Лебёдка стингера PDF

2000/3000t Pipe-laying Vessel45T Stinger Winch handbook
CATALOGUE
1 SPECIFICATION ...........................................................................3
1.1 Summary ..............................................................................................3
1.2 Main parameter ....................................................................................3
2 OPERATIONAL SAFETY ISSUES...............................................3

2.1 Preparations before running .................................................................3
2.2 Attention after running........................................................................4
2.3 Mounting base......................................................................................4
3 INSTRUCTIONS OF ANCHOR WINCHES ..................................4

3.1 Motor....................................................................................................5
3.2 coupling................................................................................................5
3.2 High speed brake..................................................................................6
3.3 Reducer.................................................................................................6
3.4Gear .......................................................................................................6
3.5 Limit device .........................................................................................6
3.6 Drum device .........................................................................................8
3.7 Band brake ...........................................................................................8
3.8 Pawl......................................................................................................9
3.9 Spooling device..................................................................................10
3.9.1 Spooling gear adjust procedure....................................................11
4 ATTENTIONS OF MAINTENANCE.............................................12
4.1 General attentions...............................................................................12
4.2 Disassembly and assembly................................................................13
4.3 Special attention ...............................................................................13
5. MAINTENANCE ........................................................................16
5.1 Operation...........................................................................................16
5.2 Management ......................................................................................16
5.3 Maintenance and overhaul .................................................................18
5.3.1 Attentions of maintenance ..............................................................18
5.3.2 Maintenance record.........................................................................18
6. ABRASION OF WINCHES.........................................................29
6.1 Mechanical parts ................................................................................29
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6.1.1 Shaft............................................................................................29
6.1.2 Gears.............................................................................................29
6.1.3 Brake ...........................................................................................29
6.1.4 Wire rope.....................................................................................30
6.1.5 Bearing ........................................................................................30
6.1.6 Steel structures ..........................................................................30
6.2 Electrical parts (refers to <Electric Manual>) ...................................30
7 RUST PROTECTION OF SPARE PARTS ..................................30

7.1 Mechanical parts ................................................................................30
7.2 Electrical parts....................................................................................31
8. COMMON FAULTS AND DEBUGGING ...................................31

8.1 Detecting faults and damage ..............................................................31
8.1.1 Mechanical parts ..........................................................................32
8.1.2 Metal structures ............................................................................32
8.1.3 Electrical parts.............................................................................33
8.1.4 Hydraulic system..........................................................................33
8.2 Causes and solutions ..........................................................................34
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1 Specification
1.1 Summary
This stinger winch is manufactured for shallow working, it’s according to

specifications and contract.
The rated static load is 45t(8th layer), line speed is 10m/min.
Power: 440VAC/60Hz/3
Various limit switches, interlockers, overspeed protectors etc. are
supplied to ensure the integrated capability of anchor winches.
1.2 Main parameter
a) Rated load and line speed:

Speed: 45t (1st layer) 0~10m/min
b)（Hold load (for band brake) ： 98MT (3rd layer)
c) I Bottom diameter of drum： φ800 mm
d) Wire rope diameter： φ44 mm(+1%~+3%)
e) Capability： 700 m(in all 9层)
f) Work space and freeboard
Length x breadth x height 4005mmx3200mmx1990mm
Side freeboard >=600mm
2 Operational Safety Issues
2.1 Preparations before running
Check the items below carefully before operating winch.
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1) Confirm oil pressure and air pressure are normal;
2) Confirm pawl is open. Winch cannot run at closing state.
3) Check gearbox oil and lubrication points for anchor lines
4) Confirm switches and control handles of electric installation are at correct positions.
5) Confirm power supply and voltage are normal.
6) Do short-time test running first, to confirm safety device and limit switches are
normal.
2.2 Attention after running
1) Return control handles and switches to the appropriate positions at the local station
and anchor winch console in operator’s cabin.
2) Turn “OFF” the power switches.
3) Check all power supplies for the next use.
4) Check and correct any faults prior to the next use.
2.3 Mounting base
Proper function of the mounting base is essential to assure normal operation of the anchor
winch. The mounting base structure should be checked frequently to confirm that there
are no loose bolts, as long-time running may loosen the joint bolts. Any loose bolts
between the barge mounts and the anchor winches shall be tightened.
3 Instructions of Anchor winches
General situation
Machine device refer to darwing.
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1 frame 2 motor 3 coupling 4 high speed 5 reducer 6 pinion 7 limit

device 8 gear 9 drum 10 band brake 11 pawl 12 spooling device
3.1 Motor
IP55/Protection level:F
AC440V/60Hz/3P
Power: 90kw
Rated speed: 1500rpm
3.2 coupling
Type : PGCLK06-500
Operation and maintenance refers to” ZPMC_PGCLK.pdf”
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3.2 High speed brake
Type : YP21-800-500*30
Operation and maintenance refers to” the Operating Instructions Of

