Instruction Manual Hydraulic Winches ASD Tug 2.0 3212-2913-2813 V0

Damen Shipyards BV
proprietors. Use only allowed within the scope of an order to

“Property of Bosch Rexroth B.V. Boxtel, the Netherlands.
whatsoever, not allowed without written consent of the
Reproduction or disclosure to third parties in any form
Hydraulic winches Tug 2.0

or from Bosch Rexroth B.V..”
2813/2913/3212
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Orgineel\Ch1 Instruction manual(GEN)\Instruction manual
Hydraulic winches ASD Tug 2.0 3212-2913-2813 V0.2
Instruction manual Hydraulic CONCEPT.docx
winches ASD Tug 2.0 PRINTED: 29/05/2018 13:49:00
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PROJECT : GENERIC
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Hydraulic winches Tug 2.02813/2913/3212 Page 2 of 85

Instruction manual Hydraulic winches ASD Tug 2.0
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Table of Contents
1 Preface ........................................................................................................................... 6
1.1 Terms and abbreviations ....................................................................................... 7
2 Safety ............................................................................................................................. 8
2.1 Safety symbols in the manual ................................................................................ 9
2.2 General safety aspects ........................................................................................ 10
Electrical system .................................................................................... 12
Hydraulic system.................................................................................... 13
2.3 Specific safety aspects ........................................................................................ 16
3 Handling & Installation ............................................................................................... 18
3.1 Requirements ...................................................................................................... 18
Personnel ............................................................................................... 18
Tools and materials................................................................................ 18
Environment ........................................................................................... 19
3.2 Handling ............................................................................................................... 19
Hoisting .................................................................................................. 20
3.3 Installation ............................................................................................................ 20
Preparation ............................................................................................ 21
3.4 Checklist .............................................................................................................. 23
4 System overview ......................................................................................................... 24
4.1 Total system overview ......................................................................................... 24
4.2 Electrical system .................................................................................................. 25
Emergency stop ..................................................................................... 25
4.3 Hydraulic system components ............................................................................. 26
Hydraulic pumps .................................................................................... 26
Hydraulic tank unit ................................................................................. 27
5 User interface .............................................................................................................. 28
5.1 Control locations .................................................................................................. 28
Bridge (Main control).............................................................................. 28
Mobile .................................................................................................... 31
Deck panels ........................................................................................... 33
Foot pedals ............................................................................................ 36
Winch Control cabinet ............................................................................ 37
6 Operation ..................................................................................................................... 38
6.1 General ................................................................................................................ 38
6.2 Start-up of WCC .................................................................................................. 39
6.3 Start-up of auxiliary pump .................................................................................... 39
6.4 Winch selection .................................................................................................... 40
FWD winch selection ............................................................................. 40
AFT winch selection ............................................................................... 40
6.5 Control station transfer ........................................................................................ 41
Station transfer bridge – mobile control unit .......................................... 42
Station transfer bridge – FWD deck panel ............................................. 44
Station transfer bridge – AFT deck panel .............................................. 45
Station transfer bridge – foot pedals ...................................................... 46
6.6 Operation ............................................................................................................. 47

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Manual - joystick (normal mode) ............................................................ 47
Manual – brake release ......................................................................... 50
Force limit control (FLC) ........................................................................ 51
Auto mode.............................................................................................. 51
Emergency control ................................................................................. 53
Manual line length control ...................................................................... 54
6.7 Auxiliary functions ................................................................................................ 54
Navigation mast ..................................................................................... 54
Towing pins ............................................................................................ 54
Deck crane (enable)............................................................................... 55
Oil recovery connection ......................................................................... 55
Towing hook........................................................................................... 55
Oil monitoring ......................................................................................... 55
Karmoy towing pins................................................................................ 56
7 Maintenance and repair .............................................................................................. 57
7.1 General notes on maintenance ............................................................................ 58
Hydraulic ................................................................................................ 59
Electrical ................................................................................................ 61
7.2 Maintenance schedule ......................................................................................... 62
7.3 Lubrication / Oil changes ..................................................................................... 66
Environmental regulations ..................................................................... 66
7.4 Preservation ......................................................................................................... 67
General remarks .................................................................................... 67
Overall preservation system .................................................................. 67
Internal preservation hydraulic parts ...................................................... 67
7.5 Repair .................................................................................................................. 68
7.6 Storage ................................................................................................................ 69
Storage .................................................................................................. 69
Long-time storage .................................................................................. 69
7.7 Disassemble and dismantle ................................................................................. 69
8 Troubleshooting .......................................................................................................... 70
8.1 Alarm list .............................................................................................................. 71
8.1 Electrical system .................................................................................................. 73
Insulation failure ..................................................................................... 73
Pushbuttons ........................................................................................... 73
Emergency-stop pushbutton .................................................................. 74
Voltage supply ....................................................................................... 74
Quick release (winch brake/ towing hook) ............................................. 74
Analog signals........................................................................................ 74
Proportional valve .................................................................................. 75
Mobile .................................................................................................... 75
Emergency stop ..................................................................................... 76
To high engine RPM .............................................................................. 76
Drum speed ........................................................................................... 77
Wire force............................................................................................... 77
Wire length ............................................................................................. 77
Auto mode.............................................................................................. 77
Control system alarm ............................................................................. 78
Clutch alarm ........................................................................................... 78
8.2 Hydraulic system ................................................................................................. 79
Unusual or excessive noise ................................................................... 79

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Fluid temperature too high ..................................................................... 80
External fluid leakage............................................................................. 80
Insufficient hydraulic pressure ............................................................... 81
Unusual/excessive pressure, fluctuations in flow, vibrations ................. 82
Non or insufficient fluid flow ................................................................... 83
Analog signals........................................................................................ 83
Proportional valve .................................................................................. 84
9 Spare parts .................................................................................................................. 85
9.1 Recommended spare parts ................................................................................. 85
9.2 Ordering spare parts ............................................................................................ 85

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1 Preface
This document contains the technical information necessary for safe and correct operation
and maintenance of the hydraulic equipment, limited to the Bosch Rexroth B.V. scope of
supply (see section 4). Furthermore, this document will inform and warn for residual risks
and/or indicate whether any particular training is required and/or specify any need to provide
personal protection equipment.
The system is designed and delivered under order numbers:

for the hydraulic installation: see diagram
for the electric installation: see diagram.
by:
Bosch Rexroth B.V.
P.O. Box 32
5280 AA Boxtel
The Netherlands
Phone : +31 (0)411 – 651 951

Fax : +31 (0)411 – 651 561
Email : services.boxtel@boschrexroth.nl
Internet : www.boschrexroth.nl
In this document, the following symbols are used to denote the several aspects:
WARNING
Warns for possible injury to the operator if the operator does not follow the
instructions carefully.
CAUTION
Warns for possible damage to the installation or the environment if the operator
does not follow the instructions carefully.
NOTE
Advises and suggests the operator to perform specific tasks and operations in
an easier and simpler manner.

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This manual is written for skilled and qualified:
 operation personnel;
 installation and maintenance personnel.
Skilled and qualified personnel must have:

 sufficient technical education and training;
 experience with comparable systems.
WARNING
All persons who are in the vicinity of, or work on the system must obey the
safety precautions according to chapter 2 of this document.
NOTE
Specific training for this system can be arranged by Bosch Rexroth B.V.
Chapter 2 deals with the safety of the installation and is of the utmost importance for
everyone who works with the installation or is even present in the vicinity of the
installation.
1.1 Terms and abbreviations
End-user : GENERIC
Customer : Damen Shipyards
Main contractor : Bosch Rexroth B.V.
Manufacturer : Bosch Rexroth B.V.
FLC : Force limit control

WCC : Winch Control Cabinet

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2 Safety
This section deals with health, safety and environmental aspects that can result from the use
of the system and gives an overview of the safety instructions that must be obeyed for a safe
and correct use of the system, including dangerous situations that arise by foreseeable
misuse of the system.
Before the initial start-up of the equipment, read these instructions, including the safety
instructions according the datasheets, in order to eliminate the risk of bodily harm or material
damage. Follow these safety instructions at all times. Do not attempt to install or start up this
equipment without first reading all documentation provided with the product.
Read and understand these safety instructions and all user documentation of the equipment
prior to working with the equipment at any time. If you do not have the user documentation
for your equipment, contact Bosch Rexroth B.V. to send this documentation immediately to
the person or persons responsible for the safe operation of this equipment. If the equipment
is resold, rented, transferred or passed on to others, these safety instructions must be
delivered with the equipment.
WARNING
 Do not use the equipment without obeying all safety instructions.
 Do not disable any safety device or make changes to the

equipment.
 Failure to obey the safety instructions or tampering with the

product or safety devices may result in material damage, bodily
harm, electric shock or even death!
Bosch Rexroth B.V.'s guarantee expires when:

 the instructions in this manual were not obeyed or not carried out properly;
 the system was overloaded or operated wrongly;
 the installation was modified without prior written consent of Bosch Rexroth B.V.;
 non-Bosch Rexroth B.V. approved spare parts were used.
The safety aspects are subdivided in general safety aspects (section 2.2) and specific safety
aspects (section 2.3). The specific safety aspects precede the disclosure of the related
specific operations.

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2.1 Safety symbols in the manual
All safety precautions used in this manual are indicated by symbols. The types of safety
precautions and symbols used in this manual are explained in the following table.
Suggests and advises the user for safe, correct and easy use of the system.
The user must put on protective footwear.
The user must put on a safety helmet.
The user must use eye protection.
Orders the user to use ear protection.
Prohibits the user to switch on a device.
Warns the user for personal danger or possible damage to system or facility.
Warns the user for the danger of an electrical hazard.
Warns the user for the danger of a hot surface.
Warns the user for the danger of a shearing hazard.
Warns for possible injury to the operator if the operator does not follow the
instructions carefully.

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2.2 General safety aspects
WARNING
Always wear the obligatory safety gear such as safety
shoes, helmet, gloves and clothing when maintenance or
repair activities are performed.
WARNING
 Only press the emergency-stop button in case of a dangerous situation
that involves injury of persons or damage to the equipment.
 Only reset the emergency-stop after the problem that causes the
dangerous situation has been solved.
CAUTION
 Only use the system for its intended purpose.
 Personnel authorized to operate or maintain the installation must be

qualified to perform their respective tasks.
 Personnel authorized to operate or maintain the installation must be

informed regarding special instructions and responsibilities.
 Personnel authorized to operate or maintain the installation must inform

their superiors regarding modifications in the installation.
 Personnel authorized to operate or maintain the installation must inform

their superiors regarding operational changes they experience, e.g.
increased noise level.
 Operate the installation carefully and cautiously. It can be expected that

personnel operates the installation and acts with care for its own safety,
health, and well-being and for that of others.
 Personnel must:
o operate and handle machinery, tools, dangerous goods and auxiliary
gear in a professional and correct manner;
o never modify, bypass or remove safeguards from the machinery;
o report dangerous situations and near misses to their superiors;
o cooperate to support a healthy environment;
o use the issued personal safety equipment according to the
regulations;
o not perform any activities that could endanger health or cause
damage to the system.

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NOTE
In the event that instructions, maintenance intervals, etc. deviate from each
other, execute the most profound instructions.
NOTE
A service/maintenance book must be prepared, in which it is laid down which
parts of the installation must be checked and where actions can be noted.
NOTE
 Distribute the instruction manual among all personnel that operates or
maintains the system. Verify that it is of the latest revision.
 Make sure that all instructions are read and clearly understood.
 Make sure that personnel comply with all relevant rules and legislation
regarding health, safety and environmental aspects.
 Maintain the installation, spare parts, machinery and tools as described

in this manual.
 Keep the installation and its environment clean and tidy.
 Maintain a log, noting and dating all inspections, maintenance, repairs,

adjustments, test results and exchange of parts.
 Maintain a log, noting and dating all failures, the cause of the failures
and the remedy.
NOTE
 Use cleaning agents and solvents sparingly. Use of aggressive products
can cause damage to parts.
 Only use recommended lubricants, tools and test equipment or

permitted alternatives, according to original Bosch Rexroth B.V.
instructions.
 Hydraulic oil and other lubricants must not pollute the environment.
Take care of environmental friendly disposal. Always obey the relevant
national rules and regulations.

