GEARBOXES FOR WINCHES - ShipServ · gearboxes for winches. ... - Fédération Européene de la Manutention), as well as DIN 15020, collective load class L2, service time category

GEARBOXES FOR WINCHESGPT-W

Copyright © ZF Industrieantriebe Witten GmbH

This document is protected by copyright.Complete or partial reproduction or dissemination of this documentis prohibited without the consent of ZF Industrieantriebe Witten GmbH.Infringements shall lead to civil and criminal prosecution.

3ZE77502 /06.2016

Gearboxes for Winches

Merkmale ∙ Compact, space-saving planetary gearbox design

∙ Planet wheel carried in full-complement bearings

∙ Robust bearing system absorbing the forces exerted

▶ by the cable pull

∙ Simple mounting

∙ Easy oil change

∙ Integrated static multiple disk brake

∙ Low-noise operation

∙ Sizes GPT-W 160 to 1,100

∙ Rope pull forces from 373 to 1,190 kN

ContentFunctional Description 4

Overview Types 5

Design and Classification 6

Dimensions and technical data 8

Standard counter-bearings 10

Customer specification 11

4 ZE77502 /06.2016

Functional Description

DescriptionZF gearboxes GPT-W are drive components for any kind of

winches in a wide range of applications, for example crawler

cranes, ship-, port- and container cranes, railway cranes, cranes

on work ships or offshore platforms.

As successor company of the former Lohmann + Stolterfoht

GmbH the ZF Industrieantriebe Witten GmbH incorporates

decades of know-how into the development and production of

gearboxes for winches. In combination with the latest calcula-

tion methods, such as the finite element method (FEM), winch

gearboxes of the highest quality, which have proven themselves

with high efficiency in hard use and under adverse conditions,

are being produced. The development and production expertise

is supplemented through an unique expertise in the dynamic

simulation and testing.

ZF winch gearboxes GPT-W are characterized by overall high

efficiency and a compact design, which allows a direct installa-

tion into the cable drum.

The exceptional resilience, reliability and low noise running of

the gearboxes GPT-W is achieved - in addition to the design and

the high manufacturing quality - through the use of case hard-

ened gears, and tempered and surface-hardened ringgears. In

addition, the ZF winch gearboxes are easy to install and easy for

maintenance in order to keep the subsequent operating costs as

low as possible.

The gearbox types listed in this catalog describe the standard

range of ZF Industrieantriebe Witten GmbH. If you need deviat-

ing gearbox types, our technical sales will be happy to assist

you anytime.

LubricationThe gears and bearings are splash-lubricated. Except for regular

oil changes, the gearboxes are free of maintanance. Only oils

specified in our operating manual should be used in the gearbo-

xes. The oil change intervals for different operating conditions

are also specified in the operating manual.

Spring pressure multiple-disc brake By default, a spring-loaded, hydraulic release spring pressure

multiple-disc brake with hydraulic release is installed on the

drive end.

TBr. sta. min = 1.6 • T1 (Input torque)

The spring pressure multiple-disk brake is not a service brake,

but a static holding brake that must not be used to brake the

load. The machine manufacturer must provide a separate

service or emergency brake if necessary. The holding torque is

multiplied according to the selected transmission.

Motor connectionThe gearbox is designed for direct flange-attachment of a

variable or fixed-displacement motor.

OptionsUpon request, the drives can be supplied with the following

accessories:

Counter bearing: In addition to the standard delivery scope, the

winch drives of series can also be delivered

with counter bearing.

Limit switches: Upon request, special counter bearings can

be designed with a connection option for

specific gear cam limit switches.

