GEARBOXES FOR WINCHES

GPT-W
Copyright © ZF Industrieantriebe Witten GmbH

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 Gearboxes for Winches

∙∙ Sizes GPT-W 160 to 1,100

∙∙ Rope pull forces from 373 to 1,190 kN

Merkmale Content
∙∙ Compact, space-saving planetary gearbox design Functional Description 4
∙∙ Planet wheel carried in full-complement bearings Overview Types 5
∙∙ Robust bearing system absorbing the forces exerted Design and Classification 6
▶▶ by the cable pull Dimensions and technical data 8
∙∙ Simple mounting Standard counter-bearings 10
∙∙ Easy oil change Customer specification 11
∙∙ Integrated static multiple disk brake
∙∙ Low-noise operation

ZE77502 /06.2016 3
Functional Description
Description
ZF 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.
Winch gearbox with spring pressure multiple-disc brake
and connection for hydraulic motor
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.
4 ZE77502 /06.2016
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.
Lubrication
The 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 connection
The gearbox is designed for direct flange-attachment of a
variable or fixed-displacement motor.
Options
Upon 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.
 Functional Description

Overview of GPT-W Winch Gearboxes

Type Output torque 1) Cable pull max. 2) Gear ratio
T2 max from/to
Nm kN 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, M5
2)
based on a theoretical 1st layer winding diameter DWS

ZE77502 /06.2016 5
Design and Classification

Operating conditions Gearbox selection

The gearboxes have been designed for use at ambient tempera- 1) Calculation of output torque
tures between -20° C and +40° C. Environmental influences such
F • DW
as salt water, salty air, sand, dust, overpressure, heavy vibrations, T2 =
2
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 T2 = output torque [Nm]
is designed to meet the safety requirements. F = cable pull in [N]
DW = relevant winding diameter in [m]
Gearbox design
The gearbox design is based on many years of practical experi-
ence. The maximum output torques T2max indicated under Techni- 2) Calculation of corrected output torque
cal Data relate to FEM Section I, 3rd issue and Section IX (FEM
- Fédération Européene de la Manutention), as well as DIN T2K = T2 • K
15020, collective load class L2, service time category T5 corre-
sponding to driver group M5. The reference output speed is 25 T2K = corrected output torque [Nm]
revolutions per minute maximum. K = Factor according to the service time category and
If the winch is classified into a different driver group, the required collective group given in the table
output torque must be converted by applying factor K (see table).
3) T2K of the gearbox to be selected must be ≤ T2max
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.

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
400 - 800 800 - 1800 1600 - 3200 - 6300 - 12500 - 25000 -
Theoretical service life in hours
3200 6300 12500 25000 50000
Load spectrum Drive group with K factor
Maximum loads occuring in
M1 M2 M3 M4 M5 M6 M7
L1 light exceptional cases only, side
0.90 0.90 0.90 0.90 0.95 1.05 1.2
loads constantly
Collective Groups

small, medium and maximum M2 M3 M4 M5 M6 M7 M8

L2 medium loads about equally distributed 0.90 0.95 0.95 1 1.15 1.30 1.50
over service time
loads always near maximum M3 M4 M5 M6 M7 M8 M8
L3 heavy
1.05 1.05 1.10 1.25 1.40 1.60 1.80
very M4 M5 M6 M7 M8 M8 M8
L4 Always maximum load
heavy 1.25 1.30 1.45 1.65 1.85 2.10 2.40

6 ZE77502 /06.2016
 Design and Classification

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

Type of crane Component Type of Driver
(Designation) operated 1)
Hoisting Swinging Level Trolley Crane
luffing travelling travelling
Assembly cranes M2-M3 M2-M3 M1-M2 M1-M2 M2-M3
Loading bridges hooks M5-M6 M4 - M4-M5 M5-M6
Loading bridges Grab or magnet M7-M8 M6 - M6-M7 M7-M8
Workshop cranes M6 M4 - M4 M5
Overhead travelling cranes, ram cranes,
Grab or magnet M8 M6 - M6-M7 M7-M8
Scrapyard cranes
Unloading bridges, container gantry
Hooks or spreaders M6-M7 M5-M6 M3-M4 M6-M7 M4-M5
cranes
Other portal cranes
hooks M4-M5 M4-M5 - M4-M5 M4-M5
(with trolley and/or slewing ring)
Unloading bridges, container gantry
Grab or magnet M8 M5-M6 M3-M4 M7-M8 M4-M5
cranes (with trolley and/or slewing ring)
Berth cranes, shipyard cranes,
Hooks M5-M6 M4-M5 M4-M5 M4-M5 M5-M6
Dismantling cranes
Dockside cranes (slewable, gantry type, .
Hooks M6-M7 M5-M6 M5-M6 - M3-M4
. .), floating cranes, floating sheerlegs
Dockside cranes (slewable, gantry type, .
Grab or magnet M7-M8 M6-M7 M6-M7 - M4-M5
. .), floating cranes, floating sheerlegs
Floating cranes and floating sheerlegs for
M3-M4 M3-M4 M3-M4 - -
very high loads (normally above 100 t)
Shipboard cranes Hooks M4 M3-M4 M3-M4 M2 M3
Shipboard cranes Grab or magnet M5-M6 M3-M4 M3-M4 M4-M5 M3-M4
Tower cranes for construction sites M4 M5 M4 M3 M3
Derrick tower gantry M2-M3 M1-M2 M1-M2 - -
Railway cranes approv. for service in trains M3-M4 M2-M3 M2-M3 - -
Vehicle-mounted cranes Hooks M3-M4 M2-M3 M2-M3 - -
1)
The column only shows some typical areas of winch use for informative purposes.