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CAUTION
 Do not start the equipment before the installation and the area around
the installation are free of obstacles.
 Never alter adjustments and parameters, unless it is disclosed in this

instruction manual.
Electrical system
WARNING
 Do not work on the electrical system with power applied unless
absolutely necessary. If maintenance must be carried out on the system
with electric power switched on, it is the responsibility of the individual to
exercise proper caution when working in the vicinity of an electrical
hazard (voltages in excess of 30 Vrms or 50 VDC). A second person
must always be in attendance. Use a padlock to lock the main switch in
the ‘OFF’ position.
 Work on/with the system must only be performed by persons who are
authorized to do so, based on their training and qualifications. In
addition, the persons must be assigned by the operating company.
 Inform the persons in charge of modifications carried out on the system

and changes in the operating behaviour (i.e. excessive noise level).
 Do not perform any activities that could endanger health or cause

WARNING
 Never work on or in the vicinity of moving parts unless it is impossible to
perform the task required in another way.
 Do not modify the settings of safety-related equipment without written

consent of Bosch Rexroth B.V.

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WARNING
 Make sure it is not possible to switch on the installation during
maintenance and repair of the installation unless it is required by
procedure. Use a padlock to lock the main switch in the ‘OFF’ position.
 Make sure that it is safe to switch on the system, especially after

maintenance or repair is performed. Make sure that all electrical and
mechanical connections are properly connected.
 Do not switch on the system unless all wiring is properly connected.
Hydraulic system
WARNING
 Use chemical-resistant gloves, splash goggles, and a chemical-resistant
apron or other impervious clothing to avoid prolonged or repeated skin
or eye contact.
 Wash off affected skin, eyes and protective clothing immediately.

Remove contaminated clothing, and launder or dry-clean it before reuse.
WARNING
 Before working with hydraulic oil, know the location of the nearest
emergency shower and eyewash station.
 After contact with hydraulic oil (and especially before breaks, meals and
at the end of shifts), always clean the skin with a waterless hand
cleanser, and then wash with soap and water.
WARNING
 Excessive leakage from hydraulic fluid precludes system operation until
the leakage is corrected.
 Clean up spilled hydraulic fluid immediately. Hydraulic fluid is an oily

substance, which can cause slipping, falling and resulting injuries.

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WARNING
 Always use the recommended hydraulic oil, refer to section 3.3.3. Never
swap to another oil brand, type or viscosity without consulting the
designer of the system.
 Review the Material Safety Data Sheets (MSDS) for all chemicals used.
 Hydraulic oil is a petroleum lubricating oil. It is a clear, light-yellow liquid

with a mild, bland petroleum odor. When working with or near this
material, avoid prolonged breathing of its vapor, mist and fumes, and
avoid prolonged or repeated skin contact.
 Elevated processing temperatures may cause release of toxic vapors,

which are harmful if inhaled.
CAUTION
 Never start working on a hydraulic system until fully trained.
 Do not work under equipment/apparatus being supported by hydraulics.

Stops, safety pins, etc. must be in place prior to beginning repairs.
 Block, secure or lower those components to the ground that may move,
rotate or fall.
 Relieve system pressures (Note: some systems use accumulators that

store pressure. Identify the system before working on it).
 Use extreme caution when hydraulic lines are being disconnected.

This can result in severe burns due to hot fluid.
 Use test equipment designed for higher pressures than the system
being repaired. Use of gauges, lines, connectors, etc., designed for
lower pressures can result in bursting or equipment damage. Start with
high-pressure gauges and work down (Note: a good rule is to use
equipment rated 1,5x of what is expected. Example: For a 300bar
system, use a 450bar gauge).
 DO NOT USE HANDS OR FINGERS to find leaks.

Fluid under high pressure can be injected into skin causing extreme
injury and serious infection.

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CAUTION
Hydraulics fluids are widely utilized for transmission of power or motion.
Pressurized oil in hydraulic systems presents a considerable health and safety
hazard. Hydraulic fluid released accidentally from the system may be ignited by
external ignition sources. Remove flammable material from the area of the
installation.
CAUTION
 General maintenance instructions for the hydraulic equipment are
provided in the following datasheets:
o “Rexroth RE 07009 B - General operating instructions”
o “Rexroth RE 07009 M - General assembly instructions”
o “Rexroth RE 07075 - Hydraulic fluids”
o “Rexroth RE 07080 - Hydraulic pumps and motors”
o “Rexroth RE 07300 - Industrial valves”
o “Rexroth RE 07800 - Proportional valves”
o “Rexroth RE 07900 - Hydraulic systems”
 Always study the concerning component datasheets as provided with

this manual before maintenance activities are performed.
 The hydraulic system contains several components, which are sensitive

to contamination. When any part of the hydraulic equipment is
dismantled, make sure to work clean, so no contamination or dust can
enter the hydraulic system, flush if necessary.
 After abnormal wear or damage of components in the hydraulic

installation is discovered, it is very important to remove all wear parts
and particles out of the hydraulic installation. In case of doubt or serious
damage dismantle the complete system, clean and replace the hydraulic
fluid.

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2.3 Specific safety aspects
Maintenance and regular checks ensure an extremely high safety for the system.
WARNING
Never operate the installation in a hazardous area, as the equipment is not
designed to be explosion proof.
WARNING
 All high-pressure hydraulic hoses that are located on open deck must be
checked for damage and corrosion prior to every handling operation.
 Prevent damage to the interconnecting cabling and hoses. Replace

interconnecting cabling and hoses when damage or corrosion is found.
 Never change the settings according to the hydraulic diagram of the

components (e.g. pressure relief valves, pressure switches and pre-fill
pressure) without written permission of Bosch Rexroth B.V.
CAUTION
 Keep away from the danger zone when the system is activated.
 Personnel that operate the system must at all times keep the system
under close observation especially during operation.

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Electrical system
WARNING
Do not switch on the electric power while maintenance is carried out on the
system unless it is required by procedure. Use a padlock to lock the main switch
at the WCC in the ‘OFF’ position.
WARNING
Not all power is switched off by the main switch. Disconnect extern power
supply while maintenance is carried out on the system unless it is required by
procedure.
WARNING
Do NOT switch of MAIN SWITCH of WCC when diesels are running.
Hydraulic system
WARNING
 The hydraulic equipment operates with oil under high pressure.
Furthermore, large amounts of energy can be accumulated in the
hydraulic system. A temperature rise will also result in a pressure
increase.
 Pressurized oil can escape during maintenance.

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3 Handling & Installation
This chapter provides the user with specific information for safe handling and transport of the
hydraulic equipment and to describe the installation instructions for this system.
3.1 Requirements
Personnel
WARNING

This manual is written for skilled and qualified installation personnel. The persons in charge
must have:
 sufficient technical education and training;
 experience with comparable systems or training in relation to this system.
Any personnel using the instructions as described in this document should be familiar with
the safety instructions according section 2.
Tools and materials
The following equipment is required during installation of the system:

 Normal tool kit

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Environment
Installation of the hydraulic equipment is performed without special measures to prevent

chemicals from entering the environment.
CAUTION
 Do not spill hydraulic oil and lubricants on the floor. Take care of
environmental friendly disposal. Always follow the relevant national rules
and regulations.
 Dispose of any waste material according local legislation. Contribute to

recycling waste material by separating and recycling refuse.
3.2 Handling
WARNING
shoes, helmet, gloves and clothing during handling and
installation of the system.
WARNING
 Personnel that handle the system must never undertake such actions
that cause damage to the installation or environment or that cause
dangerous situations.
 All persons who are near, or work on the system must obey the safety
precautions according section 2.
If any additional information is required, do not hesitate to contact the manufacturer.

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Hoisting
Each large sub-assembly is provided with connection points for safe hoisting of the
equipment.
CAUTION
 Use the proper hoisting equipment for transportation of the components.
 Take care that the centre of gravity of the components is located in the
centre of the hoisting points to guarantee stability during hoisting.
If no hoisting provisions are provided on the component, the installation/maintenance

personnel should decide where and how the individual parts are hoisted. However, it is
required to use common sense and caution when the components are handled.
3.3 Installation
This chapter provides the installation instructions for the main components of the system;
also refer to the layout drawing.
WARNING
shoes, helmet, gloves and clothing during handling and
installation of the system.
WARNING
Make sure that there are no obstacles in the installation area of the system.
CAUTION
 Prevent damage to the interconnecting hoses, cabling and piping.
 Make sure no dirt can enter the hoses and/or piping, as this will cause
serious damage to the hydraulic components.
 Strictly adhere to the minimum bending radius to prevent damage to the

hoses and cabling.

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Preparation
Before installation is started, make sure that:

 all delivered components are not damaged;
 electric power and ground connections, according to the cable diagram are
available;
 the installation area is clean and free from obstacles;
 the mounting surfaces are clean;
 tools and materials as specified in section 3.1.2 are available.
Electrical system
3.3.2.1 Interconnecting cabling
WARNING
 Strictly adhere to the minimal bending radius to prevent damage to the
cabling and dangerous situations.
 Replace interconnecting cabling when damage is found.

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Hydraulic system
CAUTION
 The approved hydraulic oil for this hydraulic system is a mineral based
oil acc. to HLP-ISO-VG68. Use only this specified type of hydraulic oil
for oil filling or topping-up.
 Hydraulic oil and other lubricants must not pollute the seawater.
3.3.3.1 Interconnecting hoses
Flush all interconnecting hoses properly to the ISO 17/15/13(NAS 1638 Class 6)(or better)
standard prior to hook-up the hydraulic equipment.
WARNING
hoses and dangerous situations.
 Replace interconnecting hoses when damage or corrosion is found.
CAUTION
 Make sure no dirt can enter the hoses and/or system lines, as this will
cause serious damage to the components.

3.3.3.2 Interconnecting piping
Installation of the hydraulic piping is performed according the product standard of Bosch
Rexroth pipe work. To ensure a clean system, in which piping can easily be mounted or
replaced, screwed or bolted connections must be used; fixed (welded) connections are to be
avoided.
All interconnecting piping must be flushed properly to ISO 17/15/13(NAS 1638 Class 6)(or
better) standard prior to hook-up the hydraulic equipment.
WARNING
Replace interconnecting piping when damage or corrosion is found.

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3.4 Checklist
Before the system is started for the first time, check that:
 all nuts and bolts are tightened with the correct torque and marked with sealing paint;
 the operational area is free from obstacles and persons;
 all safety pictograms and instruction labels/stickers are provided;
 all electrical cables are connected properly;
 all installed emergency-stop buttons are working properly;
 any waste material is disposed of according local legislation;
 All hydraulic piping is connected or plugged;
 Cooling water supply and discharge is connected;
CAUTION
Contribute to recycling waste material by separating and recycling refuse.

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4 System overview
This chapter provides a general overview of the delivered equipment.
4.1 Total system overview
As a basic system, the system consisting at least of following equipment:

 FWD Hägglunds winch double drums(dd)
 Joystick (bridge)
 Mobile controller
 main pumps
FWD deck
 Gearbox winch standard single drum (replaces standard FWD Hägglunds winch)*
 Hägglunds winch render/recovery winch (addition to FWD Hägglunds winch dd)*
AFT deck
 Gearbox winch single drum*
 Gearbox winch double drums*
Miscellaneous equipment
 Towing hook *
 Deck crane *
 Towing pins *
 Navigation mast *
 Oil recovery*
 Oil monitoring*
 Karmoy Towing pins*
NOTE
Not in the scope of supply of Bosch Rexroth B.V.:
 Motor Control Cabinet (MCC)
 Interconnecting Piping
(*) Option.

