MacGregor Deck Machinery Manuals

Offshore Division
MacGREGOR Plimsoll Pte Ltd

48 Tuas Road
Singapore 638500
Tel: +65 6861 3922
Fax: +65 6862 4334
www.macgregor-group.com
OPERATION & MAINTENANCE MANUAL

REFERENCE NO. CM/P4683/ISSUE-A
Co. Registered No. 198201285G

Registered office in Singapore
MacGREGOR Reference No.: P4683
Subject : Operational/ Maintenance Manual of Deck Machinery

1. Hydraulic Tugger Winch
2. Hydraulic Vertical Capstan
3. Hydraulic Storage Reel Winch
4. Hydraulic Anchor Handling/Towing Winch
5. Hydraulic Anchor Windlass
6. Roller Type Anchor Chain Stopper
7. Electro Hydraulic Power Pack
Hull No. : GMG0888
Project Name : 58.7m Anchor Handling Supply Vessel
Buyer : Guangdong Machinery Import &Export Co., Ltd
Owner : Tidewater Marine, L.L.C
Designed & Built By : MacGregor Plimsoll Pte Ltd
Equipment Serial No. :

Hydraulic Tugger Winch
P4683-HUW10UR-400
P4683-HUW10UL-400
Hydraulic Vertical Capstan

P4683-HVC-05/400-1
P4683-HVC-05/400-2
Hydraulic Storage Reel Winch

P4683-HSW/SD-05
Hydraulic Anchor Handling/Towing Winch

P4683-AHTW/WF-150/200
Hydraulic Anchor Windlass

P4683-HAW/GG-36
Electro-Hydraulic Power Pack

P4683-P3x90+2x7.5-001
P4683-P1x37-002
Classification Society : ABS Certification
Year Built : 2009
___________________________________________________________________________________
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Offshore Division
48 Tuas Road
Singapore 638500
Tel: +65 6861 3922
Fax: +65 6862 4334



Hull No. : GMG0889

P4684-HUW10UR-400
P4684-HUW10UL-400

P4684-HVC-05/400-1
P4684-HVC-05/400-2

P4684-HSW/SD-05

P4684-AHTW/WF-150/200

P4684-HAW/GG-36

P4684-P3x90+2x7.5-001
P4684-P1x37-002
Year Built : 2009
___________________________________________________________________________________
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Offshore Division
48 Tuas Road
Singapore 638500
Tel: +65 6861 3922
Fax: +65 6862 4334



Hull No. : GMG0899

P4685-HUW10UR-400
P4685-HUW10UL-400

P4685-HVC-05/400-1
P4685-HVC-05/400-2

P4685-HSW/SD-05

P4685-AHTW/WF-150/200

P4685-HAW/GG-36

P4685-P3x90+2x7.5-001
P4685-P1x37-002
Year Built : 2009
___________________________________________________________________________________
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Offshore Division
48 Tuas Road
Singapore 638500
Tel: +65 6861 3922
Fax: +65 6862 4334



Hull No. : GMG08100

P4686-HUW10UR-400
P4686-HUW10UL-400

P4686-HVC-05/400-1
P4686-HVC-05/400-2

P4686-HSW/SD-05

P4686-AHTW/WF-150/200

P4686-HAW/GG-36

P4686-P3x90+2x7.5-001
P4686-P1x37-002
Year Built : 2009
___________________________________________________________________________________
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INTRODUCTION
The Operation Manual consists of unit components, system, operating instruction, maintenance,
troubleshooting and recommended spare parts.
For Customer Support and Ordering of Spare Parts, please contact our Customer Service
Department and provide us with MacGREGOR Project Reference Number and Equipment
Serial Number.
Customer Service Department: -

No. 48 Tuas Road
Singapore 638500
Tel No : (65) 6868-85-62
Fax No : (65) 6862-24-52
E-mail : ofs.sgp.custsvs@macgregor-group.com
For more information, please contact:-
Head Office:-

No. 48 Tuas Road
Singapore 638500
Tel No : (65) 6861-39-22 (10 Lines)
Fax No.: (65) 6862-43-34
E-mail : ofs.sgp.corporate@macgregor-group.com
Sales Department:-

No. 48 Tuas Road
Singapore 638500
Tel No : (65) 6868-85-33
Fax No : (65) 6862-43-34
E-mail : ofs.sgp.salesmfg@macgregor-group.com
___________________________________________________________________________________
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SAFETY PRECAUTIONS
WARNING!
 CARELESS OPERATION CAN RESULT IN SERIOUS INJURY OR DAMAGE.
 READ AND UNDERSTAND ALL SAFETY AND OPERATING INSTRUCTIONS

BEFORE INSTALLING AND OPERATING THE MacGREGOR DECK
MACHINERY.
CAUTION!
 DO NOT EXCEED THE LINE PULL RATING SHOWN ON THE IDENTIFICATION

LABEL.
 DO NOT EXCEED THE MAXIMUM RATING OF THE WIRE ROPE BEING USED.
 THE EQUIPMENTS DESCRIBED HEREIN ARE NEITHER DESIGNED NOR

INTENDED FOR LIFTING NOR MOVING PEOPLE.
INCOMING INSPECTION!
 ON THE ARRIVAL OF THE EQUIPMENTS AND PACKAGING, THERE SHOULD

BE A VISUAL INSPECTION WITH REFERENCE TO THE PACKING LIST, FOR
ANY DAMAGES INCURRED DURING TRANSPORTATION.
 ALL DAMAGE REPORTS SHOULD BE SUBMITTED TO THE MANUFACTURER

WITHIN 7 DAYS FROM THE ARRIVAL OF THE EQUIPMENTS AND
PACKAGING.
___________________________________________________________________________________
-iii-
HYDRAULIC ANCHOR HANDLING TOWING WINCH
1.0 GENERAL DESCRIPTION & DATA ............................................................................................................... 2
2.0 TECHNICAL SPECIFICATION ....................................................................................................................... 3
3.0 DRIVE UNIT INFORMATION ...................................................................................................................... 4
3.1. HYDRAULIC MOTOR ......................................................................................................................................... 4

3.2. GEARS ........................................................................................................................................................... 4
3.3. CONTROLS ...................................................................................................................................................... 4
4.0 CONTROL FUNCTIONS .............................................................................................................................. 5
4.1. LOCAL CONTROL CONSOLE ................................................................................................................................. 5

4.2. REMOTE CONTROL PANEL.................................................................................................................................. 6
5.0 OPERATIONAL INSTRUCTIONS ................................................................................................................ 11
5.1. BEFORE OPERATION ........................................................................................................................................ 11

5.2. WINCH OPERATION INSTRUCTIONS .................................................................................................................... 11
5.2.1. Anchor Handling Drum ..................................................................................................................... 11
5.2.2. Towing Drum .................................................................................................................................... 13
5.2.3. After Operation................................................................................................................................. 14
6.0 MAINTENANCE ....................................................................................................................................... 15
6.1. GENERAL INSTRUCTION ................................................................................................................................... 15

6.2. PRESERVATION OF EQUIPMENT ......................................................................................................................... 16
6.2.1. Storage prior to installation ( 0 – 12 months) .................................................................................. 16
6.2.2. Lubrication / Greasing During Storage ............................................................................................. 17
6.2.3. Inspection during Storage................................................................................................................. 17
6.2.4. Lubrication Chart .............................................................................................................................. 18
6.3. BRAKE MAINTENANCE .................................................................................................................................... 19
6.3.1. Hydraulic Anchor Handling Towing Winch Brake Maintenance ....................................................... 19
6.3.2. Drum Brake Lining Wear Out............................................................................................................ 20
6.3.3. Rust Removal .................................................................................................................................... 20
7.0 REFERENCE DRAWINGS .......................................................................................................................... 21
____________________________________________________________________________
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HYDRAULIC ANCHOR HANDLING TOWING WINCH
1.0 GENERAL DESCRIPTION & DATA
The MacGREGOR Hydraulic Anchor Handling/ Towing Winch comprise of an anchor

handling drum & a towing drum mounted in a waterfall configuration. Each drum is
welded to a high tensile steel main shaft, which is supported by a pair of spherical roller
bearing. A central pinion shaft is mounted in between two drums and fitted with jaw
clutches to allow either one drum to work independently. Transmission is from both low
speed high torque medium pressure hydraulic motors via two stage guarded spur
reduction gear box.
Each drum is fitted with a spring loaded & hydraulic release fail-safe band brake. The
brake is a wrap-up design consisting of two halves wrapped around the race of the drum.
Each half has a frictional material lining bolted to the brake band.
An auto spooling gear assembly is fitted in front of the upper drum for automatic
spooling during operation. When spooling in wire rope, it will distribute the wire rope
evenly and tightly onto the drum if the rope is under sufficient tension. The wire rope
passes through two vertical rollers, which run on roller bearings around a high tensile
steel spindle held in a fabricated steel carriage. This carriage is supported on a bright
steel guide shaft and a high tensile steel lead screw.
The carriage is moved across the drum using a driving tongue, mounted in a housing
and bolted to the side of the carriage. The tongue is slotted into the scroll of the lead
screw, which is driven from the drum using a guarded chain and sprocket.
The spooling assembly can be disengaged from the drive of the drum by means of a
clutch, positioned at one side of lead screw. However, only declutch the spooling
assembly when necessary e.g., the wire rope is paying out by very high speed or free -
wheeling the drum.
When re-engaging the assemblies for spooling assembly, rotate the handwheel,
connected to the leadscrew, and re-align the wire rope with the centre of the spooling
carriage. Re-engage the clutch to allow the spooling system to return to automatic drive
mode.
____________________________________________________________________________
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2.0 TECHNICAL SPECIFICATION
EQUIPMENT HYDRAULIC ANCHOR HANDLING/TOWING WINCH

MODEL MG-AHTW/WF-150/200
SERIAL NO. P4683-AHTW/WF-150/200
P4684-AHTW/WF-150/200
P4685-AHTW/WF-150/200
P4686-AHTW/WF-150/200
QUANTITY 1 / VESSEL
4 (TOTAL)
UPPER & LOWER DRUM  

DRUM CAPACITY 1 000m x Dia. 56 mm SWR @ 10 Layers 
 
RATED PULL (1st Layer) 150T x 0~6 m/min (1st speed)
75T x 0~12 m/min (2nd speed)
25T x 0~36 m/min (3rd speed)
RATED PULL (5th Layer) 99T x 0~9 m/min (1st speed)

16T x 0~54 m/min (3rd speed)
RATED PULL (10th Layer) 69T x 0~13 m/min (1st speed)

11T x 0~77.5 m/min (3rd speed)
BRAKE HOLDING 200 T (Static, 1st Layer)

BRAKE ASSEMBLY Hyd. Released, Spring Applied, Fail Safe Type
CLUTCH ASSEMBLY Hyd. Operated Jaw Clutch
CONTROL Local Control Manifold At Winch

Remote Control Panel in Wheelhouse
CERTIFICATION ABS Witness Test Certificate
COLOUR Blue (Jotun RAL 5015)
REF. DRAWING NO. AHTW02B-04A-0

DOC NO. EN-040L-PC-AHTW/WF-150/200
REVISION A
DATE 13.07.09
____________________________________________________________________________
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3.0 DRIVE UNIT INFORMATION
3.1. Hydraulic Motor
Model : CA210-210-S-A-L-N00
Displacement : 13.2/6.6 L/Rev.
Torque Rating : 210/105 Nm/Bar
Model : CA50-50-S-A-0-N00
Displacement : 3.14 L/Rev.
Torque Rating : 50 Nm/Bar
3.2. Gears
Total Ratio : 13.95:1
1st Stage 2nd Stage

Ratio : 5.04 : 1 Ratio : 2.769 : 1
Wheel : 136T, 18 module Wheel : 72T, 12 module
Pinion : 27T, 18 module Pinion : 26T, 12 module
Pressure Angle
Pressure Angle : 20° : 20°
3.3. Controls
Local Control Console near the winch and Remote Control Panel in wheelhouse.
____________________________________________________________________________
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4.0 CONTROL FUNCTIONS
The following control functions are provided for winch unit at the following location:-
4.1. Local Control Console
Item Features Functions
1. Directional control winch It provides the winch with the payout and heave
“PAYOT” / “HEAVE” mode. In the “PAYOUT” mode it controls the
drum and allows the rope to release, while in the
“HEAVE” mode it controls the drum to coil the
rope.
2. “MAIN PRESSURE” display It indicates the main hydraulic system pressure

in bar.
3. “EMERGENCY STOP” push Push the button to stop the hydraulic pump
button. station in the HPU. The button must be reset
once it is activated, otherwise, the pump station
would not start.
Figure 1: Local Control Manifold
____________________________________________________________________________
-5-
4.2. Remote Control Panel
1. “MAIN PRESSURE” display It indicates the main hydraulic system pressure in

bar.
2. “PILOT PRESSURE” display It indicates the control hydraulic system pressure

in bar.
“PAYOUT” / “HEAVE” mode. In the “PAYOUT” mode it controls the drum
and allows the rope to release, while in the
rope.
4. “LOW OIL LEVEL” indicating It indicates the oil in the power pack is below its
light safety level.
5. “HIGH OIL TEMP” indicating It indicates the oil temperature in the power pack
light is above its safety level.
6. “OVER LOAD” indicating It indicates that load has exceeds the winch lifting
light capacity. The buzzer is activated together with
this indication light.
7. “OVER LOAD RESET” push After the over load protection has activated, push
button the buzzer-reset button. It resets the over load
function.
8. “BUZZER MUTE” button. Once the alarm has activated and the problem
been identified and rectified, to push the button to
disable the buzzer.
9. “BUZZER” An audio alarm that activates once the system

has a fault. Check the actual fault with the
indicating light.
____________________________________________________________________________
-6-
“EMERGENCY RELEASE” push It opens the drum brake and disengages the
10. button clutch from the drum so that the drum is free
to rotate.
“EMERGENCY STOP” push Push the button to stop the hydraulic pump
button station in the HPU. The button must be reset
11.
once it is activated, otherwise, the pump
station would not start.
POWER SUPPLY “ON” / “OFF” Turn this selector to switch “ON” or “OFF”
12. the power supply. Power supply is provided
for the control system.
“DC POWER AVAILABLE” It indicates the DC system power is switched

13.
indicating light on and ready for operation.
“AC POWER FAILURE” It indicates that the AC system power is not

14.
indicating light available.
Station selector “LOCAL” / To allow control from either the remote

15. “W.H.” control in the wheel house or local control
near the winch.
“W.H” indicating light To indicate wheelhouse control panel in

16.
operation.
17. “LOCAL” indicating light To indicate local control panel in operation.
Speed selector “SPEED 1”, A three speeds range control with “SPEED 1”
18. “SPEED 2”, “SPEED 3”, push as the slowest and “SPEED 3” as the fastest
button with indicating light speed.
19. “DIMMER” It controls the intensity of the indicating light.
____________________________________________________________________________
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20. Drum Selector “A.H. / TOW” A 2-position anchor handling drum or Towing
drum selection. When turn to “AH” mode the
Tow brake and clutch controls are disabled.
When turn to “TOW” mode, the AH brake and
clutch controls are disabled.
21. “LAMP TEST” push button To check the bulb is working. Push the button
and all the bulbs shall be lighted, otherwise, bulb
is faulty.
22. A.H & Towing Drum A two positions brake control. When turn to
Brake selector “HOLD” “HOLD” mode, the brake is always closed. Turn
/ ”AUTO” to “AUTO” mode, and the brake band shall open
once the winch rotates, and it automatically
closes when the winch stops. It works together
with the main control valve.
23. Brake “HOLD” indicating light This indicates the brake band is closed. The
brake is holding the drum.
24. Brake “RELEASE” indicating This indicates the brake band is open. The brake
light is not holding the drum
25.. A.H & Towing Drum To engage the clutch to the drum, turn the
Clutch selector “IN” / “OUT” selector to “IN” position. To disengage the clutch
from the drum, turn the selector to “OUT”
position. Under high load condition, the clutch
may not be able to disengage from the drum
instantly, thus the clutch has to rotate either
direction to disengage from the drum.
26. “CLUTCH IN” indicating light It indicates the clutch is engaged to the drum.
____________________________________________________________________________
-8-
27. “CLUTCH OUT” indicating light It indicates the clutch is disengaged to the drum.
28. Main Pump 1, 2 & 3 “START” / Push these buttons to switch on or off the
“STOP” push button with hydraulic pump stations on the power pack.
indicating light
29. “POWER ON” indicating light It indicates the system power is switched on, and
ready for operation
30. Pilot Pump1&2 “START” / Push these buttons to switch on or off the pilot
“STOP” push button with pump station on the power pack.
indicating light.
____________________________________________________________________________
-9-
Figure 2: Remote Control Stand
__________________________________________________________________________________________________________________
-10-
5.0 OPERATIONAL INSTRUCTIONS
5.1. Before operation
 Carry out visual inspection of the equipment.

