WINCH GEARBOXESTRANSMISSION 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 3 Design and construction of rope winches with flange drive gearbox 4 Integrated rope drum 7 Rope fixing 8 Rope grooves and rope 9 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 η 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 -20°C to + 70°C. 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 . π = 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 α 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 α 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 α 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 M L3 M 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 L L log L log L M 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 · ηs Fnom = (mload + mtackle) g · · Ψ [N] ηs = (ηR)i · ηF = (ηR)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 - (ηR)n · n 1 - ηR ηR is the efficiency of a single rope pulley ηF is the efficiency of the pulley block ηs 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 ηR = 0,96 with anti-friction bearings ηR = 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 Ψ = 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 X A M max. X Flange connection F8 G F7 Flange connection F S6 D0 Optional end support bearing G6 F6 F5 Flange connection Flange connection G5 S 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 Ø Ø ± 0,2 Ø 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 W Flange connection Gear unit to drum SS S1 S2 location pcd S3 outer S4 fixing FF S5 S6 F1 location F2 pcd Ø Ø ± 0,2 nmax. γ rpm Depending on motor and brake arrangement 2000…5000 rpm TYPE S C 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 Ø Ø ± 0,2 16 5 145 185 24 5 225 245 25 5 265 290 25 5 295 320 25 5 330 360 25 5 370 400 30 5 400 440 30 5 440 480 38 5 470 520 38 5 550 590 47 5 640 690 47 5 700 755 47 5 790 840 47 5 850 900 56 5 1000 1055 Ø 30° 203 12 * Ø 11 20° 265 18 * Ø 11 15° 310 24 * Ø 14 15° 340 24 * Ø 14 20° 390 18 * Ø 18 15° 430 24 * Ø 18 20° 480 18 * Ø 18 15° 520 24 * Ø 22 20° 560 18 * Ø 26 15° 630 24 * Ø 26 15° 750 24 * Ø 33 15° 815 24 * Ø 33 12° 890 30 * Ø 33 10° 950 36 * Ø 33 10° 1120 36 * Ø 39 10 9 120 140 10 9 150 175 12 9 175 200 12 9 175 200 16 9 200 230 16 9 200 230 20 9 230 260 20 9 260 310 24 9 260 310 24 9 300 350 30 9 325 375 30 9 325 375 30 9 375 435 30 9 375 435 36 9 430 490 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 Ø 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 A C Mmax. T1 min. 2-sta- 3-stages ges T2 W L approx. frame 2-sta- 3-stathick- ges ges X min. ZHP EG ness Ø 60° 6*Ø9 60° 6 * Ø 11 60° 6 * Ø 11 60° 6 * Ø 11 60° 6 * Ø 14 60° 6 * Ø 14 60° 6 * Ø 18 60° 6 * Ø 22 60° 6 * Ø 22 60° 6 * Ø 22 60° 6 * Ø 26 60° 6 * Ø 26 60° 6 * Ø 33 60° 6 * Ø 33 60° 6 * Ø 33 TYPE 4.13 12 8 20 36 – – 40 55 130 160 – 70 10 165 – 10 15 8 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 αG ± A Ø AB Ø B Maximum permitted deviation ∆H from the centreline in relation to L1 Type ZHP αF ± 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° 1 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 0,4 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 Ø 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 A Ø B F2 B A F1 G1 G2 ∆H Ø G4 αG F4 αF 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.] n [-] 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
[email protected] Foundry technology Postfach 12 20 D-72481 Sigmaringen Tel. +49 75 71 70 44 0 Fax +49 75 71 70 60 1 eMail
[email protected] Mannheim factory Sales: Tel. +49 7571 70246 Fax +49 7571 70275 eMail
[email protected] 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
[email protected] 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
[email protected] France ZOLLERN S.à.r.l 13, Rue Allwies F-57200 Sarreguemines Tel. +33 3 87 95 35 14 Fax +33 3 87 95 35 21 eMail
[email protected] 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
[email protected] 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 Hüttenstraße 1 D-46284 Dorsten Tel. +49 23 62 67 0 Fax +49 23 62 67 40 3 eMail
[email protected] 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
[email protected] 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
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