DUTGH MARINE TRADING GROUP

MANUAL
ANCHOR AND TOWING WINCH
TYPE 211-H19 (200KN)

DRAWING NO: 7051 Rev. 1

ORDER NUMBER 28OOB

(yard no. 51 1562)

PO BOX 481 PO BOX128 PO BOX 115

34/;0 AL Woerden 800050 Galati 5402A Nikolaev
HOLLAND ROMANIA UKRAINE

Phone: +31 620 603528 Phone: +4A236406006 Phone: +38 0512 672A21
Phone: +31621 396484 Fax: +402364il050 Fax: +38 0512 461276
E-mail: q.donselaar@dmt- E-mail: [email protected] E-mail: [email protected]
sales.nl
 -2-

ORDER NUMBER 2BOOB

(yard nr. 51 1562)

ANCHOR AND TOWING WINCH

ryPE 211-H19 (200KN)
DRAWING NO: 7051 Rev. 1

ir
',t/
 -3-

GONTENTS

PART 1 - OPERATING SYSTEM

1. Description

2. Technical data

3. Location and mounting

4. Starting instructions

5. Operating instructions

6. Stopping instructions

7. Labour Safety Precautions

PART 2 - OPERATION AND MAINTENANCE

1. Service and maintenance rules

2. Possible defects and repair procedure

3. Product assembling/ disassembling

4. Service parts

PART 3 - ANNEXES
 -4-

PART 1 -OPERATING SYSTEM

1. DESCRIPTION

Anchor and towing winches are compact and solid equipments provided to equip the
anchor and towing anangement existing on river and seagoing ships.
The winches consist of the following main parts:

r' spur reduction gear;

r' the winch is acted by a hydraulic motor type STAFFA HMc 080, with two speeds,
mounted inside the reduction gear. The hydraulic motor is connected to the
pumping unit of the vessel by means a connecting flange, placed on bottom of
reduction gear, and piping installation, placed inside the reduction gear.
r' main shaft is resting on side supports provided with sliding bearing which are
grease lubricated
r' chain wheels (sprockets) for anchor operation.
r' towing drum.
r' warping head for mooring operation.
r' Load/length measuring system fortowing cable.
Allthese mentioned parts are shown in the Annexes included in PART 3.

The reduction gear is in a watertight housing, the tightness of reduction gear is made
by sleeves and gaskets. All shafts are resting on bearings and the reduction gear is
oil-bath splash lubricated. Also, the reduction gear is provided with top filling and
breather plug and two bottom drain plugs. oil level is checked through a sight glass
located on the reduction housing. The reduction gear will be delivered without oil
inside.
The chain wheels are freely rotating on the main shaft, on sliding bearings and
connected to the main shaft by hand-operated jaw clutch and they are also provided
with braking ways for hand brakes operation.
The towing drum is also freely rotating on the main shaft, on roller bearings and
connected to the main shaft by pneumatic operated friction clutch (designed for one
hauling direction only), acting on the coupling way fifted on drum (on inside). The
drum is also provided with braking way (on outside of the same way) for the
pneumatic band brake operation.
The pneumatic control system is used to operate the friction clutch and the band
brake which equip the towing part of the winch.
Air supply consists of dry air with working pressure of 8 bar and maximum pressure of
10 bar.
The pneumatic operated clutch and the pneumatic operated band brake are
described below.

Pneumatic operated band brake

Winch drum is equipped with pneumatic air cylinderfor brake remote control.
 -c-

The brake is designed for one direction braking.

In case of a quick release, reduced pressure is maintained inside of the brake
cylinder by means of the pneumatic control system, fifted on board.

The quick release system must be independent from the ship systems. In order that
to be obtained, an air pressured bottle, dedicated of this purpose only, must be fitted
on boad. The air pressured bottle will be kept full under all circumstances and it will
supply air in case of dead ship, to enable the quick rclease slatem.
The air cylinder provided with an intemal spring ensures that, without air pressure, the
drum is engaged and locked against rotation.
Reduced braking force can be achieved by controlling the air pressure between 0 and
8 bar.

The pneumatic operated band brake is used together with a pneumatic operated
friction clutch. The pneumatic control system must be able to make possible that the
brake to be released after the friction clutch has been engaged.
All swivel points are fitted with flat head grease nipples.
The lining of the band brake is of the asbestos free and sea water resistant $pe.

Pneumatic operated friction clutch

The clutch is equipped with an air cylinder in order to ensure the clutch remotely.
It is designed for one hauling direction only.
The clutch is provided with an intemal spring that ensure the clutch to be disengaged
without air pressure. Operating force can be controlled by changing the air pressure
in the specified range. The air supply is made by a central bore thrcugh the main
shaft. A rotiary connection is fitted on the end of the main shaft in oder to supply the
extemal pressure from the pneumatic control system.
All swivel points are fitted with flat head grease nipples in order to ensure their proper
operation.
The lining of the clutch is of the asbestos free and sea water resistant type.
The clutch housing is fitted with a protection cover which should be removed when
greasing of the swivel points is necessary.

2. TECHNICAL DATA

winch type 211- H1e (200 KN)

diameter of chain @19 grade K2 mm
nominal pulling / max. pulling 18,5/37 KN
chain hauling speed 13,5 m/min
diameter of synthetic rope on drum @80 mm
nominal pulling | 2-nd layer 180/90 KN
towing speed at drum | 2-nd layer 11122 m/min
storage capacity of drum 150 m/ 6 layers
brake holding force / second layer 1300 KN
 -6-

HYDRAULIC MOTOR

o type STAFFA HMC-O8O

o rotation speed (r.p.m.) 90/180
o nominal flow (l/min) 140
o d isplacement (cmc/rev) 14751737
o nominal pressure Ap for towing (bar) 200
o nominal pressure Ap for anchoring (bar) 50
o safety pressure (bar) 250

3. LOCATION AND MOUNTING

Winches are installed on the ship main deck, in a special place established by the
ship designer.
On winch mounting will be checked the conelation between the chain wheels and the
hawse pipes.
In the winch operating anea, no obstacle (of any kind) should exist, in order to ensure
its proper operation.

A. Fixinq of the winch on deck.

Winch fixing on deck will be performed according to Annex 1 - Part 3.

The winch is delivered mounted on foundation plates (item 1) machined on the
contract surface with the winch and provided with shoulder.
The foundation plates, excluding the ones under the reduction gear, are provided with
addition (15 mm) forfifting on deck.
The fixing of the winch on these plates is made through the galvanized screws M36-
group 8.8 (item 2). The lateral supports of the winch are provided with adjustment
screws (item 3).
 -7 -

Fig. 1
At the mounting of the winch on deck, the followings will be canied out:

F The foundation plates (1) from lateral support of the winch are removed.
> Will be kept only the foundation plates placed under the reduction gear.
) The winch will be placed in the proper position on deck, considering the suitable
location of the towing drum and chain lifters.
) The requested height between deck and main shaft will be adjusted using the
adjustment screws (3) so the main shaft of the winch to be in horizontal position
and the lateral support to be in vertical position (perpendicular on main shaft).
Making this adjustment, will be checked out that the surface "S" (see Fig.1) of the
support to be parallel with the deck as much possible.
> Will be measured the distances between the surfaces ,,S" and deck at the four
comefti. Machine bottom of foundation plates (1), until plates have the measured
thickness.
F The foundation plates will be mounted on the winch. At the fifting of the screws
must be realized the complete contact between base plate of the lateral
support and the shoulders of the foundation plates; first the contact will be
checked, then the fitting bolts item 2 will be screwed on tight.
F The winch will be fixed in the proper position and will be checked if it is horizontal;
F lf after the inspections, the winch is good positioned, the foundation plates (1),
under lateral support and reduction gearwill be spot welded on deck.
> Will be carefully checked the conect and symmetrically positioning of the band
brake on the drum braking way;
D After a second checking of the mnect position of the winch, will be made the
contour welding of the plates on deck using altemative welding on one side and
another, avoiding the deformation which can appear on welding. The welding
seams size will be accoding to Annex 1.
For completing the welding in the inaccessible areas, the winch will be
I unscrewed and removed.
F Check the welding quality.
) At the remounting of the winch on the foundation plates the followings will be
taken care:
o The contact surfaces between winch and foundation plates must have the full
paint system;
o The achievement of an optimum contiact between winch and shoulders of the
foundation plates;
o Fitting bolts to be screwed on tight. The indicated torque: 1300 Nm.
They will be assured against unscrcwing with Loctite 243.
D The pneumatic band brake of the towing drum has also a support, which has to be
welded on deck.
) The Brake support position on deck will be according to Annex 1 and 3.
F Before welding, the following steps are necessary (see also Annex 3):
1. The operation will be made with the brake tighten on its braking way.
2. Will be measured the distrance "X' between the axis of Tab item 18 and the wall
Lateral support wall.
 -8-

