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ZF Drive Systems for Lift-Trucks Mobile Solutions
ZF Drive Systems
for Lift-Trucks
Mobile Solutions
ZF Gotha -- the world’s technology partner
■ ■ ■ ACTIL ■ Anhui Heli ■ Atlet ■ Big Joe ■ BT ■ CAT ■ Cesab ■ Clark ■ Doosan■ Ellat ■ Fenwick-Linde ■ FKI Logistics ■ Godrej ■ Hangzhou ■ Hyster ■
Hyundai ■ Jungheinrich ■ Kalmar ■ Kelvin ■ Linde Group ■ Lugli ■ Mitsubishi■ Montini ■ Nacco Group ■ Nilfisk ■ Nuova Detas ■ Osko ■ Rocla ■ Still ■ TCM■ Tennant ■ Toyota Group ■ Yale ■ ■ ■
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Specialized in driveline innovations
ZF Gotha -- dependable system partner
Highly individualized products -- certified quality
ZF technology for all classes of lift-trucks
Drive systems for electric counterbalance lift-trucks
Drive systems for warehouse-trucks
Drive systems for special applications
Benchmark workday stress -- ZF products under test
Complete coverage -- the ZF world-wide service network
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Specialized indriveline innovations
The increasing importance of plat-form-orientated vehicle concepts,more refined modularization of product features and components,and a world-wide, rapidly consoli-dating procurement and productionnetwork, are becoming crucial tosuccess in the market.
ZF Gotha is the specialist for electric lift-truck drivesystems within the ZF Group. Integrated into ZF’sglobal development centers and 125 productionlocations, mobile solutions are offered to customersin all the international markets: From the develop-ment of highly integrated drive systems or compo-nents, just-in-time supply for serial production --from local production as applicable -- through toaftersales service. ZF’s sales and service organiza-tion is available throughout the world.
At the modern location in Gotha a close-knit factoryhas been realized. All processes from development,through sales, purchasing and production to custo-mer service are concentrated here. Furthermore, ZFGotha produces in North America and soon also inAsia. This forms the basis of being able to give thebest support to ZF customers at any time and at anyplace.
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GP 21Dual-motor drive system for counter-balance lift-trucks with integratedwet-running multi-disc brake.
ZF Gotha – dependable system partnerIn the field of lift-trucks too, pre-finished system solutions are replacing
the assembly of single components. So ZF customers already receive a
large part of the products as complete solutions, pre-finished and fully
tested for lift-truck assembly.
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Intensive added-value pro-cesses demand short pathsand assembly times in pro-duction logistics. Thereforethe continuous optimizationof these processes is a coreobjective in the ZF systemdevelopment.An intelligent system kitunder the brand name of ZF-ERGOMAT® is being offeredfor the drive of electric lift-
trucks. These system solutions go right throughto the integration of stator/rotor kits and trans-missions into a common housing. ZF Gotha sup-plies fully tested solutions for quick and directinstallation into the vehicle. The customizeddevelopment and matching of all components forthe functions of driving, braking and steeringare carried out by ZF.
The advantages to ZF customers are:■ significantly fewer interfaces during
development■ clear line of responsibility through
one system supplier■ easier deadline management■ reduced logistics■ simpler handling■ less warehouse capacity required■ reduced assembly effort■ shorter processing times with reduced
assembly area■ no disassembly needed due to faulty
components.
And an additional bonus -- due to the pre-finished oil-filled systems, the lubricants for the drive components vanish from the lift-truckmanufacturer’s assembly line and with them the associated environmental directives.
GR 10Motor kit, transmission andbrake are integrated intoone ultra-compact unit.Compactness taken to thelimit.
GK 10Drive system for warehouse-trucks. High performancewith minimum envelope circle, highest efficiency andlowest noise level.