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4.2 Electrical system
This chapter gives some information regarding the main control components, which are
integrated into the controls of the hydraulic equipment.
The control equipment includes:

 Joystick
 Mobile control
 Winch control cabinet (WCC)
 FWD-deck control panel*
 AFT-deck control panel*
 Foot pedals (3 in total)*
NOTE
Not in scope of supply of Bosch Rexroth B.V.:
 Interconnecting cabling
Emergency stop
The functioning of the emergency-stops is set out in European standard EN 60204–1.

When one of these switches is activated, all pumps are stopped, all main switches of the
main pumps trip and all valves are disabled. An emergency-stop will shut down the system
immediately.
WARNING
The main switch does not turn the complete power supply of the system. 24 Volt
is always available.
WARNING
The emergency stop should be tested on a regular basis (minimum once a
week or before every voyage) to ensure a good functionality of the emergency
stop.
NOTE
 In the event the Emergency stop is pressed. The quick release is always
usable with the exception of the Mobile control.
 When the quick release is pressed on the Mobile control prior to

Emergency stop the quick release signal will stay active.
NOTE
After an emergency stop situation, the last active winch / drum is not active
anymore. Take over the control to bridge first and select the desired function.
(*) Option.

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4.3 Hydraulic system components
The Hydraulic Power Unit (HPU) delivers hydraulic power to all hydraulic equipment via the
hydraulic valve blocks. The HPU is installed according diagram.
 The HPU is designed, manufactured, assembled, preserved and tested according the
standards of Bosch Rexroth B.V.
 The HPU is designed suitable for HLP-ISO-VG68 range mineral oil and is delivered
flushed/cleaned to a fluid cleanliness level in accordance ISO 17/15/13(NAS 1638
Class 6)(or better).
NOTE
Not in the scope of supply of Bosch Rexroth B.V.:
 Interconnecting Piping
Hydraulic pumps
The hydraulic installation consists of four pumps, driven by two diesel engines that each
have two power take-off (PTO) shafts (C and B drive).
n-diesel : 650-1800 rpm.

i-gearbox : 1.33
n-PTO : 864-2394 rpm.
C-drive PTO : A15VLO145DPA00/10MRVD4A21SU0000-0

Vstroke : 125 cc/rev (reduced)
Qmax : 150 ltr/min/pump
Qty. installed : 2 (Item 200)
B-drive PTO : A15VLO145DPA00/10MRVD4A21SU0000-0

Vstroke : 105 cc/rev (reduced)
Qmax : 150 ltr/min/pump
Qty. installed : 2 (Item 210)
A 28 cc variable pump* with pressure control can be installed for delivering oil for clutches,
brakes, towing pins* and towing hook*.
P = 22 kW
n = 1460 rpm (1780 rpm/60 Hz)
Pump: A10VSO28DFR1/31L-PSA12N00
Vstroke = 28 cc/rev
Qmax = 39 ltr/min
(*) Option.

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Hydraulic tank unit
The tank unit has following main functions:

 Store the oil of the hydraulic system.
 Filtering the oil.
 Heating* / Cooling the oil.
 An electric powered pump set is installed* on the tank unit
 Main control of the winches
 Boost/cool pumps* are installed on the tank
 Leak oil filter fort the pumps* as well as leak oil filters* for the Hägglunds motors can
also be installed on the tank.
4.3.2.1 Hydraulic manifolds
 For energizing the brakes and clutches on the fore- and aft winch (optional), valves
are installed.
 For towing pins*, towing hook, deck crane*, and navigation mast* also valves can be
installed if option is installed
 Oil supply for Karmoy towing pins* and oil spill recovery set supply* can also be
installed on the tank.
4.3.2.2 Hydraulic accumulator
 For quick release of the towing hook and winch brakes by emergency a hydraulic
accumulator set is installed.
(*) Option.

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5 User interface
5.1 Control locations
The control and the settings of the winches, the pumps, towing hooks etc. proceeds
generally via the bridge. But the winches can be controlled both mobile and from the deck*
(fore + aft). Before the deck or mobile control can takeover, this control has to be enabled by
a selector switch on the winch control panel situated on the bridge.
Bridge (Main control)
5.1.1.1 Joystick
Controls:
1. Joystick haul / veer (forward/aft movement) or drum selection manual brake release
(left/right movement).
2. Enable joystick.
3. Friction drum 1(FWD)/ drum 3(AFT).
5. Scroll through Praxis menu or brake release.
6. Enter value or menu item.
7. Stroke control TWK winch or start/stop AUTO modus.
(*) Option.

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NOTE
The joystick is delivered by Bosch Rexroth to Damen and is built on to the
winch control panel on the bridge
5.1.1.2 Winch control panel
Besides the joystick there are also the bridge panel for controlling the winch system (not in
scope of supply Bosch Rexroth):
Controls:
1. Selector switch winch selection; AFT/ OFF/ FORE.

2. Selector switch control; REMOTE/ JOYSTICK/ PEDALS.
3. Push button QUICK RELEASE.
4. Push button EMERGENCY STOP.
NOTE
When quick release is pressed on the winch control panel on the bridge only the
brakes of the FWD and AFT* winches AND the towing hook* are released. For
emergency, this is a hard-wired function, and always usable.
NOTE
After a quick release winch brake situation, the last active winch / drum is not
active anymore. Take over the control to bridge first and select the desired
function.

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5.1.1.3 Praxis HMI
The Praxis HMI screen is situated on the bridge (not in scope of supply Bosch Rexroth).
Within this manual there will be made several references to this screen. A detailed functional
description is supplied by Damen Shipyards Gorinchem.
5.1.1.4 Towing pins control panel
The towing pins control panel* is also situated on the bridge (not in scope of supply Bosch
Rexroth).
Controls:
1. Push button towing pins PS UP*.

2. Push button towing pins PS DOWN*.
3. Push button towing pins SB UP*.
4. Push button towing pins SB DOWN*.
(*) Option.

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Mobile
Depending which winch is activated, the mobile control can be enabled by the bridge.
The mobile control can used wired or wireless.
Controls:
1. Release brake drum 1(FWD)/ drum 3(AFT).

2. Release brake drum 2(FWD)/ drum 4(AFT).
3. Joystick haul / veer.
4. Alarm light (notification).
5. Status light MCU control MCU.
6. Acknowledgment button control MCU.
7. Acknowledgment button MCU ON.
8. Status light MCU ON.
9. Mobile control unit ON/OFF.
10. Status light drum 1(FWD)/ drum 3(AFT) active.
12. Status light drum 2(FWD)/ drum 4(AFT) active.
14. Status light quick release winch brakes.
15. Quick release winch brakes.
16. Emergency stop.
17. Status light FWD winch active.
18. Status light AFT winch active.
19. Connector for wired control.

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NOTE
When quick release is pressed on the mobile control the brakes of the FWD and
AFT* winches are released.
NOTE
function.
(*) Option.

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Deck panels
Depending which winch is activated on the bridge, the control on either the fore deck or the
aft deck can be enabled via the FWD deck panel* and AFT deck panel*.
5.1.3.1 FWD deck panel
Controls:

2. Tonnage meter.
3. Emergency stop.
4. Friction button/light drum 1.
5. Release brake drum 1.
7. Friction button/light drum 2.
8. Release brake drum 2.
9. Acknowledgment button/light control deck panel FWD.
11. Joystick haul / veer FWD winch.
NOTE
When quick release is pressed on the FWD deck panel the brakes of the FWD
and AFT* winches are released. For emergency, this is a hard-wired function,
and always usable.
(*) Option.

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NOTE
function.

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5.1.3.2 AFT deck panel
Controls:

2. Emergency stop.
3. Friction button/light drum 3
4. Release brake drum 3
6. Friction button/light drum 4
7. Release brake drum 4
8. Acknowledgment button/light control deck panel AFT.
10. Joystick haul / veer AFT winch.
NOTE
When quick release is pressed on the AFT deck panel the brakes of the FWD
and AFT* winches are released. For emergency, this is a hard-wired function,
and always usable.
NOTE
function.

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Foot pedals
Foot pedals* can be installed on the bridge. De pedals can be used for basic FWD or AFT
winch operation.
Controls:
1. Release brake drum 1 or 3.

2. Haul / veer FWD or AFT winch.
3. Release brake drum 2 or 4.
(*) Option.

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Winch Control cabinet
Controls:
1. Main switch.
2. Emergency control switch; ON/OFF.
3. Emergency control winch selection switch; FWD/AFT.
4. Emergency control drum selection switch; PS/SB.
5. Auxiliary pump mode selection switch; ON/OFF/AUTO.
6. Emergency control HAUL button
7. Emergency stop reset button
8. Emergency mode active light.
9. Manual mode auxiliary pump active light.
10. Mobile control active light.
11. Emergency stop.

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6 Operation
6.1 General
This chapter contains general information necessary for the operation of the remote control
system.
CAUTION
 Do not start the equipment before the installation and the area around
the installation are free of obstacles.

 Do not use the system if cracks or damage is observed in the

mechanical construction. Replace damaged parts before the system is
restarted.
 Use the emergency stop to end the operation as soon as possible if

failures are observed. Do not restart the installation unless the failure is
corrected.
CAUTION
 Only use the system for its intended purpose.
 Operate the installation carefully and cautiously. It can be expected that

personnel operates the installation and acts with care for its own safety,
health, and well-being and for that of others.
 Personnel must:
o Operate and handle machinery, tools, dangerous goods and auxiliary
gear in a professional and correct manner;
o Never modify, bypass or remove safeguards from the machinery;
o Report dangerous situations and near misses to their superiors;
o Cooperate to support a healthy environment;
o Use the issued personal safety equipment according to the
regulations;
o Not perform any activities that could endanger health or cause
Before the equipment is started, perform the following checks:

□ Inspect the oil level visually.
□ Inspect all filter elements visually.
□ Check for oil leakage.
□ Perform a general inspection of hoses, piping, wiring and connectors.
□ Check if all suctions valves are opened.
□ Check if the installation and its surroundings are free of obstacles.
□ Make sure all emergency stop buttons are unlocked.

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6.2 Start-up of WCC
1. Set the main switch of the WCC in the “ON” position (see 5.1.4 (1)).
WARNING
Always switch on main switch WCC before starting the main diesel engines. Do
NOT switch of main switch when diesel engines are running.
2. When the WCC is switched on the “Emergency reset button” starts blinking.
3. Press the “Emergency reset button”. As soon as it is pressed de button stops blinking.
The system now has to be set on the bridge panel and Praxis screen (not in scope of supply
BR).
CAUTION
The main switch does not turn off the complete power supply of the system. 24
Volt is always available.
6.3 Start-up of auxiliary pump
The auxiliary pump* is automatically started and stopped when the control system requires
and if the Auxiliary pump mode selection switch is in AUTO (see 5.1.4 (5)). The auxiliary
pump is automatically started with:
 Accumulator pressure is low.
 Deck crane* is selected.
 Navigation mast* is actuated.
It is also possible to start and stop the auxiliary pump manually:

1. To start the auxiliary pump manually set the Auxiliary pump mode selection switch to
MANUAL. When this is done pumps starts.
2. To stop the auxiliary pump manually set the Auxiliary pump mode selection switch to
OFF. When this is done pumps stops.
CAUTION
When the auxiliary pump is installed and the Auxiliary pump mode selection
switch on the WCC is NOT in AUTO, it is not possible to proceed winch
operation.
CAUTION
When the auxiliary pump is installed and the Auxiliary pump mode selection
switch on the WCC is set to OFF, the accumulator is NOT automatically
charged.

