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Anchor Towing Winch Manual revision [-]

Yard number 513520

Order number DMT 218126
Type ATW 221-H19 350 [kN]
Drawing number 10002-2

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CONTENTS

PART 1 – OPERATING
SYSTEM ....................................................................... 2

1.
DESCRIPTION .......................................................................
......................... 2
 2. TECHNICAL
DATA ..............................................................................
............. 2

3. LOCATION AND MOUNTING

INSTRUCTIONS ...................................................... 3

4. CONSTRUCTION AND OPERATING

INSTRUCTIONS ............................................. 8

4.1 Construction
8

4.2 Operating instructions

14

5. STOPPING
INSTRUCTIONS ......................................................................
....... 17

6. LABOR SAFETY
PRECAUTIONS .......................................................................
. 17

PART 2 - SERVICE AND

MAINTENANCE ........................................................ 18

1. MAINTENANCE
RULES .............................................................................
....... 18

2. DIRECTIONS FOR
LUBRICATION .....................................................................
18

3. POSSIBLE DEFECTS AND REPAIR

PROCEDURE .................................................. 19

4. PRODUCT
ASSEMBLING/DISASSEMBLING ........................................................
19

5. SERVICE UNDER WARRANTY/NO WARRANTY

PERIOD ........................................ 20

6. SPARE
PARTS .............................................................................
.................. 20
 PART 3
ANNEXES ........................................................................ 25

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PART 1 – OPERATING SYSTEM

1. DESCRIPTION

Winches are deck equipment, installed on the barge main deck, in a special place
established by the
ship designer in relation with the winch operating field.
The winch described in the present manual is hydraulic driven and it is used for
towing operations,
manoeuvre the vessel while docking by means of warping head and lifting/lowering
the anchors.

The winch consists of the following’s components:

Reduction gear
Towing drum
Chain lifter
Hydraulic band brake
Hydraulic friction clutch
Manual operated band brake
Coupling device
Warping head
Length measurement device
Hydraulic installation

The construction and functionality of above components are described in the 4th
Chapter of Part 1.

2. TECHNICAL DATA

Technical characteristics
Two types of cases: Flow 216
(l/min) Flow 285 (l/min)
Stud link chain – U2 Ø 19
[mm] Ø 19 mm
Nominal / max pull 18.5 / 75
[kN]* 18.5 / 75 [kN]*
Anchor Hauling speed 0÷15
[m/min] 0÷19.6 [m/min]
Brake holding force (0.8x MBL) 168.8
[kN] 168.8 [kN]
Pitch diameter 486
[mm] 486 [mm]
Synthetic rope Ø 80
[mm] Ø 80 [mm]
Nominal pull/ 2nd layer 350/85
[kN] 350/85 [kN]
Towing speed/ 2nd layer 0÷9.2/28
[m/min] 0÷12/37 [m/min]
Towing
Storage capacity 150 [m]/6
[layers] 150 [m]/6 [layers]
Brakes holding force on 2nd layer
1500 kN
(total) 1500 kN (total)
(first layer for towing)
Displacement 2048/655 [

/rev] 2048 / 655 [ /rev]

Hydraulic driven Rotation speed 101 / 307
[r.p.m.] 133 / 405 [r.p.m.]
STAFFA HMC 125 Nominal flow 216
[l/min] 285 [l/min]
Nominal pressure (∆p) 202/185/82*
[bar] 202/185/82* [bar]
*) Max pull at chain lifter and warping hear must be limited be setting of max
pressure to 90 bar

drop of pressure, with motor running at high speed [655 ( /rev)]. This
setting must be
automatically controlled when the winch is operated from deck.
When the pressure increases above 185 bar, the hydraulic motor will automatically
switch from
high speed to low speed.

Note: The minimum breaking load of the towing synthetic rope must be
greater than
1875 [kN].

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3. LOCATION AND MOUNTING INSTRUCTIONS

Location

Anchor and towing winches are located at the bow of the tug boat in a special
place, reinforced,
provided by the ship designer.

IMPORTANT:
The mounting instructions, a ached on the winch a delivery, must
be duly respected.
Checking the winch is ready to be lifting with the crane and surface provided by
the ship
designer do not contain obstacles what prevent to mount the winch in safe
conditions!
Improper alignment may affect the functionality and durability of the winch.
Improper fixing of winch on deck or foundation (welding seams size and quality) may
cause breaking of the welding and injuries to operating personnel.

Legend:

*) winch sitting surface – the area of the winch in contact with the ship structure
– reinforced main
deck with or without foundation;
**) material addition – 15 [mm] material addition for footpads to allow adjustment
on deck, placed
under reduction gear, lateral support, the hydraulic band-brake support
and 50 [mm] for the
manual band brake support.

The minimum recommended height of 1000 mm, between si

ing surface and main shaft
axis, must be respected the height of the winch can vary between 1000[mm]–1015[mm],
depending of the dislevelment of the si ing surface (deck).
Drawings for mounting instruction can be found on Annexes bellow.

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Mounting and alignment of winch on ship:

1). The winch will be positioned on deck and the alignment will be
checked with its
interfaces:

The towing drum must be centred to a bollard or a different reference,

depending on the
situation;
If the winch is provided with a chain wheel, the alignment with the chain
stopper will be
checked or to ship chain pipe, again depending on situation;
Also, the distance between the chain wheel and the chain locker will be
checked;
Checking that footpads of the winch will be positioned on the sitting place
provided by the
ship design engineer, according to the information’s send by the winch
producer;
Checking the distance between footpads of lateral support and the
reduction gear to be
according the diagram fixing on deck;
2). Checking the main shaft horizontality.

• Checking can be done by measuring with one calibrated water level

instrument, guiding by
two points, one point on each side of the main shaft.

In measuring with a calibrated water level instrument take count :

- A proper calibration is vital for getting accurate data;

- The hose should contain a transparent material to be visible inside and
make sure there are not
water bullets.