3. Will be checked the brake lining to be in contact on its entire width with the braking
way, considering the contact surface in line with the tensioning direction.
4. Will be checked the conect centering of the brake bands facing the Tab item 18.
5. Will be also checked that the distance between the lateral side of the brake bands
and the edge of the braking way to be equal on the entire circumference.
6. The Brake support (dwg. 8407, Annex 3) will be placed at the distance of 665 mm
from the Main shaft axis.
7. In order the specified position of the Brake support to be achieved, an expander
(tensioning device) could be used in that purpose. The Brake support will be
positioned also at the distrance 'X" between its axis and the Lateral support wall
(see the dwgs. ofAnnex 3).
8. During the operation to bring the Brake support in the right specified position, the
checking mentioned under points 4 and 5 will be continuously done.
9. After the Brake support has been conect aligned, respecting the requirements of
points 3, 4 and 5, it will be spot welded on deck.
Remark lf, after the tensioning operation, the specified distrance of 665 mm
from the Main shaft axis can not be achieved, but the Bands item 7 and 8 are
already stuck against the Braking way and the joint surface between the bands
item 7 and item 8 is in vertical position, the Brake support can be spot welded
in the position achieved at that moment.
10. Will be made the adjustment of the Band brake, following further given
instructions.
11. Before the first air supply of the brake, with the Brake in its close (tight) position,
will be checked the correct position of Lever item 23 (as given in Adjusting
directions). lf the position of the Lever is not conect, then the adjustment of the
Brake will be repeated, until the achievement of the requested position of the
Lever.
12. Will be made repeated open and close movements of the Band brake, by using
the pneumatic controi.
13. lf any further problems do not appear, the Brake support can be final welded on
deck. The welding seams size will be according to Annex 1.

WARNING: A wrong welding of the brake support will lead to an incorrect

positioning of the band brake on the drum braking way and consequently, to a
wrong functioning or slippery of the band brake.

) The pneumatic band brake of the towing drum has also a Fork, dwg. nr. 5344, with
the purpose to stiffen the pipe frcm the brake. This fork is provided also with
addition for adjustment on deck and has to be welded on deck.

) Few conditions are necessary to be fulfilled, befone its welding:

o The addition will be adjusted as much as necessary for the fork to be fifted on
pipe and to lay on deck;
o The two halves of the fork will be fitted with their corresponding bolts;
r With the brake unfastened, the fork will be spot welded on deck;
o Will be checked the conect movement of the brake:
 -9-

. The fork will be final welded on deck, carefully, in order the welding seam not to
introduce supplementary intemaltension on brake, leading of its blocking.

B. Mountinq on deck of the Band brakes from the chain wheels.

The mounting of the chain wheels band brakes will be carried out as follows:

r araflge the brakes on their braking ways, as shown in Annex 1;

o adjust the band brakes so that the side clearance between the band and the
braking way to be uniformly distributed;
. hard fasten the brake;
. arange the brake supports on deck; these supports have a technological
allowance (50 mm) required for compensating the dislevelments;
. weld the brake supports; the fitting of the brake supports and stoppers and the
welding seams will be according to the brakes drawings, shown in Annexes of
Part 3;
o check the welding quality.

C. Mountinq of Load Pin and Proximitv Switches for Towino cable loadflenoth
measurement

Towing cable load/length measuring system consists in:

o Load pin;
.
Amplifier;
.
two proximity switches;
.
one programmable logic controller (PLC)
o and one LCD display.
The towing wire load/length measuring system is built-up around PLC, with expansion
unit for analog input and output, with micropro@ssor and an integrated power supply,
with input circuits and output circuits.

Mountinq of load oin

Towing force is measured in static conditions, by means of load pin mounted in the
brake of towing drum, in the joint between the brake support (which is welded on
deck) and the band.
The mounting of load pin will be done after the winch is mounted after all the winch
adjustments.
This mounting of load pin will be canied out as follow (see Annex 3, Band brake dwg.
6279-1):
1. will be dismounted the securing plate item 11 and the dummy bolt item 12 will
be removed . The dummy bolt is used only for transport and mounting;
2. the dummy bolt will be replaced by the load pin, witch will be secured with the
securing plate item 11 and two screws M 12x35, screwed on brake support.
 -10-

Mountinq of orcximitv switches

The proximity switches are to be mounted on a fix support, next to the towing drum, in
such way that equal displaced counting points to run in front of proximity switch
sensitive head.

The electric connection for these switches will be done in accoding with electric
diagram in connections PROX 1 and PROX 2 (see electric diagram).

NOTE: One proximity switch is necessary for length measurement and the second is
provided for winding / unwinding direction of cable, being necessary to be positioned
at a smaller distrance than the one between two counting points on towing drum.

The support for these two switches will be welded near towing drum, on winch
support. lts welding position is given in the detail drawing from Annex 6, dwg. 8873.

The mounting position of the two proximity switches on this support will be adjusted,
according to the following requirements:

) The perceptible items for these switches (counting points) are represented by 6
plates welded equidistant, on the drum stiffeners (plate item 8, as shown in
drawing from Annexes 6);
D the front distrance between the head of the switch M30 and the plates welded drum
stiffeners will be adjusted in the recommended range of 3-5 mm, see Annexes, by
means of the provided Hex. Nut M30; in this purpose, the distance between each
plate and the switch head will be checked to be the same.
F On mounting of the switches in the proMded support, the functioning presumptions
for this length measuring device will be taken into consideration: alwaya 2
proximity switches are needed, to check the length direction (pay out, pay in).

The position of the switches will be adjusted by means of the oval hole provided in
the support, so the above mentioned considerations to be respected.

4. STARTING INSTRUCTIONS

1. Before the first winch starting-up, the followings are requircd:

a) winch connection to the power supply by means of the Connecting flange shourn in
Annex 6, as follows:
o connec'tion of hydraulic installation to the ship pumping unit (connecting points P,
T, L1, LS);
o connection of the valve, used for dual displacement hydraulic motor control, and
connection of hydraulic distributor, to the electric supply (connecting point E).
b) conect device assembling;
c) conect fastening of the bearing cover screws and hydraulic motor flange;
d) suitable location of the chain wheels towards the hawse pipes;
 -11 -

e) conect engaging of chain to the chain wheels;

f) oil level in reduction gear ( to be filled up to the visible mark, by removing of the
filling plug). Lubrication of reduction gear will be carried out with oil ISO VG
150 or similar (see Table 1). The necessary quantity is about 280 litters;
g) easy rotation of the moving parts;
h) easy connection/ disconnection of the towing drum and chain wheels from the
main shaft;
i) easy and efficient action of band brakes;
j) grease lubrication of the bearings and joints in the marked area,(see Annex 1);

2. Having performed all this checking, the winch is started up by running the motorfor
5 minutes in both directions of rotation (idle running regime); lf there are no signs of
malfunction (noise, vibrations, motor or bearings overheating), the winch is rcady for a
normal operation.

After every non-operating period longer than 24 hours, before the winch starting up,
the checking specified on items "f', "h", "i", '1", should be performed again.

5. OPERATING INSTRUCTIONS

5.1. Anchor lowerino without hvdraulic drive:

The operatorwill perform the followings:

r' with fastened brake, will be checked if the chain wheel used for lowering is
disconnected frcm the main shaff;
' r' will be loosen the band brake of the chain wheel and the anchor is starting to
lower under its own weight; the lowering speed should be controlled by brake
control;
The lowering speed control is necessary because of the below reasons:
a) to prevent the early wearing of the chain wheels bearings;
b) to keep engaged the chain with the chain wheel;
c) to protect the device against the shocks generated by sudden braking under high
speed.

/ pay out the necessary chain length for anchor drop;

/ fasten the band brake, in orderto block the chain wheel.

5.2. Anchor lowerino bv hvdraulic drive:

The necessary operations for this maneuvering are as follows:

/ checking whether the chain wheel and the drum not used for this operation are
disconnected from the main shaft and the brakes are fastened prcpedy;
r' connect the chain wheel to the main shaft; act upon the electric controlled
hydraulic distributor for carrying out the connection; if the position of the jaw
 - 12.

clutch does not allow the connection, operate the air contrcl till the proper
position;

WARNING: connection should be shocks-free; Manoevring with chain lifter is not

allowed to be done from the wheelhouse.

r' bose completely the brake;

/ act upon the hydraulic motor, by means of air controlled hydraulic distributor, in
the anchor lowering sense;
r' pay out the neoessary chain length forthe anchor drop;
,t stop the motordriving;
r' fasten the band brake to block the chain wheel;
r' disconnec{ the chain wheel from the main shaft.
5.3. Anchor hoistinq bv hvdraulic drive:

Breaking the anchor out and its hoisting up are canied as follows:

r' will be checked whether the chain wheel used for this operation is connected to
the main shaft;
/ will be checked whether the drum and the chain wheel not used for the above
operation are disconnected from the main shaft and the brakes are into their
tight position;
y' connec'tion of the working chain wheel is performed as specified under 5.2.

