Sepson SEPMATIC User manual

Original User Manual
SEPDURANCE - SEPMATIC - FORCEMATIC - SEPGAIN
WORLD CLASS WINCHES
RELIABLE - DEPENDABLE - UNCOMPLICATED
Vehicle Recovery Winch - hydraulically driven

WORLD CLASS WINCHES
RELIABLE - DEPENDABLE - UNCOMPLICATED
1
Table of Contents
1 Introduction.......................................................................................................3
1.1 General .......................................................................................................3
1.2 About this manual...................................................................................4
1.3 Warranty.....................................................................................................4
2 Safety....................................................................................................................5
2.1 Introduction ...............................................................................................5
2.2 Safety symbols ........................................................................................6
2.3 Winch markings.......................................................................................8
2.4 Machine plate...........................................................................................9
2.5 General information.............................................................................11
2.6 Personal Protective Equipment ..................................................... 12
2.7 Precautions ............................................................................................ 13
3 Installation ...................................................................................................... 17
3.1 General .................................................................................................... 17
3.2 Mounting on vehicle............................................................................ 17
3.3 Lifting the winch ................................................................................... 18
3.4 Hydraulic installation .......................................................................... 19
3.5 Pneumatic or hydraulic free spooling control installation ... 20
3.6 Rope installation .................................................................................. 22
3.7 Calibration of automatic rope spooling device ........................ 25
3.8 Electrical installation........................................................................... 28
3.9 After installation.................................................................................... 28

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4 Winch basics ................................................................................................. 29
4.1 Hydraulic System Basic Information............................................ 29
4.1.1 General .................................................................................................... 29
4.1.2 Outline Diagram for Installation of Winch Hydraulics........... 30
4.1.3 Hydraulic Oil .......................................................................................... 32
4.1.4 Power Supply ........................................................................................ 33
4.1.5 Hydraulic Function Diagram............................................................ 34
4.1.6 Pressure setting of the control valve PVG32........................... 44
4.2 How to calculate required pulling force ...................................... 46
4.3 How to improve rope spooling ....................................................... 48
4.4 Wire rope selection............................................................................. 49
4.5 Dimensioning of rope sheaves ...................................................... 52
4.6 Rigging instructions ............................................................................ 53
5 Operating instructions............................................................................ 59
5.1 General .................................................................................................. 59
5.2 Pull out rope.......................................................................................... 61
5.3 Attaching the load ............................................................................. 63
5.4 Engage the rope drum ..................................................................... 64
5.5 Pull the load ......................................................................................... 65
5.6 Unhook the load.................................................................................. 66
5.7 Spool the rope back on the drum................................................. 67
6 Maintenance ................................................................................................ 68
6.1 Gear drive ............................................................................................. 68
6.2 Drum brake .......................................................................................... 69
6.3 Service and maintenance ................................................................ 71
6.4 Free-spool clutch ............................................................................... 79
6.5 Wire rope .............................................................................................. 81
7 Troubleshooting ......................................................................................... 82
8 Technical information ............................................................................. 86
8.1 General .................................................................................................. 86
8.1.1 Noise........................................................................................................ 86
8.1.2 Vibration ................................................................................................. 86
8.2 Design standard................................................................................... 86
8.3 EC declaration of conformity........................................................... 89

WORLD CLASS WINCHES
RELIABLE - DEPENDABLE - UNCOMPLICATED
3
1 Introduction
1.1 General
SEPSON’s objective, focus and single purpose is to build reliable, dependable and
uncomplicated winches that require a minimum of maintenance and are simple to
repair if this is ever needed. They are quickly and easily attached on any vehicle
chassis.
SEPSON hydraulic vehicle recovery winches from the product groups
– SEPDURANCE, SEPMATIC, FORCEMATIC as well as the worm gear driven
SEPGAIN series, meet all rescue and recovery requirements.
The SEPDURANCE winches represent the core of our range of drum winches and
are characterized by the following features.
All drum winches:
• have drum and housing made of nodular cast iron for added strength and
structural integrity
• have the free spooling feature to easily allow a manual unspooling of the wire
rope. A unique 2-speed feature controlled by a hydraulic valve system is also
standard on all models with a pulling force of 150 kN and above
• are equipped with a spring-applied, pressure-release multi-disk brake and the
optimal drum-to-wire-rope diameter ratio of minimum 10:1 which signicantly
increases the useful life of the rope and reduces operating expenses.
The SEPMATIC winches are the next step up on the ladder to higher performance
and feature an integrated automatic rope-spooling device.
The FORCEMATIC range is our most advanced family of winches. They have been
equipped with a unique feature that maintains a constant pulling force on the wire
rope regardless of its layer on the rope drum.
Documentation is available in English, French and German. All required translations
into the language of the Purchaser will be the responsibility of the Purchaser; both
as regards compliance with the European Union’s Machinery Directive and local
requirements.
Introduction