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3). On winch alignment, you can be faced two situa ions described below:

3.1). If the axe of the main shaft is horizontal and the height from the deck
to the main shaft is
correct, then go further as follows:

• The alignment between the side supports and the main shaft will
be done by making a
uniform circular clearance between the support bush and the nearest
spacer;

• Checking the clearance between the footpads and the surface of the
deck/foundation if it
allows a proper welding. Usually a maximum clearance of 2mm can be
allowed
3.1/a). The resulting space between footpads and deck allows a proper welding to be
realized:

• Then spot welding will be applied, after which examine again the align in
view of a final
welding;
• For welding in hard-reach places (ex: under the reduction gear) detach
the winch from the
screws to allow finishing the welding seams (see below information on
the welding seams
dimensions);
• Mount the winch on the footpads and tighten the screws (see
below information on the
required tightening torque).

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Alignment of the band brake on deck

• Will be made with the brake tighten on the braking way;

• The contact between the brake lining on its entire width with the braking
way will be checked,
considering the contact surface in line with the tensioning direction;
• Correct centring of the brake bands facing the brake support will be
checked;
• The distance between the lateral side of the brake bands and the edge of
the braking way to
be equal on the entire circumference will be also checked;
• After all the above are performed and the alignment is properly done, the
brake support will
be spot welded on deck;
• Depending of the frequency of their use, the ferodo lines will be checked
for wear every 15
cycles or twice a year, whichever comes first. The normal wear must not
exceed 5 mm. If
so, the head of the copper screws, that holds the ferodo line onto the
band brake, will touch
the brake way and the copper screws will be damaged. The minimum distance
between head
of screws and ferodo line surface is 1 mm;
• At every inspection of the ferodo lines, also the moving components of
the band brakes will
be checked. If necessary, repair and/or replace damaged parts;

Note: Do not let grease of oily fluid to enter the brake lines.

• Before connect the cylinder band brake to the hydraulic installation,

this must be filled with
hydraulic oil on the rod-side (filling port);

3.1/b). The sitting surface shows a dislevelment and not allow a proper welding:
 • Then the lateral support and reduction footpads will be removed. The
footpads under the
reduction gear will be processed first by reducing the height
with the amount of space
determined by measurements;
• Only the footpads of the reduction gear will be mounted (checking the
shoulder of footplates
if are in contact with the baseplate before tightening the screws, an
inappropriate contact
between the two components can grip the screws in charge of forces, this
checking needed
only if the footpads are provided with shoulders);

• Consider the reduction gear as a base reference and adjust the height of
the side supports
by means of screwing/un-screwing the adjusting bolts until the distance
between base plate
of the lateral supports and deck will be equally divided;

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• After making this adjustment, measurements will be done equal on all 4

(four) sitting points
of the base plates in order to establish the machining dimensions;

Note: The recommended height between deck and main shaft must be respected as
much as possible and the maximum addition that will be removed from one measuring
point must not exceed 15 [mm].

• When the footpads have been through the processing stage, will be mounted
(checking the
shoulder of footplates if are in contact with the baseplate before
tightening the screws, an
inappropriate contact between the two components can grip the screws in
charge of forces,
this checking needed only if the footpads are provided with shoulders);
• The resulting space between footpads and deck allows a proper welding to
be realized, then
spot welding will be applied, after which examine again the align in view
of a final welding,
aligning and welding the brakes is exactly as above;
 • For welding in hard-reach places (ex: under the reduction gear) detach
the winch from the
screws to allow finishing the welding seams (see below information on the
welding seams
dimensions);
• Mount the winch on the footpads and tighten the screws (see below
information on the
required tightening torque).

3.2). If the axe of the main shaft is not horizontal and the height from the
deck to the main shaft
is correct, then go further as follows:

3.2/a). If the height is higher between the main shaft axle in the reduction gear
area contact and
the deck:

• all the footpads will be removed and will be repeat the same operations
as above [3.1/b]
only difference of processed is now by reducing the height with the
minimum difference
between both sides of main shaft.

3.2/b). If the height is higher between the main shaft axle in the lateral supports
area contact and
the deck:

• Only the footpads from the lateral support will be removed, take the
reduction gear as a base
again and adjust the same the height by means of screwing/un-screwing the
adjusting bolts
from the side supports until the distance between base plate of the
lateral supports and deck
will be equally divided. When is succeeded until this stage, the next
steps can be follow again
at [3.1/b].

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Information’s about the fastening screws torque tightening and the welding seam:

The tightening for the fastening screws, will be 1700 [Nm]. For safety
reasons the screws
will be safe against unthreading with Loctite 243 or similar;

The welding seam will be 12 [mm] (the median of the triangle)

and will be done
alternatively, on both sides in order to prevent material deformation
because of excessive
temperature. The welding to be closed endless.
A ention!

For a proper alignment of the winch, we recommend he mounting on deck

while the
vessel is on shore.
If the mounting will be performed off shore, the sea balance can induce
errors in
measurement, which leads to a faulty alignment.
After winch installation, periodically it will check the tight seal of
the junction boxes
exposed to the sea water.

4. CONSTRUCTION AND OPERATING INSTRUCTIONS

4.1 Construction

4.1.1 Reduction gear (Annex 2)

The gearbox is made of steel plates, constructed as closed oil bath.

The gearbox has a raised bottom in order to facilitate the access for welding the
supports on deck.
Below deck, reinforcement should be fitted at the position of the gearbox.
The gearbox is arranged with 4 integrated lifting eyes.
Reduction gear is provided with toothed wheels and pinion shafts. Each toothed
wheel is mounted
on a shaft and secured with keys. The shaft is resting on roller bearings fitted in
the special made
bearings housing on the gearbox walls. The bearing covers are provided with grease
nipples.
The gearbox it is fitted with a stainless-steel oil level gauge, a filling plug and
drain plug.
The inside of the gearbox is coated against corrosion with an oil resistant primer.
The reduction gear is oil splash lubricated. Lubrication of reduction gear will be
carried out with
synthetic oil ISO VG 150. The necessary quantity is ~370 [litres].