WARNING:
Will be traken into consideration to limit the working pressure according to prescribed
pressure on Technical data (see Chapter 2). lf this prescription is not respected,
breaking of chain danger could appear. lt is not allowed the simultaneous breaking of
two anchors out. Manoevring with chain lifter is not allowed to be done from the
wheelhouse.

r' loose slightly the band brake of the chain wheel until the gears of the reduction
are taking over the weight of the chain suspended into water;
/ loose completely the band brake;
/ operate the hydraulic motor, for chain recovery from the sea bottom;
r' chain bringing to vertical position is caried out by the ship movement either by
its propelling unit or under the force generated by the anchor winch, if possible
without exceeding the winch operating data;
r' breaking the anchorout.
NOTE: The winch is capable to develop, for a short period of time, a pull twice the
nominal pull. lf breaking the anchor out is not successful, then repeat the prccedure.
Because breaking the anchor out and its hoisting are generating a high stress to the
hydraulic motor and driving system, these operations should be strictly supervised in
order not to be exceeded their operating data.
 _13_

y' anchor hoisting up;

y' motor shut down by putting the electric controlled hydraulic distributor on OFF
position;
r' fastening of chain wheel band brake;
/ disconnection of the chain wheel from the main shaft.

5.4. Anchor abandonment in case of emeroency:

In extreme necessity case, if breaking the anchor out is not possible, then its
abandonment is required in order to save the ship.
The followings are canied out:
/ the chain wheel band brake is fastening;
/ chain wheeldisconnection from the main shaft;
/ will be released the end of the chain stored in the chain well;
r' loose the chain wheel band brake;
r' if is possible, the gravity lowering of the whole anchor chain length, by
successive braking actions;
r' fasten the chain wheel band brake.
5.5. Towino maneuverinq bv means of towinq drum:

The operator performs the following operations:

r' make sure that the chain wheels are disconnected from the main shaft and their
band brakes are into their tight position;
/ connect the towing drum to the main shaft supplying with pressured air the
pneumatic clutch in order to be coupled and its pneumatic band. brake to be
uncoupled;
r' operate the e controlled hydraulic distributor for the cable uncoiling in order the
towing operation to be performed;
/ during towing operation, the pulling force from towing line will be taken by
pneumatic band brake that will be in its coupled position; in the same time, the
pneumatic clutch will be in its uncoupled position; this kind of operation protects
the hydraulic installation against the overload which could appear;
During the towing maneuvering, in order to adjust the distance between the
tug boat and the traken in tow vessel, the followings should be perform:

a. for distance reducing, the winch will be operated in the cable coiling sense
on drum, this means that the pneumatic brake is uncoupled and the
pneumatic clutch is coupled;
b. for distance increasing, the winch can be operated in two ways:
- acting the electric controlled hydraulic distributor in the cable uncoiling sense
on drum, having the pneumatic brake uncoupled and the pneumatic clutch
coupled; this kind of operation is less recommended;
- bringing graduated the pneumatic band brake into uncoupled stage by pressure
control in the range of 0-8 bar, this offering the possibility to maintiain a
 -14-

controlled drum rotation speed; during this maneuvering, the pneumatic clutch
will be in its uncoupled stage.

r' after the towing operation, act upon the electric controlled hydraulic distributor
for the cable release and recovery, in order to be stored on drum;
/ fasten the pneumatic band brake and disconnect the drum from the main shaft
by cutting the air supply for both brake and clutch;
'/ stop the hydraulic motor operation by putting the electric controlled hydraulic
distributor on OFF position;

WARNING: in orderto avoid the pulling out of the rope from the drum, minimum
4 coils should be permanently stored on drum.

5.6. Quav maneuverinq bv waminq head

The operations canied out by the operator are as follows:

r'
check if the chain wheels and towing drum are disconnected from the main
shaft and their brakes are fastened.
'z stop the hydraulic motor operation after completing the maneuvering.
NOTE : During the entire period of maneuvering, the motor technical data are
watched closely, not to be exceeded the prescribed values. Manoevring with
warping head is not allowed to be done from the wheelhouse.

6. STOPPING INSTRUCTIONS

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

prescribed hydraulic motor technical data.

In case of accidentally damages, appeared before the complete maneuvering, the

winch will be stopped by putting the electric controlled hydraulic distributor on OFF
position, then the band brakes are fastened, the winch power supply is cut out and
the prcper repairing measures should be traken.

7. LABOUR SAFETY PRECAUTIONS

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

The following rules must be observed:

. the winch to be operated by an authorized personnel, only;

. storage of various materials or components around the winch operating area is not
allowed;
 -15-

. unauthorized perconnel is not allowed into the winch operating area during its
operation;
r using of damaged cable or other cable than the prescribed one is not allowed;
'. repairs to be made afterthe device stopping and disconnecting from the mains;
operator to have a protec'tion suit;
. the winch operating area to be free from comlgations and slipping zones.

PART 2 . OPERATION AND MAINTENANCE

1. SERVICE AND MAINTENANCE RULES

The sequence of making operational the winch components was described in the
previous chaptels and the operation is canied out by properly skilled personnelwho
know the winch operating principle, technical data and operating system.

During the winch operation, the followings should be taken into consideration:

. periodical inspection of nuts and screws fastening;

'. testing of band brakes operation to provide a proper braking;
free from shock connection of the chain wheels and drum to the main shaft;
. changing of the device sense of rotation to be made by off-position, only;
. stopping the anchor chain uncoiling to be made by acting upon the band brake,
only;
. shut-down of the winch operation when any sign of malfunction o@urs (such as
shocks, vibrations, noise, overheating, possible slipping of brakes).
. operation of a winch with unrepaired damages is not allowed;
the strictly complying with the operating parameterc prescribed in the motor
specification, as follows:

('C)
- main circuit temperature : - min. 40; - max. 80;
(mm'/s)
- fluid viscosity : - min. 8; - max. 1000;
- fluid contamination level (lSO code 4406) : -18113

A. Directions for lubrication

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

a
moving parts, with grease pump type PA2 and greasing device type DB2.

The reduction gear is oil bath splash lubricated, oil level in reduction housing is
checked through the sight glass located on the reduction housing; the oil will be
changed every 12 months, after drain of the used oil and cleaning of the reduction
housing; the oil drain will be made through the drain nozzle mounted to the housing
lower side, after having rcmoved the drain plug.

The oil filling up will be made through the housing top side, after the removing of the
reduction cover.
 - 16 -

Grease lubrication will be made in those points shown in Annex 1, Part 3, including
the grease points of pneumatic clutch and pneumatic band brake shown in drawings
of these mentioned parts (such as bearings of the main shaft, of the reduction
housing, chain wheels, towing drum, side supports and joints of the band brakes and
coupling devices).

Grease lubrication will be made before and after the winch operation or once a week
if, during this period of time, the winch has not been operated.
The grease will be completely replaced during the periodic inspection or when its
color and consistency changed.

It is advisable that the grease lubrication to be checked for several weeks during the
winch operation, in order to be estrablished a prcper lubrication time. The allowable
lubricate grades are shown in Table 1.

NOTE: In case of accidentral lubrication of the braking ways, dismount the band
brake, solvent cleans the brake lining and braking way up to the complete removing
of grease.

B. Directions for adiustino

1. Adiustinq of pneumatic operated friction clutch

The following ways to adjust the friction coupling can be performed:

a. - the operating force (the torque when the clutch slipping produces) can be
adjusted and controlled by variation of the supplied air pressure in the specified
range of 0+8 bar. For a conect adjustment of friction clutch the supplied air
pressure must be close to 4,5 bar.

b. - for a normalwearing of the clutch lining in time, before this to be replaced with a
new one, a readjusting of the friction clutch can be done, as follows (see the
friction clutch drawing no.6272, in Annex 5 page 212):
r' Unscrew the adjusting screws item 5 around the coupling housing till the
extemal surface of metallic band of the house.
'/ Will be measured the distance "a" between the bolt of pneumatic cylinder rcd
and the first two fixing screws of cylinder on housing. When the cylinder is not
supplied with pressured air the distance "a" have to be 140 mm.
r' The spring item 22 must be tensioned under an initial force when the cylinder is
not supplied with pressured air. The initial stroke for the spring can be adjusted
by means of the adjusting screw item 20 fifted on housing.
r' The maxim stroke of pneumatic cylinder "b" when it is supplied with pressured
air is 140 mm. The optimum adjustment can be achieved for a cylinder rod
stroke close to 60 mm.
 -17 -

r' Adjust the position of the lever item 4, in order this to achieve an angle of 90o
when the cylinder is supplied with pressured air, acting upon the adjusting and
blocking threaded bushes item 16 and nuts item 15 on the thread of bolt item
14. For a conect functioning way of pneumatic cylinder, its maximum
developed force is reached at about 60 mm, when the angle between the
cylinder rod and the lever is 90o.