YP11.21.31.41（E).pdf”
3.3 Reducer
Operation and maintenance refers to” Instructions Of

FH1005.141.F1B-00.doc”
3.4Gear
Both forged from high quality material, tooth surface : quenching and tempering
HB240~320;
Gear covers with inspection access;
The lubricating use lubricating grease,it take selfoiling.
The gear pair’s normal back lash(min-max):0.54mm-1.08mm,contact area less
than 70%.
If the back lash exceeds limits, stop and adjust.
3.5 Limit device
Machine device refer to darwing.
The device include transfer case, limit cam, overspeed switch, absolute
value coder etc,main function check the length of steel rope and limit
manchine action
The device must adjust by professional person,any unpreofessional
person can not adjust and nodification, it’s dangerousness.
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1 transfer case 2 limit cam
3 overspeed switch 4 absolute value code
5 reducer
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3.6 Drum device
Buildup: main shaft, drum with one side fixed by Bull gear, bearing house etc.;
Lebus groove
Bearing block is fixed at one end，unfixed at one end,when you check, notice.
3.7 Band brake
Type : HBBJ1500-400
Operation and maintenance refers to” Instructions Of HBBJ1500-400

E.pdf”
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3.8 Pawl
Buildup: ratchet wheel,oil cylinder, pawl, limits etc.
When piston rod push out,it’s close,on the contary it’s open.
If pawl is inadequately opened or misaligned with the ratchet wheel, limits will
detect and send corresponding command via control system to stop the winch and
prevent it from running. Check faults.
The device must adjust by professional person,any unpreofessional
person can not adjust and nodification, it’s dangerousness.
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3.9 Spooling device
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Slide bushing component part reference diagrams

The spooling gear’s summary compose refer to the diagrams
In order to ensure spooling gear work well, when you adjustment, please refer to
this procedure.
3.9.1 Spooling gear adjust procedure
Before drum is enwinded by wire rope:

a The tooth of between adjustment panel and double screw rod is come away.
b The double screw rod shoud be adjust to ensure the slide bushing component
vertical(ensure slide bushing’s error <=3mm).then the synchronous chain is installed.
c Test run the double screw rod by hand, the upper screw and nether screw should
be synchronization,if not, the quadrant link must turn an angle to adjust(the laevogyrate
groove instead of dextral groove,or contrariwise do).
d Test run the double screw rod one circle by hand,if it is unhindered run,you must
adjust two frames’ relative position, to ensure two frame’s parallel less than 0.2mm, or
until it is slip agility.
e Turn the adjustment panel by hand,it bring along the double screw rod,the
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crosshead is set right limit or left limit(generality it begin from the side of gearwheel),
first time ,after the botton wire rope circle drum,when the out rope just at leftmost or
rightmost,the slide bushing is moved by hand,it make the wire rope through two roller
and the direction of out rope parallel with the crack of roller.
f The tooth of between adjustment panel and double screw rod is closed,the shaft
end plate should be full install,then test several cirle,it must be right.
3.10.2 maintain and service
1 There is enough lubricant grease in the surface of double screw rod (part
6),there is enough lubricant grease in the surface of chain .
2 The quadrant link can smooth run, the quadrant link must hold enough grease.
3 Long time no use, there is enough lubricant grease in the surface of double
screw rod (part 6) and it must be packed.
4 When frist time to use or change the wire rope ,it must be adjusted by this
instruction.the wire rope must accord to maritime works and this instruction,or else it
would occur the spooling device and durm out of step.
5 If the wire rope is damaged but still coercive use and the spooling device and
drum out of step,the stick must be removed.
6 After it use a period of time, the sag of chain must be checked, the sag of chain
is 0.2a(a means the distance of chain wheel.)
7 After it use a long time, even the tension pulley has been adjusted ultimate
place,the sag of chain can not accord the criterion place.please removing one or two
chain links.
4 Attentions of maintenance
4.1 General attentions
Lubrication:
Remove all used oil when changing oil. Add oil according to the appendix
instructions of all parts.
Lubricating oil (especially grease) can’t be mixed, because different thickness may
cause clogging which will induce the bearing burning.
damage
Normal wear-and-tear will not seriously compromise the function. However, the
important parts (such as gears) can affect normal operation and capability when wear
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becomes excessive. Gears and other parts should be checked periodically to confirm
no evidence of pitting, uneven or excessive wear. If such damage is detected, make
arrangements for replacing at the next major maintenance period or immediately
when justified.
Check for loose parts
Check the connection and fastening of parts for any loose nuts or bolts.
Pay special attention to the bearing bolts and gap-adjusting bolts.
Brake:
Inspect the brake once a week and when the brake does not seem to work properly.
Keep the gap between the brake disc and the brake friction pad in the range of
0.5~1.0mm.
Operate and inspect the action of the brake.
5) Limit switch and encoder:
Check the state of limit switches and encoders before running.
Operate at a slow speed to check the decelerating and stop limits.
4.2 Disassembly and assembly
Disassemble or assemble according to the operation instructions to avoid damaging

