Summary of Contents for Sepson SEPMATIC
- Page 1 WORLD CLASS WINCHES RELIABLE - DEPENDABLE - UNCOMPLICATED Vehicle Recovery Winch - hydraulically driven Original User Manual SEPDURANCE - SEPMATIC - FORCEMATIC - SEPGAIN...
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Page 2: Table Of Contents
WORLD CLASS WINCHES RELIABLE - DEPENDABLE - UNCOMPLICATED Table of Contents 1 Introduction ....................... General ....................... About this manual ................... Warranty ..................... 2 Safety ........................Introduction ....................Safety symbols ..................Winch markings ..................Machine plate ................... General information ................Personal Protective Equipment ............. - Page 3 WORLD CLASS WINCHES RELIABLE - DEPENDABLE - UNCOMPLICATED 4 Winch basics ....................Hydraulic System Basic Information ..........4.1.1 General ....................4.1.2 Outline Diagram for Installation of Winch Hydraulics ... 4.1.3 Hydraulic Oil ..................4.1.4 Power Supply ..................4.1.5 Hydraulic Function Diagram ............
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Page 4: Introduction
10:1 which significantly 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. -
Page 5: About This Manual
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. -
Page 6: Safety
WORLD CLASS WINCHES Safety RELIABLE - DEPENDABLE - UNCOMPLICATED Safety The winch must only be used for vehicle recovery and loading. 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. -
Page 7: Safety Symbols
WORLD CLASS WINCHES Safety RELIABLE - DEPENDABLE - UNCOMPLICATED 2.2 Safety symbols 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. - Page 8 A label showing drum rotation when spooling in the rope on the drum is attached on the winch by Sepson prior to shipment. Sepson supplies a sheet with self gluing symbols with the winch to be attached on the operating device by the winch installer.
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Page 9: Winch Markings
WORLD CLASS WINCHES Safety RELIABLE - DEPENDABLE - UNCOMPLICATED 2.3 Winch markings 0078-01 Machine plate (See 2.4 Machine plate). The placement of the markings varies between different winch models. -
Page 10: Machine Plate
Safety RELIABLE - DEPENDABLE - UNCOMPLICATED 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 specification the warranty is not valid. - Page 11 WORLD CLASS WINCHES Safety RELIABLE - DEPENDABLE - UNCOMPLICATED 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.
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Page 12: General Information
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. -
Page 13: Personal Protective Equipment
WORLD CLASS WINCHES Safety RELIABLE - DEPENDABLE - UNCOMPLICATED 2.6 Personal Protective Equipment It is absolutely essential that the operator uses the appropriate and required safety equipment when working with the equipment. Head protection (Hard hat) Eye protection (Goggles) Protective clothing Hand protection (Heavy duty gloves when handling the rope and rubber gloves when working... -
Page 14: Precautions
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 SEPSON cannot exclude the risk of danger outside the above zone in the event of material breakdown. - Page 15 WORLD CLASS WINCHES Safety RELIABLE - DEPENDABLE - UNCOMPLICATED 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.
- Page 16 WORLD CLASS WINCHES Safety RELIABLE - DEPENDABLE - UNCOMPLICATED – 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. –...
- Page 17 WORLD CLASS WINCHES Safety RELIABLE - DEPENDABLE - UNCOMPLICATED Caution Always put a load on the rope when spooling to the drum otherwise the rope will not spool correctly. WARNING Always inspect the wire rope’s attaching point at the load side and its condition before operating the winch.
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Page 18: Installation
– 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. -
Page 19: Lifting The Winch
WORLD CLASS WINCHES Installation RELIABLE - DEPENDABLE - UNCOMPLICATED 3.3 Lifting the winch Lifting straps Lifting eye 0070-01 Separate the straps on the drum 0014-02 as much as possible. Caution 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. -
Page 20: Hydraulic Installation
For a hydraulic system with fixed 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. -
Page 21: Pneumatic Or Hydraulic Free Spooling Control Installation
WORLD CLASS WINCHES Installation RELIABLE - DEPENDABLE - UNCOMPLICATED 3.5 Pneumatic or hydraulic free-spooling control installation Connect the free-spooling control to the winch according to the circuit. It is a threaded connection on the winch’s free- spooling cylinder. See table on page 21. - If the winch has a pneumatic free- spooling control, the air pressure shall be 6-10 bar. - Page 22 WORLD CLASS WINCHES Installation RELIABLE - DEPENDABLE - UNCOMPLICATED The different connection points for the Sepson winch groups are shown below. The arrow points at the connection point. Art. No. Art. No. 73.06- 73.09- Pne. 1/8” Pne. 1/4” 73.07- Hyd. G 3/8”...