NOTE: The optimum stroke of pneumatic cylinder and the stroke of extension spring
is not allowed to be bigger then 125 mm, to ensure the releasing of friction clutch
when the air prcssure is off, and also to ensure the spring will not achieve maximum
permissive stroke about 135 mm (the spring will be damaged).

/ change the position of the air cylinder on coupling housing, if a supplementary

adjustment is necessary; after the position of the cylinder on clutch housing has
been changed, the cylinder is supplied with prcssured air and the working
stroke has to checked out; ff the working stroke is above 60 mm, than the
position of the lever is to be adjusted (as shown at first point), until the angle of
90o to be obtained.
/ After all these adjustments, the values mentioned before can not be achieved,
a supplementary adjustment can be done by changing position for bolt item 12
(position for lever joint) from hole 2 in hole 1 and other holes 3 and 4(see the
friction clutch drawing no.6272, in Annex 5 pageZ2).

c. - when the dismounting friction clutch is ne@ssary in order to replace the wom
parts such as clutch lining; after the parts have been replaced and the clutch
remounted, in order to obtain a conect contact on the entire contact surface
between clutch lining and drum fric'tion way, the following steps are recommended
(see the friction clutch drawin g no. 6272, in Annex 5 page 212):
/ supplywith air pressure the pneumatic cylinder, in orderto bring the clutch in its
coupled position;
r' the adjusting screws around the coupling housing are completely screwed on
till the contact with the metallic band of the friction band; than they are
unscrewed in order to obtain an uniform clearance of about 0,5+1 mm,
necessary to allow the clutch release, without air pressure;
/ in order to adjust the pneumatic cylinder stroke, this can be fitted with screws
item24 in different positions on housing;
/ to ensure the releasing of the clutch in the absence of air pressure, the spring
can be adjusted by means of the adjusting screw item 20 fitted on housing;
r' after all these manual adjustments have been made, the operating force can be
readjusted by changing the air pressure on the pneumatic control system.
 _18_

2. Adiustinq of pneumatic operated band brake

The adjustment of the pneumatic operated band brake is recommended to be

done in one of the followings @ses:

r during the winch mounting on deck;

r when the brake lining wearing has to be compensated (in order the initial working
parameters to be achieved);
. affer the brake lining has been replaced due to its wearing and the remounting of
the band brake is neoessary.

The adjustment of the band brake consists in assurance of an optimum ratio between
the capable force of the springs and the releasing stroke of the cylinder rod. The
optimum adjustment can be achieved for a cylinder rod stroke in the range 125-135
mm, from a maximum stroke of 180 mm.
The followings steps will be performed in orderto make this adjustment (see the Band
brake drawing no. 6279-1 , in Annexes of Part 3):

r' when the brake is in its tight position, the following requirements must be
achieved:
- the lever item 23 has to be in its vertical position;
- the marked distance "a" (see Band brake drawing no.6279-1, in Annexes of
Part 3) has to be placed in the range of 55- 65 mm.
This adjustment will be done by means of the thread spindle item 29, in the
recommended order, considering as basic stipulations:

WARNING: ls not allowed the adjustments to be done by supplying with air

pressure the pneumatic cylinder item 6, as long as the adjusted position of
the lever in an inclined position, more than about 10o toward outside (the
thread spindle could be banded and broken.

o when the lever item 23 is in its vertical position or in inclined position toward
inside, than the adjustments can be done by suppllng with air pressure the
pneumatic cylinder item 6, in order the movement of the thread spindle to be
done easie[
r for the adjustment by means of thread spindle item 29, in order this to be
actuated, the blocking nut item 28 will be unscrewed first; the thread spindle
should be unscrewed if the distance "a" is bigger than the recommended range
or to be screwed on if the distrance "a" is smaller than the recommended range;
the nut item 31 serves as counter nut.
o the thread M27 of item 29 is right execution; one complete rotation represents a
longitudinal movement of the lever axis along the thread spindle item 2 of about
27 mm (allowing to calculate how many complete rotation are necessary to
bring the lever in its vertical position); one complete rotation of the thread
 -19-

spindle item 2 represents about 3 mm (allowing to calculate the necessary

movement in order to adjust the distrance "a" to the prescribed range).
. during adjustment, meaning screwing and unscrewing actions of thread spindle
item 29, the distance given in dwg. will be checked, not to be bigger than 125
mm (to avoid the totial unscrewing of the thread shaft).
o this adjustment should be progressively repeated till the conect position of the
lever and the prescribed distance "a" have been achieved;
o at the final, the two nuts item 28 and 31, will be checked to be screwed on
tightly.
r' after the above described adjustment has been done, the band brake is ready to
be used in its normalworking conditions.

Adiustment of the Band brake ooeninq.

When the brake is in disengaged (open) position, is very important that the fenodo
lining to be in no contact with the braking way.
In this purpose, the Brake is provided with four stoppers, item 35, and assembly
(welded on deck) by item 1,3,40, see Annex 3.
The position of these stoppers in their support welded on the Lateral support and
deck will be adjusted on board, by means of the adjusting screws, a proper contiact to
be achieved, as shown in the dwg. of Band brake, in Annex 3.
The distance between roller and the brake band, when the brake is tighten up, will be
about 1-2 mm. When the brake is open, will be taken into consideration and checked
that the fenodo lining to be in no contact with the braking way, on the entirc
circumference.

2. POSSIBLE DEFECTS AND REPAIR PROCEDURE

During the winch operation, some damages to the winch parts could be possible and
their repair is required. These possible damages are described in Table 2.

For any damages, it is required the winch stop, the chain securing and fastening, and
the electric equipment disconnection from the mains.

3. PRODUCT ASSEMBLING/ DISASSEMBLING

Anchor and towing winches generally have a simple design and consequently, their
dismounting, in order to carry out some repairs or parts replacement, does not require
use of special tools and devices.
The winches are compact and modular products; their dismounting is canied out
beginning from the main shaft to the rcduction gear, as shown in the Annexes of Part
r 3 from this Manual.

Reduction dismounting is to be made as follows:

{ remove the reduction cover;
,/ drain off the oil from the reduction housing;
 _20_

./ remove the bearing covers;

'/ pull out the main shaft and intermediate shafts.

For mounting, the operations are carried out in reverse order.

4. SERVICE PARTS
The service parts list is given herewith.
The service parts are delivered on order basis only.
To order any service parts you need, mention the following information:
.!. winch type, denomination and series for which the service parts are requested;
* item denomination, position, drawing or standard number;
{. requested quantity;
* deliveryterms;
* full delivery address;

Contacts for seruice:

Hans H.H. Hegen

Hegen Trading&Repair
Address: Singraven 13
3334 CV Zwijndrecht
The Netherlands
Phone: 0031-(0)78-8440882
Mobile: 0031-(0)61-4545844
Fax: 0031 -(0)84 -7312522
E-mail: [email protected]
Website: www.H-T-R.nl
 -21 -

TABLE 1
Aanbevolen s3neeffi tti ddelen
Lshricants c*fff
l-ubrifisffits prdmnis#s
furpfohlsne $cfimisstoffe
rss1ffi0 rs$rffitr 3ll.rt{Ftlrc
mnFtwwc lsotfGEfi rfffiuGrm gE8€,. gf-
*GITA lEF +EF sEP 6EF S8EEE. HJIE
GRESF FCXF A'fTEfrTLtE rFil GEAR
c$tr$C {1 #I I25 fsI nfifl-E*IEHTS ROSrESfiSl ffiCELS
sal4^es& rcEqg- rEtcltItffiI ttt
ffi{ffi I t2 ts al EIL ffiEL
I.*GEffi/ET ffif,€HtE
s$Ifttr'F $r$ Tflr rfim r€frt otE
HETH.ICTS-Fs REIX,'CTELF reBTrcTE.F RETT'CTEI.F H-F
alItar P68 sPt50 5F22II SRx2I}
EFEXA z
sroctdfrGE

