WINCH GEARBOXES

TRANSMISSION TECHNOLOGY

The Zollern factories

The ZOLLERN GmbH & Co. KG is a company with worldwide operations, employing over 2400 employees in the
business fields of transmission technology (automation,
gears and winches, friction bearing technology), engineering elements, foundry technology and steel profiles.

WINCHES AND GEARBOXES

Winches and Gearboxes

Design and construction of rope winches

with flange drive gearbox

Integrated rope drum

Rope fixing

Rope grooves and rope

Application factor K for lifting appliances

10

Guidance for group classification of a mechanism

10

Calculation of rope load Fnom on the rope drum

11

Calculation of rope diameters and rope drum

diameters in acc. with DIN 15020

11

Winding direction on rope drums

Available ratios for winches
Hydraulic control systems for rope winches
Recommended lubricants for ZOLLERN rope winches
Accessories for ZOLLERN Winches
Essential design data

WINCH GEARBOXES

11
15
16
16
16
17

2 3

WINCHES AND GEARBOXES

ZOLLERN Winches and Gears

have proved that they can give the best performance even under the most arduous and unfavourable conditions. Their outstanding features
and advantages are
compact, functional construction
rigid winch construction
modular design of gear unit
high efficiency
ease of maintenance
long service life
functional design
The designer is thus offered on easily installed
unit providing a cost-effective solution, even
where space is limited.

Applications:
Truck-mounted/ mobile cranes
Derrick and shipboard cranes
Dockyard and wharf cranes
Building/ constructional cranes and
materials handling equipment
Recovery and towing vehicles
Goods and personnel lifts
Container handling cranes
Loading and cargo-handling cranes
The planet gear units used in winches can also
be used for the slewing drives and traversing
units of mobile cranes and other vehicles, so that
all the gear drives are of the same construction
and incorporate the same basic components.

DESIGN AND CONSTRUCTION

OF ROPE WINCHES WITH
FLANGE DRIVE GEARBOX

2 stage
planetary gearbox
Reduction ratios from 13.1:1 to 34.5:1
Gearbox mounted inside winch drum, Parking Brake
and Hydraulic motor flange mounted externally.
Input and output in opposite sense of rotation.
Backstop option.

3 stage
planetary gearbox
Reduction ratios from 45.0:1 to 176:1
Gearbox mounted inside winch drum, Parking Brake
and Hydraulic motor flange mounted externally.
Input and output in opposite sense of rotation.
Backstop option.

2 stage
planetary gearbox
with spur stage input
Reduction ratios from 40:1 to 150:1
Gearbox mounted inside winch drum, Parking Brake
and Hydraulic motor flange mounted externally, twin
motor/brake option. Input and output in opposite sense
of rotation. Backstop option.

WINCH GEARBOXES

Winch range

Lubrication

Output torques: 1.900 to 1.400.000 Nm. Rope load at the

drum periphery: 20 kN to 1.700 kN. When calculating the
rope load at the drum periphery, the mass of the weightcarrying and stop media as well as the efficiency of the
rope drive must be allowed for (see page 11).

Gearbox and input drum support bearings are splash lubricated within the gearbox oil bath. The end support bearing
is greased and can be supplied as a sealed for life unit on
request. Recommended oils can be found from the table on
page 16.

Notes

Oil maintenance

The output torques Tdyn, listed on pages 12/13 are based

on FEM Standards I and IX as well as DIN 15020/ load
conditions L2/ running time classification T5, in accordance
with Drive unit group M5. Ambient temperature + 20 C
(FEM - Federation Europeenne de la Manutention).

An oil fill pipe is provided on the gear unit input flange.

Service intervals are given on page 16.

Oil level
A dip stick type level is provided.

4 5

Gear tooth forms

Cooling

Selected for optimum surface durability and bending

strength; also for minimum sliding velocity, according
DIN 3990. External gear teeth are case-hardened and
ground; internal gears annealed and nitride hardened.

In high ambient temperatures or where the unit is directly

exposed to sunlight forced cooling may be considered if the
duty factor is high. Should cooling be required a cooler can
be provided with the necessary gear unit connections.

Bearings

Input drive

All 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.

A choice of hydraulic motor, electric motor or free-shaft.