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Page 23: Rope Installation
WORLD CLASS WINCHES Installation RELIABLE - DEPENDABLE - UNCOMPLICATED 3.6 Rope installation Caution Always wear protective gloves when handling the rope. Never install a wire rope that does not meet the requirements in the technical information for this winch. The new rope must be uncoiled from the spool on the ground prior to installation. - Page 24 WORLD CLASS WINCHES Installation RELIABLE - DEPENDABLE - UNCOMPLICATED Wedge Lock 1. Thread the end of the rope through the wedge rope grip from its narrow end. 2. Bend the rope end around the wedge rope grip and form a loop. 3.
- Page 25 WORLD CLASS WINCHES Installation RELIABLE - DEPENDABLE - UNCOMPLICATED Screw Lock 1. Thread the end of the rope through the hole furthest from the drum flange and pull about 1 metre through (enough for 3 turns on the drum). 2. Wind the free end 3 turns on to the drum toward the flange by hand as tightly as possible.
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Page 26: Calibration Of Automatic Rope Spooling Device
WORLD CLASS WINCHES Installation RELIABLE - DEPENDABLE - UNCOMPLICATED 3.7 Calibration of automatic rope spooling device Before mounting the rope on the winch drum, follow the instructions below. The rope must be fitted underwound. Note This instruction is only valid when the spooling device is out of range and not working properly. - Page 27 WORLD CLASS WINCHES Installation RELIABLE - DEPENDABLE - UNCOMPLICATED 3. Remove the cover for the spooling device. 4. Remove the bolt, washer, key and gear. Bolt Cover Gear Washer 5. Turn the helix screw by hand until the rope guide comes to the outmost position on the same side as the rope wedge pocket.
- Page 28 WORLD CLASS WINCHES Installation RELIABLE - DEPENDABLE - UNCOMPLICATED The marking on the follower should now be pointing to the centre spot. Note The location of the punched marks can be different between different winch models. Follower Rope guide 6. Refit the gear and the cover, secure the center bolt with Loctite. 7.
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Page 29: Electrical Installation
WORLD CLASS WINCHES Installation RELIABLE - DEPENDABLE - UNCOMPLICATED 3.8 Electrical installation WARNING The emergency stop shall cut out the power supply to the winches. – For installation of electric components see attached appendix. – For installation of remote control see attached appendix. Recommendations: –... -
Page 30: Winch Basics
Fluid mechanics provides the theoretical foundation for hydrau- lics, which focuses on the engineering uses of fluid properties. These fundamentals of hydraulics apply to SEPSON winches. Note You cannot obtain maximum oil pressure and maximum oil flow at the same time. -
Page 31: Outline Diagram For Installation Of Winch Hydraulics
WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 4.1.2 Outline Diagram for Installation of Winch Hydraulics 1. Remote control (optional) 2. Connection box (optional) 3. Switch for pneumatic or hydraulic free-spool clutch 4. Connection for pneumatic or hydraulic free-spool clutch 5. - Page 32 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 10. Suction hose 2” 11. PTO 12. Hydraulic pump 13. Pressure hose ¾” 14.Directional control valve If the maximum allowed oil flow cannot be automatically set by either adjusting the maximum rpm for the engine or by a flow control function in the directional control valve, then an oil flow limiting valve needs to be installed in the pressure line before the directional control valve.
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Page 33: Hydraulic Oil
WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 4.1.3 Hydraulic Oil Temperature The oil temperature should be between +30 °C and +60 °C during normal operation. Oil life is greatly reduced if its temperature exceeds +60 °C. As a general rule, oil life is halved for each 8 °C its temperature exceeds +60 °C. -
Page 34: Power Supply
The oil flow must not be below 30 litres per minute. At a lower flow, the winch will not operate properly. • If a load sensing hydraulic system is used contact Sepson for advice on choice of control valve. •... -
Page 35: Hydraulic Function Diagram
WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 4.1.5 Hydraulic Function Diagram Auto-2-speed winches with two or more motors Winching in at high speed Oil in at V1. The shuttle valve C opens and permits oil flow to measuring point E and to the brake F which releases when the pressure exceeds 30 bar. - Page 36 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED Winching in at low speed Oil in at V1. The shuttle valve C opens and permits oil flow to measuring point E and to the brake F which releases when the pressure exceeds 30 bar.