any parts. Contact the suppliers for information to repair the motor, brake, reducer
etc.
4.3 Special attention
If the winch has not been running for a long time or has just been disassembled or
assembled, perform a no-load running test first. Check the running status and
lubricate the reducer and bearings thoroughly before loading.
Maintenance items and periods
1、All parts
a) Bolts loosening:
Check the bolt torques once a month, particularly in 7 days after first running.
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Use proper spanner to fasten the bolts when checking.
Period: daily and once a month
b) Lubrication
Add oil properly according to “Lubricant Selection Table “(in appendix A).
Period: daily.
2、Electric motor
Inspect for any abnormal heat.
2) Listen for any abnormal noise inside the motor.
Check for loose bearings and motor mount
3、Reducer
Check the existing oil volume through oil sight glass.
2) Check for leaks.
3) Check for abnormal temperatures.
If cover’s temperature exceeds ambient temperature more than 50℃(120 °

F), check the inside of gearbox.
1) Check for abnormal noise.
If there is any abnormal noise, check the inside of gearbox.
2) Other details refer to the manual.
Period: daily
4、Coupling
Check for loose bolts.
Period: daily.
5、Drum assembly
Check for loose clamps.
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Period: daily
6、Rolling bearings
1) Check for any abnormal temperature rising.
Temperature limit: ambient temperature less than 50℃ (120°F).
Period: daily
2) Check for any abnormal noise.
Period: daily.
3) Check for loose bearing bolts.
Period: daily.
7、Limit switch
Mechanical parts lubrication
Period: weekly.
2) Abrasion of the gears
Period: weekly.
3) Switches work normally:
Period: daily
8、Brake disc
Check if abrasion of the brake disc is over the limit.
Replace the disc if the thickness abraded more than 20%.
Period: monthly.
1)Is the surface damaged?
Lathe surface if the irregularity is over 2mm in size.
Period: monthly.
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1) Check for abnormal temperature rising.
1) Check for damage.
1) Check to confirm no hydraulic oil on friction pad or disc brake.
Pay special attention to any tiny crack.
9、Wire rope
Inspect for any damage. See Maintenance Manual No. 3.
2) Check wire rope end connections.
3) Inspect sheaves for proper operation.
Period: daily.
5. Maintenance
5.1 Operation
The winch cannot run, when the pawl is set due to the interlocking limit switch.
Never override the limit switch except in a special situation.
5.2 Management
The electric sets are operated by advanced programs. Operate in turn according to the
“electrical system operational manual”.
2) Check the limit switches of all mechanical parts well before running.
3) Pay attention to the bolt torques, especially the main lifting set and pitch set. The
bolts of these two sets endure most loads.
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4) Ensure the proper space between disc brakes and brake pads to avoid premature
wear and to assure proper operation. Keep the space about 0.50~1.0mm.
5) When using new wire rope, adjust the cam limit switch frequently. New wire rope
will be elongated if tensioned.
6) Replace the part if it abrades to its limit.
7) Check the ends of wire ropes, and check bolt torques at drum connections.
8) When replacing wire rope, avoid damaging the screw thread of the drum clamp.
9) After assembling and before running, re-torque the main bolts again. Otherwise it
may induce mechanical loosing, vibrations and overheating which will shorten the
winch life.
Re-torque the main bolts and nuts according to the following schedule. Re-torque
Schedule：
Aft. 7 Aft. 14 Aft. 1 Aft. 3 Aft 6 Aft 1
days days month months months year
Rmks
Motor bolts ＯＯＯ
Brake bolts ＯＯＯ
Brake jointing disc bolts ＯＯＯ
Reducer bolts ＯＯＯ
Shaft bolts ＯＯＯ
Base bolts ＯＯＯ
Drum bolts ＯＯＯＯＯ
Clamp bolts ＯＯＯ
Control cabinet joints ＯＯＯ
Operational box joints ＯＯＯ
Limit switch joints ＯＯＯ
Hydraulic piping ＯＯＯ
Notes ：
In the preceding list, “O” means check this item. If no loosening occurs in serious
condition, check period can turn to 1 year. If loosening occurs, make a proper check
plan. Proper management of bolts and nuts will ensure proper torque and prevent
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loosening.
5.3 Maintenance and overhaul
Maintenance is to assure operational capability and reliability of winches, as well as

