{"id":1002,"date":"2026-06-22T06:23:50","date_gmt":"2026-06-22T06:23:50","guid":{"rendered":"https:\/\/planetary-gearboxes.com\/?post_type=product&p=1002"},"modified":"2026-06-22T06:23:50","modified_gmt":"2026-06-22T06:23:50","slug":"zr120-winch-drive-planetary-gearbox-right-angle","status":"publish","type":"product","link":"https:\/\/planetary-gearboxes.com\/nl\/product\/zr120-winch-drive-planetary-gearbox-right-angle\/","title":{"rendered":"ZR120 Winch Drive Planetary Gearbox \u2014 Right-Angle"},"content":{"rendered":"
\n

<\/p>\n

\n
\n
FIRST 3-STAGE MINIMUM<\/span>
\n3,000 RPM<\/span>
\n95% MEGA-CLASS<\/span><\/div>\n

ZR120 \u2014 133,000 Nm<\/h2>\n

Three stages. Three thousand RPM. Near-mega-class from a perpendicular motor.<\/p>\n

\n
\n
133k<\/div>\n
Nm Cont.<\/div>\n<\/div>\n
\n
280k<\/div>\n
Nm Peak<\/div>\n<\/div>\n
\n
3-5<\/div>\n
Stages (min 3)<\/div>\n<\/div>\n
\n
3,000<\/div>\n
RPM<\/div>\n<\/div>\n<\/div>\n<\/div>\n

The EP-ZR120 is the fifth model in the right-angle winch drive planetary gearbox<\/a> series and the first to cross both thresholds: minimum 3 stages (bevel + 2 planetary), and 3,000 rpm input speed. The 2-stage compact option that the ZR55-ZR95 offered is no longer available \u2014 the bevel gear at 133,000 Nm cannot sustain the tooth loading required for a 2-stage torque path at the 100,000-hour design life. The additional planetary stage distributes the torque more evenly through the gear train, reducing the bevel tooth stress from 98% to approximately 75% of the endurance limit and restoring the safety margin. The cost: approximately 80 mm of additional axial length behind the drum.<\/p>\n<\/section>\n

<\/p>\n

\n

ZR120 Right-Angle Winch Drive Planetary Gearbox \u2014 Technical Parameters<\/h2>\n
\n\n\n\n\n\n\n\n\n\n\n\n
Continuous torque (N2xh=100,000)<\/td>\n133,000 Nm (95% of 414W3)<\/td>\n<\/tr>\n
Peak torque<\/td>\n280,000 Nm (exceeds 417W3 continuous)<\/td>\n<\/tr>\n
Input configuration<\/td>\nRight-angle (90 deg helical bevel + planetary)<\/td>\n<\/tr>\n
Maximum input speed<\/td>\n3,000 rpm (first ZR at 3,000)<\/td>\n<\/tr>\n
Available stages<\/td>\n3-5 (first ZR with 3-stage minimum)<\/td>\n<\/tr>\n
Thermal power (Pt)<\/td>\n27 – 100 kW<\/td>\n<\/tr>\n
Gear type<\/td>\nHelical bevel + helical planetary, DIN 5-6<\/td>\n<\/tr>\n
Integrated brake \/ Sealing<\/td>\nNone \/ IP67+ FKM<\/td>\n<\/tr>\n
Housing \/ Gear material<\/td>\nQT600-3 \/ 20CrMnTi HRC 58-62<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<\/section>\n

<\/p>\n

\n

3-Stage Minimum \u2014 What the Additional Planetary Stage Provides at 133,000 Nm<\/h2>\n

The ZR95 was the last model to offer 2-stage (bevel + 1 planetary). The ZR120 mandates 3 stages (bevel + 2 planetary). The difference is one additional planetary stage \u2014 but the engineering consequences extend beyond the 80 mm of extra housing length.<\/p>\n