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(*) Option.
6.4 Winch selection
After the WCC is started, it is possible to select the desired winch (FWD or AFT).
FWD winch selection
Winch selection of the FWD winch can be done on the winch control panel situated on the
bridge (see 5.1.1) via a selector switch:
 When the winch on the forward deck is required, set the winch selection switch from
OFF to FORE.
The FWD winch is now active and operation with the FWD winch can proceed.
 To deselect the FWD winch, set the winch selection switch from FORE to OFF.
NOTE
Only one winch can be selected and be used at the same time. Before using the
other winch, first the active winch needs to be de-activated.
AFT winch selection
If installed, winch selection of the AFT winch* can also be done same control panel situated
on the bridge (see 5.1.1) via a selector switch:
 When the winch on the forward deck is required, set the winch selection switch from
OFF to AFT.
The AFT winch is now active and operation with the AFT winch can proceed.
 To deselect the AFT winch, set the winch selection switch from AFT to OFF.
NOTE
Only one winch can be selected and be used at the same time. Before using the
other winch, first the active winch needs to be de-activated.
(*) Option.

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6.5 Control station transfer
After a winch is selected on the winch control panel on the bridge with the selector switch
AFT/ OFF/ FORE, it is possible to transfer the controls to another control station with the
selector switch REMOTE/ JOYSTICK/ PEDALS (See 5.1.1). Before the winch can be
controlled from another control station, this control station must be activated and
acknowledge on this station.
Control stations with FORE winch:

 Joystick Bridge
 Mobile control unit
 FWD deck panel*
Control stations with AFT winch:

 Bridge
 Mobile control unit
 AFT deck panel*
After a control station has been activated, the winch can only be controlled from this control
station, all other control stations are passive.
NOTE
Control station transfer can only take place when joystick is in 0 and drum
brakes are fully engaged.
NOTE
 When the FWD winch is active and the selector switch on the winch
control panel on the bridge is set to REMOTE, the status light MCU
control MCU (see 5.1.2(5)) as well as the acknowledgment button/light
control deck panel FWD* (see 5.1.3.1 (9)) starts blinking.
 When the AFT winch* is active and the selector switch on the winch
control panel on the bridge is set to REMOTE, the status light MCU
control MCU (see 5.1.2(5)) as well as the acknowledgment button/light
control deck panel AFT* (see 0 (8)) starts blinking.
(*) Option.

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Station transfer bridge – mobile control unit
Depending which winch is selected, the mobile control can be used for the fore or aft* winch.
The mobile control can used wired or wireless*. To use it wired connect the mobile from
connector (19) to the connector on deck. All functions are the same for wired or wireless
control.
1. Power on the mobile with switch (9). Status light MCU ON (8) is on.
2. Check if the emergency stop button (16) is not pressed and quick release winch brake
(15) button is not active.
3. Connect the mobile with the control system by pressing the Acknowledgment button
MCU ON (7).
4. The mobile is communicating with the system when the Status light MCU ON (8) is on
(Still not active control).
5. At the bridge the Selector switch control on the winch control panel is set to REMOTE
(see 5.1.1).
6. The Status light MCU control MCU (5) starts blinking on the mobile control unit.
7. By pressing the Acknowledgement button control MCU (6) the MCU becomes the active
control station. The joystick(3) and the potentiometers for releasing the drum brakes
(1)(2) have to be in 0 position.
8. The Status light MCU control MCU (5) now light continuously on the mobile control unit.

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The bridge winch control panel is the master station. Therefore it is always possible to take
back the controls to the bridge.
1. Transferring the control back to the bridge is done by switching the selector switch control
on the winch control panel is set to JOYSTICK (see 5.1.1). The joystick has to be in 0
position.
2. When the control is switched back to the bridge the Status light MCU control MCU (5)
stops.
3. The MCU can now be switched off.
CAUTION
When the mobile control unit is switched off due to radio loss during operation,
this will result in an automatic emergency stop.
NOTE
When quick release is pressed on the MCU only the brakes of the FWD and
AFT* winches are release.

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Station transfer bridge – FWD deck panel
When the FWD winch is selected and the REMOTE switch on the winch control panel on the
bridge is selected it is possible to select the MCU or the FWD deck panel* as an active
control station.
1. At the bridge the selector switch winch selection is set to FORE. (see 5.1.1).
2. At the bridge the selector switch control on the winch control panel is set to REMOTE
(see 5.1.1).
3. The acknowledgment button/light control deck panel FWD (9) starts blinking.
4. By pressing the acknowledgement button/light control deck panel FWD (9) the FWD deck
panel becomes the active control station. The joystick(11) and the potentiometers for
releasing the drum brakes (5)(8) have to be in 0 position.
5. The acknowledgment button/light control deck panel FWD (9) now light continuously on
the FWD deck panel.
position.
2. When the control is switched back to the bridge acknowledgment button/light control deck
panel FWD (9) stops.
3. The bridge panel is now the active station again.
(*) Option.

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Station transfer bridge – AFT deck panel
When the AFT winch is selected and the REMOTE switch on the winch control panel on the
bridge is selected it is possible to select the MCU or the AFT deck panel* as an active control
station.
1. At the bridge the selector switch winch selection is set to AFT. (see 5.1.1).
2. At the bridge the selector switch control on the winch control panel is set to REMOTE
(see 5.1.1).
3. The acknowledgment button/light control deck panel AFT (8) starts blinking.
4. By pressing the acknowledgement button/light control deck panel FWD (9) the FWD deck
panel becomes the active control station. The joystick(11) and the potentiometers for
releasing the drum brakes (5)(8) have to be in 0 position.
5. The acknowledgment button/light control deck panel FWD (9) now light continuously on
the FWD deck panel.
position.
2. When the control is switched back to the bridge acknowledgment button/light control deck
panel FWD (9) stops.
(*) Option.

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Station transfer bridge – foot pedals
Depending which winch is selected, the foot pedal control* can be used for the fore or aft*
winch.
1. At the bridge the selector switch winch selection is set to FORE or AFT(see 5.1.1).
2. At the bridge the selector switch control on the winch control panel is set to PEDALS (see
5.1.1).
3. The foot pedal control is now active, the joystick and rocker switch for brake release on
joystick is in active now.
4. Drum selection needs to be done on the joystick (see 5.1.1 (3)(4)).
back the controls to the joystick.
position
(*) Option.

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6.6 Operation
After a winch is selected and the desired control station is chosen, the winch can be
operated from that active control station in normal mode. Because the system is designed in
a modular way there are several modus possible with each winch type.
Winch type/modus overview

Winch operation modus
Manual – Manual - Manual – Auto Emergency Manual -
joystick brake force limit mode control line length
(Normal release control mode control
mode) brake
(FLC)
FWD winch types:
Gearbox winch ✔ ✔ ● ☓ ✔ ☓
Hägglunds winch ✔ ✔ ✔ ☓ ✔ ☓
Hägglunds R&R winch ✔ ✔ ✔ ✔ ✔ ☓
AFT winch types:

Gearbox winch ✔ ✔ ● ☓ ✔ ●**
✔: standard
●: optional
☓: not possible
**: Only required with RMRS
Manual - joystick (normal mode)
Prior to normal mode the desired drum has to be selected for winch operation:
1. Selection of the desired drum can be done via the active control station:
 Press button (3) or (4)) on joystick (see 5.1.1.1).
 Press button (11) or (13) on mobile control (see 5.1.2).
 Press button (4) or (7) on deck panel FWD* (see 5.1.3.1).
 Press button (3) or (6) on deck panel AFT* (see 0).
2. When the button of the desired drum is pressed the clutch will be engaged (friction) of the
selected drum. This will be depicted in the Praxis HMI. When the mobile control is active
status light (10) or (12) will light (see 5.1.2). For the deck panel FWD* button (4) or (7) will
light up (see 5.1.3.1). Drum selection AFT deck panel* will be depicted by button (3) or
(6) (see 0).
NOTE
Selection of the desired drum can only take place when the joystick and
potentiometers are in 0 position.
3. When the drum is selected, it is possible to control the drum speed with the active control
station with Joystick haul / veer. With pushing or pulling the joystick from minimum to
maximum position, the drum speed is controlled from minimum to maximum.
(*) Option.

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NOTE
With the joystick in neutral position, the brake is always engaged (friction).
To disengage (no friction) the active friction drum the joystick has to be in 0 position.
1. Deselection of the desired drum can be done via the active control station:
 Press button (3) or (4)) on joystick (see 5.1.1.1).
 Press button (11) or (13) on mobile control (see 5.1.2).
 Press button (4) or (7) on deck panel FWD* (see 5.1.3.1).
 Press button (3) or (6) on deck panel AFT* (see 0).
2. When the button of the desired drum is pressed the clutch will be disengaged (no friction)
of the selected drum. This will be depicted in the Praxis HMI.
When the mobile control is active status light (10) or (12) will stop lighting (see 5.1.2). For
the deck panel FWD* button (4) or (7) will stop lighting (see 5.1.3.1). When a drum is
deselected on the AFT deck panel* button (3) or (6) (see 0) will stop lightning.
NOTE
Only ONE drum can be selected at the same time for NORMAL mode
haul/veer.
NOTE
To select the other drum the joystick and potentiometers have to be in 0. When
the other is active it is possible to select the other drum on the active control
station. By doing this the active drum is automatically deactivated.
NOTE
With the TWK winch it is possible to switch the winch motor in two
displacements (reduced displacement  high speed OR full displacement 
reduced speed). For selecting displacement the “rabbit” button on the joystick
needs to be selected (see 5.1.1.1 (7)).
6.6.1.1 Wire length measurement
Each drum of the fore winch has two counters to count the rotations of the drum and the
turning direction. Depending of the wire thickness, the drum diameter, drum width and wire
length, there is an calculated wire length on one layer.
With these parameters the system is calculating the actual outstanding wire length, layer and
presents these values for each drum on the Praxis HMI. The parameters wire thickness and
wire length are adjustable on Praxis HMI screen.
NOTE
Prior to winch operation when the cable is fully on the drum, the length of the
cable has to be zeroed. This can be done on the Praxis HMI.
(*) Option.

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6.6.1.2 Wire force measurement
A load-pin mounted in the brake measures the actual force on the fore and aft winch*.
The system calculates this into the actual wire force and presents this value for each drum
on the Praxis HMI. When the brake is released, the load-pin is not usable anymore for wire
force measurement.
When the brake is released the system uses the actual hydraulic pressure and the
parameters drum width, drum radius, wire thickness and layer for calculating the wire force
and presents this value for each drum on the Praxis HMI. When the FWD deck panel* is the
active control, the wire force is also depicted on the tonnage meter (see 5.1.3.1 (2)). The
parameter maximum wire force is also adjustable on the Praxis HMI.
6.6.1.3 Layer correction
The system calculates the layer and presents these value for each drum on the Praxis HMI.
If the presented layer not corresponds with the real position, it is possible to correct this
manually.
This correction influences also the displayed wire force.
NOTE
The maximum and minimum amount of layers that can be set for correcting the
layers is 3.
6.6.1.4 Quick release
It is possible to activate the quick release from each control station:

 Joystick (see 5.1.1.2 (3))
 Mobile control (see 5.1.2 (15))
 Deck panel FWD* (see 5.1.3.1 (10))
 Deck panel AFT* (see 0 (9))
When a quick release signal is given, First the clutches must be released before the brake
can be released. For emergency, quick release is a hard-wired function, and therefore
always usable.
NOTE
 When quick release is pressed on the winch control panel on the bridge the
brakes of the FWD and AFT* winches AND the towing hook* are released.
 When quick release is pressed on the mobile control, deck panel FWD* or
deck panel AFT*, the brakes of the FWD and AFT* winches are released.
NOTE
function.
(*) Option.