 Secure any loose components e.g. cables and ropes.
 Ensure that the equipment is fully lubricated.
 Press the upper and lower isolating plungers, the oil level must be at least ¾ of
the oil meter.
 Switch ON the starter panels
5.2. Winch Operation instructions
[Switch] POWER SUPPLY to [ON]

[Observe] POWER (White light) [ON]
[Switch] STATION SELECT to [WH]
[Observe] W.H (Green light) [ON]
[Press] LAMP TEST; All bulbs shall be lighted
[Rotate] DIMMER until Red illumination light is visible
[Press] ALL PILOT PUMPS to [START]

[Observe] START (Green light) [ON]
[Observe] STOP (Red light) [OFF]
[Press] ALL MAIN PUMPS to [START]

[Observe] START (Green light) [ON]
[Observe] STOP (Red light) [OFF]
5.2.1. Anchor Handling Drum
[Switch] DRUM SELECT to [A.H]

[Switch] CLUTCH CONTROL to [IN]
[Observe] CLUTCH IN (Green light) [ON]
NOTE:
If the clutch control indicator shows it’s OUT (red), gently payout the joystick until the
clutch control indicator shows it’s IN (green).
CAUTION:
!
DO NOT HEAVE IN TO ENGAGE THE CLUTCH FOR IT WILL DAMAGE THE BRAKE.
____________________________________________________________________________
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[Press] SPEED 1 (or SPEED 2 or SPEED 3) [ON]
NOTES: 1st Layer

 SPEED 1: 150T x 6m/min
! CAUTION:
Safety Caution!
- Speed has to be selected according to the load to be handled.
- Improper selection of speed may cause over speed of the motors
and may result in hydraulic motor failure.
- DO NOT change the speed while the winch is operating.
-
 To Heave/Payout of Rope
[Switch] BRAKE CONTROL to [AUTO]

[Observe] BRAKE HOLD (Green light) [ON]
 To Payout
[Push gently] DIRECTION CONTROL JOYSTICK to [PAY OUT]
[Observe] BRAKE HOLD (Green light) [OFF]
 To Heave
[Push gently] DIRECTION CONTROL JOYSTICK to [HEAVE]
 To Stop
[Return] DIRECTION CONTROL JOYSTICK to [NEUTRAL]
____________________________________________________________________________
-12-
5.2.2. Towing Drum
[Switch] DRUM SELECT to [TOW]

[Switch] CLUTCH CONTROL to [IN]
[Observe] CLUTCH IN (Green light) [ON]
NOTE:
If the clutch control indicator shows it’s OUT (red), gently payout the joystick until the
clutch control indicator shows it’s IN (green).
CAUTION:
!
DO NOT HEAVE IN TO ENGAGE THE CLUTCH FOR IT WILL DAMAGE THE BRAKE.
[Press] SPEED 1 (or SPEED 2 or SPEED 3) [ON]
NOTES: 1st Layer

! CAUTION:
Safety Caution!
- Speed has to be selected according to the load to be handled.
- Improper selection of speed may cause over speed of the motors
and may result in hydraulic motor failure.
- DO NOT change the speed while the winch is operating.
-
____________________________________________________________________________
-13-
 To Heave/Payout of Rope
[Switch] BRAKE CONTROL to [AUTO]

 To Payout
[Push gently] DIRECTION CONTROL JOYSTICK to [PAY OUT]
 To Heave
[Push gently] DIRECTION CONTROL JOYSTICK to [HEAVE]
 To Stop
[Return] DIRECTION CONTROL JOYSTICK to [NEUTRAL]
 TOWING OPERATION
[Switch] CLUTCH to [OUT]

[Observe] CLUTCH IN (Green light) [OFF]
[Ensure] BRAKE to [HOLD]
5.2.3. After Operation
[Press] SPEED 1
[Observe] SPEED 1 (Green light) [ON]
[Switch] BRAKE to [HOLD]
[Switch] CLUTCH to [OUT]
 For all pumps
[Press] “STOP”
[Observe] STOP (Red light) [ON]
[Observe] START (Green light) [OFF]
NOTES:
 ENSURE THAT THE STARTER PANEL REMAINS ON FOR MOTOR

SPACE HEATER.
 THE OIL TEMPERATURE MUST NOT EXCEED 80oC.
____________________________________________________________________________
-14-
6.0 MAINTENANCE
 Maintenance of the equipment must be executed by qualified personnel.
 It is important to carry out maintenance at recommended interval of time in order

to keep the equipment operating at maximum condition.
 Make sure that the area around the equipment is free from personnel during
maintenance to avoid injuries.
 Make sure that all electrical supplies are disconnected before maintenance
operation to prevent injuries.
 Do consult us before conducting any major overhaul.
 Following instructions provided are guidelines only; the frequency has to be

adapted for different conditions and weather.
6.1. General Instruction
 Lubricate the parts of the equipment at recommended intervals. Refer to

the Lubrication Chart. Always move the parts as you apply grease for
thorough lubrication. Lubrication is important to prevent corrosions of
parts and also act as sealer to prevent rain/seawater from seeping in that
could damage bearings. Lubrication must be carried out inclusive of long-
term parking and storage period.
 Do tighten the screws and nuts periodically. Pay attention to fastening of

bolts of bearing housings and winch foundations.
 Check the alignment of the winch occasionally.
 Replace the brake lining when the thickness of the lining is reduced by 3-
5mm then conduct brake “wear-out” process followed by brake set
adjustment.
 Check for any damage and repair.
 Replace damaged component. Use only MacGREGOR Plimsoll

approved parts.
____________________________________________________________________________
-15-
6.2. Preservation of equipment
This work instruction provides a list of action to preserve and store the equipment before
installation at site.
6.2.1. Storage prior to installation ( 0 – 12 months)
 The whole winch, hydraulic power unit, electrical controls like starters,
drives and enclosures must be stored indoor or fully covered with
canvas to prevent any contact with water and maintain in dry
condition.
 The outside / top layer of the wire rope should be coated with grease
Shell-Malleus compound or equivalent.
 Internal areas of the oil tank must be thoroughly clean, and protected
with a layer of oil. The oil tank is then fully seal.
 All grease points / nipple to be re-greased with Total EP2 or
equivalent.
 All outside machined surface without surface protection to be applied
with grease.
 Spooling gear shafts shall be covered with grease and wrapped with
plastic foil.
 Hydraulic Cylinder extended rods, top screws and nuts are applied
with thin layer of grease and wrapped with plastic foil.
 All the loose hydraulic hoses and components ports must be fully
plugged to prevent any kind of particles, dust or other pollution from
contaminating the hydraulic system.
 Chipped paint should be prepared with wire brushing, normal thinner
and Jotun touch-up paint:
+ Primer: Shop primer iron oxide (red)
+ Tie Coat: Primastic universal
+ Finishing: Primastic universal
 The inner parts of the electrical starters, drives and enclosures should
be packed with moisture absorbing agent such as silica.
 Enclosed gear box, the gears must be immersed in oil bath. All
opening covers of the gear box, with its mounting screws, must be
water tight, sealed with silicone sealant. If breather cap is installed,
removed and tightened with solid screw cap.
____________________________________________________________________________
-16-
 All exposed cables must be covered by means of tarpaulin or similar
product.
6.2.2. Lubrication / Greasing During Storage
 Bearing / clutch – once every 3 weeks.

 Brake screw / pins - once every 3 weeks.
 Spur gear / pinion / wire rope – once every two months.
 Movable / rotatable parts are to be moved or rotated during
lubrication to facilitate full lubrication of parts.
6.2.3. Inspection during Storage
During storage, inspection of the equipment must be carried out to ensure

condition of the equipment is well preserved.
 Ensure that all external cables are adequately cleared and secured
and that there is no evidence of chafing.
 Check that all terminals are clean and tight.
 Check that fixing bolts, couplings, etc, are securely fixed. Particularly
important is the correct tightening of the bolts for the bearing housing
and winch foundation.
 Keep the motor free from oil, dirt and dust. Do not allow tools, rags,
oil cans, etc, to lie on or around the motor. Ensure that no dust
accumulates on the frame of the motor, as dust could easily get into
the motor and accumulate between the pole and drum, pole and
bracket or drum and frame.
 Ensure the moisture absorbing agent in the electrical starters and
enclosures remain effective and change when needed.
 Internal areas of oil tank remains clean and oiled.
____________________________________________________________________________
-17-
6.2.4. Lubrication Chart
LOCATION CODE LUBRICANT FREQUENCY
1. Main Gear / Pinion Omega73 Once every two

months
(Or Equivalent)
2. Bearings, Clutch TOTAL EP2 Once every three

weeks
Screw, Pins
(Or Equivalent)
3. Enclosed Gearbox, TOTAL CARTER First Oil Change After

Sprocket EP220 100 Hours of
Operation; and
(Or Equivalent) Subsequently Every
2000Hours of
Operation.
4. Wire Rope
Brilube 70 Compound Once every three
(Or Equivalent) months.
____________________________________________________________________________
-18-
6.3. Brake Maintenance
6.3.1. Hydraulic Anchor Handling Towing Winch Brake Maintenance
Drum Brake Set Adjustment (Refer Drawing No.: LDBSA-1 & UDBSA-1)
When the drum brake linings, actuating cylinder, or other major component of
the brake actuating mechanism has been replaced, or when normal wear of the
brake lining occurs, the brake must be adjusted for correct operation. When the
linings have worn to 5 mm at the edges or to within 0.5 mm above the retaining
bolt or rivet heads, the lining must be replaced. To adjust the drum brake:-
 Hydraulic pilot system is switched on.
 Select drum and winch direction control handle in neutral position.
 Ensure clutch control selectors are set to “OUT” position.
 Press the “Emergency Release” button to open the brake.
 Gently tighten the brake adjuster at the end of the brake band with a
spanner. Tighten the adjuster to the maximum.
 Turn the Emergency release push button to counter clockwise to release

the Emergency button. This action would release the spring in the
cylinder and set the brake to be on “HOLD” position.
 When this adjustment is done, the drum brake adjustment is now

complete.
WARNING!
DO NOT OPEN UP AND OVERHAUL THE BRAKE CYLINDER. THE

SPRING INSIDE IS COMPRESSED AND MAY CAUSE INJURY WHEN
OPEN.
NOTE!
AFTER CONTINUOUS OPERATION, DUE TO WEAR AND TEAR, IT MAY

BE NECESSARY TO MAINTAIN THE REQUIRED BRAKE HOLDING
CAPACITY BY SETTING THE BRAKE HOLDING ADJUSTER. TIGHTEN
THE ADJUSTER BY 1.5 ~ 2 ROUNDS EACH TIME AND TEST THE
HOLDING UNDER ACTUAL OPERATING CONDITION.
____________________________________________________________________________
-19-
6.3.2. Drum Brake Lining Wear Out
Whenever new brake linings are installed, the new lining must be seated or
“worn out” for correct operation of the brakes. To seat the new linings;
a. Remove rope from the drum or pay in all lines and then secure the loose
end to prevent unwinding.
b. Engage the clutch and operate the drum in pay out direction at low speed.
c. While the drum rotates, slowly set the brake with hand wheel until the
brake lining is in contact with the brake race and dragging slightly.
d. Rotates the drum for 45 minutes and constantly monitor the drum flange
temperature.
e. After this process, the brake should be ready for operation.
f. If not, allow the drum flange to cool down for about 15 minutes. Then,
rotate the drum for another 10-15 minutes.
WARNING!
DO NOT EXCEED 200OC DURING WEAR OUT OF BRAKE LINING. EXCESS

TEMPERATURE CAN CAUSE “GLAZING” OF THE LINING SURFACE. IF THE
BRAKE DRUM REACHES 200OC, RELEASE THE BRAKE AND ALLOW IT TO
COOL DOWN TO 150OC BEFORE PROCEEDING.
6.3.3. Rust Removal
After the initial installation or long periods of storage, the brake drum surface
should be checked for evidence of rust. A light rust coating is normal, but if
loose particle or flaking sheets are evidence, the rust must be removed down to
bare metal. To remove rust from the brake drum, perform the following steps:-
 Remove the upper half of the brake and then allowing the lower half of
the band brake to rest on the skid frame away from the brake drum.
 Pay in all wire rope line onto the drum and secure the loose end to
prevent snarling, or the remove all wire rope from the drum.
 Operate the drum in the pay in direction at a speed of 5 ~ 10 rpm.
 Using an abrasive or wire wheel, remove all rust from the brake drum
surface down to the bare metal. Make final cleaning of rust crosswise of
the braking surface so that small surface scratches are not in line with
drum rotation.
 Check the brake linings for evidence of even wear. The wear pattern
should show full even wear over the full lining surface.
 After all rust has been removed and lining wear pattern correct, replace
the brake band and tighten all fasteners, then perform the drum brake set
adjustment.
____________________________________________________________________________
-20-
7.0 REFERENCE DRAWINGS
Item Title Drawing No. Page Revision
1. Hydraulic Anchor Handling /

