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ROPE WINCHES AND GEARBOXES
TRANSMISSION TECHNOLOGY
WINCH GEARBOXES
WINCH GEARBOXES
• ZOLLERN Winch Gearboxes 3
• Design and Construction 4
• Integrated Rope drum 7
• Rope fixing 8
• Rope grooves and Rope 9
• Application Factor K 10
• Classification Guidance 10
• Calculation of Rope load 11
• Calculation of Rope diameters and Rope drum diameters 11
• Winding Direction on Rope drums 11
• Technical Data 12
• Supporting Frame Machining Tolerances 14
• Gear Reduction Ratios 15
• Hydraulic Control Layouts 16
• Recommended Lubricants 16
• Accessoires for ZOLLERN Winches 16
• Application Questionnaire 17
The ZOLLERN Group
The ZOLLERN Group is an international company with over 3000 employees. Our fields of activity include transmission technology (automation, gears and winches), plain bearing technology, mechanical engineering components, foundry technology and steel profiles.
2 3
ZOLLERN WINCH GEARBOXES
ZOLLERN Winch Gearboxeshave proved highly successful under extremeoperating conditions. Their principal features and most significant advantages are
• compact dimensions• ease of maintenance• long operation life• high performance• modular design of gear unit• functional design
With these characteristics the machine designerwill get a ready to install unit and will achieveeconomic solutions even in confined space conditions.
Potential applications:
• mobile cranes• construction cranes and conveyors• material and working elevators• loading and cargo handling cranes• shipboard and deck cranes • rescue and wrecker salvage trucks• dockyard and harbour cranes • offshore cranes• container gantries• access platforms
ZOLLERN gears use components common to our complete range (Winches, Slewing Units,Industrial Gears, Free Fall Winches) giving theadvantage of volume production: cost savingsfrom standard parts, reduced lead times, testedand proven designs across the whole range andreadily available spares for units in service.
WINCH GEARBOXES
DESIGN AND CONSTRUCTIONOF ROPE WINCHES WITH FLANGE DRIVE GEARBOX
2 stage planetary gearboxRatios from i = 21 to 29Gearbox mounted inside winch drum, Parking Brakeand Hydraulic motor flange mounted externally. Input and output in opposite sense of rotation.
3 stage planetary gearboxRatios from i = 45 to 147Gearbox mounted inside winch drum, Parking Brakeand Hydraulic motor flange mounted externally. Input and output in opposite sense of rotation.
2 stage planetary gearbox with spur stage inputRatios from i = 40 to 150Gearbox mounted inside winch drum, Parking Brakeand Hydraulic motor flange mounted externally, twinmotor/brake option. Input and output in opposite senseof rotation.
4 5
Winch Gearbox RangeOutput torques: 1,750 to 1,500,000 Nm. Rope load: 17 to1,950 kN. In calculating the rope load care must be taken to include reeving, hooks and an allowance for reeving efficiency (see page 11).
NotesThe output torques Tdyn max, listed on pages 12/13 are based on FEM Standards I/3rd edition/load conditions L2running time classification T5, in accordance with ‘Drive unit group M5’. Ambient temperature +20 C° (FEM - Federation Europeenne de la Manutention).
Gear DesignSelected for optimum surface durability and bendingstrength; also for minimum sliding velocity, according DIN 3990. External gear teeth are case-hardened andground; internal gears annealed and nitride hardened.
BearingsAll rotation parts run on rotation element bearings. Ball bearings are used to support the input gearing, needle roller bearings for the planet wheels and self aligning bearings for the drum support bearings.
EfficiencyThe efficiency per planetary stage is 98% and about 99%for the drum bearings including seals. Example: Rope winch with 2 planetary gear stages η total = 0,98 x 0,98 x 0,99 = 0,95
LubricationAll gears and anti-friction bearings are splash lubricated.Service intervals and recommended lubricants are given in the table on page 16. The end support bearing can begrease packed for lifetime operation – requiring no furtherservice attention.
Oil changeAn external fill/breather/drain pipe is fitted to the drive flange of winch gearbox.
