TRANSMISSION AND CHASSIS TECHNOLOGY

ZF-DRIVE SYSTEMS FOR LIFT-TRUCKS

MaterialHandling.

2

ZF-Drive Systemsfor Lift-Trucks

Elektric Counterbalance Lift-Trucks

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: sales.zfgotha@zf.com

aftersales.zfgotha@zf.comwww.zf.com/a-passau T

he r

ight

is

rese

rved

to

mod

ify

prod

ucts

and

tec

hnic

al d

ata.

/ D

esig

n: G

rasw

ald

& H

eili

gtag

, Pas

sau

AC

/Lif

t-T

ruck

Dri

ves

03/E

- P

rint

ed i

n Fe

dera

l R

epub

lic

of G

erm

any

/ O

stle

r-D

ruck