MacGregor Deck Machinery Technical Documentation TK1031 TK1032 – Windlass & Mooring Winch Manual

Description

MacGregor Deck Machinery Technical Documentation for Hulls TK1031 and TK1032

This is the as-built technical documentation package issued by MacGregor Germany for the deck machinery installed on hull numbers TK1031 and TK1032 (client Kouan SY, MacGregor Ref. No. 18.7537+38). It covers the complete windlass and mooring winch installation: the two combined anchor / double-drum mooring winches W1 and W2 forward, the two double-drum mooring winches M1 and M2 aft, the warping heads, chain pipe heads, brake gear and the associated electrical equipment.

The document is written for the shipyard, the operating company, and the maintenance crew who will assemble, commission, run and service this machinery over its working life. It is the reference set that tells you how the winches were built as delivered, not a generic catalogue description.

File Details

• Document type: Technical Documentation (assembly, commissioning, operation, maintenance and spare parts)
• Brand / manufacturer: MacGregor Germany GmbH & Co. KG, Uetersen
• Product: Deck Machinery – windlass / anchor-mooring winches and mooring winches
• Hull numbers covered: TK1031 and TK1032
• Client: Kouan SY
• MacGregor reference: 18.7537+38
• Revision: As built, dated 16.09.2018
• Language: English (drawings include German labels alongside English)
• Page count: 271 pages
• File format: PDF

Chapters Covered

• Section 1 – Important Information: manuals, manufacturer contact, copyright, warranty, global lifecycle support, designations, signs used, safety (intended use, banned modifications, safety equipment, operating surveillance, general and assembly safety, electrical installation, operation and service, hazard zones, ropes, mooring winches and capstans, warping heads, maintenance and repairs, waste disposal)
• Section 2 – Technical Specification: full equipment schedule for the electrically driven deck machinery with auto tension, winch control and winch operation
• Section 3 – Assembly and Commissioning: windlass part assembly manual, mooring part assembly manual with strip foundation, mooring winch assembly manual, brake band tie piece assembly (HWN 00517), welding rules (HWN 00549), lifting instruction
• Section 4 – Windlass / Anchor-Mooring Winch W1 + W2 (drawing 356241): description and operating instructions, anchor operation with chain holding device of non-MacGregor Hatlapa make, slipping clutch adjusting instruction with adjustment diagram, installation drawing, rope fastening, spare parts
• Section 5 – Mooring Winches M1 – M2 (drawing 356242): operation manual for the pole-changing mooring winch with auto tension, installation drawing, rope fastening, spare parts
• Section 6 – Maintenance: maintenance plan, quantity table of lubricating oil and lubricating grease, recommendations for operating supplies, windlass part periodic preventive maintenance, maintenance recommendations for spindle band brakes, preservation instruction, operation and adjustment of the strain gauge amplifier V3.1
• Section 7 – E-Equipment: electrical spare parts, wiring diagrams, contactor cabinet drawings, control column drawings, additional information on three-phase squirrel-cage motors and the electromagnetic spring-set brake (SFB / SFB-H)
• Section 8 – Instructions for Correctly Ordering Spare Parts

Beyond the contents list, this documentation gives a technician the working detail behind each of those headings. The anchor-mooring winch section explains the reduction gear, the main shaft, the strain gauge ring in the bearing of gear shaft III, the multiple-disc safety clutch inside the gear case, and the manual clutch/declutch procedure for the rope drums and cable lifters. The mooring winch section goes through the drive with integrated electromagnetic motor brake and anti-condensation heater, the gearbox, the split rope drums with working and storage parts, the claw coupling, the spindle band brake (both the plain mechanical type and the spring-loaded option), the capstan head and the auto-tension function. The maintenance section sets out the intervals and the lubrication points, and the electrical section carries the as-built connection diagram for each winch, the contactor cabinet layout and the control column schematics.