WARNING: Before start-up, the oil level will be checked and, if not enough, will be
added
until half of the oil level gauge is filled. Do no operate the winch with less or
with no oil
in reduction gear. If lubrication will not be carried out, the gear
wheels will be
permanently damaged.

4.1.2 Towing drum

The drum is designed for storing the entire full loaded line. The drum is provided
with stainless-steel
braking way fitted with hydraulic operated band brake and, on the inner side, with
hydraulic friction
clutch for engaging disengaging the drum.
To avoid chafing of cable, top ends of shields are tapered.
The wire winding direction is from the top of the winch. The first four windings
will remain on the
drum in order to provide proper fixing on the rope
The towing drum is moving freely on the main shaft on roller bearing and can be
connected to the
main shaft via the hydraulic friction clutch.

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4.1.3 Hydraulic installation (Annex 3)

The hydraulic drive system uses pressurized hydraulic fluid in order to drive the
machinery. The
hydraulic system can be mounted inside the reduction gear, in the same compartment
with the
toothed wheels or in a special designed compartment, independent of the
toothed wheels
compartment.
Some hydraulic systems which are receiving pressurized fluid from the HPU
of the vessel are
mounted outside the reduction gear.
The hydraulic system is constructed from hydraulic pipes. All piping material is
from Carbon Steel
ST37.4 DIN 2445/2. Welded pipe connections are pickled, neutralized and flushed.
Before mounting
the hydraulic pipes are cleaned.
In order to protect the hydraulic motor, after winch testing, the flange connecting
parts are blinded
with plugs. The rest of the hydraulic components are delivered as separate
furniture

4.1.4 Hydraulic operated band brake (Annex 4)

Each drum is fitted with a band brake. Depending on the weight they have to
sustain, band brakes
can be manual operated, hydraulic or pneumatic.
The drum is fitted with a hydraulic operated band brake. The band brake is
engaged/disengaged on
the braking way by a hydraulic cylinder. The band brake is hydraulic released and
spring engaged.
The brake support is welded on main deck or foundation plate (if the winch is
provided with one).

Before welding the brake, support followings will be checked:

The operation will be made with the brake tighten on the brake way.
Will be checked the brake line to be in contact on its entire width with
the braking way,
considering the contact surface in line with the tensioning direction.
Will be checked the correct centring of the brake bands facing the brake
support.
Will be also checked the distance between the lateral side of the brake
bands and the edge
of the braking way to be equal on the entire circumference.
After all, above are performed and the alignment is properly done, the
brake support will
be spot welded on deck.

Depending of the frequency of their use, the brake lining will be checked for wear
every 15 cycles
or twice a year, whichever comes first. The normal wear must not exceed 5 mm. If
so, the head of
the copper screws, that holds the brake lining onto the band brake, will touch the
brake way and
will damage it. The minimum distance between head of screws and brake lining
surface is 1 mm.

At every inspection of the brake lining, also the moving components of the band
brakes will be
checked. If necessary, repair and/or replace damaged parts.

The brake straps and their fastenings are resistan to sea water and petroleum
products.
The brake straps are heat-resistant at temperatures up to 250°C.

Note: Do not let grease of oily fluid to enter the brake linings.

After replacing the brake linings, for a proper operation the contact surface
between brake lining
and braking way must be adjusted:

Position the band brake in its operating position;

Rotate the drum winch under power and apply the band brake between 30%-
50% of the
maximum tightening pressure;
Now have the line burnish against the brake way for about 20 minutes;

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Remove the band brakes and check for black spots;

Grind the spots until they have completely removed from the brake linings.
Use a piece of
sandpaper in order to roughen the surface. Repeat this method until at least 85% of
the lining is
touching the braking way.

4.1.5 Hydraulic operated friction clutch (Annex 5)

Each towing drum is fitted with a friction clutch. The friction clutch is hydraulic
operated.
The friction clutch is driven by the main shaft and is actuated by a hydraulic
cylinder in order to
ensure remote control of clutch. The friction clutch is spring released and
hydraulic engaged
For protection of the friction clutch mechanism, a stainless-steel cover is fitted
over the clutch. For
easy dismounting/mounting, the cover is divided in two parts.
The hydraulic cylinder is supplied by a hydraulic line which passes through a
central bore in the
driving shafts of each drum.
The friction clutch is adjusted from factory and no other adjustments are
necessary. However, if by
accident, other adjustments are necessary please see attached ANNEX 5.

Depending of the frequency of their use, the friction linings will be checked for
wear every 20 cycles
or twice a year, whichever comes first. The normal wear must not exceed 5 mm. If
so, the head of
the copper screws, that holds the friction linings onto the friction band, will
touch the friction way
and will damage it. The minimum distance between head of screws and friction lining
surface is
1 mm.
At every inspection of the friction linings, also the moving components of the
friction clutch will be
checked. If necessary, repair and/or replace damaged parts.

The friction straps and their fastenings are resis ant to sea water and petroleum
products.
The friction straps are heat-resistant at temperatures up to 250 °C.

Note: Do not let grease of oily fluid to enter the friction linings.

After replacing the friction linings, for a proper operation the contact surface
between friction lining
and friction way must be adjusted:

Position the friction bands in their coupled operating position but set a
lower pressure than
the working pressure.
Engaged the hydraulic band brake and rotate the main shaft in the
direction for recovery
cable.
Grinded the friction lining several times to get the right fit on the
friction way.
Now have the line burnish against the friction way for about 20 minutes.
Remove the friction bands and check for black spots.
Grind the spots until they have completely removed from the friction
lining. Use a piece of
sandpaper in order to roughen the surface. Repeat this method until at least 85% of
the lining is
touching the friction way.