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This warning symbol alerts to a clear and present danger and must be
observed and understood at all times. Do not proceed with the winching
operation if there is any doubt about the meaning of this warning!
WARNING
This symbol indicates that the information in a relevant paragraph must be
observed and understood. Please contact SEPSON if there is any doubt
regarding a “caution” or “warning” frame.
Caution
1.2 About this manual
This manual contains important data concerning the maintenance, installation and
operation of SEPSON winches.
Should anyone assigned the task to attach the winch on a vehicle be uncertain
about how to perform the task, please contact SEPSON.
The information in this manual is based on current information available to SEPSON
at this time. Under no circumstance, should this information override or replace
national or international statutory instructions, regulations and safety precautions.
Introduction
1.3 Warranty
The warranty is valid in the following cases:
The winch and accessories have been used as intended regarding ”Technical data”.
All instructions in the manual have been followed.
Maintenance and inspection procedures have been followed.
Repairs have been carried out by skilled personnel.
The installation of the winch is made in accordance with Sepson’s instructions.

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2 Safety
2.1 Introduction
This introduction describes and explains the safety precautions that must be
observed and provides useful and necessary information.
Read this chapter very carefully. It is important to fully understand its content and
purpose. It concerns your safety as well as the safety of others around you in the
working area of the rescue and recovery operation and the safe utilization of the
winch.
Familiarize yourself with the winch by practising its use before attempting to save
or rescue a vehicle. This is important and will help you understand its different
functions and ensure that you will be able to operate the equipment with optimal
safety.
The winch must only be used for vehicle recovery and loading.
Safety

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Signs with the symbols below shall be attached on or near the winch operating
device(s). If a remote control is used the symbols shall be attached on the hand
held control unit.
2.2 Safety symbols
General warning
Eye protection must be used
Head protection must be used
Hand protection must be used
Safety boots must be used
Read the manual before operating the winch
Safety

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IN
Winching out (attached at the direction control valve - remote control).
Winching in (attached at the direction control valve - remote control).
Free-spool clutch (attached at the free-spool control).
Sepson supplies a sheet with self gluing symbols with the winch to be attached on
the operating device by the winch installer.
OUT
A label showing drum rotation when spooling in the rope on the drum
is attached on the winch by Sepson prior to shipment.
Safety

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2.3 Winch markings
Machine plate (See 2.4 Machine plate).
The placement of the markings varies between different winch models.
0078-01
Safety

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2.4 Machine plate
1. Winch model – Sepdurance, Sepmatic, Forcematic or Sepgain.
2. Product number.
3. Maximum allowed oil pressure to the winch. A higher pressure can
seriously damage the winch and give excessive pulling force. If the pressure is
higher than our specication the warranty is not valid.
4. Maximum allowed oil ow to the winch. A higher oil ow can seriously
damage the winch.
5. Required electrical current for the winch if applicable.
6. Diameter of steel wire rope.
7. Maximum length of steel wire rope on the winch.
8. Minimum breaking load (MBL) for the winch wire rope stated by the wire
rope manufacturer.
9. Recommended oil or grease for the winch.
Safety