# up
86fiE B€ IS SGffi s5H

E}GR6$L Gfi ETGrefr.f,# EilERGOL GF EIT,ffiG{L GS E}IEFGfiEA:SE

f,ftAL
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FRSIESM|E
sLan
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T]I.IRA{ITH
sorFfffiE BSfFCtttd) Ht Fff,.F!f;) GffiFffi.[il} GREASE EF!
TilITR.UST
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-€ffi RES'CTE1FS FtElrL/A'lf :ELf i REffi.lGTEIFS BEFXI''TEI FE

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SF*RNA# SfiARTfr!{ SARTSTT SFAETA}i FUSrgru*

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t-uEfficsifr t-tEftlffrs*T uffifiAffT UFR|GAHT

GUFCRffS.,I t{*Rllcfiff
GREASE I*.3 s'3
Htre tfitt5g rffis lGliffi
lrlClBfl-GEtR ;I$BLGETR *ffi.fEAR }IffiGEAR TXHTGNEASE ]#Er-f,*H&
;f,sl$l fln)Ffrg ffxIlF t5s 6InXP lrltl frru)F 3?rI )s#rr? s4
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ffif,Leffi stf;At-f, t5{t ffit*t*90 c$At-fr:Ils GFEASE HI
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stsEP fgm suFtEP tsg0 s$€F ilrfiI stFup fiHl
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SEffiATIl'E
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f,*f;TER S-frRIER G*RTER CARTER TRf,TXS
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 -22-

TABLE 2

DAMAGE SIGN DEFECT POSSIBLE CAUSES REPAIR PROCEDURE

0. 1. 2. 3. 4.
1. Strong noise. High wear or damage of Wearing. Wrong operation. Replace the damaged bearings.
reduction gear bearings. Unsuitable maintenance or lack of NOTE! ln case of bearing breaking, change the
greasing. oil and clean inside of reduction housing.

2. Oil leakages. Damaged gaskets or sleeves. Wearing. After the oil empting from the reduction housing,
Unsuitable maintenance. replace the worn parts.
Wrong mounting.

3. Reduction gear overheating. No sufficient oil inside of reduction Unsuitable operation. Check the oil quality (aspect, fluidity, color).
housing. Wrong maintenance. Fill-up or replace the oil as necessary, up to the
marked level of the sight glass.

4. Hydraulic motor does not Motor damages. Unsuitable operation and maintenance. Replace the damaged components.
start. Pressure loss in the hydraulic Cracked pipes. Check the hydraulic system and repair it if
system. Lack of pressure in hydraulic system necessary.
Lack of pressure to the air control of (damage of the pump unit) Check the pneumatic system and all fittings and
hydraul ic distributor. Lack of pressure in pneumatic system or replace the damaged components if necessary.
detachment of a fitting pipe-nipple.

5. Slipping of pneumatic friction The air pressure in pneumatic system Unsuitable operation and maintenance. Check the pneumatic system and all fittings and
clutch under the nominal load is insufficient (pressure loss). Cracked pipes or hoses. replace the damaged components if necessary.
applied on drum. Lack of pressure in pneumatic system or Readjust the friction clutch in order to set again
detachment of a fitting pipe (hose)-nipple. the normal working pressure (see also the
Normal wearing of the clutch lining. pneumatic friction clutch adjusting instructions).
Remove and replace the clutch lining after the
clutch dismounting.

6. Decreasing of the braking Oil spots at the interface between Wrong maneuvering and maintenance. Release the band brake from the chain wheel
capacity. the brake lining and braking way. Normal wearing of the brake lining. and clean with white spirit the brake lining and
Overheating of the chain Brake lining is removed from the Wrong maneuvering due to the sudden the braking way until the oil spots are removed.
wheel or drum braking way. brake band. braking when the chain wheel is subjected Replace the brake lining after brake dismounting.
The holes for the securing screws to high speed. For the band brake on drum check the correct
became oval. Lack of pressure in pneumatic system or adjusting (see also the pneumatic band brake
The air pressure in pneumatic system detachment of a fitting pipe (hose)-nipple. adjusting i nstructions).
is insufficient (for drum brake band).
 -23 -

SERVICE PARTS LIST

Anchor and towing winch type 211-H19(200 KN)
Project nr. 7051 Rev. 1(erc)

Pcs/
Item Denomination Drawing nr./Standard
winch
1. Ball bearins 6220 SR 3041:1993 1

2. Rolfer bearing 23026C SR 3918:1993 2

3. Roller bearins 23940MBW33 SR 3918:1993 1

4. Roller bearinq 23944CW33 SR 3918:1993 1

5. Roller beari ns 24048CAW33 SR 3918:1993 1

6. Roller bearins 23044CW33 SR 3918:1993 1

7. Nilos rinq 6048 JV 1

8. Nilos rinq 6040 AV 1

9. Seal A 200.230.015 DtN 3760 1

DIN 3760 (with stainless steel

10. Seal A 240.270.015 1
spring)
11. Seal A 240.270.015 DtN 3760 1

12. Seal A 260.300.018 DtN 3760 1

13. Rotary connector 353.107.000.0 1

U ring MA 23 code 61483

14. Dimension 200x180x15 for 1

brake cyl i nder ( Dichtomatic)

15. Pneumat c cyf inder @100 921.003.000.0 1

16.* Ferrodo I ninq 10x200x2544 6280-1/3 (drum band brake) 1

17 .* Ferrodo I ninq 10x200x2445 5193/3 (drum band brake) 1

19.* Ferrodo I ninq 10x1 20x2127 542713 (clutch band brake) 1

19.* Ferrodo I ninq 10x1 20x1854 542714 (clutch band brake) 1

20.* Screw M10x30 DIN 963 (CuZn37)** 64

21 . Screw M10x20 DIN 963 (CuZn37)** 44
22. Screw M10x18 DIN 963 (CuZn37)** 52
23. Grease nipple M10x1 DIN 3404 32
Remark: " delivered cut on requested length and not drilled

**Material CuZn 37 (symbol CU2) in according with EN 28839, has the

followi
ldentification Tensile strength Yield point Elongation
symbol (N/mm2) (N/mm2) (Yol

\
 -24-

PART 3

ANNEXES
 ANNEX 1

page 1/9

COMPONENT PARTS
ANCHOR AND TOWING WINCH TYPE 211-H19 (200KN erc)
dwg. nr. :7051 Rev. 1

Pos. DENOMINATION Pcs Drawing / Standard

1 Reduction gear 1 7235

2 Coupling device 1 6864

3 Band brake 6S00 2 2945

4 Chain wheel 1 2977-2

5 Support 1 2990-1

6 Band brake @1550 1 6279-1

7 Towing drum 1 2991

8 Support 1 2992

I Chain wheel 1 2977-1

10 Coupling device 1 6871

11 Support 1 2975

12 Warping head 1 2954

13 Hex bolt M16x100 12 DrN 933

14 Mounting pads 1 2993

15 Hex bolt M36x70 28 DrN 933

16 Hex bolt M24x50 2 DtN 933

17 End washer 1 2955

18 Key 845x25x200 2 DtN 6885/1

19 Spacer 9225 x @191 x 69 1

20 Spacer 9225 x @191 x 17 1

21 Jaw clutch 1 2994

22 Spacer 1 2995

23 Spacer 1 2996

24 Spacero.250xZ21 1x16 1
 ANNEX 1

page 219

COMPONENT PARTS
ANCHOR AND TOWING WINCH TYPE 211-H19 (200KN erc)
dwg. nr. :7051 Rev. 1

Pos. DENOMINATION Pcs Drawing / Standard

25 Slotted nut 1 3000

26 Spacer 1 2997

27 Seal A 240.270.01 S(with stainless steel spring) 1 DrN 3760

28 Cover 1 2670

29 Hex bolt M 12x40 20 DrN 933

30 Roller bearing 23944CW33 1 SR 3918:1993

31 Nilos ring 6040 AV 1

32 Spacer 1 2998

33 Main shaft 1 7062

34 Nilos ring 6048JV I

35 Roller bearing 24048CAW33 1 SR 3918:1993

36 Seal A 260.300.018 1 DtN 3760

37 Cover 1 3057

38 Spacer 1 3002

39 Key AB56x32x2OB 2 DtN 6885/1

40 Friction clutch @1500 1 6272

41 Shield 1 8559

42 Hex bolt M10x35 16 DtN 933

43 Pipe 1 4594

44 Screwed pin MGx16 1 DtN 551

45 Nylon tube @10x1 - 4 m 1

46 Reduction piece M22x1 ,5 - G114 1 51 94

47 Spacer o285 x @251 x 5,5 I

48 Spacer 1 3008
 ANNEX 1

page 3/9

COMPONENT PARTS
ANCHOR AND TOWING WINCH TYPE 211-H19 (200KN erc)
dwg. nr. :7051 Rev. 1

Pos. DENOMINATION Pcs

49 Jaw clutch 1 3009

50 Spacer 1 7563

51 Brake stopper 1 301 1

52 Brake stopper 1 3012

53 Flange 1 5091

54 Rotary connector 1 3s3 107 000 0

55 Stopper 1 4644

56 Hex bolt M8x20 4 DtN 933

57 Coupling G1 14"-@10 2

58 Packing assembly 1 4589

59 Fork 1 5344

60 Hose support 1 3626

61 Proximity switch su pport 1 8873

 t+*+t
r{
tl

iS r+;i

E
.pz
xz
ANCHOR AND TOWING WINCH TYPE 211-H19 (200KN erc) :m
tX
dwg. nr. :7051 Rev. 1 (o .r
 Technical conditions :
1 - Bearinq covers will be sealed with " Loctite 510 ":
2 - All screws, nuts and washers unless stainless steelmade,
will be hot dip galvanized:
3 - Allthe screws will be threadlocked with " Loctite 243 ".