Input shaft with keyway or splined according to DIN 5480.
A flexible coupling is used for link-up to the electric motor
to connect the gear input shaft with the electric motor.

Efficiency

Seals

The efficiency of the gearstage is 98% and about 99% for

the drum bearings including seals. Example: Rope winch
with 2 planetary gear stages
overall = 0,98 x 0,98 x 0,99 = 0,95

Input and output are protected with radial shaft seals of

double lip type. This prevents oil leakage and protects the
unit from ingress of dirt or water. Where the unit is be used
offshore or on-ship additional protection is provided with
greased felt strips and secondary radial seals.

Mounting position

Brakes

Horizontal

A 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 or barrel brakes with direct connection to the
rope drum can be fitted for additional safety back up.

Winch fitted between flanges

The flange at the driven end transmits the lateral force
and reaction torque safely to the mounting structure. The
opposite flange can be removed to enable the winch to be
mounted and compensates for length and angle tolerances.
It transmits lateral forces only.

Backstop

Electric motor

For special applications a backstop can be incorporated

between the gear transmission and the parking brake.
It operates as follows.

Standard electric motors cannot be mounted inside the

winch drum. As opposed to Electric-Compact-Winch.

Operating conditions
Lifting of load
- Parking brake closed
- Backstop open

Lowering of load
- Parking brake open
- Backstop closed

Geared limit switch

a) electrical
an electrical signal can be generated at various rope travel
or end limit position. The switch positions are infinitely adjustable. The switch is flange mounted with drive from the
rope drum through the bearing support housing.
b) hydraulic
ZOLLERN geared limit switch operating as the electrical
version with a hydraulic signal.

The gear systems are designed for use in Central European

conditions. Permissible oil temperatures -20C to + 70C.
Environmental factors such as salt water, salt-laden air,
dust, excessive air pressure, heavy vibration, high shock
loads and extreme ambient temperatures, corrosive media,
etc. must be stated.

Paint Primer
This is a specially developed multi-primer with a two-component zinc-dust epoxy resin base. Colour: light silver-grey.
A two component epoxy resin is most suitable for the finish
coat.

Choice of gear unit

In order to select the correct rope winch for a given application the output torque Tcalc calculated from the rope load
and rope drum diameter must be multiplied by the factor K.
Tdyn = Tcalc x K
For application factor K and calculation of the rope load
see pages 10/11.

WINCH GEARBOXES

INTEGRATED ROPE DRUM

6 7

With normal grooves

With special grooves

Raising wedge

This is cast on to the drum on the opposite

side of the rope entry and guides the rope
from the first to the second layer.

Dummy-lay filling wedge

With grooves of this kind the difficulties encountered in

multi-layer winding on to grooves of the usual kind do not
arise, as the crossover points of the rope in each layer always lie in the same section of the drum and the lift of the
rope into the next layer is precisely defined. 8 and more
layers can be accommodated without difficulty.

Material for rope drum:

- cast material (EN-GJS-400-15; EN-GJS-600-3; )
- steel (S355JO; )
Other material on request

This is cast on to the drum at the rope entry

point and serves to fill the gap between the
drum flange and the first rope turn.

1,5 . d
d

Rope drum diameter D1

Drum flange diameter D2

D1 = 20 x d
or as specified

D2 = D1 + 2 (z + 1) d

Length of rope

D2

D1

including 3 safety turns

LS =
LS
L2
D1
d

( )(
L2
-a
p

D1 + 0,866 . d (n-1) n .

= Length of rope [mm]

= Length of drum [mm]
= Diameter of drum [mm]
= Diameter of rope [mm]

p
n
a

= Pitch of rope groove [mm]

= Number of rope layers [-]
= 1 for normal grooves [-]
= 0,5 for special grooves

ROPE FIXING

Wedge lock for rope diameters

up to 30 mm

Clamps for ropes with a diameter

of more than 30 mm.

a) on the outside of the drum flange

a) on the outside of the drum flange

b) on the inside of the drum flange

(for up to 2 rope layers only)

b) on the inside of the drum flange

(for up to 2 rope layers)

c) within the barrel shell

c) on the drum by means of clamps. In an emergency the

rope can be pulled out of the fixing without damage to
either rope or drum.