4.1.6 Hydraulic drive system (Annex 6)

The hydraulic drive system uses pressurized hydraulic fluid in order to drive the
machinery. The
hydraulic system can be mounted inside the reduction gear, in the same compartment
with the
toothed wheels or in a special designed compartment, independent of the
toothed wheels
compartment.
Some hydraulic systems which are receiving pressurized fluid from the HPU
of the vessel are
mounted outside the reduction gear.
10

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The hydraulic system is constructed from hydraulic pipes. All piping material is
from Carbon Steel
ST37.4 DIN 2445/2. Welded pipe connections are pickled, neutralized and flushed.
Before mounting
the hydraulic pipes are cleaned.
In order to protect the hydraulic motor, after winch testing, the flange connecting
parts are blinded
with plugs. The rest of the hydraulic components are delivered as separate
furniture.

IMPORTANT: Before normal operation, the hydraulic system will be started and
checked
for abnormal noise.

4.1.7 Chain lifter

The chain should run over the chain lifter in such way that the curve around the
chain runs is large
enough. The position of the chain must form an angle of minimum 45 degrees with the
horizontal
at the hauling edge (see ANNEX 1 page 6).
At the trailing side, the chain must run smoothly in the chain locker. If
necessary, a chain guide can
be positioned so that the chain runs more smoothly
The chain lifter is moving freely on the mains shaft on brass bushes and can be
connected to the
main shaft via the coupling device (jaw clutch).

4.1.8 Main shaft

Main shaft is resting on side supports provided with roller/ball bearings or brass
bushes.
At one end, the main shaft, is resting on the reduction gear and it is provided
with roller bearings.
The main shaft is the connecting part between reduction gear and the rest of the
winch components.
The main shaft transmits the torque developed by reduction gear to the drum and
warping head.
The drum is moving freely on the main shaft on brass bushes and can be connected to
the main
shaft via the friction clutch.
The chain lifter is moving freely on the main shaft on brass bushes and can be
connected to the
main shaft via the coupling device.
The warping head is always connected to the main shaft and can be used for hauling
a wire.

4.1.9 Manual operated band brake (Annex 7)

The chain wheel it is fitted with a band brake.

The brake support is welded on main deck or foundation plate (if the winch is
provided with one).

Before welding the brake, support followings will be checked:

The operation will be made with the brake tighten on the brake way;
Will be checked the brake line to be in contact on its entire width with
the braking way,
considering the contact surface in line with the tensioning direction;
Will be checked the correct centring of the brake bands facing the brake
support;
Will be also checked the distance, between the lateral side of the brake
bands and the
edge of the braking way, to be equal on the entire circumference;
After all, above are performed and the alignment is properly done, the
brake support will
be welded on deck according Annex 7.

Depending of the frequency of their use, the brake lining will be checked for wear
every 15 cycles
or twice a year, whichever comes first. The normal wear must not exceed 5 mm. If
so, the head of
the copper screws, that holds the brake lining onto the band brake, will touch the
brake way and
will damage it. The minimum distance between head of screws and brake lining
surface is 1 mm.

11

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At every inspection of the brake lining, also the moving components of the band
brakes will be
checked. If necessary, repair and/or replace damaged parts.

The brake straps and their fastenings are resistan to sea water and petroleum
products.
The brake straps are heat-resistant at temperatures up to 250 °C.

Note: Do not let grease of oily fluid to enter the brake linings.

After replacing the brake linings, for a proper operation the contact surface
between brake lining
and braking way must be adjusted:

Position the band brake in its operating position;

Rotate the braking way under power and apply the band brake between 30%-
50% of the
maximum tightening pressure;
Grinded the brake lining several times to get the right fit on the drum;
Now have the line burnish against the braking way for about 20 minutes;
Remove the band brakes and check for black spots;
 Grind the spots until they have completely removed from the brake
linings;
Use a piece of sandpaper in order to roughen the surface. Repeat this
method until at least
85% of the lining is touching the braking way.

4.1.10 Coupling device (Annex 8 & Annex 9)

The coupling device is the connecting part between chain lifter and main shaft.
The coupling device will be used only when the main shaft is stationary.
Always use the locking pin to secure the coupling device position. When using the
winch always be
sure that the coupling device in fully in contact with the jaw clutch.
When the coupling device have to be disengaged, turn the winch back a little so
that the jaw clutch
is free and can more easily be disengaged

4.1.11 Length measuring system and force measuring system

The length measuring system designed to measure the spooled wire under towing
manoeuvres.
The length measuring system consist in the accurate communication between 3 major
components:

1) Proximity switch (see Annex 10)

A proximity switch is a sensor able to detect the presence of nearby objects

without touching them.
A proximity sensor emits an electromagnetic field or a beam of electromagnetic
radiation and looks
for changes in the field or return signal.

2) Load measuring pin

Description

Load pin is used to measure the applied force and to provide overload
protection. The load pin
is mounted in the connection point of the band brake with their supports. The load
pin is fitted with
strain gauge which allows them to produce a signal proportional to the measured
load.
The load pin is manufactured as tight constructions from high resistance stainless
steel.

Design

The load pin has 2 circular grooves and an axial bore. Inside the central
bore, adjacent to the
external grooves, the strain gauges are mounted in a full-bridge configuration.

12

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 Operating principle

When force is applied, along the load pin sensitive axis, the effect of the
strain gauge bridge
results in an output signal proportional to the applied force. The signal is then
converted by the
integrated amplifier to a standard 4 to 20 mA (4 mA for no load – 20 mA for max
load).

Mounting directions

The load pin is mounted in a rigid assembly. The lateral supports are not
moving with respect
to each other when force is applied.

The bores in the lateral supports are cylindrical and concentric to each
other.

The load pin reaction is present only when the sensitive axis is orientated
on the force direction.
The direction of the sensitive axis can be found by means of the marked arrow on
the load pin.

The load pin is secured with a safety plate. Do not remove it at any time.

