ZF Gotha – active throughout the world ....................
Dependable system partner ..........................................
Specialist for lift-truck drive systems .........................
ZF-Ergomat ...................................................................
Drive systems for electric counterbalance lift-trucks
Drive systems for warehouse lift-trucks .....................
Drive systems for special vehicles ...............................
We stack with ZF ..........................................................
Technical data ...............................................................
4
6
8
10
12
14
16
18
20
3
Index
Special VehiclesWarehouse Lift-Trucks
4
ZF Gotha is part of the division Off-Road
Driveline Technology and Axle Systems at ZF
Friedrichshafen AG. ZF Gotha is therefore not
just part of the development resources of the
ZF Group, but also integrated into the interna-
tional sales and service organisation.
As a result, our customers have 26 sales and
more than 500 service locations available –
and most certainly near to you.
Our capable logistics enables us to supply you
with complete drive systems or single compo-
nents throughout the world. The sun never sets
in ZF’s close-mesh service and logistics net-
work!
As a system manufacturer and drives specialist our efforts are dedicated to all
driveline components.
Impressive locationwith international service
ZF is orientated to market needs andconsequently lays great emphasis onpractical experience.
Apart from optimising productionsequences, we lay store by certifica-ted quality management and a testedenvironmental management system.
ZF-Gotha – active throughout the world
5
Located in the heart of Germany
In our highly modern plant at the Gotha site, we have realised a “short-path”
factory. All functional units from development through purchasing, production
and sales to after-sales service are combined here.
We develop, produce, assemble and supply drive systems for industrial trucks
according to customer requirements – all just in time. In this respect we have
defined a quality standard which is regarded as pioneering in our field.
ZF Gotha is one of the most modern sites within the ZF Group.
The highest qualified staff and the latest technology set benchmarks
within a whole industrial field.
6
Computer-aided procedures help toshorten development times.
Qualified staff and the latest develop-ment tools ensure our innovative lead– for the future too.
ZF Gotha – this is where expertise and capability
for drives and running gear for industrial trucks
come together within the ZF Group. This has
enabled ZF to set new benchmarks in the develop-
ment of drive systems for lift-trucks.
As a systems supplier and with our development
capability we offer complete systems, including
wheel, brakes, electric motor, frame plate and steer-
ing motor.
Unbeatable ease-of-use, quiet running and economy
are here the primary development objectives.
With ZF as a dependable system partner, numerous
potential savings open up for the vehicle manufac-
turer, such as reduced costs for development, logis-
tics, assembly and handling. The more extensive is
the co-operation, the greater the resulting synergies.
Highly specialised, perfectly matched individualcomponents are representative of the outstanding
quality of ZF drive systems.
Strong on detailfor more system value
ZF Gotha – dependable system partner
7
State-of-the-art gear-mesh technology ensures constant quiet running
Very quiet running, a long service life and constantly high production quality are the prin-
ciple requirements made on a modern drive. To combat the difficulty of surface deformity
due to heat treatment, which is encountered with the conventional production of gear-
wheels, we grind our gear teeth after hardening. This means that we can produce gears
with an especially high level of quiet running and with a constant quality. The bevel gear
grinding machines are directly linked to the design programs used by the design calcula-
tion specialists.
Comprehensive system integration and optimised gear-mesh technology
demonstrate the high standards of ZF drive systems.
8
Online evaluation of an acousticmeasurement.
Examining efficiency on one of ourtest rigs.
Our systems are precisely tuned to the customer’s
concept and requirements and are developed in
simultaneous engineering with the vehicle manu-
facturers.
The most modern development tools, strength
calculations following each stage of design and
close communication throughout the project
shorten the development times whilst increasing
efficiency and versatility. This means that pro-
cess optimisation is possible with regard to costs,
time and quality.
To simulate the levels of noise and efficiency
during the design phase, we use special software
tools in order to be able to assess and optimise
the influence and effects of modified parameters
at an early stage. Also, we have access to the
wealth of experience from colleagues in other
parts of the ZF Group and in the Central Re-
search and Development Department.
The optimised ZF chain of production using thelatest tools enables the development of solutions
specific to requirements.
Tailor-made quality– always customer-orientated
ZF-Gotha – Specialist for lift-truck drive systems
9
Tested through and through
Our systems are thoroughly tested before they are released for series production.
We compress testing time, for example realistic continuous stresses in accelerated
tests on fatigue test rigs. To do this, the demands of the daily operating routine are
simulated. The advantage of this testing procedure is that it avoids protracted,
expensive practical vehicle tests.