WINCH GEARBOXES

8 9

ROPE GROOVES
AND ROPE

Rope grooves

Deflection angle

On cast drums cleanly cast and trimmed, and at the flash

line carefully ground. On welded drums all edges are deburred and radiussed.

To achieve acceptable rope winding

Rope groove lead/ pitch

Right-hand lead on standard design

- the deflection angle must with special grooves be not

less than 0,5 in order to prevent the rope from riding up
the drum flange and to ensure that it is guided securely on
to the next layer.
- the deflection angle must not exceed 1,5 in order to
prevent the rope in the first layer being pulled against the
grooves and, where a number of layers occur, to enable
even winding up to the drum flanges. If the deflection angle
is greater, the working life of the rope will be negatively
affected.

Left hand lead

Direction of rope lay

For example:

right-hand
rope lay

left-hand
rope lay

APPLICATION FACTOR K FOR LIFTING APPLIANCES

Symbol
Running time
classification

Mean running time per day

in hours, related to one year
Life in hours
8 Years, 200 Days/Year

Loading cond.

log

L2

L3

log

T4

T5

T6

T7

T8

over 0,25
to 0,5

over 0,5
to 1

over 1
to 2

over 2
to 4

over 4
to 8

over 8
to 16

over 16

400 to
800

800 to
1 600

1 600 to
3 200

3 200 to
6 300

6 300 to
12 500

12 500 to
25 000

25 000 to
50 000

Drive unit class 1)

to 0,125

M1
0,90

M2
0,90

M3
0,92

M4
1

M5
1,07

M6
1,18

M7
1,24

0,125 to 0,250

M2
0,90

M3
0,92

M4
0,95

M5
1

M6
1,14

M7
1,24

M8
1,48

0,250 to 0,500

M3
0,94

M4
1

M5
1,07

M6
1,18

M7
1,24

M8
1,48

M8
1,56

0,500 to 1,000

M4
1,04

M5
1,07

M6
1,18

M7
1,24

M8
1,48

M8
1,65

M8
1,88

log

log

L4

T3

km
M

L1

T2

1)

(Example: M5-L2-T5 is equivalent to k=1)

GUIDANCE FOR GROUP CLASSIFICATION OF A MECHANISM

According FEM section I, 3rd edition, table T.2.1.3.5.

Type of appliance
Designation

Particulars concerning nature of use (1)

Erection cranes

Type of mechanism
Hoisting

Slewing

Luffing

Traverse

Travel

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

scrapyard cranes

M8

M6

M6 M7

M7 M8

M6 M7
M4 M5

M5 M6
M4 M5

M3 M4

M6 M7
M4 M5

M4 M5
M4 M5

M8

M5 M6

M3 M4

M7 M8

M4 M5

Bridge cranes for unloading,

bridge cranes for containers
Other bridge cranes
(with crab and/or slewing jib crane)

a) Hook or spreader duty

b) Hook duty

Bridge cranes for unloading, bridge cranes

(with crab and/or slewing jib crane)

Grab or magnet

Drydock cranes, shipyard jib cranes,

jib cranes for dismantling

Hook duty

M5 M6

M4 M5

M4 M5

M4 M5

M5 M6

Dockside cranes (slewing, on gantry, etc.),

floating cranes and pontoon derricks

Hook duty

M6 M7

M5 M6

M5 M6

M3 M4

Dockside cranes (slewing, on gantry, etc.),

floating cranes and pontoon derricks

Grab or magnet

M7 M8

M6 M7

M6 M7

M4 M5

M3 M4

M3 M4

M3 M4

M4

M3 M4

M3 M4

M2

M3

M5 M6

M3 M4

M3 M4

M4 M5

M3 M4

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

M3 M4

M2 M3

M2 M3

Floating cranes and pontoon derricks for

very heavy loads (usually greater than 100 t)
Deck cranes

Hook duty

Deck cranes

Grab or magnet

Tower cranes for building

Mobile cranes

WINCH GEARBOXES

Hook

CALCULATION OF ROPE LOAD FNOM ON THE ROPE DRUM

Rope load Fnom

Efficiency of rope drives

1
n s

Fnom = (mload + mtackle) g

[N]

s = (R)i F = (R)i

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 strands
and rope pulleys for a single rope running on to a rope
drum (see illustration)