Winch gearbox with spring pressure multiple-disc brake and connection for hydraulic motor

5ZE77502 /06.2016

Functional Description

Overview of GPT-W Winch Gearboxes

Type Output torque 1)

T2 max

Nm

Cable pull max. 2)

kN

Gear ratiofrom/to

i

GPT 160 W3 140,000 373 133 • 251

GPT 220 W3 200,000 471 97.7 • 293

GPT 260 W3 240,000 530 97.7 • 188,1

GPT 330 W3 275,000 595 168.9 • 252

GPT 450 W4 325,000 684 293.4 • 421.7

GPT 580 W4 375,000 730 293.4 • 609.5

GPT 600 W 435,000 965 243.5 • 520.2

GPT 800 W 580,000 990 284.8 • 632.5

GPT 1100 W 800,000 1,190 401.5 • 632.5

1) design according to FEM L2, T5, M52) based on a theoretical 1st layer winding diameter DWS

6 ZE77502 /06.2016

Design and Classification

Operating conditionsThe gearboxes have been designed for use at ambient tempera-

tures between -20° C and +40° C. Environmental influences such

as salt water, salty air, sand, dust, overpressure, heavy vibrations,

extreme shocks and ambient temperatures, aggressive media,

etc. may affect the function of the product.

Such influences must be specified to ensure that the winch drive

is designed to meet the safety requirements.

Gearbox designThe gearbox design is based on many years of practical experi-

ence. The maximum output torques T2max indicated under Techni-

cal Data relate to FEM Section I, 3rd issue and Section IX (FEM

- Fédération Européene de la Manutention), as well as DIN

15020, collective load class L2, service time category T5 corre-

sponding to driver group M5. The reference output speed is 25

revolutions per minute maximum.

If the winch is classified into a different driver group, the required

output torque must be converted by applying factor K (see table).

This results in the maximum permissbile output torque for the

new classification. Whether or not the selected overall classifica-

tion is feasible, will be determined by the specialists of ZF.

Gearbox selection1) Calculation of output torque

T2 = output torque [Nm]

F = cable pull in [N]

DW = relevant winding diameter in [m]

2) Calculation of corrected output torque

T2K = T2 • K

T2K = corrected output torque [Nm]

K = Factor according to the service time category and

collective group given in the table

3) T2K of the gearbox to be selected must be ≤ T2max

T2 =F • DW

2

Driver Groups and Service Time Categories to FEM, section I, 3rd edition 1987 (FEM: Fédération Européene de la Manutention)

Service time category T2 T3 T4 T5 T6 T7 T8

Assumed average service time per day in hours 0.25 - 0.5 0.5 - 1 1 - 2 2 - 4 4 - 8 8 - 16 > 16

Theoretical service life in hours400 - 800 800 - 1800 1600 -

32003200 - 6300

6300 - 12500

12500 - 25000

25000 - 50000

Load spectrum Drive group with K factor

Col

lect

ive

Gro

ups

L1 lightMaximum loads occuring in exceptional cases only, side loads constantly

M 10.90

M 20.90

M 30.90

M 40.90

M 50.95

M 61.05

M 71.2

L2 mediumsmall, medium and maximumloads about equally distributed over service time

M 20.90

M 30.95

M 40.95

M 51

M 61.15

M 71.30

M 81.50

L3 heavyloads always near maximum M 3

1.05M 41.05

M 51.10

M 61.25

M 71.40

M 81.60

M 81.80

L4very

heavyAlways maximum load

M 41.25

M 51.30

M 61.45

M 71.65

M 81.85

M 82.10

M 82.40

7ZE77502 /06.2016

Design and Classification

Classification examples (see FEM section I, 3rd edition, table T.2.1.3.5.)

Type of crane(Designation)

Component operated 1)

Type of Driver

Hoisting Swinging Level luffing

Trolleytravelling

Cranetravelling

Assembly cranes M 2 - M 3 M 2 - M 3 M 1 - M 2 M 1 - M 2 M 2 - M 3

Loading bridges hooks M 5 - M 6 M 4 - M 4 - M 5 M 5 - M 6

Loading bridges Grab or magnet M 7 - M 8 M 6 - M 6 - M 7 M 7 - M 8

Workshop cranes M 6 M 4 - M 4 M 5

Overhead travelling cranes, ram cranes, Scrapyard cranes

Grab or magnet M 8 M 6 - M 6 - M 7 M 7 - M 8

Unloading bridges, container gantrycranes

Hooks or spreaders M 6 - M 7 M 5 - M 6 M 3 - M 4 M 6 - M 7 M 4 - M 5

Other portal cranes(with trolley and/or slewing ring)

hooks M 4 - M 5 M 4 - M 5 - M 4 - M 5 M 4 - M 5

Unloading bridges, container gantrycranes (with trolley and/or slewing ring)

