.91 09 

112/i 1 = 4.00 11 

112/i 1 = 3.16 14 

112/i 1 = 4.91 08 

Output bearings: 

Cylindrical roller / ball bearings 3 

Angular-contact ball bearings 4 

Gearbox output: 

a 1 = 38 mm 

a 1 = 100 mm 

a 1 = 38 mm smooth, without Keyway 

a 1 = 38 mm (2K120/2K121) INLINE 

a 1 = 38 mm smooth, without Keyway (2K120/2K121) INLINE 

a 1 = 70x 70 mm (2K120/2K121) INLINE, TSC 

a 1 = 70x 70 mm, DIN5480 INLINE, TSC 

B 

C 

L 

P 

G 

U 

W 

Installation position: 

V1/ V3 / B5 / B5 (rotated around longitudinal axis to the right side) C 

V3 Central lube oil supply in output shaft/Radial lube oil supply in bearing housing B 

Motor shaft diameter “d” 

without hub 0 

28 mm 1 

32 mm 2 

38 mm 3 

42 mm 4 

48 mm 9 

Torsional backlash on gearbox output: 

Normal backlash max. 30 arcmin 1 

Reduced backlash max. 20 arcmin 3 

Minimal reduced backlash max. 15 arcmin 4 

Reduced vibration (1.2 mm/s ZF-Duoplan) (0.7 mm/s INLINE) 

Rotary union for output shaft 

S 

T 

35

ZF-Duoplan Standard, INLINE, TSC 


2 L G 

Note: 



1) RWDR = Radial shaft seal 


Special 

versions 

1 2 3 4 5 6 7 – 8 9 10 11 12 – 13 14 15 



without keyway*, central thread mandatory, motor shaft Ø max. 55 mm 1 

Full-key 4 

Half-key* 5 




Closed with hub and hub bearing and RWDR 1 ) * 3 



Input flange D = 118 (only 2K250 standard) 9 



132/i 1 = 4.00 15 

132/i 1 = 3.17 16 

132/i 1 = 5.50 (not for TSC) 17 

160/i 1 = 4.00 20 

160/i 1 = 3.17 21 

160/i 1 = 5.50 (not for TSC) 22 

Output bearings: 

Cylindrical roller / ball bearings 3 


Spindle ball bearings 6 


a 1 = 118 mm (2K250) 

a 1 = 130 mm (2K300) 

a 1 = 42 mm (2K250) 

a 1 = 42 mm smooth without keyway 


a 1 = 55 mm smooth without keyway, INLINE 

a 1 = 55 mm (2K300) 

a 1 = 42 mm INLINE 

a 1 = 130 mm wide bearing base 

a 1 = 70x70 mm INLINE, TSC 

a 1 = 70x70 mm, DIN 5480 INLINE, TSC 

a 1 = 42 mm smooth without keyway INLINE 


B5 

V1 / V3 / B5 (turned around longitudinal axis to the right side) 

V3 Central lube oil supply in output shaft/Radial lube oil supply in bearing housing 

F 

J 

K 

L 

N 

H 

M 

P 

R 

U 

W 

G 

D 

C 

B 


2K250 2K300 

without hub 0 

42 mm 55 mm 1 

48 mm 48 mm 2 

55 mm 42 mm 3 

60 mm 60 mm 4 



Reduced backlash max. 20 arcmin 3 

Minimal reduced backlash max. 15 arcmin 4 

Reduced vibration (1.0 mm/s ZF-Duoplan) (0.7 mm/s INLINE) 

Integrated oil channel version for max. speeds and dry sump 

lubrication (for B5 please order V1 version) 


S 

M 

T



Note: 



Option = Normal type * motor specific, on request 

2 L G – – 

1 2 3 4 5 6 7 – 8 9 10 11 12 13 

Sonderausführungen 

Special 

versions 



Full key 4 

Half key* 5 

Gearbox interface: 



Closed with hub and hub bearing and RWDR 1 )* 3 



160/i 1 = 4.00 spigot Ø 300 mm 30 

160/i 1 = 5.00 spigot Ø 300 mm 31 

180/i 1 = 4.00 spigot Ø 300 mm 40 

180/i 1 = 5.00 spigot Ø 300 mm 41 

200/i 1 = 4.00 spigot Ø 350 mm 42 

200/i1 = 5.00 spigot Ø 350 mm 43 

Output bearings 

without output 0 

cylindrical roller ball bearings 3 


Gearbox Output: 

without 

a 1 = 140 mm (2K450) 

a 1 = 150 mm (2K600) 

a 1 = 60 mm (2K450) 

a 1 = 60 mm - smooth without keyway (2K450) 

a 1 = 60 mm - Inline (2K450) 

a 1 = 60 mm - smooth without keyway, INLINE (2K450) 

Installation Position: 

B5 / V1 / V3 

N 

F 

J 

K 

L 

P 

G 

C 


without hub 0 

60x140 (2K450) 1 

65x140 (2K600) 2 

70x140 3 

75x140 4 

80x170 5 

55x110 6 



Reduces backlash max. 20 arcmin 3 

Neutral shift position 

N 

37


Ordering numbers for gearbox types 2K800/2K801/2K802 

Note: 