1 1 - (R)n

n
1 - R

R is the efficiency of a single rope pulley

F is the efficiency of the pulley block
s is the efficiency of the rope drive

The efficiency of a rope pulley depends not only from its

type of bearing used in it (friction or antifriction), but also
upon 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 R = 0,96
with anti-friction bearings R = 0,98

2-stranded pulley block

n=2

Twin pulley tackle

4-stranded, comprising
2 pulley blocks each 2-stranded
2 x (n = 2)

For compensating pulleys no efficiency value

must be considered.
For = coefficient of vibration see FEM-section 1
2nd Edition Dec. 1970, Page 15

CALCULATION OF ROPE DIAMETERS AND

ROPE DRUM DIAMETERS IN ACC. WITH DIN 15020
Coefficient c

Coefficient h1

Rope diameter dmin = c S

Gear
drive
group

S = Rope pull in N

C = Coefficient in mm/ N

Non rotationfree wire ropes

Rotationfree wire ropes

Coefficient h2 = 1

Rope drum diameter Dmin = h1 h2 dmin

Non
rotationfree
wire rope

Rotationfree
or low-rotation

Nominal strength of individual wires in N/mm2

1 570
1 770
1 960
2 160
2 450

1 570

1 770

wire rope
1 960

1 Bm

0,0850

0,0900

0,0850

0,0800

14

16

1 Am

0,0900

0,0900

16

18

0,0800

0,0750

0,0850

0,0950

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

Left-hand

Right-hand
Rope pull overshot

Rope entry

Rope pull undershot

Rope entry

Rope pull overshot

Rope entry

Rope pull undershot

Rope entry

10 11

L 3 stage unit
L 2 stage unit

Length depending
on motor/brake size

A
M max.
X

Flange connection

F8

F7

Flange connection

F
S6

D0

Optional end
support bearing

G6
F6
F5
Flange connection

Flange connection
G5

S5
T2

ZHP
EG
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

Nominal gearbox ratings

Output
torque (Nm)

Typical
line
pull

Tdyn. T (max.stat.)
I 70
I 70
F(nom)
I > 70
I > 70
(kN)
1 900
3000
20

4 500
7200
37
4 700
7 500
39
7 100
11 500
47
7 400
12 000
49
11 000
17 500
66
11 500
18 500
69
19 000
30 500
97
19 500
31 000
101
23 500
38 000
109
24 000
38 500
112
33 000
53 000
137
34 000
54 000
141
45 000
72 000
173
46 000
73 000
177
57 000
92 000
199
58 000
93 000
202
93 500 149000
279
96 000 153 000
288
136 000 217 000
358
139 000 222 500
366
198 000 317 000
476
200 000 320 000
481
247 000 395 000
524
250 000 400 000
531
336 000 537 000
651
340 000 544 000
659
555 000 888 000
926
560 000 896 000
935

GG

T1

T2

Flange connection Gear unit to frame

Bolts class 10.9

Max
input D O
G1
speed approx. location

G2
pcd

G3
outer

0,2

180

125

145

260

155

185

300

190

225

340

200

255

390

230

280

440

270

320

480

300

350

520

330

390

570

355

420

670

430

480

770

515

565

830

580

630

930

670

720

1030

720

770

1200

840

900

G4
fixing

G5

G6

Flange connection
Gear unit to drum

SS
S1
S2
location pcd

S3
outer

S4
fixing

FF
S5

S6

F1
location

F2
pcd

0,2

nmax.
rpm

Depending on motor and brake arrangement

20005000 rpm

TYPE

30
167 12 * M 10
20
213 16 * M 12
20
255 16 * M 16
20
285 16 * M 16
15
315 22 * M 16
15
355 22 * M 16
15
385 22 * M 20
15
425 22 * M 20
15
460 22 * M 24
15
530 22 * M 24
15
615 24 * M 30
15
680 24 * M 30
12
770 30 * M 30
10
820 36 * M 30
10
960 36 * M 36

0,2

16

145

185

24

225

245

25

265

290

25

295

320

25

330

360

25

370

400

30

400

440

30

440

480

38

470

520

38

550

590

47

640

690

47

700

755

47

790

840

47

850

900

56

1000

1055

30
203 12 * 11
20
265 18 * 11
15
310 24 * 14
15
340 24 * 14
20
390 18 * 18
15
430 24 * 18
20
480 18 * 18
15
520 24 * 22
20
560 18 * 26
15
630 24 * 26
15
750 24 * 33
15
815 24 * 33
12
890 30 * 33
10
950 36 * 33
10
1120 36 * 39

10

120

140

10

150

175

12

175

200

12

175

200

16

200

230

16

200

230

20

230

260

20

260

310

24

260

310

24

300

350

30

325

375

30

325

375

30

375

435

30

375

435

36

430

490

4.38
4.40
Nominal ratings to FEM section I
3rd edition 1987

Group classification M5, state of loading L 2

class of utilisation T5, (nout mean = 25 rpm; P [kW] = const.)