Section B-B

E
-$z
xz
ANCHOR AND TOWING WINCH TYPE 211-H19 (200KN erc) :-- m
qX
dwg. nr. :7051 Rev. 1 (or
ANNEX 1
page 6/9

g
o
zY
O
o
s,
rO)
I
+
r
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$6
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I6o
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=E
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vo)
13
o
=c
F
o
z
t
o
I
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z
 A view

Cuttino addition
To be adjusted on yard
E
.Pz
xz
ANCHOR AND TOWING WINCH TYPE21 1-H19 (200KN erc) *,. m
dwg. nr. :7051 Rev. 1
::X
(o ...
 FIXING ON DECK DIAGRAM

Main shaft
AXIS

Remark :
- All contour welding seams will be \16 unless
otherwise stated on detail drawings of parts.
E
-ez
xz
ANCHOR AND TOWING WINCH TYPE21 1-H19 (200KN erc) :m
qX
(or
dwg. nr. :7051 Rev. 1
 3x

3x

the pneumatic
l'
I

t_

GP - Grease lubrication point

For GP on reduction
gear and other subassembly see also dwg. of part.
E
-ez
xz
ANCHOR AND TOWING WINCH TYPE21 1-H19 (200KN erc) .-- rn
S{X
(or
dwg. nr. :7051 Rev. 1
 ANNEX 2
page 1/5

COMPONENT PARTS
REDUCTION GEAR
dwg. no. :7235

Pos. DENOMINATION Pcs Drawing / Standard

1 Gear case 1 6858-1

2 Nut M216x4 1 2758

3 Lubricator M 1 0x1 5 DtN 3404

4 Cover 1 2586

5 Screw M 16x65 12 DtN 933

6 Seal A 200.230.015 1 DtN 3760

7 Roller bearing 23940MBW33 1 SR 3918:1993

8 Toothed wheel m=7 1 7236

I Distance ring 1 @147x@131x18

10 Roller bearing 23026C 2 SR 391 8:1 993

11 Shaft 1 6860

12 Paralfel wedge C32x18x1 67 2 DrN 6885

13 Screw M 10x40 12 DtN 933

14 Cover 2 6861

15 Distance ring 1 6862

16 Cover 1 2590

17 Screw M 10x35 6 DtN 933

18 Cover 1 2668

19 Screw M8x20 58 DrN 933

20 Retaining ring 100x3 1 DIN 471

21 Ball bearing 6220 1 SR 3041:1993

22 Retaining ring 180x4 2 DtN 472

23 Pinion m=7 1 8530

24 Screw M 18x55 5 DtN 933

 ANNEX 2
page 215

COMPONENT PARTS
REDUCTION GEAR
dwg. no. :7235

Pos. DENOMINATION Pcs Drawing / Standard

25 Hydraulic instalation 1 7060

26 Cover 1 2592

27 Gasket 1 2593

28 Screw M8x25 28 DtN 933

29 Pinion m=10 1 7238

30 Distance ring 1 @147x@131x30

31 Paraf fel wedge C32x1 8x278 2 DtN 6885

32 Toothed wheel m=10 1 7239

33 Distance ring 1 @240x@221x32

34 Cover 1 6902

35 Seal A 240.270.015 1 DtN 3760

36 Rolf er bearing 23044CW33 1 SR 391 8:1 993

37 Parallel wedge 850x28x230 2 DtN 6885

38 Gasket 2 @30xo22x2

39 Drain screw M20x1 ,5 2 1118

40 Cover 1 2597

41 Gasket 1 2598

42 Gasket 2 2690

43 Cover 2 2691

44 Screw M 10x25 38 DtN 933

45 Cover 1 2599

46 Gasket 1 2600

47 Gasket 1 @64x@48x2

48 Breather plug 1 2754

 ANNEX 2
page 3/5

COMPONENT PARTS
REDUCTION GEAR
dwg. no.:7235

Pos. DENOMINATION Pcs Drawing / Standard

49 Level gauge 1 Nr. 1451M TEMPAX 1,5"

50 Screw M10x12 6 DtN 933

51 Screw M16x16 4 DrN 933

 Section A-A

Technical conditions :
-Lubrication of reduction gear will be carried out with oil ISO VG150. GP - Grease lubrication point
The necessary quantity -280 litters. E
DZ
-Oil level should be checked before putting into operation of the winch. 9iz
:m
IX
0tp
REDUCTION GEAR, dwg . 7235
 ANNEX2
page 5/5

ro
cr)
c{
N
ci)
T)
=
t
tU
(,
z
-t/ |

/'-r \-! .'1-r o

1 | \ tr
i,a \rt/ .i C)
/ '\r- -'
y'..
\
o
=)
\-'- J--' tU
t
 ANNEX 3
page 1/5
COMPONENT PARTS
BAND BRAKE 41550
dwg. no. .6279-1

Pos. DENOMINATION Pcs Drawing / Standard

1 Screwed pipe 1 @25M12x25

2 Thread spindle 1 31 81

3 Screw M 12x35 3 DrN 933

4 Screw M 10x20 1 DrN 933

5 Washer @25x@10,5x4 1

6 Pneumatic cylinder 1 3158-1

7 Band 1 6280-1

8 Band 1 51 93

I Support 1 3182

10 Grease nipple M10x1 8 DtN 3404

11 Securing plate 1 1422

12 Sensitive bolt 1

13 Brake support 1 8407

14 Screw M36x120 2 DrN 933

15 End washer 1 31 86

16 Screw M 12x30 2 DrN 933

17 Bush 1 3187

18 Tab 1 51 90

19 Bush 1 31 89

20 Shaft 1 3190-1

21 Pipe 1 3191-1

22 Bush 1 3192

23 Lever 1 3193-3

24 Bolt 1 3194

25 Parallel wedge A25x14x95 1 DrN 6885

 ANNEX 3
page 215
COMPONENT PARTS
BAND BRAKE 91550
dwg. no. :6279-1

Pos. DENOMINATION Pcs Drawing / Standard

26 Screw M 16x35 2 DtN 933

27 End washer 1 31 95

28 Nut M27 1 DtN 934

29 Thread spindle 1 51 91

30 Pressure washer 1 @50x@34,5x6,5

31 Nut 1 5082

32 Pipe 1 5345

33 Nut Tr24x3 1 461 0

34 Pressu re washe r @36xo24, 5x8 1

35 Brake stopper 4 3205-3

36 Plate 1

37 Screw M 16x65 6 DtN 933

38 Nut M36 2 DtN 934

39 Locking washer N36 2 DtN 127

40 Nut M12 1 DtN 934

 GP - Grease lubrication point

.z.-J.-:-
,r1lf\,
'ii i '\\\
tE
.lp+
t5-o
g:
h
/ ,,4x1**r/1,/
,'-4ir*J=4
/ ,' .r'>ryi
\ ,,,
sl dor t .7' ./
.' ./ ,' / /
-f
,dl:t /
@ U;:
Elfr$
/
/,' I
I a
lmml
12 free position
,El9E
l./,
\./'/
\a//
.,f /
,, @fTi
55-65

192
pretensioned for braking

= 12 + stroke

.'\r' /

{l- -\
IF
IF
IF
1F
xn
, r'h, q-t- vD
HA
!Px
<Jt
6p

BAND BRAKE 41550, dwg .6279-1

 ANNEX 3
page 4/5
,/' -\-.---
n \

-l

I
Support dwg. 2990-1 and Reducer gear
!