Connection of the load measuring pin

The load pins will be connected to the PLC by means of the output
connections consisting in 3
wires:

Red – Supply (+)

Black – Supply (-)
Blue – Signal (4 – 20 mA)

3) PLC (programmable logic controller)

A PLC is a programmable computer designed for multiple inputs and

outputs arrangements,
extended temperature ranges, immunity to electrical noise, resistance to vibration
and impact.
The PLC received signals from the load pins and proximity switch, will convert it
into measurement
unit (pre-established by the software engineer) and send the information to the
touchscreen display.

4) Touchscreen display

The touchscreen is located on the bridge control and displays information received
from the PLC.
From the touchscreen display you can access standard setting of force and length
measuring
system (wire diameter, drum length, drum diameter, number of layers, etc.).

Location and mounting instructions

The load measuring pin will be mounted in to hydraulic brake support according
bellow instructions.
Note: The electrical connexion for the wires of the load measuring pin,
must be in a
junction box.

Note: The proximity switches from the drum length measurement device
(which is
delivered separately) must be mounted and adjust to 3 – 5 [mm] from plate.

Note: After the winch is installed on deck, the dummy bolts from the brake supports
must
be unmounted and change it with sensitive bolts (which is delivered separately).

13

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4.1.12 Warping head

The warping head is manufactured from a casted material and secured on the main
shaft with key
and end washer
The warping head is always connected to the main shaft and can be used for hauling
a wire and/or
mooring manoeuvres.

4.2 Operating instructions

IMPORTANT:
We guarantee the proper functionality of our equipment only when the instruction
present
in this manual are duly respected.
Undertaking any work presented by this document may, directly or indirectly, create
risks
to the safety of the person(s) undertaking the work or of the product
and/or its
components.
A user without experience of working in accordance with this document or
with this
product is not allowed to operate and should seek appropriate advice to enable him
to use
the product in safety conditions.

Prior the first start-up, following checking will be performed:

Oil level in reduction gear will be checked to be at the half of the level
eye;
Check if the hydraulic motor is connected to the hydraulic
system onboard
according to connection diagram;
Check if the fixing screws from the foundation pla es are properly
tightened;
Check if the chain wheels band-brakes are properly secured and chain
wheels are
disconnected from the main shaft;
After mounting the brake, the hydraulic cylinder must be filled with
hydraulic oil on
the rod-side (filling port);
Check the hydraulic band brake to be engaged and hydraulic friction clutch
to be
disengaged.

After above checking, you can start-up the winch on idle running. While idle
running, all
bearing will be greased.
If after 15 minutes of idle running, in both ways (veering/hauling) there are no
signs of
malfunction (overheated bearings; abnormal noise; etc), the winch is ready for
normal
operation.

NOTE: After winch installation, periodically it will check the tight seal of the
junction boxes
exposed to the sea water.

4.2.1. Anchor mode

The anchor mode is automatically engaged when one of the chain lifter is connected
to the main
shaft.
The connection between chain lifter and main shaft is sensed by the proximity
sensors installed on
the coupling device.
For safety reasons, when anchor mode is detected following situation occur:
The speed and torque of hydraulic motor is reduced;
None of the push buttons or potentiometers from the bridge panel control
are active. Only
the veering/hauling lever in order the anchor to be retrieved.

14

----------------------- Page 16-----------------------

4.2.2. Anchor lowering by manual operation of chain wheels

The operation will perform as follows:

With fastened brake, will be checked if the chain wheel used for lowering
is disconnected
from the main shaft.
The band brake will be loosened and the anchor will start to lower under
its own weight.
The lowering speed must be controlled by progressive releasing of the band
brake. The
lowering speed control is necessary due to below reasons:

• To prevent early wear of chain wheel bearings;

• To keep engaged the chain with the chain wheel;
• To protect the device against shocks generated by sudden braking under
high speed;
• To keep the safety of its operator under normal limits.

Pay-out the necessary chain length for anchor drop

Fasten the band brake in order to block the chain wheel.

4.2.3 Anchor lowering by winch drive

The operation will perform as follows:

Check if the chain lifter and drum not used for this operation are
disconnected from the
main shaft and the brakes fastened properly.
Start the winch drive.
Connect the chain wheel to the main shaft; act upon the connecting device
lever. If the
position of the jaw clutch does not allow the connection, operate the winch till
the proper position
has been reached.
When engaged position is reached use the safety pin to lock the fork
position.

WARNING: Connection should be shocks free. The coupling device is fi

ed with a safety
pin which must be used every time the coupling device fork changes
position. If, the
locking pin is not use, the accidental engaging/disengaging can be done and may
have
bad impacts to the safety of surrounding personnel or may damage the equipment.

Loose completely the brake.

Pay-out the necessary chain length for the anchor drop.
Stop the winch.
Fasten the brake to block the chain wheel.
Disconnect the chain wheel from the main shaft. While anchored, the chain
wheel must
be disconnected from the main shaft. Else, all overload forces will be taken by the
reduction gear
and may result in permanent damages.
Stop the winch drive.

4.2.4 Anchor hoisting by winch drive

Breaking the anchor out and hoisting it up are carried as follows:

The chain wheel used for this operation will be connected as indicated in
4.2.3.

WARNING: is not allowed the simultaneous breaking out of two anchors

Loose slightly the band brake of the chain wheel until the gears of the
reduction gear are
taking over the weight of the chain suspended intro water
 Loose completely the band brake

15

----------------------- Page 17-----------------------

Operate the winch in its proper direction for chain recovery

Bringing the chain to vertical position is carried out by the ship
movements, by its propelling
unit or by the force generated by the anchor windlass, if possible, without
exceeding the windlass
operating data
Anchor hoisting up
Stop the winch drive
Fasten the band brake
Disconnect the chain wheel from the main shaft

4.2.5 Manoeuvres by switching from one chain wheel to the other chain wheel

Following actions must be performed in order to have a proper and safe manoeuvre:

The winch drive will be stop;

The manually band brake from chain wheel 1 will be fastened;
The coupling device from chain wheel 1 will be uncoupled;
The chain wheel 2 will be coupled trough the coupling device;
The manually band brake from chain wheel 2 will be release;
The winch drive will be start.