to prevent accidents.
The person who is responsible for preventing accidents should think of maintenance
and overhaul, as well as suggesting repair and replacement of all parts,
Maintenance includes daily and periodical checking. Otherwise, when predicting a

storm, take precautions and then deal with the problems caused by the disasters.
5.3.1 Attentions of maintenance
1) Become familiar with the instructions and recording charts before inspecting.
2) When maintaining, checking or overhauling, inform concerned persons who may

be in the area and abide the following rules.
Well-marked warning board such as “Checking!”, “Repairing!” to prevent

people getting into the working area;
Lock-out and mark warnings on power switches when power is cut off for
maintenance and repairs. No one is allowed to touch the board or switches
except the person who locked out and marked the warning. Check carefully
again before power on.
No walking through the wire rope line when a winch is working.
5.3.2 Maintenance record
Use the following sheets to inspect and record any problems with the winch.
These records can assist in maintenance and reconstruction.
Daily check item
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The operator or mechanic will check these daily to avoid accidents:
Safety and capability checking before work;
Check Item Methods

1. Wire rope break, clamp loosing Inspect
2. Disc brake status Inspect
3. Repair status after correcting faults Action
4. Brake motion Start
5. Instruments and indicator lights Start
6. Control handles and button motion (off/on, start/stop,
Start
close、emergency stop, etc.)
7. Limit switches adjusted for proper operation and motion. Start
a) Inspect when operating, and stop if there anything abnormal;
Check Item Methods

1. Abnormal noise, smell, heat, vibration Inspect
2. Abnormal voltage and current Inspect
b) Stop at the right position after work and check again.
Check Item Methods

1. Operational handle at “Stop” position Inspect
2. Hydraulic pump, pipes and hosing leaking Inspect
3. Bearing and gears lubrication Action
4. Abnormal heat Inspect
5. Mechanical cracks and damages Inspect
6. Power switches at “off” position Start
7. Cleanliness Inspect
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8 .Record condition of winch Action
c) Weekly check item
The operator or mechanic will check these weekly to find anything abnormal:
Check Item Methods

1. Bearing abrasion and bolts loosening Inspect
2. Pins, bonds, end plates loosening Inspect
3. Power cable twisted, damaged, insulation cracked and connecting Inspect
terminals loosening or corroding
4. Switches, indicator lights working properly Action
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d) Monthly and annually check item
The operator or mechanic will check the important parts monthly or annually
and suggest disassembly maintenance (which includes repairing problems found
in daily and weekly checks:
Item Monthly Check Item Annual Check Item

BASE 1. Bolts loosening 1.Weld cracks
1. Bolts loosening 1. Steel corrosion or wear
FRAME
2. Weld cracks 2. Paint flaking and cracking

3. Steel distortion, cracks 3. Pin, shaft abrasion
4. Pin, shaft lubrication
1. Abnormal noise, heat, vibration 1. Shell cracks
2. Engaging surface status 2. Bond loosening
GEARING
3. Lubrication 3. Keyway distortion

4. Oil enough? leaking? 4. Oil grime
5. Bolts loosing
1. Abnormal noise, heat 1. Any metal mixed in oil
MECHANICAL SYSTEM
BEARING
2. Abrasion and crack 2. Pin and bushing gaps

3. Bolts loosening 3. Abrasion
1. Abrasion and crack
SHAF
2. Bond loosening
3. Keyway distortion
T
1. Distortion
BOND
1. Clamp loosening 1. Groove abrasion

DRUM
2. Groove abrasion
3. Bolts loosening
4. Weld cracks
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SHEAVE 1. Rotating status
2. Cracks
3. Groove abrasion
1. Single-strand breaks
2. Abrasion or damage
WIRE ROPE
3. Kink and distortion

4. Loosening of pretension
5. Protective grease
6. Rust and erosion
MECHANICAL SYSTEM
7. Rope ends status and clamping

1. Grease dirty, aging, color-turning
OIL SUPPLY
2. Lubricating parts
3. Piping break and leak
1. Oil contamination
2. Filter cleaning
HYDRAULIC SYSTEM
3. Oil pressure
4. Abnormal noise, heat in pump, motor
5. Valves adjusting and action
6. Oil cylinder motion
7. Piping break
8. Leak
9. Bolts loosening
1. Motor dirty or oily 1. Lubricating status of bearing
2. Bearing working status 2. Air gap
ELECTRIC MOTOR
3. Mechanical break(base, end plate 3. Duct block, fan and cooling

crack，shaft break or distortion) fin in good condition
4. Lead wire insulation 4. Anti-shock rubber aging
5. Abnormal noise, heat, shake, smell 5. Insulation resistance
6. Bolts loosening and rusting
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ELECTROMAGNETIC BRAKE 1. Brake abrasion and color-turning 1. Brake disk and disc abrasion
and color-turning
2. Gap between disc brake and 2. Bond loosening
friction pad
3. Brake abrasion and roughness 3. Dust stack
4. Brake disc crack 4. Electro-hydraulic push rod
worn or leaking
BRAKE
5. Rod pin lubrication 5. Electro-hydraulic power set