Oil levelOil level is checked by either dip stick or sight glass.
CoolingCooling may be required where the unit is to operate continuously in direct sunlight or high ambient temperatureenvironments. Cooling may be also required if the power ontime is high. ZOLLERN can provide suitable coolers.
Input OptionsZOLLERN’s modular system provides for hydraulic or electric motor input interfaces. Flange mounted or freeshaftwith key to DIN 5480.
SealsInput and output are protected with radial shaft seals ofdouble lip type. This prevents oil leakage and protects theunit from ingress of dirt or water. Where the unit is be usedoffshore or on-ship additional protection is provided withgreased felt strips and secondary radial seals.
WINCH GEARBOXES
Electric motorStandard electric motors cannot be mounted inside thewinch drum. As opposed to Electric-Compact-Winch.
Operating conditionsThe gear systems are designed for use in Central Europeanconditions. Permissible oil temperatures -20°C to +70°C.Environmental factors such as salt water, salt-laden air,dust, excessive air pressure, heavy vibration, high shockloads and extreme ambient temperatures, corrosive media,etc. must be stated.
Paint PrimerThis is a specially developed multi-primer with a two- component zinc-dust epoxy resin base. Colour: Grey white. A two component epoxy resin is most suitable for the finishcoat.
Choice of gear unitIn order to select the correct rope winch for a given applica-tion the output torque Tdyn calculated from the rope loadand rope drum diameter must be multiplied by the factor K.
Tnom = Tdyn x K ≤ Tdyn max
For application factor K and calculation of the rope load see pages 10.
BackstopFor special applications a backstop can be incorporatedbetween the gear transmission and the parking brake. It operates as follows.
Lifting of load Lowering of load- Parking brake closed - Parking brake open- Backstop open - Backstop closed
Geared limit switcha) electricalan electrical signal can be generated at various rope travelor end limit position. The switch positions are infinitely ad -justable. The switch is flange mounted with drive from therope drum through the bearing support housing.
b) hydraulicZOLLERN geared limit switch operating as the electricalversion – with a hydraulic signal.
Mounting positionHorizontal
FittingZOLLERN’s winch gearbox is designed to be flange mountedin a fabricated steel structure. The drive end mounting flan-ge reacts rope load and transmission torque, the non driveend reacts rope loads only and can be safely removes tofacilitate fitting of the winch drum and gearbox.
BrakesA hydraulic multi disc parking brake with spring applied,pressure release operation is fitted. This fail safe device is a self contained piston/ brake with release pressure of 15 bar, 300 bar max. Line transient pressure of 0.5 bar permitted. The connection ports are metric M 12 x 1.5.Multi disc, single disc or barrel brakes with direct conne-ction to the rope drum can be fitted for additional safetyback up.
6 7
INTEGRATED ROPE DRUM
With normal grooves
With special grooves
This is cast on to the drum at the rope entrypoint and serves to fill the gap between thedrum flange and the first rope turn.
This is cast on to the drum on the oppositeside of the rope entry and guides the ropefrom the first to the second layer.
With grooves of this kind the difficulties encountered inmulti-layer winding on to grooves of the usual kind do notarise, as the crossover points of the rope in each layer al -ways lie in the same section of the drum and the lift of therope into the next layer is precisely defined. 8 and morelayers can be accommodated without difficulty.
Material for rope drum:- ductile graphite iron (EN-GJS-400-15; EN-GJS-600-3)- steel (S355JO)Other material available on request
Raising wedge
Dummy-lay filling wedge
WINCH GEARBOXES
Rope drum diameter D1D1 = 20 x dor as specified
Drum flange diameter D2D2 = D1 + 2 (z + 1) d
ROPE FIXING
D 1 D 2
d
1,5
. d
Length of ropeincluding 3 safety turns
LS = - a D1 + 0,866 . d (z-1) z . π
LS = Length of rope [m]L2 = Length of drum [mm]D1 = Diameter of drum [mm]d = Diameter of rope [mm]
p = Pitch of rope groove [mm]z = Number of rope layers [–]a = 1 for normal grooves [–]
= 0,5 for special grooves
L2p( () )
Wedge lock
a) on the outside of the drum flange
b) on the inside of the drum flange (for up to 2 rope layers only)
c) within the barrel shell
Rope Clamps
a) on the outside of the drum flange
b) on the inside of the drum flange (for up to 2 rope layers)
c) on the drum by means of clamps. In an emergency therope can be pulled out of the fixing without damage toeither rope or drum.
