Pellegrini Hydraulic Winch AS 500D  //  Hydraulic motor and planetary gearbox assembly

Pellegrini AS 500D Hydraulic Winch: Obsolete Drive System Modernization

Technical evaluation of a Pellegrini AS 500D hydraulic winch requiring modernization of its hydraulic drive train due to obsolescence of critical components.

FAILURE MODEObsolescence of the hydraulic drive system caused by discontinuation of the original Rexroth motor and limited long-term serviceability of the gearbox configuration.
DOWNTIME3 days
COST ESTIMATE€18,000
ROOT CAUSEThe original Rexroth AA10VM45/16HZ/50W-P.S.C.60NOD hydraulic motor reached end-of-support status, creating increasing maintenance risk and uncertainty of spare parts availability.

Incident Metadata and Classification

System Category: Marine Deck Machinery
Failure Severity: Major
Maintenance Type: Modernization
Failure Progression: Progressive Obsolescence
Classification Society: DNV

Operational Symptoms and Verification

Routine maintenance assessment identified increasing difficulties in sourcing spare parts for the installed Rexroth AA10VM45/16HZ/50W-P.S.C.60NOD dual-displacement hydraulic motor. Manufacturer support for the original motor configuration had been discontinued, creating long-term operational risk.

Engineering Assessment and Root Cause Analysis

The winch structure remained mechanically serviceable; however, continued operation depended on a hydraulic motor family no longer available in current production. The associated Brevini EC3150/FE B3C gearbox configuration also required evaluation to ensure compatibility with a modern replacement drive arrangement.

Technical Intervention and Reconstruction

Engineering review identified the Rexroth A10VM45HZ/52W1-VSC60N000 hydraulic motor as a suitable modern replacement. The gearbox assembly was upgraded to a BREVINI EC3150/FE/113/FL635 configuration equipped with an integrated brake package and motor adaptor. The selected arrangement preserved the original winch operating concept while restoring spare parts availability and long-term maintainability.

Prevention

Proactive modernization of critical hydraulic drive components and timely replacement of obsolete deck machinery before supply chain limitations affect vessel operations.

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