\"ZR120<\/p>\n

\n
Lower Bevel Stress<\/strong><\/p>\n

The additional planetary stage provides more reduction before the torque reaches the bevel. At a given output torque (133,000 Nm), the bevel input torque at 3-stage is lower than at 2-stage because the first two planetary stages have already multiplied the motor torque. Lower bevel input torque = lower bevel tooth stress = longer bevel gear life. The bevel tooth stress at 3-stage drops from 98% (the unacceptable 2-stage level) to approximately 75% of the endurance limit \u2014 restoring the design margin to comfortable levels.<\/p>\n<\/div>\n

Higher Minimum Ratio<\/strong><\/p>\n

The 3-stage minimum means the ZR120 minimum achievable ratio is higher than the ZR95 2-stage minimum. Where the ZR95 at 2-stage could reach ratios as low as 15, the ZR120 at 3-stage starts at approximately 50. For applications needing low ratios (fast drum speeds, direct-drive-like operation), the ZR95 at 115,000 Nm with 2-stage offers lower ratios than the ZR120 at 133,000 Nm with 3-stage. The ratio range is a design trade-off with the stage count.<\/p>\n<\/div>\n

Better Torque Distribution<\/strong><\/p>\n

Three stages distribute the total ratio across more gear meshes \u2014 each individual mesh carries a lower per-stage load. This reduces the contact stress on every gear in the train, not just the bevel. The result is more uniform wear across the gear train and a more predictable maintenance profile \u2014 the gears and bearings wear at similar rates rather than the bevel wearing faster than the planetary. For maintenance planning, this means the entire gear train can be inspected and overhauled on the same schedule. Contact Korea Ever-Power<\/a> for overhaul scheduling at your specific duty profile.<\/p>\n<\/div>\n<\/div>\n<\/section>\n

<\/p>\n

\n

3,000 RPM \u2014 The Final Speed Step and the Global Motor Standard<\/h2>\n

The ZR series input speed has stepped down through the range: 3,300 (ZR55) \u2192 3,100 (ZR75-ZR95) \u2192 3,000 (ZR120-ZR200). At 3,000 rpm, the ZR120 reaches the final speed level \u2014 shared with the ZR150 and ZR200. This is not coincidental: 3,000 rpm is the synchronous speed of a 2-pole motor at 50 Hz \u2014 the single most common motor speed in global industrial and marine practice.<\/p>\n

\n
Perfect Motor Match<\/strong><\/p>\n

At 3,000 rpm, the ZR120 accepts any standard 2-pole motor at 50 Hz without speed derating or VFD frequency limiting. The motor runs at its rated speed, at rated voltage, at rated efficiency. No power derating, no thermal derating, no bearing speed limit concern. For installations where the electrical supply is 50 Hz (Europe, Asia, Africa, South America, Australia, the Middle East \u2014 approximately 70% of the global electrical grid), the ZR120 at 3,000 rpm is the zero-compromise motor match.<\/p>\n<\/div>\n

60 Hz Compatibility<\/strong><\/p>\n

For 60 Hz electrical systems (North America, parts of South America, Japan, South Korea): a 2-pole motor at 60 Hz runs at 3,600 rpm synchronous \u2014 exceeding the 3,000 rpm limit. Solution: the VFD limits the motor frequency to 50 Hz (3,000 rpm), or a 4-pole motor at 60 Hz (1,800 rpm) is selected. Both are standard configurations. For marine vessels with 60 Hz generators, the VFD frequency limit is a single parameter change. The ZR120 is compatible with every global electrical standard through standard motor and VFD practice.<\/p>\n<\/div>\n<\/div>\n<\/section>\n

<\/p>\n

\n

133,000 Nm Right-Angle \u2014 Near-Mega-Class Torque from a Perpendicular Motor<\/h2>\n