Standard= Bold type 




2 L G 

1 2 3 4 5 6 7 – 8 9 10 11 12 – 13 

Special 

versions 



Full-key 4 

Half-key* 5 






Input flange (Ø= 180 k6) 9 



180/i 1 = 4.00 spigot Ø diameter 300 50 

180/i 1 = 3.19 spigot Ø 300 51 

200/i 1 = 4.00 spigot Ø 350 60 

200/i 1 = 3.19 spigot Ø 350 61 

225/i 1 = 4.00 spigot Ø 450 70 

160/i 1 = 3.19 spigot Ø 450 71 

Holding brake: 

without holding brake 1 

with holding brake 2 


without 

a 1 = 65 mm 


a 1 = 180 mm 

a 1 =.180 mm wide bearing base 

N 

H 

L 

J 

R 


V1/ B5 C 

V3 

B 


without hub 0 

60 mm 1 

65 mm 2 

75 mm 3 

80 mm 4 

70 mm 5 




N 

38


Ordering numbers for gearbox types 2K2100 

Note: 

Standard= Bold type 




2 L G 

1 2 3 4 5 6 7 – 8 9 10 11 12 – 13 

Special 

versions 



Full-key 4 

Half-key* 5 






Input flange (Ø = 190 k6) 9 



spigot Ø 450; FF500 80 

spigot Ø 400; Special motor 82 

spigot Ø 350; FF400 84 

spigot Ø 550; FF600 86 

spigot Ø 680; FF740 88 

Holding brake: 

without holding brake 1 


without 

STW 

a1 = spigot Ø 90 x 140; keyway; 2x25x14x125 

a1 = spigot Ø 90 x 140; smooth 

N 

S 

H 

G 


V1/ B5 C 

V3 Central lube oil supply in output shaft 

B 

Torsional backlash on gearbox output “d” 

without hub 0 

75 mm x 140 1 

80 mm x 170 2 

90 mm x 170 3 

95 mm x 170 4 




N 

39

Request for Quotation 

For quickest response please provide the following data to us by: 

Fax: ++49/(0)7541/77-2379 or 

E-Mail: industrial-drives@zf.com 

1. Motor 

motor brand: 

type: 

size: 

nominal power (kW): 

max. torque (Nm): 

motor operating speed n 1 to n 2 (rpm) at constant power: 

max. speed (rpm): 

motor shaft diameter d (mm): 

motor shaft length l (mm): 

pilot diameter b 1 (mm): 

pilot width f 1 (mm): 

pcd e 1 (mm): 

hole diameter s 1 (mm): 

fitting key lxbxh (mm): 

f1 

b1 

d 

e1 

l 

s1 

Motor shaft with keyway 

Motor shaft with shaft seal 

Full-key balanced motor shaft 

Motor shaft without keyway 

Motor shaft without shaft seal 

Half-key balanced motor shaft 

2. ZF-Duoplan type: 

2K120 2K300 2K800 2K2100 

2K121 2K450 2K801 

2K250 2K600 2K802 

40

Standard 

Option 

Gearbox interface open with adapter plate, hub bearing and shaft seal 

with adapter plate and shaft seal 

with adapter ring 

with input flange (2K250/300/800/2100) 

Ratio i 1 

4.00 (Standard) 

3.1 (2K120/121/250/300/800) 5.0 (2K450/600) 5.5 (2K250/300) 4.91 (2K120/121) 

Installation position B5 V1 B5 rotated longit.axis to right V3 

Holding brake without with (only available for 2K800/801) 

Output bearings Cylindrical roller bearings Angular-contact ball bearings 

Self aligning- and cylinder ball bearings (2K800/801/802) 

Lubrication system Splash type lubrication Recirculating lubrication with oil tank 

Integrated oil channel system 

Recirculating lubrication with heat exchanger 

Dry sump lubrication 

Gearbox output Gearbox with output flange Gearbox with output shaft 

100 mm (2K120/2K121) 38 mm (2K120/121) INLINE 

118 mm (2K250) 42 mm (2K250) 

130 mm (2K300) 42 mm (2K250/300) INLINE 

140 mm (2K450) 55 mm (2K300) 

150 mm (2K600) 60 mm (2K450) 

180 mm (2K800/801/802) 70 mm DIN 5480 (2K120 TSC/121 TSC/250 TSC/300 TSC) 

STW (2K800/801/802/2100) 

90 mm (2K2100) 

gearboxes for direct mounting without output 

(2K800/801/802/2100) 


Rotary union for spindle 

Torsional backlash at gearbox output 

< 30 arcmin < 20 arcmin < 15 arcmin 

< 40 arcmin (2K800/801/802/2100) 

Quantity per year: 

Order-No.: 

Application: 

Subject to technical change without notice. For installation investigation purposes, 

please request installation drawings; only the data contained therein is binding. 

Please check out our homepage: www.zf.com/industrial-drives 41

ZF Friedrichshafen AG 

Special Driveline Technology 

88038 Friedrichshafen 

Germany 

Phone +49 7541/77-3694 

Fax +49 7541/77-2379 

E-Mail: industrial-drives@zf.com 

www.zf.com/industrial-drives 

Driveline and Chassis Technology 

Print-No.: 4161 750 102 i Subject to technical change without notice. For installation investigation purposes, please request installation drawings; only the data contained therein is binding.

ZF Duoplan Gearbox Catalogue - Drive Lines Technologies

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