Grab or magnet M 8 M 5 - M 6 M 3 - M 4 M 7 - M 8 M 4 - M 5

Berth cranes, shipyard cranes,Dismantling cranes

Hooks M 5 - M 6 M 4 - M 5 M 4 - M 5 M 4 - M 5 M 5 - M 6

Dockside cranes (slewable, gantry type, . . .), floating cranes, floating sheerlegs

Hooks M 6 - M 7 M 5 - M 6 M 5 - M 6 - M 3 - M 4

Dockside cranes (slewable, gantry type, . . .), floating cranes, floating sheerlegs

Grab or magnet M 7 - M 8 M 6 - M 7 M 6 - M 7 - M 4 - M 5

Floating cranes and floating sheerlegs for very high loads (normally above 100 t)

M 3 - M 4 M 3 - M 4 M 3 - M 4 - -

Shipboard cranes Hooks M 4 M 3 - M 4 M 3 - M 4 M 2 M 3

Shipboard cranes Grab or magnet M 5 - M 6 M 3 - M 4 M 3 - M 4 M 4 - M 5 M 3 - M 4

Tower cranes for construction sites M 4 M 5 M 4 M 3 M 3

Derrick tower gantry M 2 - M 3 M 1 - M 2 M 1 - M 2 - -

Railway cranes approv. for service in trains M 3 - M 4 M 2 - M 3 M 2 - M 3 - -

Vehicle-mounted cranes Hooks M 3 - M 4 M 2 - M 3 M 2 - M 3 - -

1) The column only shows some typical areas of winch use for informative purposes.

8 ZE77502 /06.2016

Dimensions and Technical Data

Dimensionsof the counter bearing

see page 10

Optional (only in connectionwith version ≥ 4000)

Technical data

Type Output torqueT2 max

Nm

Cablepullmax. kN

Transmission ratio

i

Holding torqueTBr max

Nm

Hydraulic motor

GPT 160 W3 4000 140,000 373 133 • 210.8 • 251 1,360A6VM 200 / A6VE 107 • 160 /A2FE 107 • 125 • 160 • 180

GPT 220 W3 4000/1 200,000 47197.7 • 105.9 • 143.3 • 155.4 •

188.9 • 246.1 • 2931,360

A6VE 107 • 160 /A2FE 107 • 125 • 160 • 180

GPT 220 W3 4000/2 200,000 471 97.7 • 105.9 • 143.3 • 155.4 • 188.9 1,360 A6VM 200 • 250 / A2FM 200

GPT 220 W3 6000/1 200,000 471 188.9 • 246.1 • 293 1,360A6VE 107 • 160 /A2FE 107 • 125 • 160 • 180

GPT 220 W3 6000/2 200,000 471 97.7 • 105.9 • 143.3 • 155.4 • 188.9 2,200 A6VM 200 • 250 / A2FM 200

GPT 260 W3 4000 240,000 530 155.4 • 188.1 * *

GPT 330 W3 9000/1 275,000 595 209.8 • 252 2,860 A6VE 250 / A2FE 250

GPT 330 W3 9000/2 275,000 595 168.9 • 181.7 2x 1,700 2x A6VM 160

GPT 450 W4 6000 325,000 684 293.4 • 421.7 2,300 A6VE 250 / A2FE 250

GPT 580 W4 4000 325,000 730 609.5 * *

GPT 600 W 435,000 765 243.5 • 289.5 • 326.5 • 580.2 * A2FM 500 / 2x A6VE160

GPT 800 W 580,000 990 284.8 • 275.5 • 386.7 * 2x A2FM 250

GPT 1100 W 800,000 1,190 401.5 • 599.7 • 614.9 • 532.5 * 2x A6VM 250

GPT 220 W3 4000/2 = index no. for different structural lengths, diameter or motor attachment