AHTW02B- 04A-0 1 Of 2 C
Towing Winch
General Arrangement
2. Hydraulic Anchor Handling / AHTW02B- 04A-0 2 Of 2 C

Towing Winch
General Arrangement
(Skid Mounting Holes
Arrangement)
3. Hydraulic Anchor Handling / 1 Of 4 C1

AHTW02B- 04A-2
Towing Winch 2 Of 4 C1
Sectional General Arrangement 3 Of 4 C1
4. Hydraulic Anchor Handling /

AHTW02B- 04A-2 4 Of 4 C1
Towing Winch
Sectional General Arrangement
5. Brake Assembly 0128S 1 of 2 C4

2 of 2 C4
6. Hydraulic Motor CA210 & CA50 - N/A

Exploded Drawings
____________________________________________________________________________
-21-
CA210
HYDRAULIC MOTORS - COMPACT COPL-1.50.1
SPARE PARTS - MOTORS
05-04-28
TYPE CA 50 Replaces 04-12-03
TYPE 1 2 3 4
Draw. No
QUANTITY O- MODIFICATION Weight
ITEM 1 2 3 4
PART NO DESCRIPTION Code 0 1 2 3 4 SUPPLEMENTARY DATA Kg/pc
TYPE
Product indicated in TYPE columns 1, 2, 3 and 4 C = To be delivered with a certain delivery time from
Corresponds to QUANTITY columns 1, 2, 3 and 4. Mellansel, Sweden.
D = Standard part that can be bought locally, also immediate
ITEM delivery from Mellansel, Sweden.
When a part change Part No, there will be added a letter behind E = Not stocked.
the item No. E.g. 001, 001A the first time, 001B the second time F = Only delivered as part included in a complete set.
and so on. The change will basically NOT be shown in the G = Included in spare part set.
figure, only as a new line in the text, with the new Part No.
Spare parts sets and non standard parts have item numbers MODIFICATION
starting from 900 on the list. o = Indicates an replaced part and what modification it has been
used on. Fully interchangeable by the new identity.
QUANTITY x = indicates in which modification the part can be used or is
Indicates the quantity included in the product. included.
Columns 1, 2, 3 and 4 corresponds to the different types or - = Indicates an excluded part , or not fully interchangeable part.
designations in TYPE columns 1, 2, 3 and 4.
If interchangeable, interchangeable by means of a new
complete set.
PART NO
SUPPLEMENTARY DATA
DESCRIPTION
Parts included in a unit are marked . (point) in front of description.
WEIGHT
That means that if You order e.g. a
Weight is indicated in kg for each part.
Plug , followed by
.O-ring , in the parts list, the O-ring will be included on
When ordering spare parts please state:
the Plug at delivery.
Quantity, item number, description, part No, type designation,
and if possible Individ No.
ORDER CODE ( O- code )
Ex. 1 pc, item 011A, Cam ring, 178 2816-001 for a
Indicates stock status and delivery times. Codes with following
CA 50 50 S A 0 N 0 0 00 00 Individ No K50P 01002
meaning are used.
A = Immediate delivery from stock in Mellansel, Sweden, or
nearest reseller.
B = Immediate delivery from stock in Mellansel, Sweden.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
HÄGGLUNDS DRIVES AB . SE - 89042 Mellansel, Sweden www.hagglunds.com Page 1/5

SPARE PARTS - MOTORS COPL-1.50.1
TYPE CA 50 05-04-28
TYPE 1 Common parts 2 CA 50 SA0N00 3 CA 50

C A 0 N H C 4 Other designation
Draw. No 178 1858-xxx 178 1858-601 178 1858-102 178 1858-xxx
ITEM PART NO DESCRIPTION code 0 2 3 4 5 SUPPLEMENTARY DATA Kg/pc
1 2 3 4
001 1 1 178 1916-001 Cylinder block, splines B x x For CA 50 S x x. Note 1 42.00
002 1 1 178 1916-002 Cylinder block, hollow shaft B x x For CA 50 C A x. Note 1 46.00
003 1 178 1916-003 Cylinder block, hollow shaft B x x For CA 50 C B x. Note 1 46.00
006 1 1 178 1859-001 Connection block B - x For CA 50 x A 0. Note 2. 63.00
007 1 178 1859-002 Connection block w. spline B - x For CA 50 x B 0. Motor with Brake/TA kit. Note 3 63.00
008 1 178 1859-003 Connection block w. spline B - x For CA 50 x B L/R. With Brake/TA and 2-speed 63.00
009 1 178 1859-004 Connection block B - x For CA 50 x A L/R. Motor with 2-speed 63.00
011 1 1 1 178 1640-001 Cam ring 50 E o For CA 50 20.00
011A 1 1 1 178 2816-001 Cam ring 50 B x x For CA 50 20.00
012 1 178 2817-001 Cam ring 40 B x x For CA 50 40 20.00
016 1 1 378 1646-801 Shaft coupling B x x For CA 50 xx C 22.00
017 8 8 2121 2037-631 .Screw D x x M6S 16x55-10.9 0.120
020 1 178 2497-001 Valve plate B x x For CA 50 x x x x x x 00 13. (Special index 13) 3.500
021 1 178 1860-001 Shaft end housing B x x 21.80
022 1 178 1861-001 Valve plate B x x 3.500
023 1 378 1651-801 Cyl. roll. thrust bearing E o 3.550
023A 1 378 2322-801 Axial-radial bearing E o Replaces item 23 and 1 of item 32 5.330
023B 1 378 2414-801 Axial-rad.bear. coated B x x 5.330
024 2 378 1659-001 Wear ring B x x 0.800
025 1 378 1661-001 Seal retainer E o o 1.300
025A 1 078 0148-001 Seal retainer B x x From Ind. No. K50P 07100 V0516 1.300
027 16 478 3292-001 Compr. spring B x x 0.005
028 14 14 278 1374-001 Piston, not coated B x x For CB 50 xx x x x x x 0 0.370
029 14 478 3335-002 Solid piston ring E o When replaced, remove item 107. 0.004
029A 14 478 3721-002 Solid piston ring F x x Use to a new Cylinder block. 0.004
029B 14 478 3569-003 Splitted piston ring B x x Use for repair of motor, to used cylinder block. 0.006
030 16 478 3353-001 Balancing piston B x x 0.007
Note 1: When replacing Cylinder block, Wear ring item 34 and Cyl. roller bearing item 32 must also be replaced.
Note 2: Spare part for Mod 0, see SC-9, Design alteration No 1, page 2, Spare parts.
Note 3: TA kit = Tandem kit. Note 4: See also SC – 9 Service INFO No 8
HÄGGLUNDS DRIVES AB . SE - 89042 Mellansel, Sweden www.hagglunds.com Page2/5

TYPE CA 50 05-04-28
TYPE 1 Common parts 2 CA 50 SA0N00 3 CA 50 C A 0 N H C 4 Other designation
Draw. No 178 1858-xxx 178 1858-601 178 1858-102 178 1858-xxx
1 2 3 4
031 16 478 3354-001 Balancing sleeve B x x 0.005
032 1 478 3355-801 Cyl. roller bearing B x x 1 pc. replaced with item 23A See fig. Note 4 1.900
033 4 4 2 478 3356-001 Blind flange B x x 2 pcs for 2-speed prepared motors. ( L, or R ) 1.200
034 1 478 3357-001 Wear ring B - Used only in modification 0. 0.045
035 14 14 478 3358-001 Cam roller, coated E o Replaced from Individ No K50P 05300. 0.550
035A 14 14 478 3358-007 Cam roller, coated B x x For CB 50 xx x x x x x 0 0.550
036 1 487 5073-001 Orifice B x x Ø 1 mm. 0.001
039 2 2111 2111-563 Roll pin D x x FRP 16x40 SMS 1663 0.002
040 3 2121 2032-536 Screw E o M6S 12x30 -8.8 Zinc pl. 0.037
040A 6 2121 2037-540 -"- D x x M6S 12x40–10.9 Phosp. NB! Increased Qty (3) 0.044
041 2 2121 2552-210 Screw D x x UC6S 3/8" UNCx 89 -8.8 Zinc pl. 0.054
042 16 2121 2032-644 -"- E o M6S 16x120 -8.8 Zinc pl. 0.220
042A 16 2121 2037-644 -"- D x x M6S 16x120 -10.9 Phosp. 0.220
043 8 2121 2541-542 Screw D x x MC6S 12x50 -12.9 0.056
044 16 2121 2046-288 -"- E o U6S 1/2" UNCx45 -8.8 Zinc pl. 0.056
044A 16 16 12 2121 2552-288 -"- D x x UC6S 1/2" UNCx45 -8.8. 12 pcs. for 2-speed 0.058
045 2 2121 2592-371 Locating bolt D x x MC6S 6x23 0.012
047 3 2522 2111-110 Plug, G 1/4” D x x N.B! Earlier 5 pcs. 2 pcs replaced by item 71. 0.020
048 3 2522 2111-115 -"- D x x G 3/4" MONSUN RP 19. ( Item 111 incl.) 0.100
049 16 2126 2032-124 Nut E o M6M 16 -8 Zinc pl. 0.038
049A 16 2126 2038-124 -"- D x x M6M 16 -10 Phosp. 0.038
050 16 24 487 2826-002 Washer B x x 8 pcs used for Shaft coupling 0.004
051 1 1 1 278 1371-001 Bearing retainer E o For CA 50 x A x x 0 3.100
051A 1 1 1 278 5011-001 Bearing retainer B x x F.Ind.No K50P 05000. For CA 50 x A x x 0 x 3.900
052 1 1 1 378 1669-001 End cover E - Repl. with items: 52B+3 off item 40A 4.720
052A 1 1 1 278 2073-001 End cover E o For CA 50 xx x A x x 0 x 2.400
052B 1 1 1 378 2391-801 End cover B x x Includes glued item 115A 2.400
053 1 478 3380-001 Cover E - Replaces with item 52B 0.086
054 4 2121 2532-329 Screw D - MC6S 5x16 -8.8 Zinc pl. 0.004
055 4 2126 2032-114 Nut D - M6M 5 -8 Zinc pl. 0.002

056 8 487 2826-007 Washer B x x 0.002
059 2 2151 2052-173 -"- D x x TBRB 10.5x22x4 Zinc pl. 0.009
062 1 2522 4506-205 Protective cap E o 0.001
062A 1 1 1 2522 2111-116 Plug, G 1” D x x For CA 50 x A x x 0 0.110
068 1 478 3681-001 Lock ring B x x 0.020

071 2 2 2 2529 2412-110 Test nipple A x x G 1/4"xM16. Not to brake or TA kit motor 0.075
083 14 14 278 2328-001 Piston, coated B x From 2004-08-15. For CB 50 xx x x x x x C 0.550
084 14 14 478 3358-006 Cam roller, not coated B x From 2004-08-15. For CB 50 xx x x x x x C 0.550
090 2 478 3570-001 2-speed plug B x x For 2-speed prepared motors. ( L / R ) 0.200
091 1 478 3635-001 Gasket B x x For 2-speed prepared motors. ( L / R ) 0.100

092 1 478 3634-001 Protective cover B x x For 2-speed prepared motors. ( L / R ) 0.800
094 2 2154 2431-124 Lock ring. 22x1 DIN 472/1 B x x For 2-speed prepared motors. ( L / R ) 0.001
095 4 478 3661-001 Spacer B x x For 2-speed prepared motors. ( L / R ) 0.010
099 1 1 378 1973-601 Through hole kit E o See parts list COPL-7.4.1 0.010
099A 1 1 378 2522-801 Through hole kit B x x For CA 50 x x x x H x. See parts list COPL-7.4.1 0.010
101 2 378 1727-001 Radial lip seal E o 0.120
101A 1 378 1978-001 -"- A x x 1 of Item 101A replaced with item 171 0.120
102 1 378 1653-001 -"- E o 0.052
102A 1 378 1979-001 -"- GA - Used only in modification 0. 0.052
103 1 2152 2115-889 O-ring E o 162x3.0 NBR 70 IRH 0.008

103A 2 2152 2118-889 -"- F x x 162x3.0 NBR 90 IRH 0.008
104 2 2152 2115-947 -"- F x x 400x4 NBR 70 IRH 0.030
105 1 2152 2115-725 -"- E o 210x3.0 NBR 70 IRH 0.010
105A 1 2152 2118-725 -"- F x x 210x3.0 NBR 90 IRH 0.010
106 4 2152 2115-832 O-ring F x x 37.69x3.53 NBR 70 IRH. 2 pcs. for 2-speed. 0.001
107 14 2152 2115-696 -"- E - Excluded part. 40.95x2.62 NBR 70 IRH 0.001
110 5 2152 2115-809 .O-ring F x x 9.92x2.62 NBR 70 IRH 0.001
111 3 2152 2115-822 . -"- F x x 22.22x2.62 NBR 70 IRH 0.001
115 1 378 1778-001 Seal B - 0.001

115A 1 278 2072-001 .Seal B x x This seal is glued in End cover item 52B. 0.020
116 1 478 3376-001 Seal B - 0.001
124 1 2152 2115-839 O-ring F x x 124.5x3.0 NBR 90 IRH. From I. No. K50P 05000 0.008
133 1 2152 2115-526 -"- F x x 124.3x5.7 NBR 70 IRH. To motor w. spline 0.010
171 1 378 2626-001 Radial lip seal GA x x Fr. Ind. No. K50P 07100. Week 0516 Only 1 incl. in 0.200
Basic seal kit replaces 1 of item 101A.