All pre-finished -- optimum
productivity through system solutions
In all phases of the product devel-opment ZF Gotha can rely on thesupport of the world-wide researchand development network of thecomplete ZF Group. This extendsfrom research into fundamentalaspects and materials through totransfer of technology from theAutomotive Division. For years thisdivision has made a decisive contri-bution to the introduction of newtechnologies for leading automotivemanufacturers -- for example hybriddrive, automatic transmission oractive steering. Whereas the appli-cation development with electric
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Highly individualized products – certified quality
drive specific to lift-trucks takes place in Gotha,specialized tasks such as the design of gear systemsand tools or computations with finite elements iscarried out by experts from other divisions in thegroup.The development of the ZF-ERGOMAT® transmis-sion with life-time lubrication is one example of thesuccessful co-operation between different specialistfields. A substantial reduction in the maintenancerequired was able to be achieved through furtherdevelopment of cooling lubricants and metallicmaterials, along with optimized machining tech-niques. This efficient use of resources and synergies alsoaids in reducing the development time of new pro-ducts to a minimum. In addition, individual projectwork with the vehicle manufacturer in simultane-ous engineering also makes a contribution. Thestandardized development process applied here ful-fils current standards and customer requirements.The modular construction of ZF drive systems en-ables rapid adaptation to the individual customer’scircumstances. At the end of the process chain,there are quality solutions which take into accountall the customer specifications and are optimallymatched to the vehicle.The smooth and efficient co-operation with thevehicle manufacturer is continued after develop-ment through high quality standards in production.Apart from the current certifications and audits, arigorous quality assurance programme is carried out within the ZF Group.
The excellent quality of ZF lift-truck systems is achieved by bundling com-
petences in the ZF Group. Specialists from the various divisions contribute
the individual components to form a perfectly matched system. And natural-
ly, ZF Gotha is certified to ISO 9001:2000 and ISO 14001:2005.
Furthermore, ZF is regularly and successfully audited by quality-conscious
major customers.
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GK 20 drive systemThis pre-finished drive solution supplies the customer all the functions from driving and braking through to steering directly to the assembly line.
Success means commitment -- over 4.500 ZF development staff
ensure on-going product innovation
SimulationsKnowledge about real application conditionsis saved in duty cycles. The dimensions andquality requirements for the product resultfrom them.
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Scope of the system in warehouse-trucksDriving, braking, steering – all pre-finishedfrom one source. More and more lift-truckmanufacturers count on high performancedrive packages from ZF.
Narrow warehouse aisles, stop and go, steepramps and just-in-time transport in pieceworkand cycles tuned to seconds represent realchallenges for a lift-truck. Particularly, thedrive units are subjected to enormous stressesduring daily operation. To a large extent theydetermine the quality, performance capability,handling, service friendliness, and reliabilityof the complete vehicle. Today, logistic compa-nies as users of lift-trucks are under pressureof the world market to make continuous im-provements in productivity, flexibility, and sta-bility of the work flow. In innovative vehicledesigns highly efficient, low-maintenancedrives, almost indestructible under any load,provide a decisive contribution in this respect.
ZF Gotha belongs to the division Off-RoadDriveline Technology and Axle Systems with-in the ZF Group. In this division, amongstother products, systems for diesel-poweredlift-truck applications from 5 to 60 t liftingcapacity are developed and produced. ZF Gotha completes the range of products forelectrically powered lift-trucks of up to 6 t lif-ting capacity. Consequently, for lift-trucks of all perfor-mance classes and for special applications,there is a wide and also highly specializedspectrum of drive solutions available whichincludes the ideal transmission or completesystem for all cases of materials handling.
ZF technology for allclasses of lift-trucks
Mobile drive solutions from ZF
-- always one innovation ahead.
ZF offers its customers a wide, but nevertheless specialized range of products.
Regardless of whether counterbalance lift-trucks, warehouse-trucks, elevating
working platforms, electric tractors, cleaning vehicles, automatically guided
vehicles or special applications are involved, ZF always has a suitable transmis-
sion or drive system.
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System scope in lift-trucksThe manoeuvrability of a lift-truck with a dual-motor drive is unbeatable. In this regard, ZFhas long since set the standards and conti-nues to develop them.
GK 25This combined bevel gear trans-mission has a patented hypoidbevel gear set.
GPA 20A coaxial two-stage planetary gearwith an inline configuration of wheeland motor.