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Manual – brake release
When there is no drum selected, it is possible to control the free running of the wire with the
potentiometers on the active control stations:
 Joystick (see 5.1.1.1 (5))
 Mobile control (see 5.1.2 (1)(2))
 Deck panel FWD* (see 5.1.3.1 (5)(6))
 Deck panel AFT* (see 0 (4)(7))
 Foot pedals* (see 5.1.4 (1)(3))
With the potentiometer on position “0” (counter clockwise) the brake is engaged (friction).
With the foot pedals the brake is engaged when the pedals are not pressed. Operate one or
both potentiometers from minimum to maximum (clockwise) to increase the release of the
brake.
NOTE
When the brake is released and the maximum wire length is reached the brake
is automatically applied.
(*) Option.

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Force limit control (FLC)
If the actual wire force of the drum is higher than the force set value, the brake will be
released. When the drum clutch is released and the brake is engaged.
Actual wire force is measured by the load-pins. If the actual wire force is higher than the
force set value, the brake will be released. If the actual wire force is lower than the force set
value, the brake will be engaged.
When the drum clutch is active and the brake is engaged and the joystick in zero position. If
the actual wire force is higher than the force set value, the clutch will be released and the
brake will be released. If the actual wire force is lower than the force set value, the brake will
be engaged. The clutch will not be engaged automatically. The value of the FLC can be set
on the Praxis HMI.
NOTE
FLC is only active when the FLC page on the Praxis HMI is visible.
Auto mode
In Auto mode* the winch is used as a live winch with the brake released. Prior to Auto mode
the rendering force, recovery force and line length window can be set at the Auto mode page
on the Praxis HMI.
NOTE
In Auto mode it is also possible to change the rendering and recovery force with
the joystick:
 Tilt joystick to the LEFT and move scroll switch (see 5.1.1.1 (5)) up or
down to increase or decrease the rendering force setting.
 Tilt joystick to the RIGHT and move scroll switch (see 5.1.1.1 (5)) up or
down to increase or decrease the recovery force setting.
The desired wire length can also be set by hauling and veering of the joystick. When this is
done the Auto mode can be activated with the “rabbit” button (see 5.1.1.1 (7)).
When the automatic mode is activated the pre-set value for the wire length of the outstanding
wire is automatically the actual length of the outstanding wire.
NOTE
In Auto mode the setting for the length of the outstanding wire can be changed
during operation in the pre-set phase. The force has to be below 30T (2nd layer).
(*) Option.

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With Auto mode the following situations are possible:
 If the actual force in the outstanding wire < the pre-set recovery force and the actual
length of the outstanding wire > the pre-set min line length the winch will recover the
wire.
 If the actual force in the outstanding wire > the pre-set rendering force and the actual
length of the outstanding wire < the pre-set max line length the winch will render.
 If the wire force is between the pre-set render and recover force and the actual line
length is between the min and max set line length the winch will keep the actual line
length.
 In all other situations the band brake will engage.
NOTE
In the following situation Auto mode will be terminated:
 Joystick set out of the neutral position.
 Minimum wire length position reached (brake will be engaged).
 Maximum wire length position reached (brake will be engaged).
 Speed of the drum becomes too high (brake will be engaged).

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Emergency control
In case of emergency the winches(FWD/AFT) can be controlled by using the emergency

control buttons on the WCC (see 5.1.4). With emergency mode slack wire can be retrieved
on the winch.
Emergency control is started by the following sequence:

1. Switch emergency control switch to ON(2).
2. Switch emergency control winch selection switch to FWD OR AFT(3).
3. Switch emergency control drum selection switch to PS or SB(4).
4. Press emergency control HAUL button(6).
WARNING
Be aware that emergency control is a very basic way of winch control with little
to no safety! If emergency control is active make sure a second person has a
good view on the selected winch.
WARNING
Emergency control should be tested on a regular basis (minimum once a week
or before every voyage) to ensure a good functionality of emergency mode.
NOTE
When Emergency is selected on the WCC, the active control station is de-
activated, the winch’s brakes are engaged and emergency control on the WCC
is the only control station.

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NOTE
When Emergency control is finished, the emergency selection switch has to be
set to OFF before proceeding normal winch operation.
Manual line length control
When the maximum permissible length of the towline is paid out on the AFT winch the brake
is applied onto the winch drum. In this event it is only possible to haul the cable. The
maximum permissible length can be set on the Praxis HMI screen.
NOTE
Manual line length control is only required when RMRS is the certifying authority
of the vessel.
NOTE
To ensure a proper manual line length control, the length of the cable has to be
zeroed prior to winch operation when the cable is fully on the drum. This can be
done on the Praxis HMI.
6.7 Auxiliary functions
Navigation mast
The lowering or up-ending of the navigation mast* is controllable from the Praxis HMI. This is
possible when one of the main pumps is running or the E pump is on automatic mode. If
there is no pump running but the E pumps is on auto mode, the E pump will be automatic
started when one of the buttons from the mast is pressed.
The mast can be placed in every desired position. As long a button is pressed, the mast is
moving to the maximum position. When the pushbutton is released, the mast will stop.
Towing pins
The towing pins* are controllable from towing pins control panel on the bridge (see 5.1.1.4).
This is possible when one of the main pumps are running or the E pump is on automatic
mode. If the main pumps are not running and the E pumps is on auto mode, the E pump will
be automatic started when one of the buttons from the towing pins is pressed.
(*) Option.

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Deck crane (enable)
The hydraulic system can be used for the deck crane*. This is possible when one of the main
pumps is running or the E pump is on automatic mode. If there is no pump running but the E
pumps is on auto mode, the E pump will be automatic started when the button enable deck
crane is pressed. The pump is running as long the deck crane is released. Releasing of the
deck crane can be done on the Praxis HMI.
NOTE
After an emergency stop situation the deck crane is disabled automatically.
Oil recovery connection
The hydraulic system can also be used for the oil recovery connection*. This is possible
when one of the main pumps is running. Releasing of the oil recovery can be done on the
Praxis HMI.
NOTE
After an emergency stop situation the oil recovery function is disabled
automatically.
Towing hook
The quick release function of the towing hook* aft can be operated by pressing the quick
release button on the bridge panel.
For emergency, this is a hard-wired function, and always usable.
NOTE
When quick release is pressed on the winch control panel on the bridge only the
brakes of the FWD and AFT* winches AND the towing hook* are released.
NOTE
After a quick release winch brake situation, the last active winch / drum/ aux
function is not active anymore. Take over the control to bridge first and select
the desired function.
Oil monitoring
A oil monitor* can be installed on the reservoir. This oil measures the oil quality and the
quality(ISO) is depicted on the Praxis HMI.
(*) Option.

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Karmoy towing pins
The hydraulic system can also be used for Karmoy towing pins* operation. This is possible
when one of the main pumps is running. Releasing of the Karmoy towing pins operation can
be done on the Praxis HMI.
NOTE
After an emergency stop situation the Karmoy towing pins function is disabled
automatically.
(*) Option.

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7 Maintenance and repair
This section contains a description of the minimal required maintenance activities. Perform
all the prescribed maintenance activities before start-up of the system. In case the hydraulic
system is in operation, perform the maintenance activities according to the specified interval.
WARNING
shoes, helmet, gloves and clothing when maintenance or
repair activities are performed.
WARNING
 Do not work on the electrical system with power applied unless
absolutely necessary. If maintenance must be carried out on the system
with electric power switched on, it is the responsibility of the individual to
exercise proper caution when working in the vicinity of an electrical
hazard (voltages in excess of 30 Vrms or 50 VDC). A second person
must always be in attendance. Use a padlock to lock the main switch in
the ‘OFF’ position.

CAUTION
 The hydraulic system contains several components, which are sensitive
to contamination. When any part of the hydraulic equipment is
dismantled, make sure to work clean, so no contamination or dust can
enter the hydraulic system, flush if necessary.
 After abnormal wear or damage of components in the hydraulic

installation is discovered, it is very important to remove all wear parts
and particles out of the hydraulic installation. In case of doubt or serious
damage dismantle the complete system, clean and replace the hydraulic
fluid.

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CAUTION
 Any personnel using these instructions should be familiar with:
o safety instructions according chapter 2;
o operating instructions according chapter 6.
 General maintenance instructions for the hydraulic equipment are

provided in the following datasheets:
o “Rexroth RE 07009 B - General operating instructions”
o “Rexroth RE 07009 M - General assembly instructions”
o “Rexroth RE 07075 - Hydraulic fluids”
o “Rexroth RE 07080 - Hydraulic pumps and motors”
o “Rexroth RE 07300 - Industrial valves”
o “Rexroth RE 07800 - Proportional valves”
o “Rexroth RE 07900 - Hydraulic systems”
 Always study the concerning component datasheets as provided with

this manual before maintenance activities are performed.
7.1 General notes on maintenance
WARNING

Following general notes on maintenance can significantly increase the lifetime of the
hydraulic equipment.

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Hydraulic
NOTE

instructions.
Keep the hydraulic system clean:

 Regularly clean the outside of the manifold blocks.
 Before any hydraulic equipment or sensor is replaced, first clean the surrounding
area.
Keep the hydraulic oil in good condition:

 The normal working temperature of oil should be between 45 ºC and 50 ºC.
Regularly, check the oil temperature during operation.
 Minimum operational oil temperature : + 15 °C
 Maximum operational oil temperature : + 65 °C
 Cleanliness: 16/14/11 according ISO 4406, Class 6 according NAS 1638
Keep the oil clean:

 Replace the oil filters regularly, dependent on usage, al least every 1 or 2 years.
 Immediately replace the oil filter when the filter-dirty indicator gives a warning.
 Send oil samples for check-up each year. Oil samples can be used e.g. to check on
metal particles in the oil that indicate the amount of wear of the pumps and valves.
CAUTION
 The approved hydraulic oil for this hydraulic system is HLP-ISO-VG68
on mineral basis.
Use only this specified type of hydraulic oil for oil filling or topping-up.
 Hydraulic oil and other lubricants must not pollute the seawater.
Fill up the hydraulic power system with hydraulic fluid according original design. Flush the
hydraulic power unit according original design. Add hydraulic oil when the level in the oil
reservoir is too low. When filling hydraulic oil, always use a filter to prevent damage to the
hydraulic components caused by dirt. Please refer to hydraulic diagrams for more details.
Regularly take an oil sample of the hydraulic oil and let a qualified laboratory check the oil
quality and properties. Oil samples can be used e.g. to check on metal particles in the oil that
indicate the amount of wear of the pumps and valves. Change the hydraulic oil if necessary.
The sample intervals are:

 First inspection after 50 hours of operation.
 Second inspection after 500 hours of operation.
 Further inspections after 500 hours or at least once a year.

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7.1.1.1 Interconnecting hoses
De-pressurize the interconnecting hoses. Drain all hydraulic fluid to the main tank, before any
of the interconnecting hoses are replaced. If necessary, order new hoses according the
hydraulic diagrams.
Flush all interconnecting hoses properly to the NAS 1638 Class 6 (or better) standard prior to
hook-up the hydraulic equipment.
WARNING
Replace interconnecting hoses immediately when damage or corrosion
is found.
CAUTION
 Make sure no dirt can enter the hoses and/or system lines, as this will
cause serious damage to the components.

7.1.1.2 Interconnecting piping
All interconnecting piping must be flushed properly to the NAS 1638 Class 6 (or better)
standard prior to hook-up the hydraulic equipment.
WARNING
Replace interconnecting piping when damage or corrosion is found.