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10. Manufacturing year.
11. Manufacturing number.
12. Weight of winch excluding steel wire rope.
13. Maximum pulling force on the bottom rope layer.
14. Maximum pulling force on the top rope layer.
15. Maximum allowed load weight when lifting on the bottom rope layer.
16. Maximum allowed load weight when lifting on the top rope layer.
17. Maximum allowed number of rope layers on the winch drum.
18. Complies with EU-standard.
19. If No is stated, the specied wire rope does not comply with EU standards and
the winch is delivered for use in countries outside the European Union with
other safety standard.
Safety

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Operation of the winch requires a skilled operator.
WARNING
2.5 General information
Any use of the winch may create risks of injuries to the operator and the general
safety of people in the area as well as damage to the winch itself and other
equipment used in connection with its operation.
It is only the operator’s awareness of the necessary safety precautions and his/her
sound judgment that can eliminate or reduce the risks of personal injuries.
It is the responsibility of the operator to ensure that all appropriate precautions are
taken as required by the working environment and conditions in each individual
case.
Neither this document nor observing and applying its instructions absolve the
operator or owner from their joint responsibilities to ensure the actual
implementation of all precautions or the observance of all warnings.
If anyone becomes aware of any SEPSON supplied product or SEPSON originated
design that can create a risk to an individual working with or within the vicinity of the
product, it is an obligation to contact SEPSON immediately.
It is the user’s responsibility to make all relevant hazard identications and risk
assessment of all activities associated with the use of both the product and this
document.
It is solely the user’s and the owner’s joint responsibility to provide a safe working
environment and to provide the necessary safety equipment and ensure that
everybody who is depending on this document, understands the instructions,
warnings and caution and that they are able to operate the equipment in
accordance with these instructions.
Should an operator lack the knowledge, experience or skills to work in accordance
with the safety or other instructions in this document, immediate assistance should
be requested from SEPSON. Technical assistance sought from SEPSON will be
subject to SEPSON terms and conditions.
Safety

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2.6 Personal Protective Equipment
It is absolutely essential that the operator uses the appropriate and required safety
equipment when working with the equipment.
Protective clothing should protect the operator(s) against oil and shield from
accidental contact with the wire rope. Avoid loose clothing that may be caught in the
winch or the wire rope and cause serious injury.
Personal safety equipment does not eliminate the risk of injury but reduces the risk
and effects in case of an accident. It is only the user’s awareness of all safety risks
and his/her own judgment that will provide the necessary safety margins against
personal injury.
Protective clothing
Head protection (Hard hat)
Eye protection (Goggles)
Hand protection
(Heavy duty gloves when handling the
rope and rubber gloves when working
with oil)
Safety boots
(Steel tipped and slip resistant sole)
Safety

WORLD CLASS WINCHES
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LR
R
R
R
R
R
R
2.7 Precautions
Before starting the winch operation, always make sure that no unauthorized
personnel are in the danger zone indicated in the diagram below.
Safety
Danger zone
Distance (R)
Attachment point
Rope length (L)
SEPSON cannot exclude the risk of danger outside the above zone in the event of
material breakdown.
Length L: paid-out rope Distance R
Smaller than 3 m not permissible –
3 m to 5 m 2.0 x L
6 m to 30 m 1.5 x L
30 m to max. possible distance 1.1 x L

WORLD CLASS WINCHES
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Keep hands clear of the wire rope and all attaching components during
installation, pulling process and when spooling the wire rope in or out of
the drum. Always handle the wire rope by the rope end when spooling out
the rope by hand.
WARNING
The rst step is to create a safe working environment for each specic pull.
There are several aspects to consider depending on restrictions imposed by the
surroundings and the locations of the vehicles.
– Remove any objects that may be blocking the operation or prevent a clear view of
the pull path.
– Try to place the winch in a straight line in front of the load.
– Never try to pull the load sideways.
– If necessary, use snatch blocks or other devices to change the pulling direction or
its angle to the winch.
– Take all necessary time to plan the pulling operation and gather available
information such as the load (weight) and the surroundings (surface condition)
before the operation takes place.
– Consider all important issues that might impact the winching operation and which
may be important factors in calculating the pull and in determining the need for
special equipment.
Safety
Always follow and observe SEPSON’s and the vehicle manufacturer’s advice and
instructions with regards to the recommended location of the winch.
The hydraulic system and its applications require care and cleanliness. Always
observe and respect SEPSON assembly and installation instructions.
Never use the winch to move people and never use it as a hoist to lift
objects.
WARNING

