Rolls-Royce Marine Hydraulic Deck Machinery Instruction Manual – Winches, Windlasses, Capstans & TOWCON Systems

Description

Rolls-Royce Marine Hydraulic Deck Machinery Instruction Manual

This comprehensive instruction manual covers the operation, maintenance, troubleshooting, and repair of Rolls-Royce Marine hydraulic deck machinery installed on the FELS SETAL 103 vessel (Hull 103, project A-8908). It spans 870 pages of technical documentation, including operating instructions, maintenance procedures, hydraulic schematics, wiring diagrams, parts lists, and assembly drawings for the complete winch system.

File Details

• Manual Type: Marine Deck Machinery Instruction, Operation and Maintenance Manual
• Brand: Rolls-Royce Marine AS, Dept. Deck Machinery – Brattvaag
• Document Numbers: 389-094-00 Rev B, 815-015, 819-030GB, 414332, 324-247
• Effective Date: 30.08.2004 (main parts list); various document revisions from 1993-2004
• Language: English (with bilingual English/Norwegian sections)
• Page Count: 870
• File Format: PDF
• Vessel: FELS SETAL 103 (Hull 103, project A-8908)
• Equipment: Hydraulic deck machinery – winches, windlasses, capstans, pump units and control systems

Chapters Covered

The manual is structured into six main sections plus several standalone technical documents:

• Section 1: Introduction – How to use the instruction manual, worldwide customer support
• Section 2: Technical Specification – Operational conditions, workshop testing, counter flanges, special tools; detailed technical specifications for combined windlass/mooring winch type B842/W6315 and LBFMG63046; tugger winches type LAKMG63015; secondary winch type 50T (ALM63050U); towing/anchor handling winch type BSL300W/SL300W; capstans type CMC41 and CM 4185; pump units; oil cooler; full flow filters; expansion systems; remote control system; surface treatment
• Section 3: Operating Instructions – Main system piping diagram and parts list; symbols for piping diagrams; operation and maintenance of hydraulic deck machinery; the hydraulic power transmission principle; lubrication instructions for open gears with Klüber lubricant; anchor dropping by dynamic braking; hydraulic pumps and motors; control system E12 for motors type M4185, M2202 and M1270; control valve type E2B; safety valve operation and adjustment; full flow filter cleaning; electric motor operation (ABB); remote control servo and electrical systems; TOWCON NT 200 operating instructions; WRC1021 operating instructions; tension control; DTL-NT user instructions; wireless data acquisition system; expansion system
• Section 4: Maintenance Instructions – Hydraulic oil recommendations (ISO VG100); oil sampling procedure; filling instructions; drain/filling system; flushing; closure of open flange connections; general maintenance guidelines; lubrication charts for windlass, towing/anchor handling winch; lubrication system for large gear transmissions; gear wheel alignment; tooth engagement adjustment; welding procedures; flexible roller coupling; wireless torque/force measurement; winch alignment and pouring; mounting instructions for secondary winch, tugger winches, windlass; spooling of wire; wire rope fastener; chain wheel change; brake band support bearings; trouble shooting in general and trouble shooting lists; minor defects and repairs including stuffing arrangements for motors type M6300, MA10, M4185 & MA8
• Section 5: Spare Parts – How to order spare parts; return of spare parts to RRM Brattvaag AS
• Section 6: Drawings – Combined windlass/mooring winch assembly drawings; tugger winch drawings; secondary winch drawings; towing/anchor handling winch drawings (installation, main assembly, gearbox, brake, drum, chain wheel, bearing housing, chain stripper, emergency brake, hydraulic coupling gear, intermediate shaft, spooling gear, chain rollers, lubrication system); capstan drawings; F-valves (shock valve F48, lowering limit valve F92B/F92, intermediate piece F62B-1/F62C-2/F24, overflow valve F46B, pilot valve F122E, manifold F224, non-return valve F207/F239A/F239/F11, change over valve F204/F120C); pump units; oil cooler arrangement; full flow filters; expansion systems; remote control system diagrams including principle drawings, cable diagrams, cable lists, terminal diagrams, circuit diagrams for bridge panel interface, pump room interface, speed control interface, Towcon interface, servo unit, spooling gear; radio transmitter and receiver units
• Lubrication Instruction for Open Gears with Klüber Lubricant (414332) – Preservation at factory and installation at yard; running-in period; operational lubrication; lubricant types and quantities; forced lubrication
• Instruction for Use of Warning Signs (324-247) – Sign sizes, positioning guidelines on winches and pump units, responsibility for signs
• TOWCON NT Monitoring and Control System Manual (815-015) – System layout, workstation, interface board, user controls, CRT monitor, touch screen, trackball operation, screen elements, digital displays, bargraphs, meters, sliders, popup menus, keypad, night color/dimmer, user menu, manual operations, automatic operations (pay-out, towing, hoist), using cable lifters, alarm handling, options including isolation transformer, UPS, slave monitor, additional workstations
• Remote Control User Instruction (819-030GB) – Preparing operation, start of pumps, release brake, long time towing, limitation of maximum pull, connecting drums to motor units, rotate the winch, motor modes (1 cell, 2 cells, 3 cells), command change bridge and deck, tooth wheel lubrication, operating spooling device, emergency stop, emergency release, alarm lamps on control panel, overspeed protection, calibrating joystick for speed control, calibrating knob for tension control
• Screw Pumps Operating and Maintenance Instructions (SN…ER Series) – General information, safety, transportation and storage, description, installation/mounting, start-up/shutdown, maintenance/repair, operating faults and remedial action, dismounting and mounting instructions, spare parts
• Plate Heat Exchanger Manual – Principle and construction, function, mounting instructions, start-up operation stop and troubleshooting, maintenance and cleaning, spare parts and accessories
• ABB Electric Motor Manual – Installation and commissioning, maintenance, increased safety motors EExe II, flameproof motors EExd, prolonged storing, surface treatment, painting repair instructions, spare parts

