gearboxes for winches gpt-w
TRANSCRIPT
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
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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
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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
GPT 330 W Dimensions on request
GPT 400 W Dimensions on request
GPT 580 W Dimensions on request
GPT 600 W Dimensions on request
GPT 800 W Dimensions on request
GPT 1100 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
GPT 260 W Dimensions on request
GPT 330 W Dimensions on request
GPT 400 W Dimensions on request
GPT 580 W Dimensions on request
GPT 600 W Dimensions on request
GPT 800 W Dimensions on request
GPT 1100 W Dimensions on request
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
Customer Specification
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
You wish to receive an offer fora ZF winch gearbox?
To be able to quote, please send this customer specification to: [email protected]
Please enclose existing drawings and diagrams.
motor flange surface
frame connection
13ZE77502 /06.2016
Customer Specification
Company:
Name/Dept.:
Location/City:
Phone:
E-mail:
Date:
Page 3/3
You wish to receive an offer fora ZF winch gearbox?
To be able to quote, please send this customer specification to: [email protected]
Please enclose existing drawings and diagrams.
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