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Always handle the wire rope with gloves and pull on any device attached
to the rope end when spooling in or out by hand.
WARNING
When pulling out the rope, always leave at least the length of four (4)
revolutions on the drum.
WARNING
Always pull out the wire rope manually with the drum in the free spooling
position. Never run out the rope under power.
Caution
Never hook the wire rope on to itself, it will cause damage.
Caution
Never ll the hydraulic oil tank with more than 80% of capacity to leave 20%
space for heat expansion of the liquid.
Caution
Safety
– Always wear heavy duty protective gloves when handling the rope and never let
it slide through the palm of your hands while spooling, because wire strands may
cause painful injury.
– If a remote control is installed, always keep the control unit with you when leaving
the winch unattended.
– Always attach the wire rope to a point on the object that will support the winch’s
maximum capacity.

WORLD CLASS WINCHES
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Always put a load on the rope when spooling to the drum otherwise the rope will
not spool correctly.
Caution
Always inspect the wire rope’s attaching point at the load side and its
condition before operating the winch.
WARNING
Make sure that the rope is slack before unhooking after the pull. There is a
clear danger of injury from the rope’s rotation.
WARNING
Always stand clear of the rope and respect the danger zone. Make sure
everybody is aware of your intention to pull the load, in and outside the
danger zone.
WARNING
Damaged wire ropes or attaching devices must be replaced before the
pull.
WARNING
Safety

WORLD CLASS WINCHES
RELIABLE - DEPENDABLE - UNCOMPLICATED
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3 Installation
The winch is designed for pulling operations in recovery and rescue and is designed
for mounting on a vehicle chassis only. Please refer to the technical information for
more detailed specication on this particular winch model.
3.1 General
3.2 Mounting on vehicle
The winch is either mounted with a mounting plate or directly to the vehicle’s
chassis. When a mounting plate is required, the plate must support the force of at
least 1,25 times the maximum pulling force of the winch.
Refer to instructions about the use and dimensions of a mounting plate in the
Technical information for your winch. If in doubt, always seek the advice and
instructions from both SEPSON and the vehicle’s manufacturer.
– The emergency stop shall cut out the power supply to the winch(es).
– Never mount an operating device close to the exhaust pipe(s).
– Handholds and platform for maintenance work shall be installed if needed for
safe work.
SEPSON is not liable for the winch installation on the vehicle.
Installation

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3.3 Lifting the winch
The winch is too heavy for handling by hand. Use an adequate lifting device
and do not place lifting straps around the hydraulic motor or the hydraulic valve
block. Please refer to the technical information to obtain the exact weight of this
winch.
Caution
1. Remove the rope from the drum and refer to instructions under rope installation.
2. Create a rope sling around the drum.
3. Place the loop sling into the lifting device.
4. Check the balance before lifting.
5. Lift the winch.
If the winch is supplied with thread bolt holes for lifting eyes use lifting eyes.
Lifting straps Lifting eye
Separate the straps on the drum
as much as possible.
0014-02
0070-01
Installation

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0066-01
V1
V2
V1
V2
3.4 Hydraulic installation
All seals must be in place to protect the operator and anybody else in the
area against an escape of high oil pressure.
WARNING
Auto 2-speed block Single speed block
0033-01
M
V1
V2
1. Connect the directional control valve and the winch by the ports V1 and V2 on
the hydraulic block.
2. Inspect and test all tubing, hoses and connection points for oil leakage.
If the directional control valve is attached to the winch, connect the pressure
hose/tube to the pressure inlet and the return hose/tube to the oil outlet on the
control valve.
For a hydraulic system with xed pump the directional control valve must have an
open centre; otherwise the winch safety brake will not operate properly or not at all.
If a load sensing hydraulic system is used contact Sepson for advice on choice of
control valve.
Make sure that the hydraulic system is set to not deliver higher oil pressure and oil
ow than listed in the technical information section for the winch.
Installation