min

. Win

ding

dia

met

er 1

st la

yer

2000 = Oil inlet, oil outlet, oil level on the gear cover4000 = Oil inlet, oil outlet, motor-side oil level6000 = Oil inlet, oil outlet, motor-side oil level Installation of 2 gearboxes in a hoisting drum possible

8000 = Optional with back stop (built-in between gearbox and holding brake)

9000 = Special design

Dimensions

9ZE77502 /06.2016

Dimensions and Technical Data

Dimensions, masses

Type D1 D2 D3 D4 D5 D6 D7 D8 DWS

mm

GPT 160 W3 4000 450 510 560 30x M24x2 535 600 650 30x 30 750

GPT 220 W3 4000/1 460 600 650 30x M30 610 680 735 24x 33 850

GPT 220 W3 4000/2 460 600 650 30x M30 610 680 735 24x 33 850

GPT 220 W3 6000/1 460 600 650 30x M30 610 680 735 24x 33 850

GPT 220 W3 6000/2 460 600 650 30x M30 610 680 735 24x 33 850

GPT 260 W3 4000 560 630 685 28x M30 620 750 810 28x 33 -

GPT 330 W3 9000/1 580 680 735 28x M24 660 730 785 30x 33 925

GPT 330 W3 9000/2 580 680 735 28x M24 660 730 785 30x 33 925

GPT 450 W4 6000 580 680 735 36x M30 670 750 810 36x 33 -

GPT 580 W4 4000 - - - - - - - - -

GPT 600 W1 670 750 815 30x M30 885 975 1,055 24x 39 -

GPT 600 W2 830 980 1,050 47x M30 920 980 1,055 48x 33 -

GPT 800 W 1,100 1,230 1,310 47x M36 1,040 1,170 1,226 48x 33 -

GPT 1100 W 730 810 880 30x M30 885 965 1,020 24x 39 -

Type L1 L2 L3 L4 L5 L6 L7 A + B Mass

C Co

mm kN kg

GPT 160 W3 4000 30 168 340 538 65 131.7 20,2 783 1,557 680

GPT 220 W3 4000/1 25 170 350 565 60 155 35 710 1,560 820

GPT 220 W3 4000/2 21 170 350 560 60 155 35 710 1,560 820

GPT 220 W3 6000/1 25 170 350 565 60 155 35 710 1,560 820

GPT 220 W3 6000/2 25 170 350 560 60 155 35 710 1,560 820

GPT 260 W3 4000 55 175 412 642 30 163 37 930 930 950

GPT 330 W3 9000/1 87 188 430 705 80 190 25 1,040 2,450 1,380

GPT 330 W3 9000/2 20 188 430 705 70 190 25 1,040 2,450 1,380

GPT 450 W4 6000 87 156 532 775 37 155 39 1,040 2,450 1,460

GPT 580 W4 4000 - - - - - - - - - 1,640

GPT 600 W1 60 242 459 1,167 75 - - - - 2,500

GPT 600 W2 30 229 673 1,332 64 - - - - 3,800

GPT 800 W 72 503 585 1,524 100 - - - - 7,000

GPT 1100 W 57 245 464 1,161 75 - - - - 2,600

10 ZE77502 /06.2016

Standard Counter-Bearing

Dimensions

Gear Size D1H7/j6

D2 D3H7/j6

D4 D5

mm

GPT 160 W 260 220 180 295 12x ø22

GPT 220 W 260 220 180 295 12x ø22

GPT 260 W Dimensions on request







Gear Size D6 L1 L2 L3 Massapprox.

mm kg

GPT 160 W 8x ø18 102 25 20 30

GPT 220 W 8x ø18 102 25 20 30








11ZE77502 /06.2016

Customer Specification

You wish to receive an offer fora ZF winch gearbox?