\"ZR120<\/p>\n

\n
\n

Heavy Electric Cranes in Constrained Geometry (80-120 t)<\/h3>\n

Electric cranes at 80-120 tonne SWL where the machinery room constrains the coaxial geometry. The ZR120 delivers 95% of the 414W3 mega-class continuous from a right-angle motor mount. The slewing drive<\/a> En wheel drive<\/a> complete the all-electric crane system. The 280,000 Nm peak exceeds the 417W3 mega-class continuous \u2014 absorbing transient overloads from grab operations, subsea deployment, and emergency stops.<\/p>\n<\/div>\n

\n

Heavy Marine Anchor Handling and Mooring Winches<\/h3>\n

Main anchor handling and permanent mooring winches on AHTS vessels, FPSOs, and semi-submersible platforms where the drum axis runs athwartship. The ZR120 at 133,000 Nm provides the anchor chain tension and mooring line holding capacity that the 414W3 mega-class traditionally served \u2014 from an electric platform with regen, DIN 5-6 precision, and IP67+ sealing for the deck-mounted marine environment.<\/p>\n<\/div>\n

\n

Electric Mining Main Production Winders (500-800 m)<\/h3>\n

Main production winders on mine headframes where the motor mounts perpendicular to the drum. The ZR120 at 133,000 Nm with 600-900 kW motors at 3,000 rpm provides the winding torque for 500-800 metre shafts with 15-22 tonne skip loads. Regen recovery 20-35%. The 3,000 rpm speed matches the standard mine electrical infrastructure<\/a> \u2014 2-pole motors, 50 Hz supply, standard VFD \u2014 without special motor procurement.<\/p>\n<\/div>\n<\/div>\n<\/section>\n

<\/p>\n

\n

The ZR Right-Angle and ZL Coaxial Families<\/h2>\n
\n
\"Winch<\/p>\n
\n

ZR150 and ZR200 \u2192<\/a><\/h3>\n

160,000-175,000 Nm right-angle \u2014 the top of the right-angle catalogue.<\/p>\n<\/div>\n<\/div>\n

\"ZL<\/p>\n
\n

ZL120 Coaxial Equivalent \u2192<\/a><\/h3>\n

Same 133,000\/280,000 Nm, coaxial at 5,000 rpm, 1-5 stages for unrestricted geometry.<\/p>\n<\/div>\n<\/div>\n

\"Slewing<\/p>\n
\n

Slewing Drive Planetary Gearbox \u2192<\/a><\/h3>\n

ZR series for heavy crane rotation on the same all-electric platforms.<\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/section>\n

<\/p>\n

\n

Right-Angle Winch Drive Planetary Gearbox \u2014 ZR120 3-Stage FAQ<\/h2>\n
\n
\n

How much longer is the ZR120 at 3-stage versus the ZR95 at 2-stage?<\/h3>\n

Approximately 80-120 mm, depending on the specific ratio combination. The ZR95 at 2-stage is approximately 350-400 mm behind the drum mounting face. The ZR120 at 3-stage is approximately 450-520 mm. For installations with 400-450 mm of available depth, the ZR95 at 2-stage (115,000 Nm) is the last option. For installations with 500+ mm, the ZR120 at 3-stage (133,000 Nm) fits comfortably. The 80 mm difference is the cost of the 16% torque increase from ZR95 to ZR120.<\/p>\n<\/div>\n

\n

Does the ZR120 share planetary spare parts with the ZL120?<\/h3>\n

Yes. The planetary stages (stages 2-5 in ZR120, stages 1-5 in ZL120) share gear sets, bearings, carriers, and seals at overlapping ratios. Only the bevel stage and input housing are ZR-specific. Fleet operators running both ZR120 and ZL120 benefit from shared planetary spare parts \u2014 reducing total inventory cost by approximately 40-60% compared to maintaining separate kits.<\/p>\n<\/div>\n

\n

Can the ZR120 replace the 414W3 mega-class for marine winch applications?<\/h3>\n