1000
Fleet angleTo achieve acceptable rope winding
- the deflection angle α must with special grooves be notless than 0,5° in order to prevent the rope from riding upthe drum flange and to ensure that it is guided securely onto the next layer.
- the deflection angle α must not exceed 1,5° in order to pre vent the rope in the first layer being pulled against thegrooves and, where a number of layers occur, to enableeven winding up to the drum flanges. If the deflection angleis greater, the working life of the rope will be negativelyaffected.
Direction of rope layRope lay should be in the opposite sense to drum lead.
For example:
8 9
Rope groovesOn cast drums cleanly cast and trimmed, and at the flash line carefully ground. On welded drums all edges are de burred and radiussed.
Rope groove lead/pitch
Right-hand lead on standard design
Left hand lead
ROPE GROOVES AND ROPE
right-hand rope lay
left-hand rope lay
α
WINCH GEARBOXES
APPLICATION FACTOR K FOR WINCHES
CLASSIFICATION GUIDANCEAccording FEM section I, 3rd edition, table T.2.1.3.5.
Symbol T2 T3 T4 T5 T6 T7 T8
Running time Mean running time per day over 0,25 over 0,5 over 1 over 2 over 4 over 8 over 16classification in hours, related to one year to 0,5 to 1 to 2 to 4 to 8 to 16
Life in hours 400 to 800 to 1 600 to 3 200 to 6 300 to 12 500 to 25 000 to8 years, 200 days/year 800 1 600 3 200 6 300 12 500 25 000 50 000
Load Collective coefficient km Drive unit classconditions Application Factor K
L1 to 0,125 M 1 M 2 M 3 M 4 M 5 M 6 M 70,90 0,90 0,92 0,9 0,92 1,1 1,36
L2 0,125 to 0,250 M 2 M 3 M 4 M 5 M 6 M 7 M 80,90 0,92 0,96 1 1,07 1,3 1,6
L3 0,250 to 0,500 M 3 M 4 M 5 M 6 M 7 M 8 M 81,05 1,09 1,17 1,23 1,28 1,53 1,89
L4 0,500 to 1,000 M 4 M 5 M 6 M 7 M 8 M 8 M 81,32 1,36 1,46 1,53 1,58 1,8 2,22
log L
M
log L
M
log L
M
log L
M
Type of appliance Particulars concer- Type of mechanismDesignation ning nature of use (1)
Hoisting Slewing Luffing Traverse Travel
Erection cranes M2–M3 M2–M3 M1–M2 M1–M2 M2–M3
Stocking and reclaiming transporters Hook duty M5–M6 M4 – M4–M5 M5–M6
Stocking and reclaiming transporters Grab or magnet M7–M8 M6 – M6–M7 M7–M8
Workshop cranes M6 M4 – M4 M5
Overhead travelling cranes, pigbreaking cranes, Grab or magnet M8 M6 – M6–M7 M7–M8scrapyard cranes
Bridge cranes for unloading, a) Hook or spreader duty M6–M7 M5–M6 M3–M4 M6–M7 M4–M5bridge cranes for containers b)Hook duty M4–M5 M4–M5 – M4–M5 M4–M5Other bridge cranes (with crab and/or slewing jib crane)
Bridge cranes for unloading, bridge cranes Grab or magnet M8 M5–M6 M3–M4 M7–M8 M4–M5(with crab and/or slewing jib crane)
Drydock cranes, shipyard jib cranes, Hook duty M5–M6 M4–M5 M4–M5 M4–M5 M5–M6jib cranes for dismantling
Dockside cranes (slewing, on gantry, etc.), Hook duty M6–M7 M5–M6 M5–M6 – M3–M4floating cranes and pontoon derricks