Note: If the coupled/uncoupled of the jaw clutch from the coupling device with the
chain
wheel is not complete, the chain wheel of the winch will be rotate with the motor
to allow
a complete coupled/uncoupled of the chain wheel.

4.2.6 Anchor abandonment

In case of emergency, if breaking out the anchor is not possible, then the
abandonment is required
to save the vessel.

The followings will be carried out:

The chain wheel band-brake is fastened

Chain wheel will be disconnected from the main shaft
The end of the chain stored in the chain locker will be released
The band brake will be released
The lowering speed will be controlled by the band brake
Fasten the chain wheel band-brake

4.2.7 Towing manoeuvres by means of towing drum

Following actions must be performed in order to have a proper and safe towing
manoeuvre:

Make sure that the chain lifters and drum that it is not used are
disconnected from the main
shaft and the brake is not supplied with hydraulic oil.
Connect the towing drum to the main shaft, supplying with oil pressure
the friction clutch in
order to be engaged and the hydraulic brake to be disengaged.
Operate the hydraulic motor following the operating instructions provided
onboard by the
hydraulic installation supplier.
During towing operation all forces will be absorbed by the brake line.
The winch is operated only for adjusting the length of towing line.

NOTE: Following this step the hydraulic installation will be protected

against the
overloads which could appear!

16

----------------------- Page 18-----------------------

After the towing operation, act upon the hydraulic motor for the
cable release and
recovery.
Fasten the hydraulic brake and disconnect the drum from the main shaft by
cutting oil
pressure from both brake and clutch
Stop the hydraulic motor operation, following the operating instructions
provided onboard
by hydraulic installation supplier

4.2.8 Quay manoeuvring by warping head

The operator must follow the below indications:

Check if the drums and the chain wheels are disconnected from the main
shaft and their
brakes fastened.
Wrap at least three coils of rope, loosely, around the warping head in
order to avoid
slipping.
Apply a light hand pressure on the rope end - is not the same as pulling.
Operate the winch.
While the warping head rotates under power, tails the roper hand over hand
until the
manoeuvring is complete.
Stop the hydraulic motor.
Secure the rope after use.

WARNING: Because the operator is sited on the operating area of the warping head,
he
must be very careful due to accidents vulnerability.

5. STOPPING INSTRUCTIONS

Under normal operating conditions, is recommended the strict observance of the

winch parameters.
In case of accidentally damages or any kind of failure appeared before the complete
manoeuvring,
the winch will be stopped by shutting down the drive system (hydraulic/electric);
band brakes will
be fastened and winch power supply will be cut out

WARNING: DO NOT USE THE WINCH IF IT IS NOT RUNNING IN PERFECT CONDITIONS.

6. LABOR SAFETY PRECAUTIONS

The ship chief engineer has the obligation to instruct his personnel and
to periodically test his
knowledge as regards the devices operating systems and labour safety precautions.

The following must be observed:

The winch to be operated by authorized personnel only.
Storage of various material or components around the operating area of the
winch is not
allowed.
Unauthorized personnel is not allowed into the winch operating area during
its operation.
Using of damaged cable or other cable than the one prescribed is not
permitted.
Repairs to be made after the device is stopped and disconnected from the
mains supply
unit
Operator must use the available items for personal safety, such as
goggles, safety shoes,
work clothing, gloves, hearing protection

17

----------------------- Page 19-----------------------

PART 2 - SERVICE AND MAINTENANCE

1. MAINTENANCE RULES

The sequence of making operational the winch components was described in the
previous chapters
and the operation is to be carried out by properly trained personnel. The operator
must know the
winch operating principle, technical data and operation system.

A periodic visual inspection is recommended in order to detect and prevent possible

defects. We
recommend the following checking:

Inspection of nuts and screws fastening.

Inspection of band brakes not to overheat during operation.
Inspection of threaded spindles from band brakes.
Inspection for abnormal sounds coming from reduction gear.
Inspection for oil leakage.
Inspection for abnormal sounds coming from hydraulic system.
Inspection of coupling device.
Inspection of hydraulic friction clutch;
Check the wear of the band brake lining and the wear of the friction
clutch lining and if it is
necessary replace the band brake lining/friction clutch lining with a new one.

2. DIRECTIONS FOR LUBRICATION

It is recommended that the winches to be maintained by authorized personnel only.

Maintenance is limited to checking the oil level, regularly changing the oil from
the gearbox tank,
periodically the piston rod from the hydraulic brake cylinder and all threaded
spindles from the
brakes must be coated with a layer of grease, and lubrication via all greasing
points.

For a proper winch operation, it is recommended the periodical lubrication of the

moving parts.

Grease lubrication will be made before winch operation or once a week if, during
this period, the
winch has not been operated.

The grease will be completely replaced during periodic inspection program or when
it changes its
colour and consistency.

It is recommended that the greasing system to be checked before every greasing

period during
winch operation.

Grease lubrication will be made in all greasing points. All greasing points are
marked, depending on
their importance and greasing frequency, in Annex of this document. The greasing
period for each
point is described in the table below.
All greasing points are provided with DIN 3404 nipples. The greasing pump used for
this application
is of type PA2 with greasing device type DB2. The allowable lubricate grades are
shown in Table 1.
This table is not restrictive and equivalent brands may be used.

If is advisable that the grease lubrication to be checked for several weeks during
operation, in order
to establish a proper lubrication time.