TYPE CA 50 05-04-28
TYPE 1 Common parts 2 CA 50 SA0N00 3 CA 50

C A 0 N H C 4 Other designation
Draw. No 178 1858-xxx 178 1858-601 178 1858-102 178 1858-xxx
1 2 3 4
351 1 378 1985-001 Bearing retainer B x x For CA 50 x B x. Motor with Brake/TA kit. Note 5 2.800
900 1 378 1729-803 Basic seal kit, NITRIL A x x Incl: 1x101A,102A-106, 110, 111, 124, 133, 171. N. 6 0.540
901 1 378 1729-802 Gasket set VITON C x x For CA 50 x x x V motors 0.450
902 1 487 6236-805 Connection adapter set B x x From BSP to UNF thread 9.700
920 1 1 478 3629-801 Mounting kit A x x For shaft with spline. See -7.3.1 0.325
922 # 1853 2431-010 Natural rubber seal string B x x Ø 10 mm, length 805 mm. Glue, use Loctite 424
Note 5 : TA kit = Tandem kit. For motor with brake, replace item 351 with item 302, Disc centre. Item 302, see brakes spare parts list.
Note 6 : Item 900 is a universal Basic seal kit that fits to all COMPACT- MOTORS, but the Radial lip seal to shaft side ( this motor type,
item 101A), is not included. Add 1 of item 101A for complete Motor. See also SC – 9, Service INFO No 3.
Revision 2003-12-08: Upgraded to Modification 2 and order code for Through hole kit added. ( CA50 50 C A 0 N H 02 00.)
Item 99, Through hole kit, added.
Revision 2004-09-17: Updated with order code for coated Piston, ( CA50 50 C A 0 N H C.) Item 83, 84, and 922, added.
Revision 2004-12-03: Part No for item 83 corrected from 478 2823-001.
Revision 2005-04-05: New design for 25A Seal retainer. New Radial lip seal on connection side, item 171 replaces 1 of item 101A.
Washer item 50 moved to connection side under screw head.
Alternative assembly: Spare parts for Brakes, Tandem kit, Through hole kit, and so on, see respective spare parts list.
Accessories see page 5.
HÄGGLUNDS DRIVES AB . SE - 89042 Mellansel, Sweden www.hagglunds.com Page4/5

TYPE CA 50 05-04-28

HYDRAULIC ANCHOR WINDLASS

3.1. HYDRAULIC MOTOR ......................................................................................................................................... 4
3.2. GEAR ............................................................................................................................................................. 4
3.3. CONTROL........................................................................................................................................................ 4
4.1. LOCAL CONTROL PANEL..................................................................................................................................... 5
5.0 OPERATIONAL INSTRUCTIONS .................................................................................................................. 6
5.1. BEFORE OPERATION .......................................................................................................................................... 6
5.2. ANCHOR DROPPING .......................................................................................................................................... 6
5.3. TO USE GYPSY FOR ANCHOR HEAVING AND LOWERING ............................................................................................ 6
5.4. AFTER OPERATION ........................................................................................................................................... 7
6.0 MAINTENANCE ......................................................................................................................................... 8
6.1. GENERAL INSTRUCTION ..................................................................................................................................... 8
6.2. PRESERVATION OF EQUIPMENT ........................................................................................................................... 9
6.2.1. Storage prior to installation ( 0 – 12 months) .................................................................................... 9
6.3. BRAKE MAINTENANCE............................................................................................................................... 12
6.3.1. Manual Brake Lining Replacement ................................................................................................... 12
6.3.2. Gypsy Brake Lining Wear Out ........................................................................................................... 14
6.3.3. Rust Removal .................................................................................................................................... 15
____________________________________________________________________________
-1-
HYDRAULIC ANCHOR WINDLASS
The MacGREGOR Plimsoll hydraulic anchor windlass is located at FWD in this vessel.
The unit comprises of two cast steel gypsies, rotating on a high tensile steel main shaft
driven by a high torque hydraulic motor via spur gear reduction.
Each gypsy is installed with a pair of bronze bushings, for rotation on the main shaft.
The gypsy can be engaged or disengaged by means of a jaw clutch, which is positioned
on the hexagonal section of the main shaft. The clutch is to be operated manually
through leverage mechanism.
The main shaft is supported by heavy-duty bronze bushings enclosed into castd steel
housing that is bolted down the windlass fabricated side frames.
Each gypsy is individually fitted with a manually operated band brake. The brakes are
of wrap-up design and there are two halves around the race of the brake race. Each
half has a frictional material lining riveted to its inside. The brake halves are operated
through a screw-lever mechanism complete with hand wheel.
The windlass unit is complete with two cast steel general purpose warping heads at
each end of the main shaft.
____________________________________________________________________________
-2-
EQUIPMENT HYDRAULIC ANCHOR WINDLASS
MODEL MG-HAW/GG-36
SERIAL NO. P4683-HAW/GG-36

P4684-HAW/GG-36
P4685-HAW/GG-36
P4686-HAW/GG-36
QUANTITY 1 / VESSEL
4 (TOTAL)
WINDLASS
CHAIN SIZE 36 mm dia U2 Chain
DUTY PULL 9 T x 12m/min
CLASS REQUIREMENT
DUTY PULL 5.6 T x 12m/min
OVERLOAD PULL 8.4T
BRAKE HOLDING 33.6 T
BRAKE ASSEMBLY Manual operated band brake

CLUTCH ASSEMBLY Manual operated jaw clutch
CONTROL Local Control Stand Near Winch
HYDRAULIC MOTOR SAI GM5A
CERTIFICATION ABS Cert & Product Cert Acc to ISO 10474-2.1
COLOUR Blue( Jotun RAL 5015)
REF. DRAWING NO. NS674-0

DOC NO. EN-040L-P4683-86-HAW
REVISION A
DATE 14.07.09
REACTION LOAD : R1 = R2 = 26.5 T & R3 = 33.6 T
____________________________________________________________________________
-3-
A radial piston type motor.
Torque Rating : 22.8 Nm/Bar
Model : GM5A-1450-7EG-D40
3.2. Gear
Single stage spur wheel and pinion reduction.
Ratio : 6:1
Wheel : 126 T, 10 Module
Pinion : 21 T, 10 Module
Pressure Angle : 20o
3.3. Control
Local control stand near windlass.
____________________________________________________________________________
-4-
The following control functions are provided for windlass/winch unit at the following
location:-
4.1. Local Control Panel
1. Directional control windlass It provides the winch with the payout and
“PAYOUT” / “HEAVE” heave mode. In the “PAYOUT” mode it
controls the drum and allows the rope to
release, while in the “HEAVE” mode it
controls the drum to coil the rope.
2. “MAIN PRESSURE” It indicates the main hydraulic system

display pressure in bar.
Figure 1: Local Control Panel
____________________________________________________________________________
-5-
5.1. Before operation

 Press the upper and lower isolating plungers, the oil level must be at least ¾ of
the oil meter.
 Switch ON the starter panels
5.2. Anchor dropping
[Ensure] Gypsy band brake is closed.

[Do] Unlock chain stopper.
[Do] Disengage gypsy clutch.
[Do] Release gypsy band brake to drop anchor, apply band brake
gradually to control anchor falling speed.
[Do] Apply brake and lock the chain stopper.
5.3. To Use gypsy for Anchor heaving and lowering
[Ensure] Gypsy manual band brake is closed.

[Do] Manual clutch engagement by slowly control DCV lever to rotate
at payout mode. Stop the rotation once clutch is fully engaged.
Clutch in only one gypsy at a time.
[Do] Unlock chain stopper.
[Do] Release gypsy band brake.
 To Heave
[Push gently] DIRECTION CONTROL LEVER to “HEAVE”
 To Stop
[Return] DIRECTION CONTROL JOYSTICK to “NEUTRAL”
[Ensure] Brake applied and chain stopper locked after operation
 To Payout
[Push gently] DIRECTION CONTROL JOYSTICK to “PAY OUT”
 To Stop
____________________________________________________________________________
-6-
CAUTION!
 DO NOT USE THE CONTROL LEVER IN HEAVE MODE TO CLUTCH IN, IT WILL
DAMAGE THE BRAKE.
5.4. After Operation
 Apply brake and disengage clutch.

 Ensure that the space heater starter panel remains ON.
____________________________________________________________________________
-7-
6.0 MAINTENANCE




adjustment.

approved parts.
____________________________________________________________________________
-8-
This work instruction provides a list of action to preserve and store the equipment
before installation at site.
condition.
equivalent.
with grease.
plastic foil.
____________________________________________________________________________
-9-
product.


____________________________________________________________________________
-10-

months
(Or Equivalent)

weeks
Screw, Pins
(Or Equivalent)

Operation; and
2000Hours of
Operation.
4. Wire Rope Brilube 70 Compound Once every three

____________________________________________________________________________
-11-
6.3. BRAKE MAINTENANCE
6.3.1. Manual Brake Lining Replacement
When inspection or operation indicates that the brake linings are excessively worn
(down to 5 mm or less at the lining edge, the lining must be replaced). To replace the
linings:-
Brake Lining Replacement Procedure (Refer To Drawing No. : 011150E)
 For Windlass, ensure chain is locked by the chain stopper. For winch, Pay in all
wire rope line onto the drum and secure the loose end to prevent snarling; or
remove all wire rope from the drum.
 Ensure hydraulic system is switched off.
 Remove bolt and lock plate at end of brake spindle.
 Release brake by turning hand wheel continuously until the brake spindle
completely detaches from brake band.
 Remove Pin B.
 Remove the Band Brake Support Adjuster.
 Using a hoist to hold the brake assembly, remove Pin D and F. Be cautious
when both lever plate and lower brake band is lowered. Use a hand jack to
support the lower Band Brake if necessary.
 When lower Band Brake is fully lowered, remove Pin C.
 Remove Pin A to detach upper Brake Band from the lower Brake Band.
 Gently hoist the half top and bottom Brake Band and place them on the ground.
 Remove the worn lining by drilling out the rivets or taking out the bolts holding
the filing to the band.
 With the lining removed, inspect the inner surface of the bands. This inner
surface should be free of rust, oil and paint with a roughened texture. If required,
the inner band surface may be sandblasted with coarse sand to obtain the
desired surface.
 To check the bands for distortion, place on a flat surface with the ends pointing
up and check the ends for proper alignment with the centre. Twist the band
ends as required until both ends line up with the centre.
 To check the bands for correct curvature, draw a circle diameter on a flat surface
and place the band on the circle. Kinks or change in curvature may be corrected
by pressing or using a hammer with two backups as shown. Work with from the
____________________________________________________________________________
-12-
centre of the band towards the ends, and from bottom to top across the band
using equal force each time.
 When distortion has been corrected and bands have the proper curvature, the
lining can be replaced. Rivet or bolt the new lining in place, observing care not
to over tighten the fasteners.
 Ensure both brake gypsy race and bands are cleaned and free from rust (see
rust removal).
 Reassemble the upper brake band with a hoist (if necessary). Link the lower
brake band to the upper band with Pin B and Pin A.
 Insert the rest of the pins and secure it with cotter pins.
 Place brake spindle to pivot pin and tighten by turning with the hand wheel.
Fasten locking plate and bolt.
 The lining replacement is complete.
 Perform brake lining wear-in.
WARNING!
 WHEN REMOVING THE BRAKE BANDS, DO NOT CHANGE THE

CURVATURE BY STRETCHING, DROPPING OR DISTORTING THE
BANDS.
____________________________________________________________________________
-13-
6.3.2. Gypsy Brake Lining Wear Out
temperature.
WARNING!

____________________________________________________________________________
-14-
6.3.3. Rust Removal
bare metal. To remove rust from the brake drum, perform the following steps:-
drum rotation.
adjustment.
____________________________________________________________________________
-15-
1. Hydraulic Anchor Windlass NS674-0 1 Of 2 C1

General Arrangement
2. Hydraulic Anchor Windlass NS674-0 2 Of 2 C1

General Arrangement
(Skid Mounting Holes Arrangement)
3. Hydraulic Anchor Windlass NS674-2 1 Of 2 C

4. Hydraulic Anchor Windlass NS674-2 2 Of 2 C

Sectional General Arrangement (Part List)
5. Brake Assembly BM860x150A 1 Of 1 C1
Anchor Chain Stopper

6. - 1 Of 1 B
Technical Speciation
RCS-3436-
7. Anchor Chain Stopper 1 Of 1 C
01-0
8. Hydraulic Motor –GM5A-1450-7EG-D40

- - -
Exploded View
9. Hydraulic Motor –GM5A-1450-7EG-D40

- - -
Parts List
____________________________________________________________________________
-16-
GM5
GM5
HYDRAULIC TUGGER WINCH

2.1. LEFT HAND SIDE .............................................................................................................................................. 3
2.2. RIGHT HAND SIDE............................................................................................................................................. 4
3.1. HYDRAULIC MOTOR ......................................................................................................................................... 5
3.2. GEARS ........................................................................................................................................................... 5
3.3. CONTROLS ...................................................................................................................................................... 5
4.1. LOCAL CONTROL PANEL..................................................................................................................................... 6
5.1. INTRODUCTION ................................................................................................................................................ 7
5.2. OPERATION INSTRUCTIONS ................................................................................................................................ 7
5.3. AFTER OPERATION ........................................................................................................................................... 7
6.0 MAINTENANCE ......................................................................................................................................... 8
6.3. MANUAL BRAKE MAINTENANCE ....................................................................................................................... 12
6.3.1. Drum Brake Lining Replacement (Refer To Drawing No. : 011150E) ................................................ 12
6.3.2. Drum Brake Lining Wear Out............................................................................................................ 14
6.3.3. Rust Removal .................................................................................................................................... 15
____________________________________________________________________________
-1-
HYDRAULIC TUGGER WINCH
This unit consists of a drum fitted with a pair of bronze bushing, rotating on a shaft and
driven by a hydraulic motor via an open spur gear reduction unit.
The drum can be engaged or disengaged by means of a manual operated jaw clutch. It
is positioned on the hexagonal section of the shaft.
The drum is fitted with manual-operated band brake. The brake is a wrap-up design
and there are two halves around the race of the brake drum. Each half has a frictional
material lining riveted to it. The brake halves are operated via a screw lever mechanism
and completed with hand wheel.
The main shaft is support at two positions with bronze bushing enclosed in cast steel
housing and bolted to the structural steel skid.
___________________________________________________________________________________
-2-
2.1. Left Hand Side
EQUIPMENT HYDRAULIC TUGGER WINCH

MODEL MG-HUW-10UL-400
SERIAL NO. P4683-HUW-10UL-400
P4684-HUW-10UL-400
P4685-HUW-10UL-400
P4686-HUW-10UL-400
QUANTITY 1 / VESSEL
4 (TOTAL)
 
DRUM CAPACITY 2 50m x Dia. 22mm SWR @ 7 Layers 
 
RATED PULL 10T x 15m/min (1st Layer)
BRAKE ASSEMBLY Manually Operated Band Brake
CLUTCH ASSEMBLY Manually Operated Jaw Clutch
CONTROL Local Control Stand
HYDRAULIC MOTOR GM4
CERTIFICATION Product Cert Acc to ISO 10474-2.1
COLOUR Blue RAL 5015
REF. DRAWING NO. HUW10-5UL-0

DOC NO. EN-040L-P4683-86-HUW-10UL-400
REVISION A
DATE 16.07.09
REACTION LOAD : R1 = R2 = 10 T & R3 = 15 T
___________________________________________________________________________________
-3-
2.2. Right hand Side
EQUIPMENT HYDRAULIC TUGGER WINCH

MODEL MG-HUW10UR-400
SERIAL NO. P4683-HUW10UR-400
P4684-HUW10UR-400
P4685-HUW10UR-400
P4686-HUW10UR-400
QUANTITY 1 / VESSEL
4 (TOTAL)
 
DRUM CAPACITY 2 50m x Dia. 22mm SWR @ 7 Layers 
 
BRAKE ASSEMBLY Manually Operated Band Brake
CLUTCH ASSEMBLY Manually Operated Jaw Clutch
CONTROL Local Control Stand
HYDRAULIC MOTOR GM4
REF. DRAWING NO. HUW10-5UR-0

DOC NO. EN-040L-P4683-86-HUW10UR-400
REVISION A
DATE 16.07.09
REACTION LOAD : R1 = R2 = 10 T & R3 = 15 T
___________________________________________________________________________________
-4-
High torque single speed motor.
Model : GM4-1300-7-G-D40
3.2. Gears
Single stage spur wheel and pinion reduction.
Ratio : 6.76 : 1
3.3. Controls
Local control console near the winch.
___________________________________________________________________________________
-5-
4.1. Local Control Panel
“PAYOUT” / “HEAVE” mode. In the “PAYOUT” mode it controls the
rope.

in bar.
___________________________________________________________________________________
-6-
5.1. Introduction

5.2. Operation Instructions
a. Switch ON the starter panels.

b. Switch ON the motor pumps on the remote control panels.
c. Ensure that the brake is engaged.
d. Engage the clutch by slowly control DCV lever to rotate in payout mode.
e. Release the brake once the clutch is fully engaged.
 To Heave
[Push gently] DIRECTION CONTROL JOYSTICK to “HEAVE”
 To Stop
 To Payout
 To Stop
 Engage the brake.