For cyclic duty where sustained torque stays below 133,000 Nm: yes. The ZR120 provides 95% of the 414W3 continuous with 280,000 Nm peak (exceeding the 417W3 continuous), regen braking, DIN 5-6 precision, and the right-angle geometry that athwartship marine winches require. For sustained multi-hour holding above 133,000 Nm (AHTS weather standby, permanent mooring tensioning), the 414W3 at 140,000 Nm continuous remains the correct specification.<\/p>\n<\/div>\n

\n

What motor frame is typical for the ZR120 at 100 t crane duty?<\/h3>\n

At ratio 100, 600 mm PCD drum, 10-part reeving, 100 t at 10 m\/min: motor power approximately 700-900 kW. At 3,000 rpm: IEC 355-400 frame (900-1,400 kg). The perpendicular motor mount places this weight beside or below the drum rather than behind it \u2014 improving the structural load distribution on the drum support. For marine winches where the motor mounts on a steel foundation bolted to the deck, the motor weight is transferred directly to the vessel structure rather than cantilevered from the drum.<\/p>\n<\/div>\n

\n

What overhaul interval applies to the ZR120?<\/h3>\n

The 100,000-hour life rating applies. The 3-stage configuration distributes wear more evenly across the gear train than the 2-stage models \u2014 the bevel gears no longer wear faster than the planetary gears. Target first overhaul at 25,000-30,000 hours for industrial and mining applications, 20,000-25,000 hours for marine. Oil changes every 1,500-2,000 hours depending on environment. Oil sampling every 500-1,000 hours. Bevel and planetary gears inspected together at each overhaul. Contact Korea Ever-Power<\/a> for the environment-specific maintenance schedule.<\/p>\n<\/div>\n<\/div>\n<\/section>\n

<\/p>\n

\n

Field Reports<\/h2>\n
\n
\n
\n
N<\/div>\n
\n
Nils A. \u2014 Heavy Electric Crane Retrofit Programme Lead<\/div>\n
Verified Purchase \u00b7 Stavanger, Norway \u00b7 Jan 2026<\/div>\n<\/div>\n
\u2605\u2605\u2605\u2605\u2605<\/div>\n<\/div>\n

100 t offshore platform crane, hydraulic-to-electric conversion. The machinery room offered 480 mm behind the drum \u2014 enough for the ZR120 at 3-stage (465 mm installed depth) but not enough for the ZR95 at the required 4-stage ratio (510 mm). The ZR120 at ratio 100, 3-stage, 800 kW motor delivered 133,000 Nm \u2014 95% of the 414W3 that the crane originally used. The 5% torque reduction was approved by the classification society because the crane’s maximum operating torque (measured from 3 years of load recorder data) was 118,000 Nm \u2014 well within the ZR120 capacity. The conversion eliminated the HPU and 180 metres of hydraulic hose. Regen recovery: 21% over 10 months. The crane is now the largest right-angle electric crane conversion in the North Sea fleet.<\/p>\n<\/div>\n

\n
\n
J<\/div>\n
\n
James K. \u2014 FPSO Mooring Winch Systems Lead<\/div>\n
Verified Purchase<\/div>\n<\/div>\n
\u2605\u2605\u2605\u2605\u2605<\/div>\n<\/div>\n

Permanent mooring winch on an FPSO, ZR120 at ratio 80, 3-stage, 600 kW AC motor at 3,000 rpm. The winch maintains constant tension on 8 mooring lines at 40-70% of continuous rating (53,000-93,000 Nm) for months at a time. The ZR120 3-stage thermal distribution at this sustained duty keeps the oil temperature stable at 62-68 deg C in the tropical environment (32 deg C ambient) \u2014 well within limits. The 280,000 Nm peak absorbed a sudden squall event that produced 2.6x line tension on the windward mooring point \u2014 the highest transient the vessel has experienced since commissioning. The winch system automatically adjusted the line length through the VFD speed control to restore the target tension within 8 seconds.<\/p>\n<\/div>\n