__l
I

a)
I

i IJ
I

ffi
rB
l- ir
i?

p+
rB
f* BAND BRAKE g1 550, dwg.6279-1
 PLACEMENT OF BAND STOPPERS

EZ
Efr
qx
O<.^t

BAND BRAKE @1 550, dwg.6279-1

 ANNEX 4
page 112
COMPONENT PARTS
BAND BRAKE @5OO
dwg. nr. :2945

Pos. DENOMINATION Pcs Drawing / Standard

1 Support 1 2946

2 Bolt 1 2947

3 Screw M 10x16 4 DrN 933

4 Plate 1 1744

5 Cleat 2 2948

6 Pfate washer @29x@9x4 1

7 Thread spindle 1 1746

8 Screwed bolt 1 2949

I Lower band 1 2950

10 Thrust ring 1 1751

11 Screwed pin M8x10 1 DtN 553

12 Bolt 1 2951

13 Ring @37x424.5x10 1

14 Ring @38x@24,2x20 1

15 Upper band 1 29s2

16 Bolt 1 2953

17 Screw M8x16 4 DrN 933

18 Plate 2 1755

19 Crank handle 1 1756

20 Pfate washer @40xZ9x4 1

21 Grease nipple M10x1 3 DtN 3404

 Section C-C

Section A-A

Brake stopper
dwgs. 301 1 ,3012

Section B-B

adjustment on
deck

E
GP - Grease lubrication point E=
offi
BAND BRAKE A500, dwg.2945
NX
N5
 ANNEX 5
page 112
COMPONENT PARTS
FRICTION CLUTCH @1500
dwg. no. :6272

Pos. DENOMINATION Pcs Drawing / Standard

1 Coupling housing 1 6273

2 Friction band 1 5427

3 Cleat 1 5429

4 Lever 1 5432
5 Hex. screw M12x45 19 DrN 933

6 Hex. nut M12 21 DtN 934

7 Bolt @55x131 1 5435

8 Grease nipple M10x1 4 DfN 3404

9 Hex. screw M10x25 4 DrN 933

10 Securing plate 4 5436

11 Bolt @55x123 1 5437

12 Bolt @45x131 1 5438

13 Bolt @45x109 1 5439

14 Bolt 1 5440

15 Hex. nut M24x2 2 STAS 4373-80

16 Threaded bush 2 5443
17 Bolt 1 5444

18 Securing plate 8 5445

19 Hex. screw M8x20 16 DrN 933

20 Eye bolt M 12x110 1 DIN 444

21 Shackle A 0.4 2 Df N 82101
22 Extension spring 1 5446-2
23 Washer 13 4 DtN 125
24 Hex. screw M12x15 4 DrN 933

25 Pneumatic cyl .9100 1

3l Pipe 1 4448
 Section B-B

cD
az
GP - Grease lubrication point vz
:-m
eix
luol

FRICTION CLUTCH @ 1500, dwg . no. GZTZ

 ANNEX 6
page 112
COMPONENT PARTS
Proximity switch support
dwg. no. :8873

Pos. DENOMINATION Pcs Drawing / Standard

1 Support 1

2 Plate 1

3 Hex. screw M12x40 2 DtN 933

4 Hex. nut M12 2 DtN 934

5 Plate 1

6 Hex. screw M12x25 2 DtN 933

7 Proximity switch 2

I Plate 6
 ANNEX 6
page 212

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 ANNEX 7
page 114

COMPONENT PARTS
HYDRAU LIC I NSTALLATION
dwg. nr. :7060
DENOMINATION Pcs Drawing / Standard

1 Hydraulic motor HMC 080 FM3 1

2 Winch Manifold 1
 ANNEX 7
page 214

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HYDRAULIC INSTALLATIO
dwg. nr. :7060
*t
 I lr I

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page 414
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 Drwo 1 terminal22
Onrvd t termina!23
Drwd 1 terminal24
Druf t terminal25

$?B?$ e !
Amplifier to be mount
in the near from loadPin Amplifier type AL

Supply 24 VDC

f Lorijn & Loos Multi Function BV

W.M.Dudokweg 40, 1703 DB Heerhugowaard
I The Netherlands
7 T"l.'+31 (0) 725745254 Fax.:+31 (0)725745285 Wiring diagram
URL www.loriinenloos'nl E-mail: info@lorijnenloos'nl
WINCH DRUM Payout and Linepull measurement
S iemen s PIC- S7-2 22 lFj|dz3 l/TD 200C

LORUN & LOOS MULTI FTJNCTION BV

W.M.Dudokweg 40 t703 DB Heerhugowaard
TEL: +31(0)72 5745254 FAX: +31 (0)72 5745285

Website http://www.lorijnenloos.nl E-mail : info @ lorijnenloos.nl

 Page

r. PLC....... 3

2. m200coperatorinterface................ 4

3. MMI Winch drum menu..... 4

4. Restoring factory defaults 6

5. Preset. winch dn:n:r from horne position. 6

6. Alarm message's................ j
7. Maximum linepull warning / brake setting. j
8. Manual working layer override / escort mode... g

9. Pay out cable length net/gross........ g

10. Appendix MMI Winch drum parameters................ A

ll. AppendixMMIWinchdrumoperatorinterfacemenu............ B

| 2. Appendix MMI Winch drum operator interface releasing password....... C

13. AppendixMMlWinchdlunrFault/Wamingrnessages....... D
14. Appendix Winch drum parameter 1isr................... E

Pagina 2 WINCHDRUM 12-t2-2408

 1. PLC

The winch drum system is build-up around a Siemens plc 57-200/222CPU with an expansion
unit for analog in and output. The 57-200 CPU combines a microprocessor, an integrated
power supply, input circuits and output circuits in a compact housing to create a powerful
Micro PLC.

Program and data are placed into a memory cartridge ( Flash memory ) and must be replaced
when a new CPU is installed.

The memory cartridge can be found on the upper side of the CPU unit at the left. The memory
cartridge can be installed/removed when powered-on or off.

Accgss door:
lvlode sobctor switch (RUNISTOP)
Anabg adjustrnenl polontiom€te(s)
€xpansbn port (ficr mcl CPUS)

OptiJflal cartsidgs: T€rminsl conn€ctot

EEPROM (re|rFvabts on CPV 224. CPU 226
R6al-timo Clock and CPU 226XM)
Banery
'-
Conrnunications port CIp for inslaltatiqr on a slandard (DlN) rail

Fig. 1 CPU overview

Pagina 3 WINCHDRUM L2-t2-2008

l
2. TD200 operator display

The TD200C operator interface is a text display and operator interface also called MMI ( men
machine interface). The TD200C can hold up sixty-four messages, each containing two lines
of twenty characters . The display is powered by the PLC and don't need to be programmed.

The operator interface shows the payout length (M) in rnetres, linepull (T) in Ton and the
working layer on the drum (L) where 1 is the inner layer on the drum.

fli: ia1a'i"erEg

0.0 T 30.0 T(bs) ffi

0.0 ll 6L
ffiffi
ffiffiffi ffi ffi
ffi
W ffiffi
Fig.2

3. MMI Winch drum Menu

With the TD200 operator interface it's possible to adjust the winch parameters for payout and
Iinepull calculation depended on the working layer and drum parameters like windings per
layer, number of layers, number of pulses per revolution etc.

The menu is activated by pressing the Fl button.

ffi
fr;.'"..,.'::,,,;.3

Drum settings
Cable length L1-L8
ffiffi
ffiffiffi ffi ffi
ffi ffiffi
Fig.3

Pagina 4 WINCHDRUM t2-12-2408

See appendix A for the MNII winch drum parameters and menu structure.

A parameter group can be selected with ENTER. For example; after selecting the drum
parameters the display will corne up with de text;

Fig.4

With the UP and DOWN arrow keys it is possible to go to other drum parameters. For
changing a parameter press ENTER ( the value starts to blink ) and change the value with the
arrow keys. Save the pararneter with ENTER. For leaving the menu press the BSC button.

See appendix B for menu handling.

In the menu it is also possible to select the working screen ( with the linepull, payout and
laver information ).

NOTE! Changing the parameter-value requires a password. When the password is accepted it
is possible to change parameters until a power-off/on situation is passed. To prevent that
anyone can change the parameters you have to release the password acceptant after leaving
the menu. This can be done by;

From the working screen press twice the ESC button. Press the affow DOWN button until
RELEASE PASSWORD is displayed and then press ENTER. See appendix C.

!!! The is 1703 !!!

Pagina 5 WINCHDRUM L2-12-2008

4. Restorins factory defaults

The default parameter values, as programmed by delivery, can always be restored. For
restoring press, from the operator interface working screen with payout, linepull and layer
information, on the SIIIFT button. In the right-bottom corner a S will start blinking. Now
press the F4 button. All parameters are now restored to factory defaults.