 Release the clutch.
 Switch OFF the motor pumps.
 Ensure that the starter panel remains ON for motor space heater.
! CAUTION!
DO NOT USE THE CONTROL LEVER IN HEAVE MODE TO CLUTCH IN, IT

WILL DAMAGE THE BRAKE.
___________________________________________________________________________________
-7-
6.0 MAINTENANCE
 It is important to carry out maintenance at recommended interval of time

in order to keep the equipment operating at maximum condition.
 Make sure that the area around the equipment is free from personnel
during maintenance to avoid injuries.
 Make sure that all electrical supplies are disconnected before

maintenance operation to prevent injuries.
 Following instructions provided are guidelines only; the frequency has to

be adapted for different conditions and weather.

the Lubrication Chart and lubrication drawings attached. Always move
the parts as you apply grease for thorough lubrication. Lubrication is
important to prevent corrosions of parts and also act as sealer to prevent
rain/seawater from seeping in that could damage bearings. Lubrication
must be carried out inclusive of long-term parking and storage period.

adjustment.

approved parts.
___________________________________________________________________________________
-8-
This work instruction provides a list of action to preserve and store the
equipment before installation at site.
condition.
equivalent.
with grease.
plastic foil.
___________________________________________________________________________________
-9-
product.


___________________________________________________________________________________
-10-

months
(Or Equivalent)

weeks
Screw, Pins
(Or Equivalent)

Operation; and
2000Hours of
Operation.

___________________________________________________________________________________
-11-
6.3. Manual Brake Maintenance
6.3.1. Drum Brake Lining Replacement (Refer To Drawing No. : 011150E)
When inspection or operation indicates that the brake linings are excessively
worn (down to 5 mm or less at the lining edge, the lining must be replaced). To
replace the linings:-
a. Pay in all wire rope line onto the drum and secure the loose end to
prevent snarling; or remove all wire rope from the drum.
b. Ensure hydraulic system is switched off.
c. Remove bolt and lock plate at end of brake spindle.
d. Release brake by turning hand wheel continuously until the brake spindle
completely detaches from brake band.
e. Knock out gently Pin C to release the triangular plates from the brake
band.
f. Remove Pin D and Pin F to release the brake band from the drum.
g. Remove the bolts securing the brake band support adjuster.
h. Using a hoist to hold the brake assembly, knock out Pin B followed by Pin
A and use a hand jack to support (lift) the lower half of the band if
necessary.
i. Lower the bottom half of the brake band and lift the upper half with the
hoist gently.
j. Remove the worn lining by drilling out the rivets or taking out the bolts
holding the filing to the band.
k. With the lining removed, inspect the inner surface of the bands. This
inner surface should be free of rust, oil and paint with a roughened
texture. If required, the inner band surface may be sandblasted with
coarse sand to obtain the desired surface.
l. To check the bands for distortion, place on a flat surface with the ends
pointing up and check the ends for proper alignment with the centre.
Twist the band ends as required until both ends line up with the centre.
___________________________________________________________________________________
-12-
m. To check the bands for correct curvature, draw a circle on a flat surface
the diameter of the drum brake flange, and place the band on the circle.
Kinks or change in curvature may be corrected by pressing or using a
hammer with two backups as shown. Work with from the centre of the
band towards the ends, and from bottom to top across the band using
equal force each time.
n. When distortion has been corrected and bands have the proper
curvature, the lining can be replaced. Rivet or bolt the new lining in
place, observing care not to over tighten the fasteners.
o. Ensure the brake drum is cleaned and free from rust (see rust removal).
p. Replace the upper brake band with a hoist (if necessary). Link the lower
brake band to the upper band with Pin B and Pin A.
q. Insert the rest of the pins and secure it with cotter pins.
r. Place brake spindle to pivot pin and tighten by turning with the hand
wheel. Replace locking plate and bolt.
s. The lining replacement is complete.
t. Perform brake lining wear-in.
WARNING!
 DO NOT OPEN UP AND OVERHAUL THE BRAKE CYLINDER. THE

SPRING INSIDE IS COMPRESSED AND MAY CAUSE INJURY WHEN
OPEN.
 WHEN REMOVING THE BRAKE BANDS, DO NOT CHANGE THE

CURVATURE BY STRETCHING, DROPPING OR DISTORTING THE
BANDS.
___________________________________________________________________________________
-13-
6.3.2. Drum Brake Lining Wear Out
temperature.
WARNING!

___________________________________________________________________________________
-14-
6.3.3. Rust Removal
bare metal. To remove rust from the brake drum, perform the following steps :-
drum rotation.
adjustment.
___________________________________________________________________________________
-15-

General Arrangement HUW10-5UR-0 1 Of 2 C
(Right Hand Version)

General Arrangement HUW10-5UR-0 1 Of 2 C

Sectional General Arrangement HUW10-5UR-0 1 Of 2 C

Sectional General Arrangement (Part HUW10-5UR-0 1 Of 2 C
List)

General Arrangement HUW10-5UL-0 1 Of 2 C
(Left Hand Version)
6. Hydraulic Tugger Winch HUW10-5UL-0 2 Of 2 C

General Arrangement
(Left Hand Version)
7. Hydraulic Tugger Winch HUW10-5UL -2 1 Of 2 C

(Left Hand Version)
___________________________________________________________________________________
-16-

Sectional General Arrangement HUW10-5UL -2 2 Of 2 C
(Part List)(Left Hand Version)
9. Hydraulic Motor- GM4

- -
Exploded View -
10. Hydraulic Motor- GM4

- - -
Parts List
___________________________________________________________________________________
-17-
GM4
GM4
HYDRAULIC VERTICAL CAPSTAN

3.1. HYDRAULIC MOTOR ......................................................................................................................................... 4
3.2. GEAR UNIT ..................................................................................................................................................... 4
3.3. CONTROL........................................................................................................................................................ 4
4.1. LOCAL CONTROL STAND .................................................................................................................................... 5
5.1. BEFORE OPERATIONS ........................................................................................................................................ 6
5.2. OPERATION INSTRUCTIONS................................................................................................................................. 6
5.3. AFTER OPERATION ........................................................................................................................................... 6
6.0 MAINTENANCE ......................................................................................................................................... 7
6.1. OVERVIEW ................................................................................................................................................... 7
6.2. MAINTENANCE OF GEARBOX ...................................................................................................................... 7
6.3. LUBRICATION .............................................................................................................................................. 8
6.4. OVERHAUL................................................................................................................................................... 9
7.0 REFERENCE DRAWING ............................................................................................................................ 10
___________________________________________________________________________________
-1-
HYDRAULIC VERTICAL CAPSTAN
The MacGregor Plimsoll hydraulic vertical capstan comprises of a warping head

vertically mounted to a fabricated pedestal and driven through a planetary gearbox and
hydraulic motor.
The fabricated pedestal is bolted down to the ship seating which is welded to the deck.
The capstan can be controlled with a control valve (DCV) at the local control stand,
which is mounted near the capstan. Once the control valve handle is activated, the
capstan shall start to rotate in the decided direction, and it shall stop rotating when the
joystick is return to neutral position.
___________________________________________________________________________________
-2-
EQUIPMENT HYDRAULIC VERTICAL CAPSTAN

MODEL MG-HVC-05/400
SERIAL NO. P4683-HVC-05/400-1
P4683-HVC-05/400-2
P4684-HVC-05/400-1
P4684-HVC-05/400-2
P4685-HVC-05/400-1
P4685-HVC-05/400-2
P4686-HVC-05/400-1
P4686-HVC-05/400-2
QUANTITY 2 / VESSEL
8 (TOTAL)
RATED PULL 5T x 15 m/min
CAPSTAN HEAD DIA. SIZE 400mm
CONTROL Local Control Stand Near Caspton
HYDRAULIC MOTOR OMSs-160
GEARBOX RR-1010
REF. DRAWING NO. HVC05-400-0

DOC NO. EN-040L-P4683-86-HVC-05-400
REVISION A
DATE 16.07.2009
___________________________________________________________________________________
-3-
Displacement : 159.7 cm3/Rev.

Model : OMSs-160
3.2. Gear Unit
Model : RR1010DFS
Ratio : 35: 1
3.3. Control
Local control stand near the capstan.
___________________________________________________________________________________
-4-
The following control functions are provided for the capstan at the following location.
4.1. Local Control Stand
1. Directional control capstan To control the capstan to rotate in the clockwise

“PAYOUT” / “HEAVE” or counter clockwise direction
2. “MAIN PRESSURE” It indicates the main hydraulic system pressure

display in bar.
___________________________________________________________________________________
-5-
5.1. Before operations
 Press the upper and lower isolating plungers, the oil level must be at least ¾
of the oil meter.
5.2. Operation instructions
b. To rotate the capstan:
 To Heave
[Push gently] DIRECTION CONTROL LEVER to “HEAVE”
 To Stop
 To Payout
 To Stop
CAUTION!
 CAPSTAN IS NOT DESIGNED FOR BOLLARD APPLICATION.
WRONG USAGE CAN RESULT IN SERIOUS INJURY OR EQUIPMENT
DAMAGE.
___________________________________________________________________________________
-6-
6.0 MAINTENANCE
6.1. OVERVIEW
The following maintenance program must be carried out every 3 months.
 Visually inspect all welds for cracks.

 Tighten all bolts and nuts accordingly.
 Periodically check the plugs (breather sight, magnet, and plain) seated.
 Ensure that the breather is free from debris. If necessary, remove the
breather and flush it out with a cleaning solvent.
 Check the magnetic plugs and ensure that it’s clean. Do contact us if you
notice heavy deposits.
6.2. MAINTENANCE OF GEARBOX
 Run the planetary geared unit at full speed without loading.

 Check for vibrations and irregular noises.
 Check the alignment of the planetary unit.
 Ensure that the gear unit is securely bolted down to the seating.
 The casing of the planetary unit should not exceed 80oC during normal
operation.
 After operation, check for any leakages or damages.
NOTE!
THE PLANETARY GEARED UNIT IS ALREADY PRE-FILLED WITH

LUBRICATING OIL, SO DO NOT MIX OR ADD ANY LUBRICANTS INTO
THE PLANETARY GEARED UNIT.
___________________________________________________________________________________
-7-
6.3. LUBRICATION
 It’s important to select the suitable lubricant which meets the EP (extreme
pressure Gear Lubrication Specification) (refer to the table 1).
 The first oil change must be made after 50 – 100 hours of operation and
subsequently every 1000 hours or every 6 months (refer to table 1).
 The volume of oil for the gearbox is 6 litres.
 Check the oil level after every refill and at least once a month.
 The lubricant can be recycled provided it’s filtered with filter with rating
above 10 microns.
 Do not mix lubricant of different types e.g. mineral and synthetics.
 Failure to comply correct lubrications routine may result in premature
wear and failure of components.
1. Main Gear / Pinion Omega73 Once every week
(Or Equivalent)
2. Bearings, Clutch TOTAL EP2 Once every two weeks

Barrel Screw, Pins
(Or Equivalent)

Operation; and
2000Hours of
Operation.
4. Wire Rope Brilube 70 Compound Once After Operation.

(Or Equivalent)
Table 1: Lubrication Chart
___________________________________________________________________________________
-8-
6.4. OVERHAUL
The overhaul is recommended to be carried out once in two years, and

recommended to be carried out by the original manufacturer.
The capstan only required overhaul when the following situation happens:-
 Warping drum seized on the gearbox shaft.