\n
\n
D<\/div>\n
\n
Daniel F. \u2014 Mine Winder Modernisation Director<\/div>\n
Verified Purchase \u00b7 April 2026<\/div>\n<\/div>\n
\u2605\u2605\u2605\u2605\u2606<\/div>\n<\/div>\n

Main production winder at a 720-metre gold mine, ZR120 at ratio 280, 4-stage, 750 kW AC motor at 3,000 rpm mounted vertically. Skip weight 20 tonnes; rope weight at full depth 3,800 kg. Sustained drum torque during loaded hoist: 124,000 Nm \u2014 93% of ZR120 continuous. Regen recovery: 26% of hoist energy (USD 380,000 annual saving at current electricity rates). The 4-star reflects a motor alignment observation: at 3,000 rpm through the right-angle bevel, the alignment tolerance between the motor shaft and the bevel input shaft is tighter than at the 3,100 rpm models \u2014 the laser alignment required two iterations during commissioning instead of the typical one. For ZR120 installations at 3,000 rpm, specifying laser alignment with a 0.02 mm tolerance (instead of the 0.05 mm standard for the 3,100 rpm models) would reduce the commissioning alignment time.<\/p>\n<\/div>\n<\/div>\n<\/section>\n<\/div>","protected":false},"excerpt":{"rendered":"

The EP-ZR120 crosses two thresholds simultaneously: it is the first ZR right-angle winch drive to require a minimum of three stages (bevel + 2 planetary), and the first to operate at 3,000 rpm rather than 3,100. Both changes follow from the same cause \u2014 the larger bevel gears at 133,000 Nm produce higher tooth stresses and higher peripheral velocities that demand additional torque distribution and a lower speed ceiling. At 133,000 Nm continuous and 280,000 Nm peak, the ZR120 delivers 95% of the 4xxW 414W3 mega-class from a right-angle electric platform \u2014 for installations where the motor must mount perpendicular to the drum at near-mega-class torque.<\/div>","protected":false},"featured_media":1003,"comment_status":"open","ping_status":"closed","template":"","meta":{"_et_pb_use_builder":"","_et_pb_old_content":"","_et_gb_content_width":""},"product_brand":[],"product_cat":[969],"product_tag":[],"class_list":["post-1002","product","type-product","status-publish","has-post-thumbnail","product_cat-winch-drive-planetary-gearbox","first","instock","shipping-taxable","product-type-simple"],"_links":{"self":[{"href":"https:\/\/planetary-gearboxes.com\/nl\/wp-json\/wp\/v2\/product\/1002","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/planetary-gearboxes.com\/nl\/wp-json\/wp\/v2\/product"}],"about":[{"href":"https:\/\/planetary-gearboxes.com\/nl\/wp-json\/wp\/v2\/types\/product"}],"replies":[{"embeddable":true,"href":"https:\/\/planetary-gearboxes.com\/nl\/wp-json\/wp\/v2\/comments?post=1002"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/planetary-gearboxes.com\/nl\/wp-json\/wp\/v2\/media\/1003"}],"wp:attachment":[{"href":"https:\/\/planetary-gearboxes.com\/nl\/wp-json\/wp\/v2\/media?parent=1002"}],"wp:term":[{"taxonomy":"product_brand","embeddable":true,"href":"https:\/\/planetary-gearboxes.com\/nl\/wp-json\/wp\/v2\/product_brand?post=1002"},{"taxonomy":"product_cat","embeddable":true,"href":"https:\/\/planetary-gearboxes.com\/nl\/wp-json\/wp\/v2\/product_cat?post=1002"},{"taxonomy":"product_tag","embeddable":true,"href":"https:\/\/planetary-gearboxes.com\/nl\/wp-json\/wp\/v2\/product_tag?post=1002"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}