WINCH GEARBOXES

Winch corresponding to European Norm

Draft CEN TC 151 (Edition 14/12/90)

ZOLLERN have a policy of continuous

product improvement, and detail may
be changed without notice.

H2
H2

G4
Cut out for lube oil pipework
4.13 to 4.29 required in
winch frame
From 4.31 oil filling
within gear flange

H1

12 13

Flange Connection End support bearing

to frame Bolts class 8.8
F3
outer

F4
fixing

F5

F6

F7

F8

160
200
225
225
260
260
290
360
360
400
425
425
500
500
550

Assembly length E = T1 + 2 T2 + W
depending on design
H1

H2

Mmax.

T1
min.
2-sta- 3-stages
ges

T2

W
L
approx.
frame 2-sta- 3-stathick- ges
ges

X
min.

ZHP
EG

ness

60
6*9
60
6 * 11
60
6 * 11
60
6 * 11
60
6 * 14
60
6 * 14
60
6 * 18
60
6 * 22
60
6 * 22
60
6 * 22
60
6 * 26
60
6 * 26
60
6 * 33
60
6 * 33
60
6 * 33

TYPE

4.13

12

20

36

40

55

130

160

70

10

165

10

15

25

50

26

93,5

55

70

140

180

250

85

15

220

290

15

15

10

30

64

26

111

60

75

170

200

280

95

15

255

330

15

15

10

30

64

26

117

60

75

140

230

320

95

15

275

375

15

18

12

35

71

26

132

60

75

170

250

350

100

15

305

415

15

18

12

35

71

26

152

60

80

170

260

370

100

20

315

425

20

18

15

40

78

30

168

75

95

160

270

400

120

20

350

485

20

25

15

50

92

30

184

75

95

210

330

440

120

20

400

505

20

25

15

50

92

30

195,5

90

110

200

330

440

140

20

425

545

20

30

15

50

104

30

233

90

115

200

360

520

145

25

455

620

25

35

15

70

134

235

110

140

200

360

540

180

30

500

685

30

35

15

70

134

268

110

140

150

440

630

180

30

565

750

30

40

15

80

144

298

110

160

150

465

665

180

40

670

870

40

40

15

80

144

335

120

160

140

480

680

200

40

685

895

40

40

15

90

180

385

140

190

110

660

920

240

50

850

1100

50

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

Please refer to your ZOLLERN representative

4.38

Please refer to your ZOLLERN representative

4.40

Installation instructions
To ensure correct operation of the winch, the frame location
centres must be within the specified tolerances and the flange pieces square to the base plate. Care should be taken to
design an adequately rigid support and sub support as

G/Box flange connection

deflections during installation and subsequent operation can

take up working tolerances. These are given in the accompanying table.