Dockside cranes (slewing, on gantry, etc.), Grab or magnet M7–M8 M6–M7 M6–M7 – M4–M5floating cranes and pontoon derricks
Floating cranes and pontoon derricks for M3–M4 M3–M4 M3–M4 – –very heavy loads (usually greater than 100 t)
Deck cranes Hook duty M4 M3–M4 M3–M4 M2 M3
Deck cranes Grab or magnet M5–M6 M3–M4 M3–M4 M4–M5 M3–M4
Tower cranes for building M4 M5 M4 M3 M3
Derricks M2–M3 M1–M2 M1–M2 – –
Railway cranes allowed to run in train M3–M4 M2–M3 M2–M3 – –
Mobile cranes Hook M3–M4 M2–M3 M2–M3 – –
10 11
CALCULATION OF ROPE LOAD FNOM ON THE ROPE DRUM
CALCULATION OF ROPE DIAMETERS AND ROPE DRUM DIAMETERS IN ACC. WITH DIN 15020
Efficiency of rope drives
ηs = (ηR)i · ηF = (ηR)i · ·
ηR is the efficiency of a single rope pulleyηF is the efficiency of the pulley blockηs is the efficiency of the rope drive
The efficiency of a rope pulley depends not only from itstype of bearing used in it (friction or antifriction), but alsoupon the ratio rope pulley diameter: rope diameter (D:d),upon the design of the rope and upon the rope lubrication. If no more exact values have been obtained by experiment,the following values are to apply
with friction bearings ηR = 0,96with anti-friction bearings ηR = 0,98
For compensating pulleys no efficiency value must be considered.
For Ψ = vibration coefficient see FEM-Section 1,3. Edition October 1998
1n · ηs
1n
1 - (ηR)n
1 - ηR
Rope load Fnom
Fnom = (mload + mtackle) g · · Ψ [N]
Meaning: i is the number of rope pulleys between the rope drum
and pulley block or load (e. g. with the lifting gear on jib cranes)
n is the number of rope strands in a single pulley block. A single pulley block is the total number of rope strandsand rope pulleys for a single rope running on to a ropedrum (see illustration)
2-stranded pulley blockn = 2
Twin pulley tackle4-stranded, comprising2 pulley blocks each 2-stranded2 x (n = 2)
Coefficient c Coefficient h1 Coefficient h2 = 1
Gear Rope diameter dmin = c · √ S S = Rope pull in N C = Coefficient in mm/√ N Rope drum diameter Dmin = h1 · h2 · dmindrivegroup Non rotationfree wire ropes Rotationfree wire ropes Non Rotationfree
rotationfree or low-rotation Nominal strength of individual wires in N/mm2 wire rope wire rope
1 570 1 770 1 960 2 160 2 450 1 570 1 770 1 960
1 Bm 0,0850 0,0800 0,0750 – 0,0900 0,0850 0,0800 14 16
1 Am 0,0900 0,0850 – 0,0950 0,0900 16 18
2m 0,0950 – 0,106 18 20
3m 0,106 – 0,118 20 22,4
4m 0,118 – 0,132 22,4 25
5m 0,132 – 0,150 25 28
WINDING DIRECTION ON ROPE DRUMS
Rope entry Rope entry Rope entryRope entry
Rope pull undershot
Right-hand Left-hand
Rope pull overshot Rope pull overshot Rope pull undershot
WINCH GEARBOXES
Rating according to FEM section I Drive unit class M5Load condition L 2 (P = const. / nab = 15 rpm)Running time class T5# With clamping sleeves
ZOLLERN have a policy of continuousproduct improvement, and detail may be changed without notice.