In the test laboratory the drive components are tested under simulated
real conditions for noise emission, loading capacity and quiet running.
10
Axle as single-motor frontwheel drive
Rearwheel servodrive
The quality of the lift-truck is determined by the com-
ponents used.
Anyone watching lift-trucks at work soon realises that
the drive units must be subjected to enormous stresses
in daily operation.
The functional capability of the systems under these
extreme requirements demands innovative and opti-
mised solutions with regard to mounting, economy,
reliability and service-friendliness.
The ZF Ergomat range of transmissions and drives
was developed to meet these challenges. ZF-Ergomat
is a complete range of models offering solutions for
all classes of lift-trucks.
As a systems supplier and with our development capa-
bility we offer complete systems, including wheel,
brakes, electric motor, frame plate and steering unit.
Along with the system responsibility, we then relieve
the customer of the effort needed for the whole logis-
tics for additional components. In a lift-truck there
can never be too much of ZF!
ZF-ERGOMAT combinesERGOnomics with efficient
MATerial transfer.
Lift-truck expertise formanoeuvrability in all classes
11
System solutions at a glance:
Rearwheel drive system Dual-motor frontwheel drive system Single-motor frontwheel drive system
Comprehensive system integration and consistent process optimisation are the
prerequisites for high customer benefits.
12
The challenge for drive systems lies in the compact construction in
three or four-wheel counterbalance lift trucks. This is because hand-
ling heavy loads demands soft, stepless manoeuvring with precise,
accurately controlled actions. In this respect, the ZF-Ergomat range
offers rugged and compact solutions.
With frontwheel-drive vehicles the GP planetary-spur gear is instal-
led in pairs. We can produce customised transmission variants using
spur gears. The wet-running multi-disc brake ensures increased
braking power and operates almost without wear. An optimised
gear-mesh geometry produces a noticeable reduction in noise.
As an alternative to the electrical single-wheel drive, ZF offers the
GK range as rearwheel servodrive. The finely graded range enables
the gear unit to be closely matched in size and performance to suit
the vehicle parameters. For AC technology high transmission ratios
can also be provided. With a vertical arrangement in the vehicle, the
small operating radius enables the available installation space to be
used effectively, giving particularly high manoeuvrability.
Electric lift-trucks with frontwheel drive demand a compactconstruction with minimised external dimensions. So there is
little space left for the installation of the drive.
Compact, manoeuvrable, powerful– the answer lies in the detail
ZF-Drive systems for electric counterbalance lift-trucks
Technical Specifications: from p. 20
GK 15
The Gleason hypoid gear drive on
the crown wheel provides high
strength under shock loads and
higher power transfer due to a
greater transmission ratio.
GK 25 LD
The fully integrated helical gear
stage enables the gradual loading
and relieving of the teeth, giving
the effects of low noise, extremely
high load-bearing capability and
smooth running at high circumfe-
rential speeds.
13
GP 20
The combination of spur-gear and plane-
tary drive fulfils the fundamental requi-
rement for an installation width of less
than 1,000 mm.
The planetary gear with wheel bearings
is fully integrated into the wheel. In con-
trast the spur gear which is very narrow
in terms of space requirement is positio-
ned directly adjacent to the wheel.
14
Just-in-time production and supply, customised production from a batch
size of one up to mass production along with the networking of supp-
liers and customers cannot be mastered these days without highly mo-
dern materials handling technology and logistics. When lift-trucks are
on the move, components from ZF-Ergomat very often come into play.
The GK range represents the core of the classical drive with bogie
wheel, brake and vertically mounted electric motor. Consequently, the
spur-bevel gear drive enables the design of very compact units. Easy
fitting to the vehicle is taken as a matter of course, as is the unbeatable,
small operating circle and the service-friendly concept.
For transporting extremely heavy loads, we offer the rugged planetary
wheel-hub gear in the HFP range. Its coaxial in-line design facilitates
high lifting loads and the use of motors with large control ranges and
power reserves.
Our traction drive HFD 80 is predestined for the requirements of hand-
guided pallet-trucks and lift-trucks. The concept is designed such that
the standard version can be employed almost without modification.
Between the racks every centimetre counts towards speedand manoeuvrability in the narrow gangways and tight
corners. The trend is demanding integrated drive systems.
Precision means low play– silently through all gangways
ZF-Drive systems for warehouse lift-trucks
Technical Specifications: from p. 20
15
HFP 40
The basic unit consists of a planetary
gear with high power reserves, quiet
running and high operational reliabi-
lity. Customised designs are possible
through varied transmission variants.