ELECTRO-HYDRAULIC PSHROD
gets weak with aging

6. Brake torque (spring) reaches the
nominal rating
7. Rod, pin, bolts loosening, break
BRAKE
8. Oil pressure status

9. Oil mass status
10. Rod working stroke
11. Abnormal noise, heat, vibration,
odor
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1. the crack and damage of grid 1. Abnormal heat of grid
RESISTOR
2. Bolts loosening of grid 2. Grid dirty
3. the crack and damage of insulator
4. Bolts loosening
1. Joy stick contact shoe abrasion 1. Free position limiter action
2. Joy stick combine flage bolts
loosening
3. Joy stick center verticality
JOY STICK
4. Trouble-free operation
5.Bearing gear and roller lubricate
6. Contact shoe state
7. Bolts loosening
1. Contact state 1. Configuration bolts
loosening
2. several rod lubricative state
2. Contact reverse spring state and rusty state
LIMIT SWITCH
3. Bolts loosening 3. Limit switch dustproof,

damp-proof
4. Gear state and loosening 4.Limit switch gear and shaft
abrade
5. Throw rod operate condition 5. Key loosening
6. whether induction coil is damaged
whether distance is displacement
1. Contact state 1. Switch box insulated state

BUTTON
2. Bolts loosening 2. Switch box rust

SWITCH
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SIGNAL 1. Lamp light or not
LAMP
2. Bolts loosening
1. roughness and abrasion of contact 1. Lubrication of knife switch
RELAY AND ELECTROMAGNETIC CONTACTOR CLOSING SWITCH,ZERO
OVERVOLTAGE RELAY
part contact
AND AIR-BREAK ETC.
2.Gemel of knife switch and binding 2. Insulation resistance

PHASE-SEQUENCE
post touch or not determine
3. Rating capability of fuse

4. Air circuit breaker(zero sequence
CONTROLLER AND DISTRIBUTOR BLOCK
overvoltage relay)mold damage

5. Bolts loosening
1. Contact state(crisscross) 1. wire-break and braided

wire of wire
2. Abnormal state of arc box and arc 2. Fixed state of connection
groovy point
3. Electromagnet beat 3. Abnormity of flexible cord
coil
4. Lack and damage of insulating 4. Resistor and resistance of
bush etc. electromagnet
5.State of movability mandrel 5.Dirty of structural details
suction side and surface of coil and electromagnet
6.Ordain time of time delay relay 6. Rating set point of thermal
relay and overcurrent relay
7. Rust of plunger in the overcurrent
relay
8. Bolts loosening
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1. Instrument parts affirm 1. Error of instrument
CONTROL BOX AND PC BOX
MISCELLANEO
INSTRUMENT
2. Abnormal heat,turn clolrs,crack of

meter transformer and convertor 2. Board canker and defile
AND
3. Leak or not
4. Bolts loosening
1. Contact state of conposite type 1. Error state of printing plate
SEMICON
DUCTOR
teminal and parts

2. Dirty of printing plate and parts 2.Rating output
3. All kinds of resistor set
points
1. Space of collector ring 1. Fixed state of carbon brush
SLIP-RINGS
2. Roughness and abrasion rotor 2.Current collector spring

state
3. Abrasion of carbon brush 3. Decentration or not
CURRENT SUPPLY DEVICE
4. Crack,damage,grime of insulator 4. Insulationg resistance

determine
6. Lubricant state of machine parts
1. Cable oriented operate condition
BOBBIN
2. Lubricant state of structure

CABLE
DISK
division
1. Rubber insulation damage

INSULATION
2. Abnormal bend, contort,tensile

superposition of cable
RUBBER
CABLE
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1. Dirty 1.Braided wire is break or not
TERMIN
AL
2. Bolts and connector loosening 2. Damage ofstructure division
3. Abnormal state of cable inlet
1. Insulation resistance of
RESISTANCE
INSULATION
every circuit
200v more than 0.2MΩ
400V more than 0.4MΩ
600V more than 10MΩ
1.Fixed part loosening of junction 1. Wiring damage
BOX WIRE AND INBOARD WIRE
2.Intrusion of outdoor junction