30° 30°180 125 145 167 12 * M 10 16 5 145 185 203 12 * Ø 11 10 9
20° 20°260 155 185 213 16 * M 12 24 5 225 245 265 18 * Ø 11 10 9
20° 15°300 190 225 255 16 * M 16 25 5 265 290 310 24 * Ø 14 12 9
20° 15°340 200 255 285 16 * M 16 25 5 295 320 340 24 * Ø 14 12 9
15° 20°390 230 280 315 22 * M 16 25 5 330 360 390 18 * Ø 18 16 9
15° 15°440 270 320 355 22 * M 16 25 5 370 400 430 24 * Ø 18 16 9
15° 20°480 300 350 385 22 * M 20 30 5 400 440 480 18 * Ø 22 20 9
15° 15°520 330 390 425 22 * M 20 30 5 440 480 520 24 * Ø 22 20 9
15° 20°570 355 420 460 22 * M 24 38 5 470 520 560 18 * Ø 26 24 9
15° 15°670 430 480 530 22 * M 24 38 5 550 590 630 24 * Ø 26 24 9
15° 15°770 515 565 615 24 * M 30 47 5 640 690 750 24 * Ø 33 30 9
15° 15°830 580 630 680 24 * M 30 47 5 700 755 815 24 * Ø 33 30 9
12° 12°930 670 720 770 30 * M 30 47 5 790 840 890 30 * Ø 33 30 9
10° 10°1 030 720 770 820 36 * M 30 47 5 850 900 950 36 * Ø 33 30 9
10° 10°1 200 840 900 960 36 * M 36 56 5 1 000 1 055 1 120 36 * Ø 39 36 9
# 10° # 10°1 360 1 060 1 140 1 210 36 * M 30 78 26 1 240 1 320 1 390 36 * Ø 33 45 13
# 10° # 10°1 530 1 160 1 240 1 310 36 * M 30 78 26 1 340 1 420 1 490 36 * Ø 33 45 13
# 7,5° # 7,5°1 800 1 250 1 350 1 441 48 * M 30 105 25 1 630 1 725 1 820 48 * M 33 55 25
120 140
150 175
175 200
175 200
200 230
200 230
230 260
260 310
260 310
300 350
325 375
325 375
375 435
375 435
430 490
600 680
600 680
750 850
FF 1 F 2
location pcd
Ø Ø± 0,2
Nominal gearbox ratings
Output Typicaltorque (Nm) line
pullZHP
Tdyn max Tstat maxEG I ≤ 70 I ≤ 70 Fnom
I > 70 I > 70 (kN)
4.13 1 650 2 650 171 750 2 800 18
4.15 4 000 6 400 334 150 6 650 34
4.19 7 000 11 200 467 300 11 700 48
4.20 11 200 18 000 6711 600 18 500 69
4.22 18 800 30 000 9519 400 31 000 98
4.24 25 000 40 000 11625 500 41 000 119
4.25 35 000 56 000 14336 000 57 500 147
4.26 47 000 75 000 18048 000 77 000 184
4.27 61 000 97 500 21363 000 101 000 220
4.29 102 000 163 000 304105 000 168 000 313
4.31 150 000 240 000 395155 000 248 000 408
4.32 229 000 366 500 549236 000 377 500 566
4.33 300 000 480 000 637311 000 497 500 660
4.34 392 000 627 000 760406 000 649 500 787
4.36 623 000 997 000 1 038644 000 1 030 500 1 073
4.38 1050000 1 680 000 1 4501100000 1 760 000 1 520
4.40 1400000 2 240 000 1 8201500000 2 400 000 1 950
4.44 2400000 3 840 000 2 5402500000 4 000 000 2 650
Flange connection – Gear unit to frame Flange connection – Gear unit to drumBolts class 10.9 Bolts class 8.8
MaxG S
input D O G 1 G 2 G 3 G 4 G 5 G 6 S 1 S 2 S 3 S 4 S 5 S 6speed approx. location pcd outer fixing location pcd outer fixing
nmax.Ø Ø Ø Ø Ø Ø
(rpm) ± 0,2 ± 0,2
Depe
ndin
g on
mot
or a
nd b
rake
arr
ange
men
t20
00…
5000
rpm
G S FTYPE
Oil pipe connection ports
Sizes 4.13 to 4.29: the oil pipeconnection ports are on the gearmounting flange.