Four types for wheel loads up to
3,200 kg can be supplied.
GK 5
The drive system for light pallet-
trucks up to 700 kg wheel load
consists of a gear unit with elec-
tric motor, wheel and brake. With
a drawbar connection, the system
can be easily expanded.
HFD 80
The complete system unit
consists of a two-stage gear
unit with belt and spur-gear
stages, stored-spring brake,
tillerbar interface, swivel
bearing and wheel.
16
CLEANING EQUIPMENT
The greatest manoeuvrability in tight spaces is essential for sweepers.
The GK range offers ideal features in this respect. With the vertical
mounting orientation for the electric motors they achieve the smallest
possible operating circle, giving extreme mobility.
ELECTRIC TRACTOR UNITS
High performance capabilities with the lowest width and greatest
manoeuvrability enables towing tractors to efficiently transport peo-
ple and goods in almost all industrial and commercial areas, public
amenities and in municipal applications. The driveline solutions in
the GP range are ideally suited to these tasks.
AGVs
The technology of automatically guided vehicles is suited to the most
varied tasks: It is employed for horizontal transport, with lifting de-
vices for warehouse duties or also as a working platform for installa-
tion. To meet these demands you can make use of the well-proven
HFP range with its very low installation height.
Power plus intelligence is an increasingly recurring mantra for requirements on powered machines which also demand a
high level of adaptability in terms of driveline technology.
Variety and versatility– individual drives technology
ZF-Drive systems for special vehicles
Technical Specifications: from p. 20
17
HFP 40
The basic unit consists of a planetary gear with high
power reserves, quiet running and high operational
reliability. Customised designs are possible through
varied transmission variants. Four types for wheel
loads up to 3,200 kg can be supplied.
GK 25 LD
The fully integrated helical gear
stage enables the gradual loading
and relieving of the teeth, giving
the effects of low noise, extremely
high load-bearing capability and
smooth running at high circumfe-
rential speeds.
GP 20
The combination of spur-gear and plane-
tary drive fulfils the fundamental requi-
rement for an installation width of less
than 1,000 mm.
The planetary gear with wheel bearings
is fully integrated into the wheel. In con-
trast the spur gear which is very narrow
in terms of space requirement is positio-
ned directly adjacent to the wheel.
18 Proven a thousand times overin everyday use...
Baumann Clark
JungheBT
IndumatHakoFenwick
Daewoo
HangzouHyster
CesabCAT
Blue Giant
Crown
BT
Cesab
Jungheinrich
Crown
Hyster
Indumat
We stack with ZF
Fiat
19
Kalmar
Mitsubishiinrich
Nuova Detas
Lugli SchaeffSIP
Steinbock
Still
TCM
YaleTennant
LocLinde
Rocla
Montini
Lugli
Montini Steinbock
Still
BT-Cesab
Daewoo
MCFFenwick
FEATURES:
• very small gear set width due
to the innovative gear drive
concept
• customer specific gear ratios
are realized within the helical
gear set step
• further noise level reduction
thanks to optimised gear
geometry
• increasing braking power
through wet-running multiple
disk brake
• maintenance-free operation
with rugged gearbox compo-
nents
20
Front Drive Concept forElectric Counterbalance Lift-Trucks up to 2t
2,000
2,500
5
1,320
26.6
31
ZF spur gear planetary drive GP 20LIFT CAPACITY* (max.)
WHEEL LOAD (max.)
DRIVING POWER**
WHEEL TORQUE ACCELERATION
GEAR RATIO (max.)
WEIGHT without oil
* depending on configuration of vehicle** depending on configuration of motor and controller
kg
kg
kW
Nm
i
kg
GP 20
GP Series
Side view
Subject to technical modifications. For installation investigation purposes and in order to ascertain final version, please request relevant installation drawings.
Dimensions in mm
253.4
228
190
Ø 1
45
M14
x1.5
(5x
)
Ø 1
10h1
0
258 (200/50-10)
243.5 (18x7-8)
SER.N
TYPE
ZF GOTHA GMBHMADE IN GERMANY
21
Steerable Drive Systems forLift-Trucks and AGVs
1,000
700
0.8
220
37
110
15
ZF-ERGOMAT GK-Series GK 51,000-1,200
1,100
1.2
490
22
125
24
GK 101,000-1,500
1,400
2
564
25
140
37
GK 151,500-2,000
2,000
3.2
980
24
168
46
GK 202,000-3,000
2,600
4.5
1,400
24
182
57
GK 252,000-3,000
2,200
4.5
1,400
25
205
55
GK 25LDLIFT CAPACITY* (max.)