2.Wiring break
3.Terminal parts loosening 3. Terminal parts break
4. Crack of pressure wading
terminal
5. Wire size dirty
6. Wire dirty
7 Crack,damage,fixed of
trunking andconduit
8. Cable tie loosening
1. Damage of machine 1. Fixed state of base
LIGHT
2. Terminal parts loosening

3. Lamp lingt or not
1. Audible alarm 1. Fixed state of device setting

COMMUNI
-CATOR
ALARM
1. Action of machine
ATOR AND
WARMING
REFRIGER
MACHINE
2. Fixation of machine
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1. Terminal parts loosening 1. Dust of coil
TRANSFORMER
TRANSFORMER 2.Abnormal noise, heat, odor 2. Rust of mandrel

DRY-TYPE
3. Bolts loosening 3. Ground connection

4. Crack,damage,grime of
insulator
5. Insulationg resistance
determine
1. Leaking 1. Insulationg resistance
determine
POWER CAPACITOR
2. Action of discharge device 2.Distortion, damage of

capability
3. Rating capability of fuse element 3. Crack, damage of insulator
4. Ground connection
4. Abnormal noise, heat, odor
5. Bolts loosening
ELECTRIC SAFEGUARD
1. Action place of limit switch

LIMIT SWITCH AND
EMERGENCY STOP
SAFEGUARD
1. According to the standard of 1. According to the standard

ACCESSO
WINCH
machine to inspect of machine to inspect

RIES
FIX
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6. Abrasion of winches
Control the abrasion limits of main parts as it shows below.
6.1 Mechanical parts
6.1.1 Shaft
1) Clearance between shaft and bearing shell

10~ 16~ 25~ 40~ 64~ 100~ 160~
Diameter <10 >250
16 25 40 64 100 160 250
Gear shaft 0.6 0.8 1.0 1.2 1.6 2.0
Others shafts 0.3 0.4 0.6 1.0 1.6 2.0 2.5 3.1 4.0
2) Clearance between shaft and rolling bearing according to the tolerance in the
blueprints. No abrasion is allowed.
6.1.2 Gears
Tooth flank abrasion
1) Hard tooth flank:
First stage: 20% of hardened layer.
Rest stage: 40% of hardened layer
2) Open gear
10% of tooth profile.
6.1.3 Brake
1) ) Brake disc abrasion
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50% of normal thickness, or keep >1mm space close to the setscrew.
2) Unexpected abrasion on the brake disc
Modify if the roughness reaches 1mm.
6.1.4 Wire rope
Aging: too many broken wires, a broken strand, diameter worn more than 3 mm (no
significant kinking, distortion and corrosion).
6.1.5 Bearing
Bearing house: check after 12500 hrs.
6.1.6 Steel structures
1) Erosion: 10% thickness.
2) Painting: 10% painting chipping, flaking, cracking, scarred.
6.2 Electrical parts (refers to <Electric Manual>)
7 Rust protection of spare parts
7.1 Mechanical parts
Spare parts should be put into operation as soon as needed. Storage protection is
very important.
1) Keeping place:
Avoid from high humidity, direct sunshine. Keep in the shady place.
2) Anti-rust oil change:
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Although spare parts are all oil-coated, the effect can’t keep long. So check it
every 3 months and smear new oil.
3）Keeping method:
Smear anti-rust oil, and then pack the spare parts to prevent
oxidation.
7.2 Electrical parts
1) Keeping place:：
Avoid high humidity, direct sunshine. Keep in a shady place.

2) Anti-rust oil change:
Although spare parts are all oil-coated, the effect can’t last long. So check it every
3 months and smear new oil.
3) Keeping method:
Smear anti-rust oil, and then pack the spare parts with desiccant and seal with
polyethylene film to prevent air circulation.
8. Common faults and debugging
8.1 Detecting faults and damage
Anchoring winches are used for holding the floating crane barge in position.
After working for a period of time, abrasions and wear and tear can cause excessive
clearances that will decrease reliability and safety. The fatigue of main parts can
cause sudden failures, which can endanger the winch and personal safety of those
working nearby.
The operator and mechanic must know how to estimate the common faults of the
winch and find the cause by analyzing the abnormal phenomena. They should detect
and repair the winch in time to assure reliable and safe operation.
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8.1.1 Mechanical parts
Every machine consists of mechanical parts, including winches.
Mechanical parts are mostly from motor, brake, reducer, sheave, drum, coupling
etc. The interface abrades when working. When the abrasion accumulates to some
extent, faults come.
Brake is one of the most important parts on the winch, which is directly
concerned to the working accuracy and safety. Any fault of brake may bring danger,
so check it every run. If the gap exceeds limit, stop and adjust it. Most brake faults are
caused by misadjusted gap between friction clamp and brake disc. Sometimes the
hydraulic handspike (brake cylinder), incorrect setting of brake torque or brake pad
or disc abrasion will cause the brake not to work or work unreliably.
Reducer is used to under speed and transfer torque, the quality of which refers to
the working safety. After working for some time, the tooth flank pitting and abrasion
will breed abnormal noise, with unbalanced working, vibration and heating. Stop
and repair when such a phenomenon occurs.
Coupling is used to transfer torque without speed changing. Coupling includes