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GP rangeThe combination of spur gear and planetary drive fulfils the require-ment for an installation width of less than 1,000 mm. The planetarygear with wheel bearings is fully integrated into the wheel. In con-trast, the spur gear drive which is very narrow in terms of spacerequirement is positioned directly adjacent to the wheel. A widerange of transmission ratios and various brake actuation systemsmake this drive very flexible.
Drive systems for electric counterbalance lift-trucks
GPA 20 axle systemThis consists of a coaxial two-stage planetary gear. The wheels andAC drive motors are arranged coaxially to one another. As standard,this drive has an integrated wet-running multi-disc brake which is optimized for efficiency. The lifting frame is mounted directly on theaxle. As with the GP Series, two independent wheel drives enable the smallest turning circles.
Front or rear drive lift-trucks -- the wide product range from ZF Gotha offers
optimum drive solutions for any lift-truck for powerful, reliable stacking.
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For their drive systems, three or four wheelcounterbalance lift-trucks demand a tightspace-saving design because only very littleinstallation space is available. Handlingheavy loads is only possible through soft, stepless manoeuvring with precise, accurate-ly controlled actions. ZF responds to thesechallenges with robust and compact drivesolutions.The planetary drives on the basis of the GPrange are the ideal drive systems for frontwheel drive vehicles up to 3.5 t lifting capa-city. Customized variants of transmissionratios are realized with the spur gear stage.The wet-running multi-disc brake ensures ahigh braking capacity and operates almostwear-free. The optimized gear geometry pro-duces a noticeable noise reduction.As rear wheel steering drives, ZF offers long-drop versions of the GK range with hightransmission ratios for AC technology. With a vertical arrangement in the vehicle,the small envelope circle allows efficient uti-lization of the installation space and highmanoeuvrability.The GP range and the GK Long-Drop varianthave become established as reliable drives onthe market.
The new AT 35 and GPA 20axles are further variants for the drive on front wheel drivecounterbalance lift-trucks. Theaxles themselves carry the liftmast so that it does not need tobe joined to the main frame.Due to the dual-motor drive,GPA 20 offers minimum turningcircles for 2 t lift-trucks. The AT 35 axle is designed as asingle-motor drive for the smal-lest frame widths.
Market leader with GP and GK Long-Drop
for electric counterbalance lift-trucks
AT 35The new T axle from ZFoffers an ideal alternative to the GP dual-motor driveconcept because it is onlyequipped with one motorand a differential. A wet-running multi-disc brake isintegrated into the axle.The type of brake actuationcan be matched to custo-mer requirements.
GK Long-DropThe LD version of the GKtransmission is the firstchoice for rear-wheeldriven three-wheel counter-balance lift-trucks. Thecombination of a helicalspur gear stage and bevelgear set produces a highperformance, quiet runningpower package in thesmallest of spaces.
GR 10The GR 10 is a fully integra-
ted wheel hub drive. Theplanetary gear transmission,AC motor kit and brake are
completely integrated withinthe envelope circle of the
wheel (230 mm diameter).The drive system has an
extremely low installationheight and is maintenance-
free because it is lifetimelubricated.
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Just-in-time production and sup-ply, customized production froma batch size of one up to massproduction along with the net-working of suppliers and custo-mers cannot be mastered thesedays without the latest materialshandling technology and logis-tics. When lift-trucks are conti-nuously on the move, then forgood reason oftentimes drivesand complete systems from ZFare at work. After all, betweenthe shelves every minute, everycentimetre and every ease ofwork counts.
Drive systems forwarehouse-trucks
The GK range represents the core of the clas-sical drive with wheel, brake and verticallymounted electric motor. Through this combi-nation, the bevel gear drive facilitates theproduction of very compact units which arealso easy to install. Apart from the incompa-rably small envelope circle, the lubricationand oil filling for the whole service life aswell as the service-friendly design prove to be significant advantages for the customer.The GR range is offered as a coaxial inlinedesign. These compact and rugged planetarywheel hub transmissions have integratedmotors and brakes so that the envelope circleis solely determined by the size of the wheel.These drive systems enable the application ofmotors (AC) with large control ranges andpower reserves -- ideal for the easy handlingof heavy loads.The spur gear transmission GS 10 is predes-tined for fulfilling the requirements of tiller-guided pallet trucks and lift-trucks. The con-cept is designed such that the standard ver-sion can be applied almost without modi-fication.The GK, GR and GS ranges offer variousalternatives for different vehicle designs andcan therefore meet all the drive require-ments.