To be able to quote, please send this customer specification to: [email protected]

Company:

Name/Dept.:

Location/City:

Phone:

E-mail:

Date:

Page 1/3

Rope pull (top rope layer) 2)

Rope speed (1. rope layer) 2)

Rope speed (top rope layer) 2)

Rope diameter

Number of rope layers, max. 2)

Winding diamet. (1. rope layer) 2)

Winding diamet. (top rope layer) 2)

Techn. data gearboxSelected gearbox type

Max. output torque 2)

Max. drive speed 2)

Ratio 1)

Multiple-disk parking brake

Min. park. torque multiple-disk

parking brake

Release pressure, max.

Release pressure, min. 1)

Top coat specific

Color

F N

V1 m/min

V2 m/min

d mm

DWS

mm

DWx

mm

D2 mm

GPT-W

T2 max

kNm

n2 1/min

i yes no

Nm

Pmax

bar

Pmin

bar

no yes

RAL

Standard scope of supplyTransmission unit

Optional scope of supply Counter bearing

Rope drum 3)

Winch frame

Device type

Hoisting winch Boom hoist winch Auxiliary winch Pulling winch

Other:

Rating acc. to FEM section I T L M

or alternatively load spectrum

Ambient temperature from/to °C

Operating machine weight 1) t

Lifting capacity, max. 1) t

1) Optional entry2) Mandatory field if T2 max is not specified

Please enclose existing drawings and diagrams.

Operating data / design(all values based on the 1. rope layer)

12 ZE77502 /06.2016


Dimensions of gearbox• Standard dimensions see valid „technical data sheet“

• in case of differing requirements/ Dimensions, please complete table

D1

D2

D3

D4 No. of threads

D5

D6

D7

D8 No. of threads

L2

Tech. basic data hydraulic motorHydraulic circuit

Motor type code

Displacement

Displacement

Flushing valve

Speed sensor, if yes: type

Counter balance valve

Pressure relief valve

Pressure relief valve setting

Working pressure

Input flow, max.

mm

mm

mm

Pcs.

mm

mm

mm

Pcs.

mm

open closed

Vg min cm3

Vg max cm3

yes no

yes, type no

yes no

yes no

bar

∆p bar

qv max

l/min

Estimated number of transmission units per year 1)

Price range

Requested ship date RSD

Special operating conditions

Further customer-specific requirements

Are there any legal requirements and/or other standards to be considered?

no yes if yes, please specify

1) Optional entry

Company:

Name/Dept.:

Location/City:

Phone:

E-mail:

Date:

Page 2/3




motor flange surface

frame connection

13ZE77502 /06.2016


Company:

Name/Dept.:

Location/City:

Phone:

E-mail:

Date:

Page 3/3




Other (e.g. load spectra, application-relevant data, customer drawings, nameplate):

Travel Drive Gearboxes

∙ Planetary Gears GPT ∙ Planetary Gears GFA

Technical Documentation RE 77110

Swing Gearboxes

∙ Planetary Gears GFB

Technical Documentation RE 77201

Winch Gearboxes

∙ Planetary Gears GPT-W Technical Documentation RE 77502

Pump Distribution Gearboxes

∙ GFC

Products for movable applications

Products for industrial applications

14 ZE77502 /06.2016

Industrial Gearboxes

∙ Redulus GMH/GME Technical Documentation RE 76120

Product Programm

15ZE77502 /06.2016

Notes

ZF Industrieantriebe Witten GmbHMannesmannstraße58455 Witten, GermanyTel. +49 2302 877-0Fax +49 2302 [email protected]

MOTION AND MOBILITY

Prin

tnum

ber

ZE7

7502

/06

.201

6

Documents

GEARBOXES FOR WINCHES - ShipServ · gearboxes for winches. ... - Fédération Européene de la Manutention), as well as DIN 15020, collective load class L2, service time category