fast coupling and slip coupling. A cinquefoil coupling is used in this project, which
has greater axial, radial, angle compensation. This kind of coupling doesn’t need
lubrication (less maintenance and longer-term running).
Sheave and drum are both rotating parts, so their bearings friction should be as
tiny as possible. A common problem is groove abrasion from the wire rope on the
drum. The main cause is failure to maintain proper pretension on the wire rope at all
times during use. When the wire rope wraps in the grooves loosely, the wire rope is
tensioned and impacts the grooves while also damaging the rope. Relative friction
also occurs between ropes and sheave or drum grooves. The wire rope also abrades
the peak of drum grooves. When excessive wear and abrasion of the drum grooves or
sheaves occurs, they should be repaired or replaced to avoid damaging the wire rope.
A damaged drum or sheave flange may damage or seize the wire rope, leading to
breaking of the wire rope or components.
8.1.2 Metal structures
The quality of metal structure affects safety. Structural damage can cause
serious accidents. The design of metal structure must be qualified for the strength,
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rigidity and stability demand.
Structural distortion or bolts loosening will cause the bolts to break.
Welding quality or cracks also impact the normal operation.
8.1.3 Electrical parts
According to the work characteristics of winches, the motor should have high
mechanical robustness and overload rating; sustain mechanical vibrations and
impact; have a small moment of inertia; enable quick start and stop. If there is any
abnormal noise as friction, screech or other hum, stop and check. Never let water or
oil get inside of the motor when working. The main faults of motor: cannot start,
overheat, power cannot reach the rated value. Electric parts are very complex.
Serious work condition as vibration, impact and swinging often brings faults,
especially working at high temperature, dusty and wet condition. The faults will
influent production and even cause accidents. Electric equipment includes: motor,
controller, resistor, protective disc, conductor etc. More details refer to <Electric
Manual>.
8.1.4 Hydraulic system
Hydraulic system fault is inevitable during working process. The faults can be
divided into paroxysmal and abrasive. Paroxysmal faults such as pump burning
loss, components broken, piping broken etc. These are always be concerned with
manufacture, assembly and operation. The faults often occur at first or medium
work-term. Abrasive faults such as seal failures, work speed slow down etc. These
are always be concerned with mechanical abrasion. The faults often occur near the
end of the useful service life of hydraulic components. Good maintenance and
preventing contamination of hydraulic oil always brings less abrasive faults. To
extend the hydraulic system service life and keep good service behavior for
long-term, not only obey the operational rules to avoid paroxysmal faults, but also set
up a necessary daily maintenance system to reduce the abrasive faults. More details
refer to <Hydraulic manual>.
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8.2 Causes and solutions
As it shows below, causes and solutions of normal faults:

Fault CAUSE SOLUTION
Abnormal intense Lack of lubricating grease Add lubricating grease
heat in rolling
Contamination in bearing Clean bearing with coal oil,
bearing
then add lubricating grease
Abnormal noise in Bad assembly, skew or Check the assembly and
rolling bearing over-tightened make the bearing adjust or replace bearing
lock, causing damage or abrasion to
some parts
Recurrent Gear pitch inaccuracy over limit; Repair and reassemble
vibrating noise black lash over limit
noise in gearbox,
esp. the engaged
gear wheel
Sharp metal Clearance of gears not enough, gears Repair, reassemble or replace
scratching noise in not centering; peaked crest edge;
gearbox with tooth flank abraded unevenly
vibration (concave and convex )
Irregular but Flank defective (lamellar structure) Replace
continuous slaps
when engaging with
the shell shaking
Gearbox heating Too much lubricating oil Control the oil mass under
the limited line.
Too much noise Gear over abraded Replace gear
with impulse
Rubbish in gear box Get rid of the rubbish
sound in gearbox
Bearing break Replace bearing
Bearing overheat Contamination in bearing Clean bearing
Clearance not enough Adjust clearance
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Oil loss -break Add oil according to oil sight
glass
Brake cannot close Active joint in leverage block Clean brake, remove any
blockage, add oil to the joint
Brake disc is stained with oil Clean the brake disc, brake
shoe or brake band by coal oil
Brake shoe or brake band over Replace the brake shoe or
abraded brake band
Main spring broken or loose causing Replace spring or adjust

tensile force reduction regulating nut to make the
tension normal
Lever locknut loose, lever movable Adjust the lever and screw
down the locknut
Brake cannot open Main spring tensile force overtop Adjust the spring tension
Hydraulic pushrod broken Repair or replace pushrod
Spot on brake disc, Clearance of brake disc and brake Adjust clearance to make
brake shoe or shoe or brake band asymmetric. them open symmetrically
brake band is Abrading when opening, band brake
abraded quickly overheats.
Helper spring broken or bend Replace helper spring