5. Preset winch drum from home position

After installing, power failures, cable shortening or whenever the working layer and/or payout
length are not correspondent with the actual situation, the system needs to be preset.
Presetting requires that the actual payout length is known or must be accepted as an indication
as close as possible.

Thirst, the parameter 6.0 - payout preset - must be filled in with de desired payout length.
When the cable is completely on the drum this will be 0 meter. Also make sure that al
parzrmeters from the drum settings are still correct, that means the total layers on the drum (
when completely spoiled up ) etc.

Press the pushbutton on the desk once and the display will show an 0.0m payout length and
preset all parameters to the upper layer of the drum.

Pagina 6 WINCHDRUM t2-12-2008

6. Alarm message's

When an alarm has occurred the alarm sign will start blinking in the right side of the TD200C
as shown below;

rffnss$
0.0 T 30.0 T(bs) m
0.0 li 6L A
ffiil
mmn ffi il
ffi mffi[
Fig.5

Press the F2 button to see which alarm(s) is/has occurred. When more then one alarm is
active" it is possible to see all alarms by pushing the DOWN or UP button. The alarm
message's from group I can be reset by pressing the F3 button ( working layer and linepull
correction can be different from the actual situation ) or by presetting the payout length (
chapter 5 ). Press the ESC button for returning to the working screen.

7. Maximum linenull warning / brake settins

An maximum linepull force catx be set by potentiorneter. When this maximum linepull is
overreached the display comes up with an alarm warning sign and a relay will be activated.
This alarm will open the brake of the winch ( quick release ). The hysteresis of this alarm is
57o of the value. The alarm will not show up or disappear when the cable is on layer 1

The brake setting can be read from the display. The maximum value of the potentiometer can
be changed within the menu ( see appendix A - maximum linepull alarm setting ).

See alarm message's for checking the alarm(s) and chapter 3 for changing the maximum
linepull alarm setting.

It is not possible to reset this waming otherwise than lowering the linepull.

Pagina 7 WINCHDRUM 12-12-2008

8. Manual workins layer override / escort mode

Whenever the working layer isn't correct it can be corrected by manual override. The working
layer is important for calculating the load on the wire from the load pin signal in the band
brake. The manual override can be activated by changing the switch on the desk to escort
mode and the layer selection potentiometer.

The alarm sign ( if not already in the working screen ) will be shown. Increasing or decreasing
the active working layer is done by changing the potentiometer clock- or anticlockwise.
The display shows the manual working layer.

During manual layer override the winch drum rotation will still be counted, so pay out
changes will be seen on drum rotation but the working layer is not changed, otherwise
than manual

The manual override mode can be stopped by changing the switch position from escort mode
to normal. The layer will go back to the working layer belonging to the payout.

9. Pav out cable length net/sross

It is possible to zero the pay out length at every time. Just press F3 and 0.0 meter will be
shown. The working layer will not be changed. All corrections in pay out and wire load will
still be made from the active working layer on the working screen. Pressing F3 again will
shown the gross length again.

Pagina 8 WINCHDRI-]]\4 r2-12-2008

MMI WINCHDRT'M PAR;N{ETSRS

number Parameter

1.0 Total ot layers on drum 5.0 Linepull / layer 9

1.1 Windings per layer 5.1 Linepull / layer.l0

1.2 Windings on lasl layer

Pulses per revolution o,u PayoLlt preset

2.0 Cable length / layer 1 7.0 Maximum linepull alarm setting

2.1 Cable lenglh / layer 2

2.2 Cable lenglh I layer 3
2.3 Cable lenglh / layer 4
2.4 Cable length / layer 5
z.J Cable length / layer 6
2.6 Cable lenglh / layer 7
Cable length / layer 8

3.0 Cable length I layer I

J.l Cable length / layer 10

4.0 Linepull / layer 1

Linepull / layer 2
Linepull / layer 3
4.3 Linepull / lai,€r 4
4.4 Linepull / layer 5
4.5 Linepull / layer 6
4.6 Linepull / layer 7
4.7 Linepull / layer 8

APPENDIX A
MMI WTNCHDRI,M OPERATOR INTERFACE MENU

WORKING SCREEN fENrtf,t

H
T
l-3fl
DRUM SETTINGS Total layers on drum
Windings per layer
Windings last layer
Pulses / revolution

CABLE LENGTH SETTING Cable length / layerl

n
Cable length / layer 10

E LINEPULL SETTING Linepull / layerl

Linepull / layer 10

PAYOUT PRESET Preset drum / payout

ALARM SETTING Maximum linepull alarm setting

APPENDIX B
WORKING SCREEN
UMIITINCIIDRWOPERATORINTERTACEREI,TASINGPASSI{ORJ)

screen

ESC

l
Y
ALARM SETTING
WORKING SCREEN

ESC

I
DISPLAY ALARMS
OPERATOR MENU

r-*E-l
---
|
t I

RELEASE PASSWORD

I
ENTER

APPENDIX C
MMI WINCITDRT'M FAULT / WARNING I{ESSAGES

Group Display Detected problem Causes

Payout / Payin cable length J1W Payin mo\€ment after preset Preset faillure
12W Counter negative (out ot range) Preset faillure
13W Layer out of range Preset faillu16
l4w Counter overllow PLC temp. without supply or drumspeed too high

2 ComDensated load ?1F Amplifier underrange ALM / loadpin faillure

22F Amplifier o\€rrange ALM / loadpin faillure or overload
23F Maximum linepull (userl

3 PLC 31F EM23 ! hardware faillure Hardware maltunction i check plc

F : faillure - laillure will be displayed ( annunciator ) until orror is nol active

W: warning - warining will be displayed ( annuncialor ) until reset / accepted with F3 key

APPENDIX D
Winch drum parameter list
Parameter Value

1.0 )
1.1
1.2
1.3 5

2.0 19.0
2.1 18"0
2.2 20.0
2.3 22.0
2.4 24.0
2.5 25.0
2.6 t.0
2.7 0.0

3.0 0.0
3.1 0.0

4.0 152.2
4.1 135.7
4.2 122.5
4.3 111.6
4.4 102.5
4.5 94.7
4.6 0.0
4.7 0.0

5.0 0.0
5.1 0.0

6.0 0.0

7.O 175.0

Appendix E
Signal transducer for potentiometer
Gharacteristics
Input: potentiometer 0...400 ohms up to 0...100 kohms
Analog output 4...20 mA
Optional output 0...10 V
Supply voltage 24VDC +l'20%
Optionalsupply 12 VDC, 230 VAC or 115 VAC
Zero drift < / 10 K
O,2o/o

Gain drift < 0,1o/o | 10 K

Easy mounting with top hat rail case
Degree of protection lP 20
Adjustment of zero and gain
Low-cost model

Connection

12 VDC | 24VDC

position sensor beginning

position sensor taP
position sensor end

+ (L) - (N) + (0...10 V) + (4...20 mA,0...10 V)

Supply - (0...10 v) - (4...20 mA,0...10 V)

Dimension, note
Note:
When it's because of the technical conditions not
possible to use the whole length of the position
sensor, it is possible to fit the output signal with a
shifting of the zero point and a changing of gain.
Z= adjustment zero
G= adjustment gain
l"'"*
The signal transducer is suitable as an interface adaption between potentimeter (position sensor)
and cdntrol units. The standard output signal of the transducer can be processed, eg with a SPS

ffiri
*'ff'
ll;r .
7
-rt5:
v
:
'f
t
.:

h -H
 Ordering code, technical data

Ordering code

P U X x x x x X X X x
lnput: 0...400 ohms up to 0...100 kohms
Output: 4...20 mA
0...10 v

Supply: 24VDC 0
12VDC (output 0...10 V only) 4
I
230 VAC z
115 VAC 3

Enclosure: top hat rail case lP20

Customized type: on request

Input Ambient conditions

Potentiometer 0...400 ohms up to 0...'100 kohms Nominal temperature 10...40'c
Output Operating temperature 0...60'c
Current 4...20 mA, nominal load <500 ohms Storage temperature -10...70 "c
Voltage 0...1 0 V nominal load >2kohms Mechanics
Accuracy Enclosure syntetic material PA6
Dimension W38xD76xH74
Resolution dependent on position sensor
Gain drift <0,1o/ol10K Mounting top hat rail

TemDerafure coefficient <0,2%t10K Colour black

Degree of protection tP 20
Supply
Weight approx. 80 g (supply DC)
Supply voltage 24VDC +l-20o/o approx. 160 g (supply AC)
Optional 12VDC,230 VAC or 115 VAC Connection pfug-in terminal strip up to 2,5 mm2
Residual ripple 1oo/o

Current consumption < 50 mA with supply 24 VDC

su-Rx-2 Subject to change, version 37-773