ZE77502 /06.2016 7
Dimensions and Technical Data

Dimensions

Dimensions
of the counter bearing
see page 10

min. Winding diameter 1st layer

Optional (only in connection
with version ≥ 4000)

Technical data
Type Output Cable Transmission ratio Holding Hydraulic motor
torque pull torque
T2 max max. TBr max
Nm kN i Nm
A6VM 200 / A6VE 107 • 160 /
GPT 160 W3 4000 140,000 373 133 • 210.8 • 251 1,360
A2FE 107 • 125 • 160 • 180
97.7 • 105.9 • 143.3 • 155.4 • A6VE 107 • 160 /
GPT 220 W3 4000/1 200,000 471 1,360
188.9 • 246.1 • 293 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
A6VE 107 • 160 /
GPT 220 W3 6000/1 200,000 471 188.9 • 246.1 • 293 1,360
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

2000 = Oil inlet, oil outlet, oil level on the gear cover 8000 = Optional with back stop (built-in between gearbox
4000 = Oil inlet, oil outlet, motor-side oil level and holding brake)
6000 = Oil inlet, oil outlet, motor-side oil level 9000 = Special design
Installation of 2 gearboxes in a hoisting drum possible

8 ZE77502 /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

ZE77502 /06.2016 9
Standard Counter-Bearing

Dimensions
Gear Size D1 D2 D3 D4 D5
H7/j6 H7/j6

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 Mass

approx.
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

10 ZE77502 /06.2016
 Customer Specification

You wish to receive an offer for

a ZF winch gearbox? Company:
To be able to quote, please send this customer Name/Dept.:
specification to: sales.ii@zf.com Location/City:
Please enclose existing drawings and diagrams.
Phone:
E-mail:
Date:

Page 1/3

Operating data / design Device type

(all values based on the 1. rope layer)
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
1)
Operating machine weight t
1)
Lifting capacity, max. t

2)
Rope pull (top rope layer) F N
2)
Rope speed (1. rope layer) V m/min
1
2)
Rope speed (top rope layer) V m/min
2
Rope diameter d mm
2)
Number of rope layers, max. D mm
WS
2)
Winding diamet. (1. rope layer) D mm
Wx
2)
Winding diamet. (top rope layer) D mm
Standard scope of supply 2

Transmission unit
Techn. data gearbox
Optional scope of supply Selected gearbox type GPT-W
2)
Counter bearing Max. output torque T kNm
2 max
2)
Rope drum
3) Max. drive speed n 1/min
2
1)
Winch frame Ratio i
Multiple-disk parking brake yes no
Min. park. torque multiple-disk
parking brake Nm
Release pressure, max. P bar
max
1)
Release pressure, min. P bar
min
Top coat specific no yes
Color RAL

1)
Optional entry
2)
Mandatory field if T2 max is not specified

ZE77502 /06.2016 11
Customer Specification

You wish to receive an offer for

a ZF winch gearbox? Company:
To be able to quote, please send this customer Name/Dept.:
specification to: sales.ii@zf.com Location/City:
Please enclose existing drawings and diagrams. Phone:
E-mail:
Date:

Page 2/3

Dimensions of gearbox
• Standard dimensions see valid
„technical data sheet“
• in case of differing requirements/
Dimensions, please complete table

D1 mm
motor flange surface
D2 mm
D3 mm
D4 No. of threads Pcs.
D5 mm
D6 mm
D7 mm
frame connection D8 No. of threads Pcs.
L2 mm

Tech. basic data hydraulic motor

Hydraulic circuit open closed
Motor type code
3
Displacement Vg min cm
3
Displacement Vg max cm
Flushing valve yes no
Speed sensor, if yes: type yes, type no
Counter balance valve yes no
Pressure relief valve yes no
Pressure relief valve setting bar
Working pressure ∆p bar
Input flow, max. q l/min
v max

1)
Estimated number of transmission units per year
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

12 ZE77502 /06.2016
 Customer Specification

You wish to receive an offer for

a ZF winch gearbox? Company:
To be able to quote, please send this customer Name/Dept.:
specification to: sales.ii@zf.com Location/City:
Please enclose existing drawings and diagrams. Phone:
E-mail:
Date:

Page 3/3

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

ZE77502 /06.2016 13
Product Programm

Products for movable applications

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 industrial applications

Industrial Gearboxes
∙∙ Redulus GMH/GME
Technical Documentation RE 76120

14 ZE77502 /06.2016
 Notes

ZE77502 /06.2016 15
ZF Industrieantriebe Witten GmbH
Mannesmannstraße
58455 Witten, Germany
Tel. +49 2302 877-0
Fax +49 2302 877-148
sales.ii@zf.com
www.zf.com

Printnumber ZE77502 /06.2016

MOTION AND MOBILITY