Brake departs Adjusting nut not tightened or is Adjust adjust nut or replace
from adjusted broken the broken nut
position often
Wire rope abraded Dirty condition without grease Clean and lubricate the wire
quickly or breaks rope
often
Sheave not No lubrication between shaft and Unpack and wash the parts
rotating sleeve and add oil
Cannot work at Motor or electric system fault, Check and adjust
rated load overload set needs adjustment
Brake starting time Swivel joints resisting force is too Clean swivel joints and add
too long strong oil to make them flexible
Inner leaking, oil pressure low or oil Add oil, check noise in
passage block hydraulic pushrod. Replace
the broken parts in time
Hydraulic pushrod Orifice of spill valve is blocked Clean spill valve
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has no pressure Loops power pole connected Adjust connection
and cannot brake inversely. Control handle cannot get
down.
Oil filter blocks Clean oil filter
Vane pump tie-in unscrewed Screw down the tie-in
Oil pressure of Spill adjust setting control rod not Find the location of problem,
hydraulic pushrod adjusted correctly; control rod and adjust in allowed range
cannot reach injection head not centering and
working value, deflecting
braking time too
Electro-hydraulic adjust coil’s Increase the current value
long
current is too low
Clearance of brake shoe too big Adjust the clearance within
0.5~1.5mm
Hydraulic pushrod The distance between control rod and Screw the cross-spring nut a
declutch time too injection head too short little
long, residual
The aperture of injection head too Increase the aperture size
pressure too high
small
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2000/3000t Pipe-laying Vessel45T Stinger Winch handbook

2 OPERATIONAL SAFETY ISSUES...............................................3

3 INSTRUCTIONS OF ANCHOR WINCHES ..................................4

7 RUST PROTECTION OF SPARE PARTS ..................................30

8. COMMON FAULTS AND DEBUGGING ...................................31

This stinger winch is manufactured for shallow working, it’s according to

1.2 Main parameter

a) Rated load and line speed:

f) Work space and freeboard

Length x breadth x height 4005mmx3200mmx1990mm

Side freeboard >=600mm

2 Operational Safety Issues

2.1 Preparations before running

Check the items below carefully before operating winch.

2) Confirm pawl is open. Winch cannot run at closing state.

3) Check gearbox oil and lubrication points for anchor lines

5) Confirm power supply and voltage are normal.

2.2 Attention after running

2) Turn “OFF” the power switches.

3) Check all power supplies for the next use.

4) Check and correct any faults prior to the next use.

2.3 Mounting base

3 Instructions of Anchor winches

Machine device refer to darwing.

1 frame 2 motor 3 coupling 4 high speed 5 reducer 6 pinion 7 limit

Rated speed: 1500rpm

Operation and maintenance refers to” ZPMC_PGCLK.pdf”

3.2 High speed brake

Operation and maintenance refers to” the Operating Instructions Of

Operation and maintenance refers to” Instructions Of

3.5 Limit device

Machine device refer to darwing.

The device must adjust by professional person,any unpreofessional

person can not adjust and nodification, it’s dangerousness.

1 transfer case 2 limit cam

3 overspeed switch 4 absolute value code

3.6 Drum device

3.7 Band brake

Operation and maintenance refers to” Instructions Of HBBJ1500-400

Buildup: ratchet wheel,oil cylinder, pawl, limits etc.

The device must adjust by professional person,any unpreofessional

person can not adjust and nodification, it’s dangerousness.

3.9 Spooling device

Slide bushing component part reference diagrams

3.9.1 Spooling gear adjust procedure

Before drum is enwinded by wire rope:

4.1 General attentions

Check for loose parts

Pay special attention to the bearing bolts and gap-adjusting bolts.

Operate and inspect the action of the brake.

5) Limit switch and encoder:

Check the state of limit switches and encoders before running.

Operate at a slow speed to check the decelerating and stop limits.

4.2 Disassembly and assembly

Disassemble or assemble according to the operation instructions to avoid damaging

4.3 Special attention

Maintenance items and periods

Use proper spanner to fasten the bolts when checking.

Period: daily and once a month