Sizes 4.31 and above: the oil pipeconnection is on the gearbox face.
H1
H2H2
G4
Integrated drive unit
Drive unit with spur gear
12 13
Assembly length = L2 + 2 * T2 + Wdepending on design
A C Mmax. T 1 T 2 W L X
ZHPmin. approx. min.2-sta- 3-sta- frame 2-sta- 3-sta-
ges ges thick- ges gesness EG
40 55 130 165 – 70 10 170 – 10
55 70 140 185 255 85 15 225 295 15
60 75 170 190 290 95 15 245 340 15
60 75 140 225 295 95 15 270 350 15
60 75 170 245 345 100 15 300 410 15
60 80 170 270 405 100 20 325 460 20
75 95 160 270 395 120 20 350 480 20
75 95 210 305 445 120 20 375 510 20
90 110 200 325 455 140 20 420 560 20
90 115 200 370 520 145 25 465 620 25
110 140 200 375 540 180 30 515 685 30
110 140 150 465 695 180 30 590 815 30
110 160 150 470 720 180 40 675 925 40
120 160 140 495 760 200 40 700 975 40
120 190 110 685 970 240 50 875 1 160 50
130 170 – 960 1 320 230 60 1 195 1 555 50
130 170 – 1 235 1 650 195 60 1 320 1 735 50
115 210 – – 1 750 220 80 – 1 690 70
4.13
4.15
4.19
4.20
4.22
4.24
4.25
4.26
4.27
4.29
4.31
4.32
4.33
4.34
4.36
4.38
4.40
4.44
60°160 6 * Ø 9 12 8 20 36 – –
60°200 6 * Ø 11 15 8 25 50 26 93,5
60°225 6 * Ø 11 15 10 30 64 26 111
60°225 6 * Ø 11 15 10 30 64 26 117
60°260 6 * Ø 14 18 12 35 71 26 132
60°260 6 * Ø 14 18 12 35 71 26 152
60°290 6 * Ø 18 18 15 40 78 30 168
60°360 6 * Ø 22 25 15 50 92 30 184
60°360 6 * Ø 22 25 15 50 92 30 195,5
60°400 6 * Ø 22 30 15 50 104 30 233
60°425 6 * Ø 26 35 15 70 134 – 235
60°425 6 * Ø 26 35 15 70 134 – 268
60°500 6 * Ø 33 40 15 80 144 – 298
60°500 6 * Ø 33 40 15 80 144 – 335
60°550 6 * Ø 33 40 15 90 180 – 385
30° 460750 12 * Ø33 50 20 80 180 – 497
30° 460750 12 * Ø33 50 20 80 180 – 545
15° 675950 24 * Ø33 60 25 110 230 – 675
Flange Connection – End support bearingto frame – Bolts class 8.8
F 3 F 4 F 5 F 6 F 7 F 8 H 1 H 2outer fixing
Ø Ø
TYPE
FLANGECONNECTION
FLANGE CONNECTION
FLANGECONNECTION
FLANGECONNECTION
Connecting flangefor geared limit switch
3 stage unit
2 stage unitLENGTH DEPENDING ONMOTOR/BRAKE SIZE
4.38 and 4.40 have sameconnecting flange as 4.36
F5
D0S5
G5
F6
LL
X
AX
F7
S6
L2T2 T2 W
C
M maxF8
INSTALLATION DIMENSION
G6
To ensure correct operation of the winch, the frame locationcentres must be within the specified tolerances and the flan-ge pieces square to the base plate. Care should be taken todesign an adequately rigid support and sub support as
deflec tions during installation and subsequent operation cantake up working tolerances. These are given in the accom-panying table.