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Electrical
WARNING
 Never work on or in the vicinity of moving parts unless it is impossible to
perform the task required in another way.
 The electrical system contains capacitors. Because of this, an electrical

hazard can still exist 5 minutes after the electric power is switched off.
Measure the voltage before work on the electrical system is started to
make sure that the equipment is safe to touch.
WARNING
maintenance and repair unless it is required by procedure. Use a
padlock to lock the main switch in the ‘OFF’ position.
 Make sure it is safe to switch on the system, especially after

maintenance or repair is performed. Make sure that all electrical and
mechanical connections are properly connected.
 Do not switch on the electrical power if one or more cables are not
connected.
NOTE
Keep the electric system clean:
 Keep the control cabinets clean.
 Remove dust on the control cards, these get heated too much when
dust accumulates on the cards.
 Check the functioning of the cabinet heating, thermostat and hydrostat.
 Keep the cooling fans of the E-motors clean.
 Check the functioning of the cooling-fans on the motor.
7.1.2.1 Interconnecting cabling
WARNING
cabling and dangerous situations.
 Replace interconnecting cabling when damage is found.

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7.2 Maintenance schedule
CAUTION
In the event that instructions, maintenance intervals, etc., deviate from each
other, execute the most profound instructions.
NOTE
A service/maintenance book must be prepared, in which is laid down which
parts of the installation must be checked and where actions can be noted. All
check and inspection results must be documented in this service book.
Maintain a logbook of the installation. In this logbook must be noted when, what, why and
how repairs were done and when certain maintenance tasks were performed.
Record the findings during routine and/or special maintenance.
NOTE
Regularly check the installation for:
 Corrosion  oxidation of metal parts.
 Damage  deformation of parts.
 Leakage  drops of liquid are formed at a part.
 Wear  signs of excessive use.
The maintenance intervals in the following maintenance schedule are only suggestions due
to the wide operational range of the installation. Because of the various operational
circumstances, it is only feasible to supply generic maintenance intervals. The generic
maintenance intervals must be adapted by the operator to meet the actual local operational
circumstances, as there are; dirt, sand, moisture, ambient temperature, load-cycle etc. It is
sensible to base the most economic intervals on gained experience and good practice.
When failures or extraordinary circumstances that cause an electrical and or mechanical

overload of the installation or parts thereof, such as overload or short-circuit, are
experienced, perform the related maintenance task(s) immediately.
Do the maintenance tasks regularly and correctly to achieve an undisturbed operation, long-
life cycle and to prevent extensive damage.
To ensure trouble-free operation of the system, it is necessary to perform the maintenance

work as described in the following subsections.

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Electrical system
Act. Component 1 Month 3 months 1 year 10 years > 15 years Reference

(before every documents
operation)
E1 Components • Check the • Visually • Check the • Replace all
bridge joystick, check the functions. moving
control buttons and inside and • Measure contacts of
station indicators. outside. the insulation switches.
• Check the • Check the value.
E-stop stop voltage and • Check the
and quick the insulation moving
release contacts of
functions. the switches.
• Check all
connections
both
electrical and
mechanical
• Clean from
dust.
E2 Mobile • Check the • Check the • Check the
control buttons and cable and functions.
stations indicators. connectors. • Grease the
• Visually electrical
check the connection
outside for points with
damage and Vaseline.
leakage.
• Check the
E-stop stop
and quick
release
functions.
E3 Deck • Check the • Check the • Check the • Replace all
(panels) buttons and cable and functions. moving
control indicators. connectors. • Grease the contacts of
stations • Visually electrical switches.
check the connection
outside for points with
damage and Vaseline.
leakage.
• Check the
E-stop stop
and quick
release
functions.

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Act. Component 1 Month 3 months 1 year 10 years > 15 years Reference

(before every documents
operation)
E4 Pressure • Visually • Check the • Replace all
transmitters, check the function. Pressure
temperature inside and • Check all transmitters,
sensor, outside. connections temperature
pressure • Check the both sensor,
switches, power electrical and pressure
sensors supply. mechanical. switches,
• Check the • Calibrate sensors
insulation. and set the
pressure
transmitters,
temperature
switches and
sensors.
E5 Cabling • Visually • Check the

check for voltage and
damage. the
• Check for insulation.
loose cables.
E6 Batteries • Visually • Clean the • Replace the

mobile check for outside and batteries.
damage and connection
corrosion. points.
• Grease the
electrical
connection
points with
Vaseline.
E7 Cabinet • Check and • Visually • Check the • Replace all

clean the check the functions. moving
filters from inside and • Check all contacts of
the cooling outside. connections switches and
fans. • Check the both relays.
• Check the power electrical and
temperature supply. mechanical.
inside • Check the • Clean from
cabinet. insulation. dust.
• Check the
fan with the
thermostat.
E8 Electric • Check for • Clean the • Check the • Check • Complete

motor abnormal motor insulation. alignment shop
noise. housing from • Check the • Check the overhaul.
• Keep the the outside foundation torque of all
cooling fans for cracks bolts.
clean. and • Check all
• Check the impressions. cables and
functioning of • Check the insulation.
the cooling operational
fans. parameters.

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Hydraulic system
Act. Component 1 Month 6 months 1 year 6 years Reference

(before/during documents
every
operation)
H1 Hydraulic • Check for oil • Check the • Complete "Rexroth"
pumps leakage. wear of the shop RE07080
• Check the oil shaft seals. overhaul. RE07075
level. • Check the RE92800
• Check the oil flows and RE97111
temperature pressures. RE10335
and oil • Take an oil
pressures. sample for a
• Check for lab test.
abnormal
noise.
H2 Proportional • Visually • Check the • Complete "Rexroth"

valves check for flow and shop RE07800
leakage and pressure overhaul. RE64279
damage. settings. RE29156
RE29175
RE18139-05
H3 Filters • Exchange • Check both • Change all "Rexroth"

only if the differential filters RE51425
“filter dirty” pressure- RE51450
indication is indicators on RE51456
active and the electric and
oil temperature hydraulic side.
is above 15°C.
H4 Parts, • Visually • Complete "Rexroth"

solenoid- check for shop RE18323-05
operated leakage and overhaul. RE48050
valves, damage. RE23178
pressure- RE25402
relief/reduce RE18318-51
valves, check RE21010
valves. rvsaeds_170
-p-060100-en
RE20380
Check valves
RH
H5 Hydraulic • Visually • Tighten the • Replace all

hoses check for couplings. hoses that
leakage and are located in
damage. the open air.
H6 Heat • Visually • Complete the2000

exchanger check for shop
leakage and overhaul.
damage.

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7.3 Lubrication / Oil changes
NOTE
instructions.

WARNING
 Excessive leakage from hydraulic fluid precludes system operation until
the leakage is corrected.
 Do not spill hydraulic oil and lubricants on the floor. Take care of
environmental-friendly disposal. Always follow the relevant national rules
and regulations.
 Clean up spilled hydraulic fluid immediately. Hydraulic fluid is an oily

substance, which can cause slipping, falling and resulting injuries.
 Do only pour the oil into the reservoir by a filter with an appropriate
mesh.
Environmental regulations
CAUTION
Hydraulic oil and other lubricants must not pollute the environment.
Take care of environmental friendly disposal. Always follow the relevant

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7.4 Preservation
All sub-systems/parts that are not made out of stainless steel, are provided with a
preservation system, which complies with the environmental conditions as specified in
section of this document.
General remarks
 For the repair on site of all coating systems, described hereafter and all surfaces
without a coating system after the final mounting of the installation, such as bolts,
nuts, matching parts, etc., change the pre-treatment into hand- or power-tool wire
brushing up to a grade of ST3 according to the ISO standard 8501-1:1988. Replace
the first coating by primer with a Dry Film Thickness (DFT) of 50 microns. Apply by
brush only. Finish off with the second and third layer as described for each respective
item.
 All surfaces not within easy reach for application with a spray pistol must be pre-
treated by brush for each layer before the spray application of this layer.
 Application must be in accordance with the paint manufacturers’ specification.
Required data sheets can be downloaded from the website: www.sigmacoatings.com
Overall preservation system
The following three-layer paint system is used:

1. Pre-treatment:
 Remove all contamination, oil and grease.
 Remove all rust and mill scale by means of grit blasting up to a grade of SA2½
according to the ISO standard 8501-1:1988.
 Roughness according ISO 8503-2 : 30-85 μm, Ry5
2. Paint system:
Paint System for equipment inside, under deck:
- 1st layer 50 [µm] Epoxy Sigma Cover 280 Primer
2nd layer 75 [µm] Epoxy Sigma Cover 456 Coating
3rd layer 75 [µm] Sigmadur 520
Total DFT: 200 [µm]
End colour RAL 9002 – Grey White
Paint System for equipment on open deck:

- 1st layer 75 [µm] Epoxy Sigma Cover 280 Primer
2nd layer 100 [µm] Epoxy Sigma Cover 456 Coating
3rd layer 60 [µm] Pol Sigmadur 520
Total DFT: 235 [µm]
End colour RAL 7001 – Silver Grey
All cavities will be sealed against sea water with a silicone sealant
5.3. After-treatment:
Remove the mask tape and any remains of the tape glue.
All protective caps of the valve adjustments must be filled with grease after final adjustment
and must be protected by suitable stainless steel covers.
Internal preservation hydraulic parts
After testing of the hydraulic equipment, the system is drained. Then are all hydraulic
connections plugged with steel plugs (type VSTI) or plates with sealing.

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7.5 Repair
CAUTION
Keep the components, the tools and the grease to be used in a clean condition.
Dirt can cause damage to the seals and to other components in the hydraulic
system.
WARNING
authorized to do so, based on their training and qualifications. In addition,
the persons must be assigned by the operating company.

maintenance and repair unless it is required by procedure. Use a padlock
to lock the main switches in the ‘OFF’ position.

 Do not perform any activities that could endanger health or cause damage
to the system.
NOTE
Contact Bosch Rexroth B.V. or Bosch Representatives for council before
repairs are carried out. The guarantee expires when repairs are carried out by
unauthorized persons.
NOTE
At the end of their lifetime, dispose of replaced parts or wearing parts according
local legislation. Contribute to recycling waste material by separating and
recycling refuse.

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7.6 Storage
Storage
For proper storage and conservation of all equipment during sea transport for final deck
mating operation, the following guidelines must be followed:
 Close the housing of the central control system properly.
 Check that all electrical wiring is free of obstacles and suitably protected against
damage.
 Check that all hydraulic piping is free of obstacles.
Long-time storage
For proper long-time storage of the deck mating equipment after disassembly, the following
guidelines must be followed:
 All equipment must be stored in a clean and dry environment. The storage
temperature must be between 0 °C and 45 °C with a maximum humidity of 80 %.
 The 230 V power supply must remain connected and available. This power supply is
required for the standstill heating of the main motors.
 Inspect all equipment and the proper functioning of the stand still heating regularly,
but at least every 6 months.
7.7 Disassemble and dismantle
CAUTION
At the end of their lifetime, dispose of replaced spare parts or worn parts
according local legislation. Contribute to recycling waste material by separating
and recycling refuse.

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8 Troubleshooting
This section provides guidelines to find and remedy the cause of several known failures.
An error has occurred if:

 the system does not react to the command of the operator;
 the system interrupts normal operation;
When an error occurs, all information provided by the system must be checked and
observed.
CAUTION
 When abnormal wear or damage of components in the hydraulic
installation is detected, it is very important to remove all wear parts and
particles out of the hydraulic installation.
 In case of doubt or serious damage dismantle the complete system,

clean the system and replace the hydraulic fluid.
NOTE
Always contact Bosch Rexroth B.V. for council before repairs and
troubleshooting are carried out. The guarantee expires when repairs are carried
out by unauthorized personnel.