18
----------------------- Page 20-----------------------

It is recommended periodical inspection of oil quality from reduction

gear and replacement, if
necessary.
The reduction gear is oil bath splash lubricated. The oil will be changed every 12
months or after
first 600 operational hours. After drain of the used oil, the reduction gear
housing will be completely
cleaned. The replaced oil will be drained trough the drain nozzle fitted on the
housing lower side.

If the oil level in the gearbox rises, this may mean that water is getting into the
oil, in this situation
it is recommended to completely replace the reduction gear oil.

GREASING PLAN

Greasing
Greasing period Location
Remarks
category

Before each operation with the winch, the

Weekly / Before each Reduction gear

grease nipple from the reduction gear, and

GP1 winch operation –

lateral support must be re-greased.

minimum 5 grease cycles Lateral support

The
band brakes threaded spindles will be
Hydraulic band
coated with a layer of grease and all bolts
brakes who
have lubricator must be greased. When
Once at 2 (two) weeks –
greasing caution will be paid not to drop
GP2
minimum 2 grease cycles
grease over the braking way. If, by accident,
Manual band the
brake bands are contaminated with
brakes
grease these must the dismounted and

replaced.

3. POSSIBLE DEFECTS AND REPAIR PROCEDURE

During winch operation, some damages can occur due to excessive wear, improper
operation, bad
maintenance and their repair is required. Because these damages can have bad
consequences on
sailing capacity of the vessel, below you can find the possible damages list and
their repair procedure
(Table 3).

4. PRODUCT ASSEMBLING/DISASSEMBLING

The anchor towing winches generally have a simple design and consequently, their
dismounting, in
order to carry out some repairs or parts replacement does not require use of
special tools and
devices.

The winch is a compact and modular product, its dismounting is carried out
according with the
annexed drawings of Part 3 from this Manual.

19

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5. SERVICE UNDER WARRANTY/NO WARRANTY PERIOD

The warranty period is 12 months from product start-up but not more than 18 months
from product
delivery.
For any service requests the last page with warranty/service form should be filled
in and sent to our
After Sales Department.
If damages described previously in Part 2 Chapter 3 cannot be
permanently repaired, by the
personnel onboard, the supplier’s professional assistance must be required.

Warning: service by unauthorized personnel is not allowed and will lead to

guarantee
lose. In warranty period any service job will be carried out by DMT service
technicians.
Any service job by a third parties must be discussed upfront with DMT
representative.

6. SPARE PARTS

All spare parts required are delivered on order basis only.

For any order of spare parts please contact our After Sales Department.
The spare part list is provided starting with the first page of every annex.
Hereby you have our contact details for Service and Spare Parts:

DMT MARINE EQUIPMENT S.A. - After Sales Department

Prelungirea Foltanului No. 13, COD 807325,

Sat Costi, Comuna Vanatori, Galati, Romania

Mr. Bogdan Constandache

Tel. Mobile: +40 730 711 960

Tel.Office: + 40 236 406 006

Fax.Office: + 40 236 464 050

E-mail: aftersales@dmt-winches.com

Web: www.dmt-winches.com

20

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TABLE 1

Table 1.1 Usual Lubricants and Gear Oils

chart
 2
mm /S/
ISO ISO ISO
ISO

STORAGE
o VG68 VG150 VG220
VG320
40 C

BEARING OIL

GREASE HUILE
AGMA 2EP 4EP 5EP
6EP
OPEN GEAR

GRISSE POUR ANTI-ROUILLE

WHEELS

ROULEMENTS ROSTBESTÄND
cSt/50°C 43 90 125
180
OPEN

WALZLAGER- IGES ÖL

WIELEN
E/50°C 6 12 16
24 FETT ROEST

LAGERVET WERENDE
SSU/
OLIE
315 700 1000
1500
100°F

MOBIL MOBIL MOBIL

MOBIL MOBILGREASE MOBILARMA
MOBIL
SHC 626 SHC 629 SHC 630
SHC 632 XHP 222 522
DYNAGEAR

MEROP
MEROPA MEROPA
MEROPA MULTIFAK STARPLEX
MULTIFAK
A
68 220
320 Ep 2 EP 2
Ep 2
 150

OMALA OMALA OMALA

OMALA GADUS ALVANIA
GADUS

68 150 220
320 S2 A320 RL 2
S2 A320

CARTER CARTER CARTER

CARTER MULTIS MULTIPLEX
CARTER
EP68 EP150 EP220
EP320 EP2 EP 2
ENS-EP 700

ALPHA ALPHA ALPHA

ALPHA SPHEEROL
SPHEEROL

BioTac EP 2
SP68 SP150 SP220
SP320 AP 2
SX 2

Table 1.2 Biodegradable Lubricants and Gear

Oils chart

Grease Lubricants
Gear Oil

Works atWorks at
Works atWorks at

Salt water
LGGB2 LGGB2 Salt waterSalt
water ISO150
Salt water
-40/90°C -40/90°C
-40/220°C resistant
resistantresistant
resistant

Works at
BioTran Works at
Salt waterSalt
water
No logo found 600 -29/332°C resistantresistant

21

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TABLE 2

Tabel 2.1 Usual

Hydraulic Oil chart
 Tabel 2.2 Biodegradable
Hydraulic Oil chart

Works at
Works at
Biobar Salt water
Salt water
32 -40/120°C resistant
resistant

22
----------------------- Page 24-----------------------

TABLE 3

Investigation procedures in the following issues

DAMAGE SIGN DEFECT

POSSIBLE CAUSES REPAIR PROCEDURE

0 1 2
3 4

Replace the ball bearing.

Wearing. Unsuitable NOTE! In case of bearing

High wear or damage of
A Strong noise.
maintenance. Wrong breaking, change the oil
ball bearings.

operation. and clean inside of

reduction housing.

Wearing. Unsuitable After the oil empting from

Damaged gaskets or
B Oil leakages.
maintenance. Wrong the reduction housing,
sleeves.

mounting. replace the worn parts.