Maximum permitted deviation ΔH from the centreline in relation to L1
Support frame connectionG/Box flange connection
αG αF L1 250 500 750 1 000 1 500 2 000 2 500
4.13 0,1 0,3 20° 0,2 0,2 60° 1 0,1 0,2 0,2 0,3 4.13
4.15 0,1 0,3 20° 0,2 0,3 60° 1 0,2 0,2 0,3 4.15
4.19 0,1 0,4 20° 0,2 0,3 60° 2 0,2 0,2 0,3 4.19
4.20 0,1 0,4 20° 0,2 0,3 60° 2 0,2 0,2 0,3 0,4 4.20
4.22 0,1 0,4 15° 0,2 0,3 60° 2 0,2 0,2 0,3 0,4 4.22
4.24 0,1 0,4 15° 0,2 0,3 60° 2 0,2 0,3 0,4 0,5 4.24
4.25 0,1 0,5 15° 0,4 0,5 60° 2 0,2 0,3 0,4 0,5 4.25
4.26 0,1 0,5 15° 0,4 0,5 60° 3 0,2 0,3 0,4 0,5 4.26
4.27 0,1 0,5 15° 0,4 0,5 60° 3 0,3 0,4 0,5 4.27
4.29 0,1 0,5 15° 0,4 0,5 60° 3 0,3 0,4 0,5 4.29
4.31 0,2 0,5 15° 0,6 0,5 60° 3 0,3 0,4 0,5 4.31
4.32 0,2 0,5 15° 0,6 0,5 60° 3 0,3 0,4 0,5 0,7 4.32
4.33 0,2 0,5 12° 0,6 0,5 60° 3 0,3 0,4 0,5 0,7 4.33
4.34 0,2 0,5 10° 0,6 0,5 60° 3 0,3 0,4 0,5 0,7 4.34
4.36 0,3 0,5 10° 0,8 0,5 60° 3 0,3 0,4 0,5 0,7 4.36
4.38 0,3 0,1 10° 0,8 0,5 60° 3 0,4 0,5 0,7 4.38
4.40 0,3 0,1 10° 0,8 0,5 60° 3 0,4 0,5 0,7 4.40
Type
ZHP
Type
ZHP
The fixing hole centres should lie within 0,1 of a theoretical cylinder about the winch centreline.
The locating flange diameter should be flat within 0,2 about the winch centreline.
AB Ø A
Ø 0,1 B
AB Ø B
AB0,2
SUPPORTING FRAME MACHINING TOLERANCES
WINCH GEARBOXES
Surface to kept free of oil/grease Surface to kept free of oil/grease
14 15
GEAR REDUCTION RATIOS
Ratio 4.13 4.15 4.19 4.20 4.22 4.24 4.25 4.26 4.27 4.29 4.31 4.32 4.33 4.34 4.36 4.38 4.40
21
25
29
45
53
60
63
70
71
83
93
99
107
112
127
147
173
206
245
267
301
317
357
429
464
557
670
761
866
1000
2-stages – coaxial
3-stages – coaxial
4-stages – coaxial
Other ratios available on request
WINCH GEARBOXES
RECOMMENDED LUBRICANTS FOR ZOLLERN ROPE WINCHESTable of Lubricants
HYDRAULIC CONTROL LAYOUTS
open loop closed loop
Simplified view
ACCESSORIES FOR ZOLLERN WINCHES (ON REQUEST)
• Winch frame• Lay-on roller• Spooling guide• Load holding valve• Rope limit switch• Fail save brake
• Rope tension control• Cam limit switch (hydraulic/electric)• Bevel gear input• Switch speed gearbox (hydraulic/manual)• Differential (Vario-speed) drive system
Lubrication frequency
Oil 1st oil change after 200 operating hours Grease Once a week or on recommissioning2nd oil change after 1000 operating hoursfurther oil change after every 1000 operating hours; at least once a year
Lubrication type only according indication in the installation drawing resp. in the maintenance manual.
Attention: Mineral and PAO-based gearbox oils are not to be mixed with PG (polyglycol)-based synthetic oil.
Greases with different soap bases are not to be mixed.