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8.1 Alarm list
Alarm text Reference

Oil temperature
Oil TEMPERATURE LOW <15 [°C] See chapter 8.2.2
Oil TEMPERATURE HIGH >60[°C]: See chapter 8.2.2
Oil TEMPERATURE TOO HIGH >70[°C]: See chapter 8.2.2
Oil pressure
Oil pressure accumulator LOW See chapter 8.2.5
Oil pressure accumulator TOO LOW See chapter 8.2.5
Oil PRESSURE Deviation, Set Pressure CY1 not reached See chapter 8.2.5
BOOST pressure LOW FWD winch PS motor (pressure<15bar) See chapter 8.2.5
BOOST pressure LOW FWD winch SB motor (pressure<15bar) See chapter 8.2.5
Clutch FWD PS pressure switch error See chapter 8.2.5
Clutch FWD SB pressure switch error See chapter 8.2.5
Clutch AFT PS pressure switch error See chapter 8.2.5
Clutch AFT SB pressure switch error See chapter 8.2.5
Brake FWD PS pressure switch error See chapter 8.2.5
Brake FWD SB pressure switch error See chapter 8.2.5
Brake AFT PS pressure switch error See chapter 8.2.5
Brake AFT SB pressure switch error See chapter 8.2.5
Oil level
Critical Warning: Oil level low, only reduced speed possible See chapter 8.2.3
Oil cleanness
Return filter 1 POLLUTED See chapter 8.2.2
Return filter 2 POLLUTED See chapter 8.2.2
Leak oil filter 1 (pumps) POLLUTED See chapter 8.2.2
Leak oil filter 2 (motors) POLLUTED See chapter 8.2.2
Oil CLEANNES ALARM See chapter 8.2.2
Analog signals
OOR_NT1_FWD_PSMotorSpeedRR See chapter 8.1.6
OOR_CS1_OilContamination See chapter 8.1.6
OOR_PT1_SystemPressure See chapter 8.1.6
OOR_PT2_LoadSensePressure See chapter 8.1.6
OOR_PT3_PilotAccuPress See chapter 8.1.6
OOR_PT4_FWD_PSMotorPressHP See chapter 8.1.6
OOR_PT4_FWD_PSMotorPressHP See chapter 8.1.6
OOR_PT5_FWD_PSMotorPressLP See chapter 8.1.6
OOR_PT6_FWD_SBMotorPressHP See chapter 8.1.6
OOR_PT7_FWD_SBMotorPressLP See chapter 8.1.6
OOR_PT8_KamroyTowingPin See chapter 8.1.6
OOR_TT1_ResevoirOilTemp See chapter 8.1.6
OOR_FT1_FWD_PSDrumLoadpin See chapter 8.1.6
OOR_FT2_FWD_SBDrumLoadpin See chapter 8.1.6
OOR_FT3_AFT_PSDrumLoadpin See chapter 8.1.6
OOR_FT4_AFT_SBDrumLoadpin See chapter 8.1.6
OOR_FP_324R1_MiddleFootpedal_Haul_Veer See chapter 8.1.6
OOR_FP_324R2_PSFootpedalBrake See chapter 8.1.6
OOR_FP_324R2_1_SBFootpedalBrake See chapter 8.1.6
OOR_JS_302R1_DriveControlFWD See chapter 8.1.6
OOR_JS_302R1_1_BrakeControlPS_FWD See chapter 8.1.6
OOR_JS_302R2_BrakeControlSB_FWD See chapter 8.1.6
OOR_JS_302R1_DriveControlAFT See chapter 8.1.6

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
OOR_JS_302R1_1_POT_BrakeControlPS_AFT See chapter 8.1.6
OOR_POT_BrakeControlSB_AFT See chapter 8.1.6
Wire force
Towline force too-high to engage clutch See chapter 8.1.12
AFT Towline force too-high to engage clutch See chapter 8.1.12
FWD winch: wire force TOO HIGH(FLC mode) See chapter 8.1.12
AFT winch: wire force TOO HIGH(FLC mode) See chapter 8.1.12
FWD PS: wire force 10% from FLC mode See chapter 8.1.12
FWD SB: wire force 10% from FLC mode See chapter 8.1.12
AFT PS: wire force 10% from FLC mode See chapter 8.1.12
AFT SB: wire force 10% from FLC mode See chapter 8.1.12
Wire length
FWD PS Wire length calculation not set, reduced starting force on FWD PS See chapter 8.1.13
FWD SB Wire length calculation not set, reduced starting force on FWD SB See chapter 8.1.13
FWD PS Wirelength monitor inactive, SET ZeroM! See chapter 8.1.13
FWD SB Wirelength monitor inactive, SET ZeroM! See chapter 8.1.13
AFT PS Wirelength monitor inactive, SET ZeroM! See chapter 8.1.13
AFT SB Wirelength monitor inactive, SET ZeroM! See chapter 8.1.13
End of wire drum 1 (PS) FWD winch reached See chapter 8.1.13
End of wire drum 2 (SB) FWD winch reached See chapter 8.1.13
End of wire drum 3 (PS) AFT winch reached See chapter 8.1.13
End of wire drum 4 (SB) AFT winch reached See chapter 8.1.13
MIN. WIRE LENGTH drum 1 (PS) FWD winch reached See chapter 8.1.13
MIN. WIRE LENGTH drum 2 (SB) FWD winch reached See chapter 8.1.13
MIN. WIRE LENGTH drum 3 (PS) AFT winch reached See chapter 8.1.13
MIN. WIRE LENGTH drum 4 (SB) AFT winch reached See chapter 8.1.13
ALMOST MIN. WIRE LENGTH drum 1 (PS) FWD winch reached See chapter 8.1.13
ALMOST MIN. WIRE LENGTH drum 2 (SB) FWD winch reached See chapter 8.1.13
ALMOST MIN. WIRE LENGTH drum 3 (PS) AFT winch reached See chapter 8.1.13
ALMOST MIN. WIRE LENGTH drum 4 (SB) AFT winch reached See chapter 8.1.13
ALMOST MAX. WIRE LENGTH drum 1 (PS) FWD winch reached See chapter 8.1.13
ALMOST MAX. WIRE LENGTH drum 2 (SB) FWD winch reached See chapter 8.1.13
ALMOST MAX. WIRE LENGTH drum 3 (PS) AFT winch reached See chapter 8.1.13
ALMOST MAX. WIRE LENGTH drum 4 (SB) AFT winch reached See chapter 8.1.13
Auto mode
Auto mode blocked: Set length outside window See chapter 8.1.14
RR mode Shutdown See chapter 8.1.14
ACTUAL WIRE LENGTH outside window L-margin CL mode See chapter 8.1.14
Boost pump failure during auto operation See chapter 8.1.15
Control alarm
Auxiliary pump NOT on automatic mode See chapter 8.1.15
Boost pump 1 (EM2) NOT OK See chapter 8.1.15
Boost pump 2 (EM3) NOT OK See chapter 8.1.15
Diesel motor speed PS TOO HIGH See chapter 8.1.10
Diesel motor speed SB TOO HIGH See chapter 8.1.10
Quick RELEASE active See chapter 8.1.5
Auxiliary pump (EM1) not OK See chapter 8.1.15
Cool pump 1 running, tem oil reservoir low See chapter 8.1.15
Cool pump 2 running, tem oil reservoir low See chapter 8.1.15

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
8.1 Electrical system
Insulation failure
Cause Solution
Certain electrical components of the circuit  Check the wiring for defects in the
are located outside the cabinets. Therefore, insulation and replace the damaged
the possibility exists that these are connected parts.
to earth because of the penetration of
seawater or damage of the insulation.  Check if seawater has entered the
junction boxes; replace the gaskets. Rust
on the inside of the junction boxes can be
an indication of a faulty gasket.
 Systematically disconnect parts of the

circuit to localize the cause of the failure.
 Use a suitable earth-fault finding

apparatus (resistance check) to check
the disconnected parts of the circuit.
 Check for wrong connections.
 More faults can be present in a

disconnected part of the circuit.
The conductors are not connected properly  Visibly check the conductors for wrong
upon finishing repair or maintenance tasks. connections.
 Check the connection of the conductors

using a suitable apparatus (resistance
check).
 Reconnect all conductors properly.
The insulation-monitoring device is defective.  Check the insulation-monitoring device.
 Replace the insulation-monitoring device.
Pushbuttons
Cause Solution
The pushbuttons are not working.  Check for loose contact elements directly
behind the button.
 If the signal is read by the PLC, check the

PLC with the help of the circuit diagram
of the corresponding cabinet.

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
Emergency-stop pushbutton
Cause Solution
Emergency stop active  Check that all emergency-stop
pushbuttons are unlocked.
The emergency-stop pushbutton is not  Check for loose contact elements directly
working or cannot be reset. behind the emergency-stop pushbutton.
 Check that all emergency-stop

pushbuttons are unlocked and the
system is reset.
 Check the emergency-stop relay located

in the WCC for proper functioning.
 Check for tripped circuit-breakers.
Voltage supply
Cause Solution
Voltage supply too high / too low  Check the power supply
Quick release (winch brake/ towing hook)
Cause Solution
Quick release activated  Check quick release buttons
 Check the signals with the help of the

circuit diagram inside the winch cabinet
electric.
Analog signals
Cause Solution
Measurement out of reach  Replace sensor/potentiometer
Sensors / potentiometers not working Loose connector or damaged cabling.

 Reconnect the connector.
Check for wire break.

 Replace cabling.
Complete failure of sensor / potentiometer.

 Replace sensor / potentiometer.

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
Proportional valve
Cause Solution
Valve not working Loose connector or damaged cabling.
 Reconnect the connector.
Check for wire break.

 Replace cabling.
Complete failure of valve.

 Replace valve.
Mobile
LED flashing pattern Cause Solution

Steady light Normal condition, terminal is  None
tuned ON, battery voltage is
OK, NO fault is detected.
No LED Mobile OFF.  Ensure mobile contains a

charged battery and is turned
ON. If the mobile has turned
itself off due to inactivity, turn
mobile OFF and ON again to
start normal operation.
Slow flashing light Low battery voltage.  Replace battery with a fully
without stop (1 charged one.
flash/sec.).
Slow flashing light Programming code.  Turn mobile OFF and ON
without stop (2 again to start normal
flash/sec.) operation.

1 flash with long stop Processor fault or test mode.  Check if boot jumper is not on.
(every 2 seconds) Indicates a processor
module fault and/or a  Replace processor module
processor fault. and/or processor.
2 flashes with a stop Activity at start-up. A joystick  Set all switches / joystick /
is out of centre position, or a potentiometers of OFF-position
switch is in ON-position. and/or neutral position.

3 flashes with a stop Radio fault.  Replace radio module.
4 flashes with a stop Shutdown due to low battery.  Replace battery with a fully
charged one.

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
5 flashes with a stop Keyboard fault. Receiver is  There is a fault in the input
not able to “read” the module.
switches, joystick,
potentiometers from the
mobile.
6 flashes with a stop Shutdown due to inactivity.  Turn mobile OFF and ON
The mobile will soon “turn again to start normal
itself OFF” since no operation.
switches, joystick,
potentiometers have been
activated.
7 flashes with a stop Emergency stop has been  Ensure emergency stop button
activated. is out and turn mobile OFF and
ON again to start normal
operation.
Emergency stop
Error Reason Solution

Faulty test pulse Error caused by the test  Check wiring to all emergency
pulse. stop buttons
Feedback loop External error at the  Check wiring inside the cabinet
feedback loop. to the relay.
Faulty output External error on the output.  Check wiring inside the cabinet
to the relay.

Output with advanced External error on the output  Check wiring inside the cabinet
fault detection with advanced fault to the relay.
detection.
Load supply Internal error on the relay  Measure power supply.

unit.
 Check wiring inside the cabinet
to the relay.
Faulty device Internal error on the relay  Replace emergency stop relay.
unit.
To high engine RPM
Cause Solution
The RPM of the main engines is not within  Reduce the RPM of the engines.
the admissible range.