What This Manual Provides

This is a complete technical documentation package for the Rolls-Royce Marine hydraulic deck machinery installation on the FELS SETAL 103. It covers every major system on the vessel: the combined windlass/mooring winch, two tugger winches, secondary winches, the towing/anchor handling winch, and two capstans. Each system is documented with operating instructions, maintenance schedules, troubleshooting guides, and detailed assembly drawings.

The manual includes complete hydraulic schematics showing the piping arrangement for the entire winch system, with port and starboard distribution, pump units, change-over valves, oil coolers, and expansion systems. Electrical documentation covers the remote control system, including bridge control panels, pump room interfaces, servo units, and the TOWCON NT monitoring and control system with touch screen operation.

For maintenance and repair, the manual provides step-by-step disassembly and reassembly instructions for major components: hydraulic motors, pumps, valves, brake assemblies, clutches, and gearboxes. It includes torque values, clearance specifications, adjustment procedures, and wear limits. The parts lists and assembly drawings allow identification and ordering of spare parts using Rolls-Royce Marine part numbers.

The TOWCON NT section is particularly detailed, covering both manual and automatic operations. Operators can learn how to use automatic pay-out, dynamic towing, and automatic hoist functions. The manual explains how to set wire length limits, tension alarms, pressure limits, and overspeed protection. It also covers the alarm system, trend monitoring, and print-out functions.

Safety information is integrated throughout, including warning signs, emergency stop and release procedures, brake operation precautions, and safe working practices around winches, chains, and wires.

Who This Manual Is For

This manual is essential for marine engineers, deck officers, winch operators, and maintenance technicians working with Rolls-Royce hydraulic deck machinery. It is also valuable for vessel superintendents and technical managers responsible for maintaining anchor handling and towing equipment. The level of detail makes it suitable for both experienced technicians familiar with the equipment and those new to Rolls-Royce Brattvaag winch systems.

Why This Manual Matters

Hydraulic deck machinery operates under extreme loads and in harsh marine environments. Incorrect operation or maintenance can lead to equipment failure, safety incidents, or damage to the vessel. The procedures and specifications in this manual ensure that winch systems are operated within safe limits, maintained correctly, and repaired to the manufacturer’s standards. The troubleshooting guides help identify and resolve faults quickly, minimizing downtime during critical anchor handling or towing operations.

Delivery

IMAGES PREVIEW

This Rolls-Royce Marine hydraulic deck machinery instruction manual is delivered as an instant PDF download after purchase. There is no shipping, no waiting for a physical book, and no risk of a damaged or lost package. The PDF can be viewed on any computer, tablet, or smartphone. Individual pages can be printed for use in the engine room or at the winch control station. The searchable text allows quick location of specific procedures, part numbers, or specifications.