Support frame connection

Type
ZHP

AB

AB

Maximum permitted deviation H

from the centreline in relation to L1

Type
ZHP

L1

250

500

750

0,1

0,2

0,2

0,3

4.13

1 000 1 500 2 000 2 500

4.13

0,1

0,3

20

0,2

0,2

60

4.15

0,1

0,3

20

0,2

0,3

60

0,2

0,2

0,3

4.15

4.19

0,1

0,4

20

0,2

0,3

60

0,2

0,2

0,3

4.19

4.20

0,1

0,4

20

0,2

0,3

60

0,2

0,2

0,3

0,4

4.20

4.22

0,1

0,4

15

0,2

0,3

60

0,2

0,2

0,3

0,4

4.22

4.24

0,1

0,4

15

0,2

0,3

60

0,2

0,3

0,4

0,5

4.24

4.25

0,1

0,5

15

0,4

0,4

60

0,2

0,3

0,4

0,5

4.25

4.26

0,1

0,5

15

0,4

0,5

60

0,2

0,3

0,4

0,5

4.26

4.27

0,1

0,5

15

0,4

0,5

60

0,3

0,4

0,5

4.27

4.29

0,1

0,5

15

0,4

0,5

60

0,3

0,4

0,5

4.29

4.31

0,2

0,5

15

0,6

0,5

60

0,3

0,4

0,5

4.31

4.32

0,2

0,5

15

0,6

0,5

60

0,3

0,4

0,5

0,7

4.32

4.33

0,2

0,5

12

0,6

0,5

60

0,3

0,4

0,5

0,7

4.33

4.34

0,2

0,5

10

0,6

0,5

60

0,3

0,4

0,5

0,7

4.34

4.36

0,3

0,5

10

0,8

0,5

60

0,3

0,4

0,5

0,7

4.36

0,1 B

0,2

The fixing hole centres should lie within 0,1 of a

theoretical cylinder about the winch centreline.

AB

The locating flange diameter should be flat

within 0,2 about the winch centreline.

Surface to kept free of oil/ grease

Surface to kept free of oil/ grease

F2

B
A

F1

G1

G2

G4

F4

AB

AB
L1

WINCH GEARBOXES

AVAILABLE RATIOS FOR WINCHES

Type

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

approx.
13
15
18
21
25

35
45

Gear unit ratios i

53
63
70
83
84
95
99
107
113
114
129
136
147
176

Please refer to your ZOLLERN representative

29

14 15

HYDRAULIC CONTROL SYSTEMS FOR ROPE WINCHES

open loop

closed loop

Simplified view

RECOMMENDED LUBRICANTS FOR ZOLLERN ROPE WINCHES

Type/Specification

Aral

Avia

BP

Chevron

Esso

SAE 90 EP *
MIL-L-2105 B

ARAL Gear oil

Hyp 90

AVIA Gear oil

Hypoid 90 EP

BP Multi-purpose
gear oil
EP SAE 90

CHEVRON Universal
gear lubricant
SAE 90

ESSO Gear oil

GX 90

Lith. MZ-Grease NLGI 3

K 2 K DIN 51825

ARAL
Multi-purpose grease
ARAL Grease HL 3

AVIA
Multi-purpose grease

BP Multi-purpose
grease L 3
BP Energr. LS 3

CHEVRON
Dura-Lith
Grease 3

Beacon 3
ESSO
Multi-purpose grease

Type/Specification

Fuchs

GULF

Mobil

Shell

Texaco

SAE 90 EP *
MIL-L-2105 B

FUCHS Gear oil

Hypoid EW
SAE 90

GULF Multi-Purpose
gear lubricant
SAE 90

MOBILUBE
HD 90

SHELL Spirax
HD 90

Multigear
lubricant EP 90

Lith. MZ-Grease NLGI 3

K 2 K DIN 51825

FUCHS Grease
FWA 220 FUCHS
Multi-purpose grease

GULF Crown
Grease No. 3

Mobilgrease
MP
Mobilux

Shell Retinax A
SHELL Alvania
Grease R 3

Marfak All
Purpose
Glissandro FL 30

* Mineral oil based, before using biodegradable oil (e.g. synthetic oil)
please consult the manufacturer

Lubrication frequency
Oil: 1st oil change after 200, 2nd oil change after 1000, further oil changes
after every 1000 operating hours; at least once a year.
Grease: Once a week or on recommissioning.

ACCESSORIES FOR ZOLLERN WINCHES (ON REQUEST)

Winch frame
Lay on roller
Spooling guide
Over centre valve
Rope pay out limit switch
Safety disc-brake

WINCH GEARBOXES

Drum rotation limit switch (hydraulic/ electric)

Bevel input gearbox
Change speed gearbox (manual)
Change speed gearbox (hydraulic)
Differential speed drive
(Vario-speed-winch)

ZOLLERN Rope winches

Essential design data
Company/Address
Proper department
Number of inquiry
Demand
Application

Person concerned
Telephone-No.
Email
Used for

Date

(e.g. mobile crane, shipboard, off-shore, mobile wharf, construction crane)

Telefax-No.