WHEEL LOAD (max.)
DRIVING POWER**
WHEEL TORQUE ACCELERATION
GEAR RATIO (max.)
ENVELOPE CIRCLE
WEIGHT without oil
* depending on configuration of vehicle** depending on configuration of motor and controller
kg
kg
kW
Nm
i
mm
kg
GK-Series
Subject to technical modifications. For installation investigation purposes and in order to ascertain final version, please request relevant installation drawings.
GK 20Side view
A
C
DE
B
FEATURES:
• smallest envelope possible due to
vertical mounting position of the
electric motor
• customised gear ratio reduction
and layout for the drive system by
flexible modular GK gearbox series
• minimum noise emission of the
gearbox by using ground gears
• serviceable turntable bearing for
longer life
• alternative chain or gear steering
• no additional components are
required due to integrated chain
flange with adjustable chain anchor
• the conception of the motor place-
ment is easy to service
• very low maintenance
3,000-3,500
3,400
6
1,700
25
208
66
GK 30
200
65
148
169
183
GK 5Installation dimensions in mm:
ABCDE
230
75
197
220
240
GK 10254
125
208
220
240
GK 15310
140
249
270
289.5
GK 20350
140
275.5
270
289.5
GK 25457
178
324
270
289.5
GK 25LDReifendurchmesser (max.)
Reifenbreite
Mitte Radwelle bis zur Schnittstelle zum Fahrzeug
Lochkreisdurchmesser Drehkranzlager
Durchmesser Drehkranzlager
400
160
305.5
270
289.5
GK 30
FEATURES:
• compact arrangement for gear drive components featuring small envelope circle and overall size
• low stress for the pivot bearing with the design position directly over the drive wheel
• integrated brake dispenses with the need for additional braking
• minimum noise emission due to belt drive reduction in 1st step
• almost maintenance-free due to lifetime lubrication in gearbox and pivot bearing
22
Drive System fortiller-bar operated Lift-Trucks
ZF helical bevel gear drive HFD 80
HFD 80
HFD 80
Side view
Subject to technical modifications. For installation investigation purposes and in order to ascertain final version, please request relevant installation drawings.
800
0.9
350
25
18
WHEEL LOAD (max.)
DRIVING POWER**
WHEEL TORQUE ACCELERATION
GEAR RATIO (max.)
WEIGHT without oil
** depending on configuration of motor and controller
kg
kW
Nm
i
kg
498.
7
198.
3
80
105
Ø 230
132
75max
. Mot
or Ø
150
Dimensions in mm
23
Planetary Wheel-hub Drive Systems for Warehouse Lift-Trucks and AGVs
ZF planetary wheel-hub drive0.8
210
22.9
195
11.5
HFP 100.8
210
22.9
195
HFP 10A/S1.1
540
34
256
21
HFP 203
1,210
36.8
209-285
44
HFP 404.5
2,040
18.8
292.5
65
HFP 50DRIVING POWER**
WHEEL TORQUE ACCELERATION
GEAR RATIO (max.)
ENVELOPE CIRCLE
WEIGHT without oil
** depending on configuration of motor and controller
FEATURES:
• extremely low installation
high by housing electric
motor and brake into the
wheel hub
• high efficiency of the drive
unit
• minimum noise emission of
the gearbox
• simple installation of the
drive unit in the vehicle
using a standardized joints
• adjustable braking torque
• customized design to
customer’s data
• accessory range includes
tachometer, angle encoder,
line-driver, adjustable chain
anchor and several kinds of
brake
HFP-Series
Subject to technical modifications. For installation investigation purposes and in order to ascertain final version, please request relevant installation drawings.
HFP-SeriesSide view
kW
Nm
i
mm
kg
Installation dimensions in mm:
ABCDE
225
70
150
-
-
HFP 10225
70
192
-
-
HFP 10A/S260
100
189.5
270
289.5
HFP 20406
406
255
285
310
HFP 50Reifendurchmesser (max.)
Reifenbreite
Mitte Radwelle bis zur Schnittstelle zum Fahrzeug
Lochkreisdurchmesser Drehkranzlager
Durchmesser Drehkranzlager
381
127
245
270
289.5
HFP 40
B
E
C
A
D
TRANSMISSION AND CHASSIS TECHNOLOGY
ZF GOTHA GMBHLift-Truck Drives
Karl-Liebknecht-Str. 26 • D-99867 GothaTel. +49 (0)36 21 311-0
Fax +49 (0)36 21 311-45 99e-Mail: [email protected]
[email protected]/a-passau T
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ight
is
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to
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and
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