Type/Specification Lubricants to DIN 51502
Mineral Oils to Synthetic Lubricants to Grease to
DIN 51 517 T3 CLP 220 CLP PAO 220 PG 220 DIN 51825 KP 2 K
Aral Degol BG 220 Aral Degol PAS 220 Degol GS 220 Aralub HLP 2
Avia Gear RSX 220 Avia Synthogear 220 EP Avilub VSG 220 Avialith 2 EP
BP Energol GR-XP 220 Enersyn HTX 220 Energol SG-XP 220 Energrease LS-EP 2
Castrol Alpha SP 220 – – Spheerol EPL 2 Grease
Esso Spartan EP 220 – Umlauföl S 220 Beacon EP 2
Fuchs Renolin CLP 220 – Renolin PG 220 Fuchs Renolit FEP 2
Gulf EP Lubricant HD 220 – – Gulf Crown Grease No. 2
Klüber Klüberoil GEM 1-220 N Klübersynth GEM 4-220 N Klübersynth GH 6-220 Centoplex 2 EP
Mobil Mobilgear 630 Mobil SHC 630 Mobil Glygoyle 30 Mobilux EP 2
Shell Omala 220 Omala HD 220 Tivela WB Alvania EP 2
Texaco Meropa 220 – Synlube CLP 220 Multifak EP 2
Total Carter EP 220 Carter SH 220 Carter SY 220 Multis EP 2
ZOLLERN – Winch GearboxesApplication Questionnaire
Company/Address Proper department Person concerned Number of inquiry Date Telephone-No. Telefax-No. Demand Email Application Used for
Technical dataDiameter of rope drum D1 [mm] Drum Lead No. of rope layers z [–]Length of drum right left Length of rope tobetween flanges L2 [mm] Type of rope groove be wound includingRope diameter d [mm] DIN 15061 Special 3 safety turns Ls [m]Rope groove pitch p [mm] grooveless
Position of rope anchor Diameter of drum flanges D2 [mm]drive side opposite to drive Ratio i [–]
(e.g. mobile crane, ship-offshore-harbour cranes, tower cranes) (e.g. hoisting-, luffing-, pulling winch)
Drive hydraulic motorManufacturerTypeAvailable oil flow Q [l/min]Available differential pressure ∅p [bar]
Drive electric motorManufacturerTypePower [kW]Speed [rpm]Control (Frequency inverter; ON/OFF; Softstarter)
BrakeApply as Design Actuation
Parking brake Spring loaded multi disc brake Disc brake hydraulically min. release pressure [bar]Service brake with backstop Drum brake electric max. release pressure [bar]
Brake motor expected back pressure [bar]
Please fill in all known data.
Remarks and special operating conditions
Voltage, AC/DCStarting torque TA [Nm]Breakdown torque Tk [Nm]Power-on time ED [%]Starting per hour
Rope speed v [m/min]for P = constant
Line
pul
l at d
rum
F [k
N]
v1 vempty
F1
Fempty
16 17
Operating conditions – Design criteria (All values related to first/ top rope layer)Rope loads and winch ratingsNo. of ropes on drum w Alternative ratingNominal line pull (for each rope) Load F1 Tdyn v1 n1 Time sliceLine pull at drum F1 [kN] cond. [kN] [Nm] [m/min] [min-1] [%]Rope speed v1 [m/min]Empty hook 1 Line pull at drum Fempty [kN] 2 Rope speed vempty [m/min] 3 Installed power P [kW] 4 Rating acc. to FEM Section I 100 %Drive unit class Load conditions Running time class
M L T Calculated life time [hour]Approval acc. to classification society Safety against [–]
ABS DNV GL Yield strength Break LRS RMRS Others with
Tdyn Tstat [Nm]Fdyn Fstat [kN]
Scope of supplyMotor Steel mesh guard Lay-on roller Incremental encoderLoad holding valve Rope guard Rope spooling device Hydraulic power packBrake for drive unit Rope drum Rope tension control Frequency controlMotor flange End support bearing Rope Hydraulic controlReaction torque arm End support bearing with plate Rope limit switch ApprovalWinch frame Fail save brake Geared limit switch Material Certificates
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ZOLLERN GmbH & Co. KG
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