(e.g. lifting, luffing, level luffing gear)

Operating data - Design criteria (All values based on 1st rope layer)
Rope pull on drum
Rope velocity
Rope pull on drum
Rope velocity

F1
v1
F2
v2

P
K

[kW]

Rope pull on drum

Rope velocity
Rope pull on drum
Rope velocity
Rope pull on drum
Rope velocity
Rope pull on drum
Rope velocity

F1

F1
v1
F2
v2
F3
v3
F4
v4
Rope pull on drum F [kN]

Rope pull on drum F [kN]

Installed power
Regulation factor

[kN]
[m/min.]
[kN]
[m/min.]

F2
v1

[kN]
[m/min.]
[kN]
[m/min.]
[kN]
[m/min.]
[kN]
[m/min.]

F2
F3
F4

v2

[-]

16 17
[kN]
[hrs.]
[kN]
[m/min.]

Design in acc. with FEM Section I and DIN 15020

Gear drive group
Running time class.
Loading cond.

F1

v1 v2 v3 v4

Rope velocity v [m/min.]

Safety factor (e.g. 1,5)

against yield strength of material
with rope pull on drum of F1
Calculated service life
in operating hours
h
with rope pull on drum of F1
and rope velocity
v1

Design in acc. DIN Design Principles on lifting gear

Operatig hour class.
Hazard class.
Standard cond.
Lifting class.

Rope velocity v [m/min.]

Acceptance in acc. with Classification Society

GL, LROS, DNV, USSR Register etc.

Technical data
Diameter of rope drum
Length of rope drum
between drum flanges
Diameter of rope
Rope groove lead

D1

[mm]

L2
d
p

[mm]
[mm]
[mm]

Direction of drum lead

right-hand
left-hand
Type of drum groove
DIN 15061
special
grooveless
Point of rope fixture
drive-side
opposite to drive

Number of rope layers

Length of rope to be
wound including
3 safety turns

Drive hydraulic motor

Drive electric motor

Make
Type
Available displacement Q
Available pressure p

Make
Type
Power
Speed revs

[l/min]
[bar]

[kW]
[min.]

[-]

Ls

[mm]

Diameter of drum flanges D2

Gear transmission
i

[mm]
[-]

Voltage, kind of current

Starting torque
Overload torque
Duty factor
Starts per hours

[Nm]
[Nm]
[%]

TA
Tk
ED

Brake
Used as
Parking brake
Service brake

Design
spring loaded multi disc brake
with addit. back stop
band brake

Operation
hydraulic
electromagnetic

Remarks and special operating conditions

Please complete this sheet and return.

Minimum release pressure

Maximum release pressure
Anticipated back-pressure

[bar]
[bar]
[bar]

Factories of the Zollern group of companies

Laucherthal factory

Steel profiles
Postfach 12 20
ZOLLERN GmbH & Co. KG D-72481 Sigmaringen
Tel. +49 75 71 70 24 6
Fax +49 75 71 70 27 5
eMail zst@zollern.de

Foundry technology
Postfach 12 20
D-72481 Sigmaringen
Tel. +49 75 71 70 44 0
Fax +49 75 71 70 60 1
eMail zgt@zollern.de

Mannheim factory

Sales:
Tel. +49 7571 70246
Fax +49 7571 70275
eMail zst@zollern.de

ZOLLERN ISOPROFIL
GmbH & Co. KG

Portugal factory

Steel profiles
Postfach 24 03 59
D-68173 Mannheim
Tel. +49 62 18 45 90
Fax +49 62 18 45 92 63
eMail zst@zollern.de

France factory

62, Rue Pierre Curie

B.P.No 1055
ZOLLERN TLC SAS F-78131 Les Mureaux CEDEX
Tel. +33 1 34 74 39 00
Fax +33 1 34 74 28 52

Sales offices

Foundry technology
Rua Jorge Ferreirinha, 1095
Apartado 1027
P-4470-314 Vermoim MAIA
Tel. +351 22 94 14 68 1
Fax +351 22 94 14 69 5
eMail zcp@zollern.pt

France

ZOLLERN S..r.l
13, Rue Allwies
F-57200 Sarreguemines
Tel. +33 3 87 95 35 14
Fax +33 3 87 95 35 21
eMail zollernsarl@wanadoo.fr
www.zollern.fr

No. 33, 7th Avenue

TEDA-TIANJIN 300 457
Peoples Republic of CHINA
Tel. +86 22 25 32 38 11
Fax +86 22 25 32 38 10
eMail sales@zollern.sina.net

Great Britain

Zollern UK Limited
Castle Hill
Kenilworth
GB-CV8 1NB
Tel. +44 19 26 51 54 20
Fax +44 19 26 85 34 11

Drive technology
Gears
Httenstrae 1
D-46284 Dorsten
Tel. +49 23 62 67 0
Fax +49 23 62 67 40 3
eMail ZDA@zollern.de

Italy

ZOLLERN Italiana S.r.L.