 Abnormal or sharp rubbing sounds from the gearbox unit.
 Abnormal or heating up of the gearbox unit at short periods of operation.
 Warping drum wobbling on pedestal.
 Warping drum does not turn when motor is running.
 Gearbox seized.
 Electric motor burnt out (if it is run by electric motor/driven).
 Before carrying out any overhaul, cut-off electrical supply electrical
cables are to be disconnected at the motor terminal box.
___________________________________________________________________________________
-9-
7.0 REFERENCE DRAWING
1. Hydraulic Vertical Capstan HVC05-400-0 1 Of 1 C

General Arrangement
2. Hydraulic Vertical Capstan HVC05-400-2 1 Of 2 C


HVC05-400-2 2 Of 2 C
(Part List)
Hydraulic Motor – OMSs-160

4. - - -
Exploded View
5. Hydraulic Motor – OMSs-160

- - -
Parts List
6. Gear Box RR-1010DFS
___________________________________________________________________________________
-10-
OMSs-160
RR-1010 DFS
RR-1010 DFS
HYDRAULIC STORAGE REEL WINCH

3.1.1. Hydraulic Motor.................................................................................................................................. 4
3.1.2. Gears .................................................................................................................................................. 4
3.1.3. Controls .............................................................................................................................................. 4
4.1. LOCAL CONTROL CONSOLE ................................................................................................................................. 5
5.1. BEFORE OPERATION ......................................................................................................................................... 6
5.2. OPERATION INSTRUCTIONS ................................................................................................................................ 6
5.3. AFTER OPERATION ........................................................................................................................................... 6
6.0 MAINTENANCE ......................................................................................................................................... 7
6.2.2. Lubrication / Greasing During Storage ............................................................................................... 9
6.2.3. Inspection during Storage................................................................................................................... 9
-1-
HYDRAULIC STORAGE REEL WINCH
The MacGREGOR Plimsoll Hydraulic storage reel winch comprises of a fabricated steel-
hauling drum rotating on a common high tensile steel main shaft. The main shaft is
supported by two bush bearings with mild steel housing and bolted down the structure
steel fabrication skid. The unit is driven by a low speed, high torque piston type
hydraulic motor via a single stage open spur gear unit.
It is also provided with a parking stopper.
-2-
EQUIPMENT HYDRAULIC STORAGE REEL WINCH

MODEL MG-HSW/SD-05
SERIAL NO. P4683 -HSW/SD-05
P4684 -HSW/SD-05
P4685 -HSW/SD-05
P4686 -HSW/SD-05
QUANTITY 1 / VESSEL
4(TOTAL)
DRUM CAPACITY 1000 m x Dia. 56 mm SWR@11 Layers
BRAKE ASSEMBLY Manually Operated Parking Stopper
CONTROL Local Control Stand On Winch
HYDRAULIC MOTOR HMB080
COLOUR Blue [RAL No: 5015]
REF. DRAWING NO. HSW-05-0

DOC NO. EN-040L-P4683-86-HSW
REVISION A
DATE 15.07.09
REACTION LOAD : R1 = R2 = 2.6T & R3 = 5T
-3-
3.1.1. Hydraulic Motor
Torque Rating : 19.9Nm/Bar
Model : HMB080-S-S03-70
3.1.2. Gears
Ratio : 7.79 : 1
3.1.3. Controls
Local control console near the winch.
-4-
4.1. Local Control Console
“PAYOUT” / “HEAVE” mode. In the “PAYOUT” mode it controls the
rope.

in bar.
-5-
5.1. Before Operation

 Press the upper and lower isolating plungers, the oil level must be at least ¾
of the oil meter.
5.2. Operation Instructions

b. Switch ON the motor pumps on the remote control panels.
c. Unlatch the parking stopper.
 To Heave
[Push gently] DIRECTION CONTROL JOYSTICK to “HEAVE”
 To Stop
 To Payout
 To Stop
 Latch the parking stopper.

CAUTION!
-6-
6.0 MAINTENANCE
 It is important to carry out maintenance at recommended interval of time

in order to keep the equipment operating at maximum condition.
 Make sure that the area around the equipment is free from personnel
during maintenance to avoid injuries.
 Make sure that all electrical supplies are disconnected before

maintenance operation to prevent injuries.
 Following instructions provided are guidelines only; the frequency has to

be adapted for different conditions and weather.


adjustment.

approved parts.
WARNING:
 DO NOT DISMANTLE THE SPRING CYLINDER. A SPRING IS PRE-COMPRESSED

IN THE CYLINDER AND IT IS VERY DANGEROUS TO OPEN UP THE CYLINDER.
-7-
This work instruction provides a list of action to preserve and store the equipment before
installation at site.
condition.
equivalent.
with grease.
plastic foil.
-8-
product.


-9-

months
(Or Equivalent)

weeks
Screw, Pins
(Or Equivalent)

Operation; and
2000Hours of
Operation.

-10-
1. Hydraulic Storage Reel Winch HSW-05-0 1 Of 2 C

General Arrangement

General Arrangement

4. Hydraulic motor-HMB080 -
Exploded view
5. Hydraulic motor-HMB080 -
Parts list and sectional view
-11-
HMB080
ELECTRO-HYDRAULIC POWER PACK
1.0 DATA OF POWER PACK ............................................................................................................................. 2

1.1. RATING .......................................................................................................................................................... 2
1.2. ELECTRIC MOTOR............................................................................................................................................. 2
1.3. HYDRAULIC MAIN PUMP ................................................................................................................................... 2
1.4. HYDRAULIC PILOT PUMP ................................................................................................................................... 2
1.5. OIL RESERVOIR ................................................................................................................................................ 2
1.6. MOTOR STARTER ............................................................................................................................................. 2
2.0 DATA OF POWER PACK FOR HAW ............................................................................................................ 3
2.1. RATING .......................................................................................................................................................... 3
2.2. ELECTRIC MOTOR............................................................................................................................................. 3
2.3. HYDRAULIC MAIN PUMP ................................................................................................................................... 3
2.4. OIL RESERVOIR ................................................................................................................................................ 3
2.5. MOTOR STARTER ............................................................................................................................................. 3
3.0 HYDRAULIC OIL SELECTION....................................................................................................................... 4
4.0 MAINTENANCE ......................................................................................................................................... 5
4.1. GENERAL INSTRUCTIONS .................................................................................................................................... 5
4.2. ROUTINE MAINTENANCE ................................................................................................................................... 5
4.3. FLUSHING OF HYDRAULIC SYSTEM........................................................................................................................ 7
4.3.1. Introduction ........................................................................................................................................ 7
4.3.2. Flushing procedure ............................................................................................................................. 7
4.4. SOLID CONTAMINATION..................................................................................................................................... 9
5.0 TROUBLESHOOTING ............................................................................................................................... 10
5.1. GENERAL INSTRUCTIONS .................................................................................................................................. 10
5.2. TROUBLESHOOT & REMEDY ............................................................................................................................. 11
5.3. FLOW CHART OF BASIC TROUBLESHOOTING OF HYDRAULIC POWER ......................................................................... 14
5.4. PUMP CAVITATIONS ........................................................................................................................................ 15
5.5. AERATION OF FLUIDS ...................................................................................................................................... 16
5.6. SYSTEM TEST FOR DIRECTIONAL CONTROL VALVES ............................................................................................... 17
5.7. SYSTEM TEST FOR PRESSURE RELIEF VALVES ........................................................................................................ 18
5.8. SAFETY PROCEDURE FOR SHUTTING DOWN OF MACHINES .................................................................................... 19
5.9. GEAR OIL SELECTIONS ..................................................................................................................................... 22
6.1. HYDRAULIC ................................................................................................................................................... 23
6.2. ELECTRICAL ................................................................................................................................................... 25
-1-
ELECTRO-HYDRAULIC POWER PACK
1.0 DATA OF POWER PACK
1.1. Rating
3 x 90 kW (200 LPM x 270 Bar) + 2 x 7.5 kW (35 LPM x 60 Bar + 95 LPM x 10 Bar)
1.2. Electric Motor
Output : 3 x 90 kW + 2 x 7.5 kW
Supply : 415V, 3- Phase, 50 Hz
1.3. Hydraulic Main Pump
Displacement : 140 cc/rev

Working Pressure : 270 Bar
Model : A10VSO140DFLR/31RPPB12N00
1.4. Hydraulic Pilot Pump
Displacement : 67 cc/rev & 18 cc/rev

Working Pressure : 60 Bar & 10 Bar
Model : 2520V-21A-5-1-DC-22-R
1.5. Oil Reservoir
Steel fabricated oil reservoir with an oil capacity of 2400 litres.
1.6. Motor Starter
Auto-Trans Starter to suit 90kW motor, Direct-On-Line Starter to suit 7.5kW Pilot
Motor, IP54 enclosure containing all main circuit control breakers, relays,
contractors, transformer, fuses, terminals and interlink cables.
__________________________________________________________________________________
-2-
2.0 DATA OF POWER PACK FOR HAW
2.1. Rating
1 x 37 kW (80 LPM x 220 Bar)
2.2. Electric Motor
Output : 1 x 37 kW
Supply : 415V, 3- Phase, 50 Hz
2.3. Hydraulic Main Pump
Displacement : 71 cc/rev
Working Pressure : 220 Bar
Model : A10VSO71DFLR/31R-PPA12N00
2.4. Oil Reservoir
Steel fabricated oil reservoir with an oil capacity of 800 litres.
2.5. Motor Starter
Star/Delta Starter to suit 37kW motor, IP54 enclosure containing all main circuit
control breakers, relays, contractors, transformer, fuses, terminals and interlink
cables.
__________________________________________________________________________________
-3-
3.0 HYDRAULIC OIL SELECTION
The recommended standard hydraulic oil is decided based on the part of the world the vessel is
based. They are as shown below:
Tropical Zones Temperate Zones-Tropical Zones

VG68 VG46
Arctic Zones Temperate Zones-Arctic Zones

VG 22 VG32
The recommended brand would be as listed below:
BRAND PRODUCT RANGE
BP OIL Energol HLP, Energol SHF
GULF Harmony AW, Harmony HVI
SHELL Tellus, Tellus T
TOTAL Azolla, Equivis
TEXACO Rando HD, Rando HDZ
FINA Hydran, Hydran HVI
MOBIL MOBIL DTE
* For extremely cold areas, specifically selected hydraulic oil is used.
__________________________________________________________________________________
-4-
4.0 MAINTENANCE
4.1. General Instructions


4.2. Routine Maintenance
The practice of planned maintenance at fixed intervals using a logbook is strongly

recommended.
Check and record the following:-
 The running temperature of the fluid.

 The readings of the various pressure gauges.
 Unusual noise.
 Measure the leakages rate from piston unit castings under identical pressure and
temperature conditions. Changes in these leakages give a good indication of the
condition of the unit.
 Significant changes in any of the above five items may require further investigation
regarding their cause and the service necessary to correct them.
 Clean the exterior of all equipment to check for leakages. Tighten joints where
necessary and replace any fittings and associates pipes, which leak persistently.
 Sample the hydraulic fluid and check for chemical condition and level of
contamination.
 The first oil change should take place 50 - 100 hours after commissioning.
Subsequent oil changes will last in many cases for 3,000 to 5,000 working hours
or longer, particularly when regular maintenance of the oil is being carried out.
 To keep a running check on the condition of the oil, take a sample of the oil and
pass it through a filter paper or clean cloth once a week.
__________________________________________________________________________________
-5-
 Clean or replace filters as necessary.
 We recommend an overhaul of the powerpack after several years of usage.
__________________________________________________________________________________
-6-
4.3. Flushing of Hydraulic system
4.3.1. Introduction
In our pass experiences, our customer had encountered equipment problem due to oil
contamination and caused heavy losses. Our company are looking very seriously into the matter
and strongly emphasize towards the cleanliness to NAS 1638 (Class 8) or ISO 4406 scale 17/14
4.3.2. Flushing procedure
A. Check that all connection on the lines are free from leakage,
i. This may be done by applying compressor air (6Bar) and test the
connections with soap water or hydrostatic test to ensure no leak on all
joints.
o i l r ar
ii. If no bubbles are observed at all the joints are acceptable and the flushing
can be prepare.
lination gly
B. Provide necessary equipment
i. Flushing unit ( min 1.5 m/sec oil flow velocity ) depend on the pipe
size.For flushing to be effective, the flow must be turbulent ( Reynolds
Number, Re > 4000 ).
ii. The max flushing pressure must not exceed the design pressure of the
actual pipes.
iii. Temperature of flushing oil should not exceed +70 deg.
iv. Oil reservoir should be three time of the pump delivery per minute.
v. Return line filter c/w spare filter element (5 & 10 Micron).Recommended
Fibrous media type.
vi. Loop line hoses, valves and fittings.
vii. Workshop working air.
C. Set up
i. Flushing pump outlet should connect to the main pressure line and other
end should loop to next pipe and the last pipe should be connected to the
filter unit.
ii. All pipe branches outlet should connect with the isolated valves and back
to the return line before the filter,
iii. Venting valves must be provided at high points in the pipe work system in
order to be certain that the pipes are completely full of fluid.
iv. All pipe end to the equipment connection points must be replace by the
suitable flexible hose.( Do not flush the system with connected to the
equipment that could damage the components).
v. Drains must be provided at low points and in dead end so that and dirty
fluid can be drained off.
__________________________________________________________________________________
-7-
D. Prepare to start up flushing
i. Check ensure that all connection is properly connected.

ii. First start with the 10 micron filter and continue run for two hours to collect
foreign substances after that replace with 5 micron element and continue
run for four hours, then replace new element and repeat for minimum total
16 hours and check the cleanliness.
iii. While flushing is in progress keep a close monitoring on the clogging
indicator of the filter so that the element can be change at the right time.
iv. Take the oil samples from the system at before filter and see whether the
required cleanliness of the fluid has been achieved, if not then repeat
flushing until the cleanliness able to achieve to NAS 1638.
E. REMARKS:-
i. In good practice hydraulic system which is properly cleaned and free from
particles will safeguard the components and given better operation of
equipment, as well as prolong the life span of the components.
ii. Our site engineer will not start-up the system and commissioning the
equipment unless the flushing is properly done.
iii. A third party oil test report must be presented by yard to MacGREGOR
Plimsoll prior to commissioning commence.
__________________________________________________________________________________
-8-
4.4. Solid contamination
The contamination of hydraulic fluids by solid

particles is dealt with by a number of different NAS ISO MIL SAE
classification systems 1638 4406 or STD 749
Cetop 1246 D
There are 5 in all at present: RP 70 A
H
- SAE 749 D
26/23
- ISO 4406 25/23 1000
23/20 700
- CETOP RP 70 H 12 21/18
20/18 500
- NAS 1638
11 20/17
20/16
- MIL STD 1246 A
10 19/16
9 18/15 6
Table 1 compares the classification system with 8 17/14 300 5
each other. The different classes of 7 16/13 4
contamination define the quantity of particles of a 6 15/12 3
certain size in a 100 ml sample of fluid. 14/12 200
5 14/11 2
4 13/10 1
3 12/9 0
2 18/8
10/8 100
1 10/7
10/6
0 9/6
00 8/5
7/5 50
6/3
5/2 25
Table 1 : Approximate Equivalents

of contamination classes
__________________________________________________________________________________
-9-
Table 2 National Aerospace Standard (NAS 1638) contamination classification system
(Number/100ml)
Size of Particles Grade / Permissible number of particles

(µm)
00 0 1 2 3 4 5 6 7 8 9 10 11 12
12 250 500 1000 2000 4000 8000 16000 3200 64000 128000 256000 512000 1024000
5-15
5 0
15-25 22 44 89 178 356 712 1425 2850 5700 11400 22800 45600 91200 182400
25-50 4 8 16 32 63 126 253 506 1012 2025 4050 8100 16200 32400
50-100 1 2 3 6 11 22 45 90 180 360 720 1440 2880 5760
Over 100 0 0 1 1 2 4 8 16 32 64 128 256 512 1020
Table 3 ISO 4406 Allocation of Scale Numbers
Scale
Number of Particles
Number
20 500000 1000000
19 250000 500000
18 130000 250000
17 64000 130000
16 32000 64000
15 16000 32000
14 8000 16000
13 4000 8000
A code of 17/14 signifies the presence of