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
Drum speed

Drum speed to high Warning on Praxis HMI that  Reduce drum speed
speed it to high.
Over speed Warning on Praxis HMI that  None.

over speed occurs.
Wire force

Wire force to high Wire force too high.  Reduce wire force.
Setting maximum wire force.
Setting FLC.  Modify the maximum wire
setting of FLC setting.
Wire length

Maximum wire length Maximum wire length  Go to other wire positon by
drum position is reached. hauling in the wire.
First the warning is given. At
alarm the system  Modify the maximum wire
automatically stop and only length settings.
haul is possible.
Minimum wire length Minimum wire length position  Go to other wire positon by
drum is reached. veering the wire.
First the warning is given.
Both haul and veer is  Modify the minimum wire
possible. length settings.
Auto mode

actual wire length difference between actual Modify set point length
outside window L margin length and set wire length is
not within the admissible
range.
RR mode is shut down Conditions for operation RR

mode are not OK

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
Control system alarm
Cause Solution
One of the control alarm is given.  Solve the designated control alarm.
Clutch alarm
Cause Solution
Clutch is not pressurised (engaged)  Check clutch cylinders.
 Check clutch actuation valves.

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
8.2 Hydraulic system
Unusual or excessive noise
Possible cause Reason Solution

Cavitation in the The hydraulic fluid is too cold Heat up the hydraulic fluid
hydraulic pump. (< -10°C). (system) by using the
conditioning pumps.
The air breather is clogged. Check the air breather.
Air bubbles in the Penetration of air through the  Check the seal housing (on
hydraulic fluid or pump shaft sealing. the pump) for damage.
formation of foam.  Replace the pump by the
spare pump.
Penetration of air through the Tighten the connections and/or

suction pipe connections. replace the seals.
The hydraulic system air-bleed Air-bleed the system (after a

is insufficient. period of rest).
The fluid level is too low. Fill up the fluid reservoir.
Mechanical vibrations Incorrect alignment or loose Re-align or re-install the shaft

and/or noise. shaft coupling. coupling.
Hydraulic pump Worn, damaged or incorrect Repair or replace the

operating pump. concerning parts.
Vibration and/or shocks of Improve the installation of

interconnecting piping. interconnecting piping.
Pressure- or flow- Unstable pressure or flow- Correct if possible.

control valves. control valves.

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
Fluid temperature too high

Internal leakage from The setting of the relief valve is Re-adjust to correct settings.
pressure-line to too low.
return-line.
 The control valves function See section 8.2.4.
incorrectly.
 The seals are worn.
Insufficient or no  Cooling water lines not Connect the water lines

cooling water available connected
 Cooling water not available Check the water supply
Excessive heating of Loss of efficiency caused by Repair or replace.
the hydraulic pump. wear.
The temperature of the The temperature is above the Install an additional cooler.
environment is too design conditions.
high.
The system is The pressure does not equalize Re-adjust the hydraulic
overloaded. the load sufficiently. pressure.
External fluid leakage

Abnormal hydraulic Damaged seals. Remedy the cause and replace
pressure. the seals.
Stretched bolts or screws. Remedy the cause and replace

the bolts or screws.
Incorrect or damaged Porous or damaged parts. Replace the part.

components / parts.
Damaged seals. Remedy the cause and replace
the seals.
Incorrect connection bolts are Replace with correct connection

used. bolts.
Incorrect installation / Incorrect placed seal. Replace the seal.

assembly.
Bolts or screwed connections Tighten properly, not excessive.
are tightened incorrectly.
Incorrect or damaged seals. Place new seals.

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
Insufficient hydraulic pressure

Cavitation in the See section 8.2.1. See section 8.2.1.
hydraulic pumps.
Fluid temperature is The pump is damaged or worn. Repair or replace the pump.
too high.
Excessive heat generation in the Find and remedy the cause.
system.
Speed of the hydraulic Slipping drive or incorrect  Remedy the cause.

pump is too low. driving motor, the frequency of  Check the shaft coupling.
the power supply is too low.
The by-pass valve is not closed Remedy the cause.

completely.
Incorrect pressure Incorrect pressure settings. Re-adjust the settings.

adjustments, internal
leakage from pressure- The by-pass valve is not closed Remedy the cause.
line to return-line. completely.
The control valves do not  Try to find the malfunctioning

close/open (sufficiently) caused component, clean, repair or
by dirt, damage, wear or replace.
electrical failure.  Check the functioning of the
electrical equipment.

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
Unusual/excessive pressure, fluctuations in flow, vibrations

hydraulic pump.
Air bubbles in the See section 8.2.1. See section 8.2.1.

hydraulic fluid or
formation of foam.
Air pockets in the The hydraulic system air-bleed Air-bleed the system.
hydraulic system. is insufficient.
Mechanical vibrations. See section 8.2.1. See section 8.2.1.
Unstable pressure of See section 8.2.1. See section 8.2.1.

flow-control valves.
Damaged valve seat. Repair or replace the
concerning valve.
 Insufficient dampening  Re-adjust the concerning

function of a valve. valve.
 Power frequency fluctuates.  Stabilize the generator.
Incorrect adjusted or Incorrect settings. Adjust and secure adjustment.

obstructed control
valves. Worn or damaged control Clean, repair or replace the
valves. concerning component.
The control valves function  Replace the hydraulic fluid.

incorrectly caused by  If necessary, clean the
contaminated hydraulic fluid. components and piping
separately.

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
Non or insufficient fluid flow

hydraulic pump.
Air bubbles in the See section 8.2.1. See section 8.2.1.

hydraulic fluid or
formation of foam.
Pump is worn. See section 8.2.1. See section 8.2.1.
Rotation speed of the See section 8.2.1. See section 8.2.1.

hydraulic pump is too
low.
Incorrect rotation Incorrect connected E-motor. Re-connect the E-motor.

direction of the
hydraulic pump.
Internal leakage from See section 8.2.4. See section 8.2.4.

the pressure-line to the
return-line.
Flow-control valves, The valve is adjusted Re-adjust the valve.

throttle valves. incorrectly.
The valve is clogged or blocked, Clean or replace the concerning

caused by dirt, or damaged. valves.
Frequency power The rotation frequency is too Check and remedy the rotation
supply. low. frequency.
Analog signals
Cause Solution
Measurement out of reach None
Sensors not working Loose connector or damaged cabling
 Reconnect the connector
Check for wire break
 Replace cabling
Complete failure of sensor
 Replace sensor

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
Proportional valve
Cause Solution
valve not working Loose connector or damaged cabling
 Reconnect the connector
Check for wire break
 Replace cabling
Complete failure of sensor
 Replace sensor

REV. : 00
DATE : 16-04-2018
PROJECT : GENERIC
9 Spare parts
9.1 Recommended spare parts
A recommended spare part list is made by Bosch Rexroth which provides an overview on
what parts need to be considered to have as spare back-up.
NOTE
The recommended spare part list is provide with the data package of each boat
send by Bosch Rexroth (SPAREPARTSLIST BN GENERIC TUG 2).
9.2 Ordering spare parts
CAUTION
 Spare parts must always comply with the specifications.
 When spare parts are ordered from Bosch Rexroth directly, it is

guaranteed that these spare parts comply with the specifications as
required by the system.
In this section, the procedure how to order spare parts from Bosch Rexroth is disclosed.
The next information is a prerequisite in order to be able to deliver the required spare parts in
the shortest possible time:
 Order number
for hydraulics and mechanical or general: see diagram.
for electric / control components: see diagram.
 Full drawing number or the parts list that contains the required spare part(s)
 Position number of the required spare part(s)
 Number of required spare part(s)
A spare parts order must always be done in writing. In urgent cases however, it is possible to
order by telephone or fax.
Phone : +31. (0)411 651 951*

Fax : +31. (0)411 651 483
Email : service@boschrexroth.nl
*) In that case, such an order must always be backed-up by a written order-confirmation as

soon as possible.
Spare parts orders must be send to:
Bosch Rexroth B.V.

P.O. Box 32
5280 AA Boxtel
The Netherlands


Instruction Manual Hydraulic Winches ASD Tug 2.0 3212-2913-2813 V0

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proprietors. Use only allowed within the scope of an order to

Hydraulic winches Tug 2.0

geoorloofd. Gebruik slechts toegestaan in kader van opdracht

REV. DESCRIPTION DATE DRAWN CHECKED PASSED APPR.

TITLE: FILE: V:\DIVERSEN\DIV-DCNL\SLE-PROJECTS-SEF-SET-

SEL\5xM-orders\53-orders\5312374 DSG ASD 3212 BN

Explanation of revision marks:

Hydraulic winches Tug 2.02813/2913/3212 Page 2 of 85

Hydraulic winches Tug 2.02813/2913/3212 Page 3 of 85

Hydraulic winches Tug 2.02813/2913/3212 Page 4 of 85

Hydraulic winches Tug 2.02813/2913/3212 Page 5 of 85

The system is designed and delivered under order numbers:

Phone : +31 (0)411 – 651 951

Hydraulic winches Tug 2.02813/2913/3212 Page 6 of 85

Skilled and qualified personnel must have:

1.1 Terms and abbreviations

FLC : Force limit control

Hydraulic winches Tug 2.02813/2913/3212 Page 7 of 85

 Do not disable any safety device or make changes to the

 Failure to obey the safety instructions or tampering with the

Bosch Rexroth B.V.'s guarantee expires when:

Hydraulic winches Tug 2.02813/2913/3212 Page 8 of 85

The user must put on protective footwear.

The user must put on a safety helmet.

The user must use eye protection.

Orders the user to use ear protection.

Prohibits the user to switch on a device.

Warns the user for the danger of an electrical hazard.

Warns the user for the danger of a hot surface.

Warns the user for the danger of a shearing hazard.

Hydraulic winches Tug 2.02813/2913/3212 Page 9 of 85

 Personnel authorized to operate or maintain the installation must be

 Personnel authorized to operate or maintain the installation must be

 Personnel authorized to operate or maintain the installation must inform

 Personnel authorized to operate or maintain the installation must inform

 Operate the installation carefully and cautiously. It can be expected that

Hydraulic winches Tug 2.02813/2913/3212 Page 10 of 85

 Maintain the installation, spare parts, machinery and tools as described

 Keep the installation and its environment clean and tidy.

 Maintain a log, noting and dating all inspections, maintenance, repairs,

 Only use recommended lubricants, tools and test equipment or

Hydraulic winches Tug 2.02813/2913/3212 Page 11 of 85

 Never alter adjustments and parameters, unless it is disclosed in this

 Inform the persons in charge of modifications carried out on the system

 Do not perform any activities that could endanger health or cause

 Do not modify the settings of safety-related equipment without written

Hydraulic winches Tug 2.02813/2913/3212 Page 12 of 85

 Make sure that it is safe to switch on the system, especially after

 Do not switch on the system unless all wiring is properly connected.

 Wash off affected skin, eyes and protective clothing immediately.

 Clean up spilled hydraulic fluid immediately. Hydraulic fluid is an oily

Hydraulic winches Tug 2.02813/2913/3212 Page 13 of 85

 Hydraulic oil is a petroleum lubricating oil. It is a clear, light-yellow liquid

 Elevated processing temperatures may cause release of toxic vapors,

 Do not work under equipment/apparatus being supported by hydraulics.

 Relieve system pressures (Note: some systems use accumulators that

 Use extreme caution when hydraulic lines are being disconnected.

 DO NOT USE HANDS OR FINGERS to find leaks.

Hydraulic winches Tug 2.02813/2913/3212 Page 14 of 85

 Always study the concerning component datasheets as provided with

 The hydraulic system contains several components, which are sensitive

 After abnormal wear or damage of components in the hydraulic