Via C. Battisti, 1
I-21045 Gazzada (VA)
Tel. +39 03 32 46 20 59
Fax +39 03 32 46 20 67
eMail zollern@tin.it
www.zollern.it

Braunschweig factory

Drive technology
Friction bearing technology
ZOLLERN BHW Gleitlager Postfach 32 13
GmbH & Co. KG
D-38022 Braunschweig
Tel. +49 53 12 60 50
Fax +49 53 12 60 52 22
eMail bhw@zollern.de

Netherlands

ZOLLERN Nederland B.V.

Postbus 134
NL-5150 AC DRUNEN
Tel. +31 41 63 22 92 0
Fax +31 41 63 20 93 6
eMail zollern@zollern.nl
www.zollern.nl

Osterode factory

Sweden

Kvalitetsstal AB
P. O. Box 233
SE-73224 Arboga
Tel. +46 58 91 60 35
Fax +46 58 91 20 02
eMail kvalite@kvalitetsstal.se
www.kvalitetsstal.se

USA

ZOLLERN North America L.P.

9364 Wallisville Rd., Suite 150
Houston, Texas 77013
USA
Tel. +1 71 36 73 79 02
Fax +1 71 36 73 79 50
eMail zollernna@aol.com

ZOLLERN & Comandita

China factory
ZOLLERN (Tianjin)
Maschinery Co., LTD.

Dorsten factory
ZOLLERN Dorstener
Antriebstechnik
GmbH & Co. KG

Drive technology
Friction bearing technology
ZOLLERN BHW Gleitlager Rolandsweg 8 12
GmbH & Co. KG
D-37520 Osterode am Harz
Tel. +49 55 22 31 27 0
Fax. +49 55 22 31 27 99

Brazil factory
ZOLLERN LTDA

Drive technology
Friction bearing technology
Av. Manoel Incio Peixoto 2147
BR-36770-000 Cataguases MG
Tel. +55 32 42 92 00 2
Fax +55 32 42 92 00 3
eMail zollern@net.em.com.br

eMail sales@zollern.co.uk
www.zollern.co.uk

Aulendorf factory

Engineering elements
Postfach 12 65
ZOLLERN GmbH & Co. KG D-88322 Aulendorf
Tel. +49 75 25 94 81 30
Fax +49 75 25 94 81 00
eMail zmb@zollern.de

WINCH GEARBOXES

www.zollern.com

CONTACT
18 19
ZOLLERN GmbH & Co. KG
Drive Technology
Gears and Winches
Heustrae 1
D-88518 Herbertingen
Tel. +49 75 86 95 95 47
Fax +49 75 86 95 95 75
eMail zat@zollern.de

ZOLLERN GmbH & Co. KG

Drive Technology
Heustrae 1
D-88518 Herbertingen

Automation
Division
Tel. +49 75 86 95 95 86
Fax +49 75 86 95 95 85
eMail zht@zollern.de

Herbertingen factory

We offer comprehensive project management:

Many years of project experience
CAD masters
Project meetings on-site and plant inspections
Detailed, binding offers

Gears and Winches

Division
Tel. +49 75 86 95 95 47
Fax +49 75 86 95 95 75
eMail zat@zollern.de

Friction Bearings
Division
Tel. +49 75 86 95 95 20
Fax +49 75 86 95 97 15
eMail zat@zollern.de

www.revoLUZion.de

ZOLLERN Getriebe + Winden

Heustrae 1
D-88518 Herbertingen
Tel. +49 75 86 95 90
Fax +49 75 86 95 95 75
zat@zollern.de
www.zollern.com

Z237 09.2004

ZOLLERN GmbH & Co. KG