64000 to 130000 numbers of particles of size ≥
5 µm and 8000 to 16000 numbers of particles
of size ≥ 15 µm per 100ml of oil.
-9-
5.0 TROUBLESHOOTING
5.1. General Instructions
This section contains troubleshooting information for correcting the

problem to an adjustment, part repair or replacement. To be able to
execute an effective troubleshooting it is important to understand the
design/intended operation of the equipment, its parts and assembly and
also the control systems and components. The Troubleshooting
Guidelines are provided to help correct the problem. When a problem
cannot be corrected or part replacement is required, please contact us for
assistance at:
Customer Service Department / After-Sales Department

No. 48 Tuas Road, Singapore 638500
Telephone: (65) 6868-85-62
Facsimile: (65) 6862-24-52
Email Address: ofs.sgp.aftersales@macgregor-group.com
The Troubleshooting Guidelines are as follows:
__________________________________________________________________________________
-10-
5.2. Troubleshoot & Remedy
FAULT CAUSE REMEDY
1. System Does Not a) MCCB is at “OFF” position a) On it

Start
b) Starter Isolator at “OFF”
b) On it
position
c) No incoming supply c) Check in coming supply
d) Starter fuses blown d) Replace new fused
e) Oil level low e) Fill up to the required level
f) Ensure Cooling pump is

f) High Temperature switched on & sufficient
flow to cooler.
g) Emergency Stop activated g) Reset
2. Equipment Not a) HPU not started a) Start the HPU

Working
b) No system pressure a) Ensure the damping

valve is fully closed.
b) Ensure rotation is
correct
c) Component highly
internal leakage,
replace or service are
required.
__________________________________________________________________________________
-11-
FAULT CAUSE REMEDY
3. Equipment a. Clutch disengaged a) Ensure the clutch is fully

Malfunction engaged.
b) Check the incoming
signal at the local, if not
check the panel supply.
c) Solenoid valve
malfunction, service or
replace.
b) When towing brake not a) Adjust brake adjuster by

holding every ¼ turn until is
hold, BEWARE do not
over tighten.
b) Brake solenoid valve
has activated or
jammed, service or
replacement are
required.
c) Wheelhouse control panel a) Check and ensure the

no respond incoming supply is
available.
b) Try local control.
c) If still Malfunction
consult manufacturer.
4. Mechanical Noise a) Foreign matter stuck between a) Examine and remove the
gearing. foreign matter.
b) Bearings damaged or worn b)Examine, clean and if

excessively. necessary, replace.
c) Drive out of alignment with c) Check and realign.

coupled.
__________________________________________________________________________________
-12-
FAULT CAUSE REMEDY
5. Bearing Failures a) Inadequate, excessive or a) Check with

unsuitable lubrication. manufacturer on the
amount and type of
lubrication to be used.
b) Overload. b) If radically overloaded,

check for misalignment
of shaft. In severe thrust
over loadings, check
assembly and
connections of the
equipment being driven.
6. Overheating a) Motor wrongly connected. a) Check connections with

diagram.
b) Three phase motor may be

b) Check for bad starter
running single-phase, in
contacts, blown fuse or
which case, motor would
faults in wiring, cabling or
be noisier and the speed
connections.
slower.
c) Ambient temperature is c) Check that cooling fans are

excessive. operating, clean and that
they are rotating in the
correct direction. Check
that quantity of air sufficient
and motor speed is correct.
__________________________________________________________________________________
-13-
5.3. Flow Chart of Basic Troubleshooting of Hydraulic Power
START
TROUBLESHOOTING OF
HYDRAULIC POWER UNIT
Yes
CHECK OIL LEVEL

CHECK FLUID CONDITION
OIL TANK IS IT IN GOOD CHANGE OIL IF REQUIRED
CONDITION
No CHECK TEMPERATURE OF HYDRAULIC OIL
CHANGE FILTER ELEMENT IF REQUIRED
CHECK OIL COOLER
Yes
CHECK ELECTRIC MOTOR

CHECK MCB
ELECTRIC MOTOR IS IT
FUNCTIONING PROPERLY
No CHECK WIRING CONNECTION
CHECK DIRECTION OF ROTATION
REPLACED IF DAMAGED
Yes
CHECK PUMP
CHECK PRESSURE SETTING
PUMP IS IT FUNCTIONING
No CHECK CONTROL OF PUMP
PROPERLY
REPLACED IF DAMAGED
REPLACED SEAL IF REQUIRED
Yes
CHECK DIRECTIONAL VALVE

RELIFE VALVE IS IT CHECK SOLENOID CONDITION
No REPLACED IF DAMAGED
Yes
CHECK FLOW CONTROL VALVE

DIRECTIONAL VALVE IS IT CHECK ADJUSTMENT
No REPLACED IF DAMAGED
Yes
CHECK THE HYDRAULIC

CHECK THE CYLINDER MOTOR
CHECK THE PRESSURE IF CAN CHECK THE RPM
BUILD CHECK FOR LEAKAGE
FLOW CONTROL VALVEIS IT CHECK FOR LEAKAGE HYDRAULIC MOTOR IS IT CHECK FOR WEAR AND
No CHECK FOR WEAR AND TEAR FUNCTIONING PROPERLY
No TEAR
REPLACED SEAL IF REQUIRED REPLACED SEAL IF
REPLACED CYLINDER IF BADLY REQUIRED
DAMAGED REPLACED HYDRAULIC
MOTOR IF BADLY DAMAGED
Yes Yes
HYDRAULIC POWER UNIT IN GOOD WORKING CONDITION
__________________________________________________________________________________
-14-
5.4. Pump cavitations
FAULT CAUSE REMEDY
Suction strainer clogged or

Clean or renew
too small
Bore of suction line too

Fit larger bore pipes
small
Too many bend in suction

Modify pipe layout
line
Reduce length or fit larger

Suction line too long
bore pipes
Heat fluid to
Fluid too cold
recommended
PUMP CAVITATION Unsuitable fluid Replace with correct fluid
Air breather blocked or too

Clean or replace element
small
Local restriction in suction

Open or modify valves
line, e.g. partly closed
renew hoses, etc.
valve or hose collapse
Failure of boost pump Repair or replace boost
Reduce to recommended
Pump running too fast
speed
Pump mounted too high

Modify pump installation
above oil level
__________________________________________________________________________________
-15-
5.5. Aeration of Fluids
FAULT CAUSE REMEDY
Reservoir fluid level low Fill to correct level
Poor reservoir design Modify Design
Return line in reservoir Extend return pipe below

above fluid level fluid level
Unsuitable fluid Replace with correct fluid
AERATION OF FLUID
Pump shaft seal worn or

Renew seals
damaged
Suction line joints allowing

Renew or tighten joints
entry of air
Porous suction hose Renew hose
Improper bleeding Re-bleed system
__________________________________________________________________________________
-16-
5.6. System Test for Directional Control Valves
DG17S4-06 DG3S4-06 DG5S4-06

-10 -10
Insert gauges
TP1 & TP2
Operate valve Operate valve

manually „P‟ manually „P‟
to „A‟ to „B‟
Is there a Is the Is there a NO Is the NO

NO NO Load the Load the
reading system reading system
system system
on TP1 on load on TP2 on load
YES YES
YES Check pilot YES Check pilot

supply supply
Is there Is there
Is reading Is reading NO NO
NO motion NO Check the motion Check the
full system full system
taking valve taking valve
pressure pressure
place place
YES
YES YES
YES
Wait until motion Check next units Wait until motion
has finished on list has finished
__________________________________________________________________________________
-17-
5.7. System Test for Pressure Relief Valves
CT-06 CG-06
CT-10 CG-10 CF-16
Insert
pressure
gauge in TP1
Is the
pressure Is the
NO NO
maximum system Load the system
system on load
pressure
YES
YES
Is the
system NO Is there
Check pressure
motion YES
pressure when motion is
lack of flow taking
stopped
place
YES
NO
Is there flow
passing Is the
NO Continue on relief NO Re-adjust relief
down relief
next chart valve valve
valve tank
line adjusted
YES YES
Check the Is there a

Check for
flow from any YES
relief valve leakage in the
valve tank
system
return line
Check the
relief valve
__________________________________________________________________________________
-18-
5.8. Safety Procedure For Shutting Down Of Machines
LOWER OR
MECHANICALLY
SECURE ALL
SUSPENDED LOADS
EXHAUST ANY
PRESSURE LOCKED IN
THE SYSTEM
DRAIN DOWN ALL

ACCUMULATORS
DISCHARGE BOTH
ENDS OF INTENSIFIER
ISOLATE THE
ELECTRICAL CONTROL
SYSTEM
ISOLATE THE
ELECTRICAL POWER
SUPPLY
__________________________________________________________________________________
-19-
No or Insufficient No or Inadequate Pressure of Flow Fluid Temperature
Components Abnormal Noise
Flow Pressure Fluctuation Too High
Incorrect viscosity, pressure
Oil level too low, foaming of oil, Oil level too low, high
Oil level too low, tank Air bubbles, turbulence from medium too thin, insufficient
Tank Pressure Fluid water in oil (milky), tank breather leakage losses, clearance
breather choked. return line to suction inside. oil, component wear,
choked. losses.
tolerance looses.
Suction line not all right, air

Suction line not all right, air Suction line not all right, air Suction line not all right, air
Suction Conditions bubbles. Low oil level, shut-off Cavitation low oil level.
bubbles. bubbles. bubbles.
valve on suction line not open.
Internal leakage, wear

Suction in air, cavitations, Pump not swiveling out, Intake of air, internal leakage, damage. High temperature
Internal leakage, wear due to
Pump mechanical damage, turbulence on internal leakage, wear due to wear due to dirt, damage to as a result of high leakage
dirt.
suction side dirt, damage to rotary group. rotary group. indicates impending failure of
a component.
Coupling assembly defective,

Coupling defective or wrongly Coupling defective or wrongly
Coupling alignment error, flexible elements
fitted. fitted.
defective.
Incorrect direction of rotation, speed Incorrect direction of rotation, Irregularity of drive motor too
Electric Motor too high, play on bearing, damage Rotation speed too low. drive power too low, electric great, electric motors
to bearing. motor incorrectly connected. frequency fluctuation.
Not sufficiently vented,
internal rubber section of
Line burst, joints leaking. hoses loosened by incorrect
Pressure Lines / Improper fixings, mechanically Joint/block leaking. Back
Gauges or measuring assembly and acting as
Manifold transmitted noise. pressure (line chocked)
devices defective. flutter valve. Gauges or
measuring devices defective,
incorrect reading.
Inadequately dimensioned,
cooling action too low, room
or ambient temperature too
Air/oil cooler – ventilator noise.
Cooler high, ventilation or water feed
Mechanical vibration.
interrupted, surface area
contaminated, bypass valve
open.
Return Lines Mechanical Vibration Filter clogged.
-20-
No or Insufficient No or Inadequate Pressure of Flow Fluid Temperature
Components Abnormal Noise
Flow Pressure Fluctuation Too High
Setting too high, increased
Setting too low, valve seat tolerance, looses in all
Jarring, changing
Vibrating, chattering, fluttering damaged, jammed due to Setting too low, valve seat component parts, Increase
Pressure Control backpressure, pressure valve
indicate air pockets or lack of contamination. Do not set damaged, broken spring, leakage. Setting too low,
Valves setting too low, valve seat
damping relief valve setting above the foreign bodies in valve seat. power loss, heat generation,
damage. Air pockets.
limit of the allowable setting. valve poppet jammed in open
position.
Flow losses influencing spool
Incorrect setting, Incorrect position, throttling
Incorrect or imperfect valve operation and opening
Directional Control mechanically jammed, return looses. Valve not at extreme
Control defective positioning negative overlap movements, air pockets
Valves spring broken, leaking, plugs switching point. Wear
– not switching properly. pressure differential too
loose. damage, internal leakage.
small.
Accumulator bladder defective,
System sensitive to
nitrogen getting into hydraulic
Nitrogen charging pressure oscillation between hydraulic
circuit, defective seals, inflow or
Nitrogen charging pressure too low or too high. accumulator, pressure and
Accumulator outflow speed too high.
too low. Accumulator pressure flow control valves and
Accumulator in conjunction with
adequate. pump. System pressure
throttling losses can load to
change with load.
vibration in system
No or inadequate venting,
defective seals stick clip
Internal losses, seals leaking, Internal or external leakage, Internal leakage, tolerance
Hydraulic Cylinder Faulty internal seal. effect, changing load
wear due to contamination. wear due to contamination. looses, wear damaged.
direction. Air pocket in the
cylinder.
Air pockets, pressure
Control orifice clogged,
Air pockets, pressure differential too differential too small flow
Flow Control Valves throttle/non-return valve Wear, tolerance looses
small. valve contaminated non-
incorrectly set.
return valve defective.
Check sequence of Check sequence of Check sequence of Check sequence of

Electrical Sequence Check sequence of operation.
operation. operation. operation. operation.
-21-
5.9. Gear Oil Selections
Ambient
-20oC / +5oC +5oC / +40oC +30oC / +55oC +40oC / +65oC -30oC / +65oC
Temperature
Lubricant VI 95 MIN VI 95 MIN VI 95 MIN VI 95 MIN VI 140 MIN
ISO 3448 VG 100 VG 150 VG 220 VG 320 VG 150 ~ 220
ARAL Degol BG 100 Degol BG 150 Degol BG 220 Degol BG 320 Degol GS 220
Enersyn HTX
BP GR XP 100 GR XP 150 GR HP220 GR XP 320
220
CASTROL Alpha SP 100 Alpha SP 150 Alpha SP 220 Alpha SP 320 Alphasyn 150
Gear Gear Gear Gear

CHEVRON Compounds Compounds Compounds Compounds N/A
100 150 220 320
MOBIL Mobil Gear 627 Mobil Gear 629 Mobil Gear 630 Mobil Gear 632 N/A
SHELL Omala Oil 100 Omala Oil 150 Omala EP 220 Omala EP 320 Tivela Oil S
TOTAL Carter EP 100 Carter EP 150 Carter EP 220 Carter EP 320 N/A
___________________________________________________________________________________
-22-
6.1. Hydraulic
1. Hydraulic Anchor Handling Towing AH-AHTW150-UVS- 1 Of 3 C

Winch Hydraulic Tugger Winch H 2 Of 3 C
Hydraulic Storage Reel Winch 3 Of 3 C
Hydraulic Anchor Handling Towing
2. Hydraulic Anchor Windlass WB-HAW20-H 1 Of 1 C

Hydraulic Anchor Handling Towing
3. Hydraulic Anchor Handling Towing

Winch /Hydraulic Tugger
Winch/Hydraulic Storage Reel Winch P3x90+2x7.5-001 1 Of 1 C
3 x 90kW + 2 x 7.5kW Electro -
Hydraulic Power Pack General
Arrangement