Equipment Covered

The specification chapter lists the full machinery set as built:

• Two combined anchor / double-drum mooring winches 68U3 / 150 (W1; W2, fore ship), Decco Design – anchor part with 68 mm U3 chain data, water depth 82.5 m, nominal pull 220 kN at 3 m/min and 220 kN at 9.2 m/min, short-period maximum pull 330 kN, brake holding load 1,575 kN, declutchable cast steel cable lifter with stainless steel brake rim (SUS 316); split-type rope drums prepared for brake test kit (25/50/75/100%) with stainless steel brake rim surface; non-declutchable warping head 640 mm diameter x 560 mm length with 37 m/min slack hawser speed
• Two chain pipe heads for 68 mm U3 stud link chain (loose supply)
• Two double-drum mooring winches 150 (M1; M2, aft ship), Decco Design – polypropylene rope 64 mm diameter, 200 m, required MBL of rope 547 kN, split-type drum 508 mm / 330 mm and flange 750 mm / 1,100 mm, working part 25 m, storage part 175 m, nominal pull 150 kN at 5 m/min and 150 kN at 16 m/min, slack hawser speed 32 m/min with 5 m/min adjustable pull, static holding load 438 kN, stainless steel brake rim (SUS 316); warping head 640 mm x 560 mm with 37 m/min slack hawser speed
• Drive: three-phase AC squirrel-cage pole-changing motor with built-in electromagnetic brake and anti-condensation heating, form B5, 12/4/2 poles, duty S2-5/30/10 min, insulation class F, 16/48/48 kW, IP56, 440 V 60 Hz, weight approx. 600 kg per motor
• Contactor cabinets placed below deck with anti-condensation heating, IP54, ammeter and running-hour meter
• Control stations: single control stand (IP56) per winch W1, W2, M1, M2, plus one double control stand (IP56) per ship side, each with heating element, master switch for speed and direction, analogue tension/current indicator (0-200%), take-over and emergency-stop buttons, ready/disturbance indicator lamps and a manual / auto-tension selector (25/50/75/100%)

What This Documentation Enables

With this file in hand, a deck crew or shipyard team can assemble the winch halves in line with the installation drawing, check the claw coupling alignment (maximum height and lateral offset 0.5 mm, maximum angular offset 0.5 degrees), set the air gap between winch and foundation at the recommended 30 mm, weld the stoppers and brake band tie piece correctly, fill the gearboxes to the middle of the oil level glass, and get the rope onto the drum with the correct winding pattern.

It also supports the continuing jobs: adjusting the slipping clutch on the windlass so it slips when the anchor is in front of the hawse hole at nominal speed, checking the slip torque test by test, bleeding down the multi-plate slipping clutch, maintaining the spindle band brakes, reading the strain gauge amplifier set points (OFFSET 4 mA at 0 load, SCALE 12 mA at 100% load), and troubleshooting the control system using the fault tables and wiring diagrams.

The maintenance plan gives inspection and lubrication intervals from before each operation through monthly, every two months, yearly and 24-month intervals, with the first gear oil change 500 working hours after commissioning (at least after 9 months). The spare parts lists in each section are keyed to drawing numbers, so parts can be ordered against a specific position rather than by description alone.

Why It Matters

Deck machinery operates under heavy loads, and the documentation itself is explicit about the hazard zone around a rope or chain under pull, the safe working distance from a warping head, and the fact that the brake holding load on the windlass part is set to 45% of the chain breaking load. Working from the manufacturer’s own procedures and the correct tightening torques, air gaps, slip settings and lubrication data is what keeps the equipment inside its design envelope and the crew out of the hazard zone.

Because the winches are electric with an integrated motor brake, a multi-disc slipping clutch in the gear case and a PLC-based auto-tension function, the electrical and control side of this documentation is as important as the mechanical side. The wiring diagrams, contactor cabinet layouts and PLC input/output tables give a technician the actual as-built configuration for these hulls.

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Instant Delivery

This MacGregor Deck Machinery Technical Documentation for TK1031 and TK1032 is supplied as a PDF download. There is no shipping and no waiting – the file is available as soon as checkout completes. You can open it on a laptop, tablet or phone, zoom into the drawings, print the pages you need for the workshop or engine room, and keep a working copy on board while the original stays safely archived.