Check the quality of the

oil (aspect, fluidity,

Reduction gear No sufficient oil inside of
Unsuitable operation. color). Fill-up or replace
C
overheating. reduction housing.
Wrong maintenance. the oil as necessary, up

to the mark level of the

sight glass.

Unsuitable operation

and maintenance. Replace the damaged

Cracked pipes or broken
Hydraulic motor does not
D
fittings. Lack of
start.
components. Check and
Motor damages. Pressure
repair the hydraulic
loss in hydraulic system.

pressure (pump unit system if necessary.

damaged).

Check the hydraulic

system and all fittings

Unsuitable operation

and replace the damaged

and maintenance.

components if necessary.

Cracked pipes or hoses.

Readjust the friction

Lack of oil in
Slipping of hydraulic The pressure in
clutch in order to set

hydraulic system or
friction clutch under the hydraulic system is
again the normal working
E
detachment of a fitting
nominal load applied on insufficient (pressure loss).
pressure (see also the
drum.
pipe(hose), nipple. hydraulic friction clutch

Normal wearing of the

adjusting instructions).

clutch lining.

Remove and replace the

clutch lining after the

clutch dismounting.

Release the band brake

from the drum and clean

with white spirit the brake

Wrong maneuvering

lining and the braking

Oil spots at the interface
and maintenance.
between the brake lining
Normal wearing of the way until the oil spots are
Decrease the braking and the braking way.
brake lining. Cracked removed. Replace the
Brake lining is removed
brake lining after brake
capacity. Overheating of
pipes or hoses. Lack of
F from the brake band. The
dismounting. For the
the chain wheel braking
pressure in pneumatic
holes for the securing
band brake on drum
way. screws became oval. The
system or detachment

check the correct

air pressure in pneumatic
of a fitting pipe (hose)-

adjusting (see also the

system is insufficient.
nipple.

pneumatic band brake

adjusting instructions).

23

----------------------- Page 25-----------------------

WIRE CAPACITY CALULATION OF WINCHDRUM

Project/yardno:A&TW winch dwg. No. 10002- 2

Wire type:

INPUT:
Wire diameter (d ) =
80 mm
w
 Drum diameter (D) 8.888dw =
711 mm

Space between winding 1,03dw

82.4 mm

Drum length (L) 9dw =

720 mm

Extra space on drum (for stretchers) =

200 mm

Hold.force 2nd layer =

150.0 Ton

OUTPUT:
No of. layer Layer Stored Stored
Stored length Pull Speed Pull Speed Holding Brake holding
diameter length wire length on
drum (1) (1) (2) (2) force torque

per spire wire per layer

1/2 2 2 2 1/2
Total
D+dw[1+(z-1)3 ] [π D inf+d w]

[mm] [m] [m]

[m] [ton] [m/min] [ton] [m/min] [ ton] [N*m]

First 791 2.486365563 21.73

21.73 41.1 7.85 10.2 24.2 176.3 697173.0

Second 929.5640646 2.921473911 25.53

47.25 35.0 9.2 8.6 28.4 150.0 697173.0

Third 1068.128129 3.35663503 29.33

76.58 30.4 10.6 7.5 32.6 130.5 697173.0

Fourth 1206.692194 3.791830751 33.13

109.72 26.9 12.0 6.7 36.9 115.6 697173.0

Fifth 1345.256258 4.227050387 36.94

146.65 24.2 13.4 6.0 41.1 103.6 697173.0

Sixth 1483.820323 4.662287241 40.74

187.39 21.9 14.7 5.4 45.3 94.0 697173.0

2
4

----------------------- Page 26-----------------------

PART 3 ANNEXES

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LOAD CASE
DIAGRAM FOR ANCHOR AND TOWING WINCH, drw no. 10002 rev.2

Case 1 [kN] Case 2 [kN] Case 3 [kN]

Case 4 [kN] Case 5 [kN] Case 6* [kN] Case 7 *
[kN]

Y X Y X Y
X Y X Y X Y X
Y

Point S -25 83 -479.4 262 -695.8

296 -736.4 476 -952.8 44.1
-137.7
Point T -30 83 -102.4 262 114.0
296 154.6 476 371.1 44.1
-63.3
Point P -32 667 -983.7 488 -766.7
454 -725.9 274 -508.9 32.4 -120.1 8.8
-24.4
Point R -40.5 667 704.2 488 487.1
454 446.4 274 229.3 32.4 4.9 8.8
-7.9
Point Q -2 0 731.9 0 731.9
0 731.9 0 731.9
Point M -8 0 -8 0 -8
0 -8 0 -8 20.4 -105.8
Point N -3 0 -3 0 -3
0 -3 0 -3 20.4 -12.3
Point K -0.25 0 -0.25 0 -0.25
0 -0.25 0 -0.25 13.6 114.0
Point T -0.25 0 -0.25 0 -0.25
0 -0.25 0 -0.25 13.6
114.0

Σforces= -141.0 1500.0 -141.0 1500.0 -141.0

1500.0 -141.0 1500 -141 119.4 -119.4 119.4
-119.4

Case 1 - Forces on winch foot pad due to weight [kN]

Vertical on deck , Y axis " - " =pushing forces
Remark:
" + " = traction forces
- the positive values are vertical upright and horizontal backward
Horizontal on deck, X axis " - " = from front to back side of the winch
* - load case 6 & 7 (for chain wheels) are calculated for an angle of chain of
45°
" +" = direction- back to front side of the
winch and without taking in consideration the weight
of the winch

1 / 1
`

----------------------- Page 70-----------------------

WARRANTY SERVICE REQUEST

FORM

Request No:

Date:

To: DMT MARINE EQUIPMENT S.A. From:

Attn: Mr. Bogdan Constandache Fax:
Phone: +40 730 711 960 Phone:
Email: b.constandache@dmt-winches.com Email:

Unit:
Type:
Ship Name:
Yard No.:
Delivery date:

Malfunction description:

Action(s) taken:

Requested by: (name/title/ date)