1 x 37kW Electro - Hydraulic Power P1x37-002 1 Of 1 C
Pack General Arrangement
5. Hydraulic Anchor Handling Towing LS-6MB-W 1 Of 1 C

Winch
Local Control Manifold
6. Hydraulic Storage Reel Winch LS-1PVG32-W 1 Of 1 C

Local Control Stand
7. Hydraulic Tugger Winch/ LS-1PVG32-G01 1 Of 1 C

Hydraulic Anchor Windlass/
Local Control Stand
8. Hydraulic Pump - - -
A10VSO140DFLR/31RPPB12N00+
A10VSO71DFLR/31RPPA12N00
___________________________________________________________________________________
-23-
9. Hydraulic Pilot Pump - - -

2520V-21A-5-1 DC-22-R
___________________________________________________________________________________
-24-
A10VSO
Item Designation Qty.
1 Pump 1
2 Control valve DF-S 1
3 Control valve LR 1
4 Adaptor 1
Item Designation Qty.
1 Piston 9
2 Cylinder 1
3 Distributor plate 1
4 Retaining plate 1
6 Retaining ball 1
7 Spring 1
9 Pressure-Pin 3
10 Retaining-ring 1
11 Seeger-ring 2
Item Designation Qty. Item Designation Qty.
5 Pump housing 1 22 O-ring 1

6 Port plate 1 23 O-ring 4
7.1 Cradle 1 25 Seeger-ring 1
7.2 Stop part 2 27 Socket screw 4
8 Drive shaft 1 30 Plug 1
9 Key 1 31 Snap-off Pin 1
10 Drive shaft 1 33 Pin 1
11 Disc 1 2.1 Control piston 1
12 Adjustment disc 1 2.2 Piston guide 1
15 Taper roller bearing 1 2.3 Counter piston 1
16 Taper roller bearing 1 2.4 Piston guide 1
17 Bearing shell 2 2.5 Socket screw 4
20 Radial seal ring 1 2.6 Spring 1
29 O-ring 2 2.7 Threaded Pin 1
2.10 Head nut 1 2.8 Nut 1
Item Designation Qty. Item Designation Qty.
1 Valve housing 1 15 Threaded pin 1
2 Piston 2 16 Threaded pin 1
3 Spring cup 1 17 Plug 2
4 Spring cup 1 18 Plug 1
5 Plug 1 19 O-ring 3
6 Plug 1 20 O-ring 1
7 Disc 1 21 O-ring 1
8 Disc 1 22 O-ring 1
9 Spring 1 23 O-ring 1
10 Spring 1 24 Nut 1
11 Spring 1 25 Nut 1
12 Jet 1 27 Head nut 1
13 Jet 1 28 Head nut 1
14 Threaded pin 1
6.2. Electrical
1. Hydraulic Anchor Handling/Towing Winch PC-AHTW-A1 1 of 1 C

General Electric Cable Layout
2. Hydraulic Anchor Handling/Towing Winch PC-AHTW-B1 1 of 2 C

Main Starter Panel Layout
3. Hydraulic Anchor Handling/Towing Winch PC-AHTW-B1 2 of 2 C

Pilot Starter Panel Layout
4. Hydraulic Anchor Handling/Towing Winch PC-AHTW-C1 1 of 2 C

Main Pump Starter Electrical Schemetic
5. Hydraulic Anchor Handling / Towing PC-AHTW-C1 2 of 2 C

Pilot Starter Electrical Schematic
6. Hydraulic Anchor Handling / Towing PC-AHTW-D1 1 of 1 C

Remote Control Panel Layout
7. Hydraulic Anchor Handling / Towing PC-AHTW-E1 1 of 6 C

Remote Control Circuits 2 of 6 C
3 of 6 C1
4 of 5 C
5 of 6 C
6 of 6 C1
8. Hydraulic Anchor Handling / Towing Winch PC-AHTW-E2 1 of 5 C

PLC Input /Output Circuit 2 of 5 C1
3 of 5 C
4 of 5 C
5 of 5 C
9. Hydraulic Anchor Handling / Towing Winch PC-AHTW-F1 1 of 2 C

Electrical Connection Diagram 2 of 2 C1
___________________________________________________________________________________
-25-
10. HYD. Power Pack for Hydraulic Anchor PC-EPP-1x37-A1 1 of 1 C

Windlass General Electric Cable Layout
11. HYD. Power Pack for Hydraulic Anchor PC- EPP-1x37-B1 1 of 1 C

Windlass Starter Panel Layout
12. HYD. Power Pack for Hydraulic Anchor PC- EPP-1x37-C1 1 of 1 C

Windlass Starter Electrical Schematic
13. HYD. Power Pack for Hydraulic Anchor PC- EPP-1x37-F1 1 of 1 C

Windlass Starter Connection Diagram
14. Electric Motor 90kw&37kw - - -
.
15. Electric Motor 7.5KW - - -
___________________________________________________________________________________
-26-
Frame sizes 180M to 250M
14BG, 16BG
Frame sizes 280S to 315L

14BG, 16BG
RECOMMENDED ONBOARD SPARES LIST
The following items are recommended standard spare for each equipment for two years.
1.0 Hydraulic Components (AHTW / HUW / HSW / HVC)
Item Description Qty Plimsoll Part No.
1 Level Gauge 1 No 02
2 Filler Breather 1 No 03
3 Return Filter Element 1 No 04
4 Rotex Coupling 1 No 06
5 Rotex Coupling 1 No 06a
6 Seal Kit for Hydraulic Pump 1 Set 08
7 Seal Kit for Hydraulic Pump 1 Set 08a
8 Check Valve 1 No 09
9 Check Valve 1 No 09a
10 Check Valve 1 No 09b
11 Check Valve 1 No 09c
12 Check Valve 1 No 09f
13 Check Valve 1 No 09h
14 Relief Valve 1 No 10
15 Relief Valve 1 No 10a
16 Relief Valve 1 No 10b
17 Relief Valve 1 No 10c
18 Needle Valve 2 Nos 11
19 Needle Valve 1 No 11a
______________________________________________________________________________________
-1-
20 Pressure Gauge (0-350bar) 1 No 12
21 Pressure Gauge (0-350bar) 2 Nos 12a
22 Pressure Gauge (0-100bar) 1 No 12b
23 Shuttle Valve 2 Nos 13
24 Seal Kit for Main DCV 1 Set 15
25 Pressure Reducing Valve 1 No 15
26 Proportional Valve 1 No 15
27 Control Card 1 No 15
28 Seal Kit for Proportional DCV 1 Set 15b
29 Seal Kit for Proportional DCV 1 Set 15c
30 Seal Kit for Proportional DCV 1 Set 15d
31 Counter Balance Valve 1 No 16
32 Counter Balance Valve 1 No 16a
33 Cross Relief Valve 1 No 17
34 Cross Relief Valve 1 No 17a
35 Seal Kit for Hyd Motor (AHTW) 1 Set 18
36 Seal Kit for Hyd Motor (AHTW) 1 Set 18a
37 Seal Kit for Hyd Cylinder (Brake) 1 Set 18b
38 Seal Kit for Hyd Cylinder (Clutch) 1 Set 18c
39 Seal Kit for Hyd Motor (HUW) 1 Set 18d
40 Seal Kit for Hyd Motor (HSW) 1 Set 18f
41 Seal Kit for Hyd Motor (HVC) 1 Set 18g
42 Flow Control Valve 1 No 19

______________________________________________________________________________________
-2-
43 Flow Control Valve 1 No 19a
44 Flow Control Valve 1 No 19b
45 Flow Control Valve 1 No 19c
46 Level Switch 1 No 20
47 Temperature Sensor 1 No 20a
48 Pressure Transducer 1 No 20b
49 Solenoid D.C.V 1 No 21
50 Solenoid D.C.V 1 No 21a
51 Solenoid D.C.V 1 No 21b
52 Pilot Operated D.C.V 1 No 21c
53 Solenoid D.C.V 1 No 21d
54 Pressure Reducing Valve 1 No 22
55 Pressure Reducing Valve 1 No 22b
NOTE!
PLEASE CONTACT OUR AFTER SALES FOR ORIGINAL SPARES QUOTATION AND
DELIVERY ADVICE.
Tel: (65) 68688562

Fax: (65) 6558 7751
E-mail: Goh.Bee.Boon@cargotec.com
Attn: Goh Bee Boon
______________________________________________________________________________________
-3-
2.0 Hydraulic Components (HAW)
1 Level Gauge 1 No 02
2 Filler Breather 1 No 03
3 Return Filter Element 1 No 04
4 Rotex Coupling 1 No 06
5 Seal Kit for Hydraulic Pump 1 Set 08
6 Check Valve 1 No 09
7 Relief Valve 1 No 10
8 Needle Valve 1 No 11
9 Needle Valve 1 No 11a
10 Pressure Gauge (0-350bar) 1 No 12
11 Seal Kit for Proportional DCV 1 Set 15
12 Counter Balance Valve 1 No 16
13 Cross Relief Valve 1 No 17
14 Seal Kit for Hyd Motor 1 Set 18
NOTE!
DELIVERY ADVICE.
Tel: (65) 68688562

Fax: (65) 6558 7751
Attn: Goh Bee Boon
______________________________________________________________________________________
-4-
3.0 Electrical Components
1 Fuse Holder 5 Nos L501
2 Fuse, 2A 1 Box -
3 Fuse, 4A 1 Box -
4 Fuse, 6A 2 Nos -
5 Fuse, 10A 2 Nos -
6 Fuse, 16A 2 Nos -
7 Relay c/w Base & Clips (2P, 24VDC) 2 Sets -
8 Relay c/w Base & Clips (4P, 24VDC) 2 Sets -
Relay c/w Base & Clips -

9 5 Sets
(2P, 110VAC)
10 Dimmer 1 Set -
11 Power Supply Unit 1 Unit -
12 Joystick 1 Unit S22
13 Contactor (90KW) 1 No -
16 Thermal Overload Relay (90KW) 1 No -
19 Thermal Overload Relay (37KW) 1 No -
20 Aux. Contact (37KW) 1 No -
______________________________________________________________________________________
-5-
23 Contactor (7.5KW) 1 No -
24 Thermal Overload Relay (7.5KW) 1 No -
25 Mini Contactor 1 No -
26 Timer 1 No -
27 Selector Switch (2 Positions) 2 Nos -
28 Buzzer 1 No -
29 Pilot Light (White), 110VAC 2 Nos -
30 Pilot Light (Green), 110VAC 2 Nos -
31 Pilot Light (Yellow), 110VAC 2 Nos -
32 Pilot Light (Blue), 110VAC 2 Nos -
33 Pilot Light (White) - RCP 2 Nos -
34 Pilot Light (Green) - RCP 2 Nos -
35 Pilot Light (Yellow) - RCP 1 No -
36 Pilot Light (Red) - RCP 2 Nos -
37 Pilot Light (Blue) - RCP 2 Nos -
38 Illuminated Push Button (Green) 2 Nos -
39 Illuminated Push Button (Red) 2 Nos -
40 Illuminated Push Button (Yellow) 1 No -
41 Illuminated Push Button (Blue) 1 No -
42 Push Button (Green) - RCP 1 No -
43 Push Button (Yellow) - RCP 1 No -
44 Push Button (Green) 1 No -

______________________________________________________________________________________
-6-
45 Push Button (Red) 1 No -
Emergency Push Button c/ w Safety -

46 1 Set
Cover - RCP
NOTE!
DELIVERY ADVICE.
Tel: (65) 68688562

Fax: (65) 6558 7751
Attn: Goh Bee Boon
______________________________________________________________________________________
-7-
4.0 Mechanical Components
1 Brake Lining (AHTW) 1 Lgth 0128S
2 Brake Lining (HAW) 1 Lgth BM860X150A
3 Brake Lining (HUW) 1 Lgth 0228O
NOTE!
DELIVERY ADVICE.
Tel: (65) 68688562

Fax: (65) 6558 7751
Attn: Goh Bee Boon
______________________________________________________________________________________
-8-

MacGregor Deck Machinery Manuals

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Offshore Division

MacGREGOR Plimsoll Pte Ltd

OPERATION & MAINTENANCE MANUAL

Co. Registered No. 198201285G

Subject : Operational/ Maintenance Manual of Deck Machinery

Hull No. : GMG0888

Project Name : 58.7m Anchor Handling Supply Vessel

Buyer : Guangdong Machinery Import &Export Co., Ltd

Owner : Tidewater Marine, L.L.C

Designed & Built By : MacGregor Plimsoll Pte Ltd

Equipment Serial No. :

Hydraulic Vertical Capstan

Hydraulic Storage Reel Winch

Hydraulic Anchor Handling/Towing Winch

Hydraulic Anchor Windlass

Electro-Hydraulic Power Pack

Classification Society : ABS Certification

Year Built : 2009

OPERATION & MAINTENANCE MANUAL

Co. Registered No. 198201285G

Subject : Operational/ Maintenance Manual of Deck Machinery

Hull No. : GMG0889

Project Name : 58.7m Anchor Handling Supply Vessel

Buyer : Guangdong Machinery Import &Export Co., Ltd

Owner : Tidewater Marine, L.L.C

Designed & Built By : MacGregor Plimsoll Pte Ltd

Equipment Serial No. :

Hydraulic Vertical Capstan

Hydraulic Storage Reel Winch

Hydraulic Anchor Handling/Towing Winch

Hydraulic Anchor Windlass

Electro-Hydraulic Power Pack

Classification Society : ABS Certification

Year Built : 2009

OPERATION & MAINTENANCE MANUAL

Co. Registered No. 198201285G

Subject : Operational/ Maintenance Manual of Deck Machinery

Hull No. : GMG0899

Project Name : 58.7m Anchor Handling Supply Vessel

Buyer : Guangdong Machinery Import &Export Co., Ltd

Owner : Tidewater Marine, L.L.C

Designed & Built By : MacGregor Plimsoll Pte Ltd

Equipment Serial No. :

Hydraulic Vertical Capstan

Hydraulic Storage Reel Winch

Hydraulic Anchor Handling/Towing Winch

Hydraulic Anchor Windlass

Electro-Hydraulic Power Pack

Classification Society : ABS Certification

Year Built : 2009

OPERATION & MAINTENANCE MANUAL

Co. Registered No. 198201285G

Subject : Operational/ Maintenance Manual of Deck Machinery

Hull No. : GMG08100

Project Name : 58.7m Anchor Handling Supply Vessel

Buyer : Guangdong Machinery Import &Export Co., Ltd

Owner : Tidewater Marine, L.L.C

Designed & Built By : MacGregor Plimsoll Pte Ltd

Equipment Serial No. :

Hydraulic Vertical Capstan

Hydraulic Storage Reel Winch

Hydraulic Anchor Handling/Towing Winch