In cold stores, high bay warehouses, narrow-shelved stores, when loading and
unloading trucks or when commissioning -- ZF drive systems for warehouse-
trucks carry out their duties reliably and ensure the highest mobility with low
operating noise in enclosed warehouses.
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Matched solutions for
different vehicle concepts
GS 10The system has a fully integrated AC motor moun-ted horizontally over the wheel in the transmissionhousing. The tiller connection is positioned central-ly on the aluminium housing between motor andwheel. This gives a simple interface to the vehicle.The transmission is maintenance-free and has life-time oilfilling.
GK 30This high performance bevel gear drive for 3.4 twheel load has a patented hypoid bevel gearset and ensures high transmission ratios for ACdrives. Its advantages lie in the minimal enve-lope circle, one-piece integral housing, zeromaintenance, lifetime lubrication and oil filling,high strength, integral motor pinion, very solidspur gear steering and in the reduced noiselevel due to optimized gear technology.
GK 10This is the standard drive for walkies of up to 2 tlifting capacity. With the patented hypoid bevelgear set and the optimized gear technology itsupplies advantages such as minimal envelopecircle, zero maintenance, low noise level, highefficiency and high performance complying withthe GK range.
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GP 21This drive system has proven itself in practice more than100,000 times over. It is therefore consistently applied forelectric tractor units and other special vehicles. As stan-dard, this drive has an integrated wet-running multi-discbrake which is optimized for efficiency.
Drive systems forspecial applicationsPower plus intelligence is the formula of increasing requirements
on powered machines which also demand a high level of technical
flexibility from the drive technology.
GK 16Another example from the finely graded GK construction kit.With the patented hypoid bevel gear set and the optimizedgear technology it supplies advantages such as minimal enve-lope circle, zero maintenance, low noise level, high efficiency,and high performance complying with the GK range.
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Cleaning equipment
The greatest manoeuvrability for squeezing intotight spaces is especially important for sweepers tobe able to clean effectively. The GK range offers theideal prerequisite for this, in particular the GK 20LD. Due to the vertical mounting orientation of theelectric motors, they achieve the smallest possibleenvelope circle radius and give extreme freedom ofmovement.
Electric tractor units
High performance capabilities with the lowestwidth and greatest manoeuvrability enable towingtractors to efficiently transport people and goods inalmost all industrial and commercial areas, publicamenities and in municipal applications. The drivesolutions of the GP range are predestined for this.
Elevating working platforms
For this application ZF Gotha also offers ideallysuitable drives such as the GR 10. Small, high per-formance and robust -- moving heavy loads presentsno problem. ZF drive technology here stands forefficiency, safety and reliability.
The modular system design of the ZF drive compo-nents is open for the most varied vehicle designs.ZF has a solution ready for any customer vehicle!
When versatility is needed --
specialized drive concepts for special cases
GK 20 LDThis long-drop version of the GK drive is parti-cularly used for cleaning equipment. Oneadvantage is the vertical motor position in con-junction with the large wheel diameter.
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The secret of every continuingcompany success is consistentlyhigh quality and the characteri-sing feature of reliability. ZFcustomers and lift-truck userscan rest assured that carefullydesigned test systems back upeach individual developmentstep. Along with innovative,leading-edge technology, anuncompromising qualitymanagement system ensuresthat ZF customers are alwaysahead in the world market interms of reliability.
Benchmark workday stress– ZF products under test
Realistic test sequences prove the practicalcapability of ZF drive systems. Fully automa-ted special test rigs working in 24-hour opera-tion quickly and reliably supply data whichotherwise could only be obtained throughyears of continuous testing. The validity ofthe 100% data recording is guaranteed by apractically orientated definition of the loadsimulation.Using the latest measurement technology, customized and application-specific long-termexaminations of all important vehicle dataare carried out. The high dynamic acquisitionof torque and even torque frequency in theoily interior of transmissions are part of thetest repertoire.Whether telemetry, digital data acquisitiontechnology, or refined acoustic tests -- the testexperts from ZF Gotha fulfil every customerrequirement to optimize the interaction ofthe ZF drive components with the completevehicle. The excellent quality and reliabilityof ZF’s test procedures are a direct conse-quence of quality consciousness obtainedthrough decades of responding to stringentrequirements in all automotive fields.
At the start of the product development, there is the specification of practi-
cal requirements. Exact measurements of application conditions in the field
are therefore essential. Later, when tested, the new products must prove
that they are a match for real workday stresses.
Innovative drive technology demands
comprehensive testing methods
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Measurements under real conditionsOn the test-rig, real conditions are replicatedand load cycles followed. These cycles are derived from measurements on the vehicleduring operation. The knowledge gained isincorporated into the on-going development of the current series.
Drive tests under field conditionsDrive tests represent a real challenge. No mat-ter how many sensors are applied and piles ofadditional ”luggage“ on the vehicle, the opera-tor should not be impeded during a long-termacquisition of measurement data. Using mobilemeasurement technology, an exact replicationof the practical application can be derived.
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To ensure this success during all theups and downs on the market, ZF doesnot just offer the latest technology, butalso a comprehensive world-wide ser-vice network for each production loca-tion and the full range of servicesneeded by lift-truck manufacturers toprovide planning dependability indaily practice. World-wide coverage with factories,subsidiaries, branches, and partnercompanies along with an internationalnetwork of service centers guaranteefast and reliable support for ZF custo-mers and lift-truck users.
Consultancy
Consultancy includes informationgiven on the correct use and applica-tion of ZF products. It also providesdetails on the subjects of maintenanceand service and lends support in an-swering all other open queries.
Genuine ZF spare parts
Only with ZF spare parts, a productcan remain genuine ZF. Through theuse of genuine ZF parts, qualitativeand cost-intensive risks can be avoi-ded. Genuine spare parts guarantee ahigh life expectancy for the ZF drivesystem. The use of ZF parts can there-fore only be in the user’s best interest.ZF supports its customers quickly withits specialist knowledge in the selec-tion of the correct components andensures the shortest possible deliverytime. Due to world-wide presence, ZFspare parts are in stock at the mostvaried locations, so they can be sup-plied at short notice.
Repair
A vehicle breakdown is always associ-ated with costs. ZF Gotha and the net-work of the ZF service organizationare ready to help in such cases and,
Complete coverage – the ZF world-wide service networkCustomer satisfaction and customer proximity are the main
defining values and the engine of innovation behind all com-
pany activities. At the end of the day, ZF’s success is defined
by the success of its customers!
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besides quickly providing replacementunits, also offer repair by trained ser-vice teams.
On-site service
Experienced customer service techni-cians also support users on site, e.g.with complicated installation situationsin the field of product application.
Training
Continually increasing demands on ZFproducts require the application of thelatest technologies. Dealing with suchtechnologies in turn demands a highlevel of knowledge and experience.The training sessions needed for thisare offered in theoretical and practicalcourses in the ZF Training Center.
Documentation
In order that ZF products can developtheir full performance capability, cor-
rect installation and operation togetherwith regular maintenance are essentialrequirements. In this respect, ZF custo-mers receive guidance in the form ofdetailed product documentation. Noti-fications about updates and improve-ments follow on a regular basis. Thecurrent ZF list of lubricants can befound on the Internet.
Industrial reconditioning
Before a unit starts to give frequentproblems and incurs costs, industrialreconditioning by ZF is a possible con-sideration. In this way, significantrepair costs can be saved. The custo-mer receives a completely tested pro-duct with the parts renewed which aremost susceptible to failure.
Driveline and Chassis Technology
ZF Gotha GmbHLift-Truck DrivesKarl-Liebknecht-Str. 26D-99867 GothaGermanyPhone: +49 (0)36 21 311-0Telefax: +49 (0)36 21 311-4599e-Mail: [email protected]
www.zf.com
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