- Page 37 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED Winching out Oil in at V2. The shuttle valve C opens and permits oil flow to measuring point E and to the brake F which releases when the pressure exceeds 30 bar. The pilot line K leads oil to the Over Centre Valve L.
- Page 38 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED Diagram for 2-speed hydraulic system 1.1.4 1.1.1 0003-02 Position Part Explanation Winch with hydraulics Hydraulic block Combining sequence valve, double overcentre valve, shuttle valve and pressure gauge outlet mounted direct on to one of the motors.
- Page 39 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 1.1.2 Double overcentre valve This allows the load to be spooled out at a controlled rate. It also provides burst hose protection. It is adjusted and sealed in our factory. 1.1.3 Shuttle valve Supplies pressure for the spring loaded...
- Page 40 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED Hydraulic oil tank Return oil filter Must filter to 10 microns or better and accept required oil flow. Pipe, hoses and Must be approved for min. 25 MPa connectors (250 bar) working pressure and have the following dimensions: - Pump inlet line min.
- Page 41 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED Single Speed Winches with one motor Winching in Oil in at V1. The shuttle valve C opens and permits oil flow to measuring point E and to the brake F which releases when the pressure exceeds 30 bar.
- Page 42 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED Winching out Oil in at V2. The shuttle valve C opens and permits oil flow to measuring point E and to the brake F which releases when the pressure exceeds 30 bar. The pilot line K leads oil to the Over Centre Valve L.
- Page 43 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED Diagram for single speed hydraulic system 1.1.4 0003-01 Position Part Explanation Winch with hydraulics Hydraulic block Double overcentre valve, shuttle valve and pressure gauge outlet mounted direct on to one of the motors. The ports marked V1 and V2 are for the hydraulic connections from the control valve on the vehicle´s hydraulic system.
- Page 44 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED Hydraulic motor Hydraulic spring loaded This automatically brakes the load when brake the control valve is put in the neutral position or if the oil pressure is lost. Control valve unit Directional control valve 4-way, 3 position with spring-centred motorised spool and built-in pressure...
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Page 45: Pressure Setting Of The Control Valve Pvg32
WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 4.1.6 Pressure setting of the control valve PVG 32 Note Only authorized personnel are allowed to adjust the Pressure setting. 1. Remove the protection cap for the adjustment point. 2. Remove the plug and connect a pressure gauge outlet and a manometer at to the measuring point. - Page 46 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED Hydraulic circuit for control valve PVG 32 7503175...
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Page 47: How To Calculate Required Pulling Force
WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 4.2 How to calculate required pulling force The required pulling force (RPF) can be calculated according the formula: M (sinα + Rr) × (1 + Ff) g RPF (kN) = 1,000 Where: M = the load’s weight in kg. - Page 48 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED Example: A vehicle is stuck in sand in a slope with an inclination of 15°. The Vehicle weight is 10,000 kg. M (sinα + Rr) × (1 + Ff) g 10,000 (0.26 + 0.325) ×...
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Page 49: How To Improve Rope Spooling
WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 4.3 How to improve rope spooling It is very essential that the rope is spooled on with as small angle as possible to a line perpendicular from the centre of the rope drum. The fleet angle (a) in the sketch below should not be much greater than 2°... -
Page 50: Wire Rope Selection
4.4 Wire rope selection WARNING Never use a damaged rope. In doubt contact your rope supplier or Sepson. During the useful life of a winch, the wire rope replacement costs are often the highest expenditure. It is very important to select a rope that corresponds to the intended use of the winch itself. - Page 51 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED The wire rope should have at least six (6) strands and if it is to pass through several line guides, a higher number of strands are recommended. A wire rope with fewer strands may be more resistant to wear whereas a rope with a higher number of strands is more flexible and bends easier through the guides which will make it more user-friendly.
- Page 52 The rope must have a rigid stiff core and tight braid cover to ensure that the rope does not cut into underlying rope layers. Note that the synthetic rope must be approved by Sepson for Sepson Winch warranty to be valid.
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Page 53: Dimensioning Of Rope Sheaves
Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 4.5 Dimensioning of rope sheaves The rope sheaves in Sepson’s snatch block have a ratio of 10 times the rope diameter. For fixed installation on vehicles where the winch is used intermittently and during short periods the ratio between sheave diameter and rope diameter should be 20 if the rope turns more than 45°. -
Page 54: Rigging Instructions
WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 4.6 Rigging instructions WARNING Before starting the recovery, it is important that all safety instructions are observed and that nobody is within the hazard zone. WARNING These guidelines and instructions do not eliminate or replace the operator’s full and unlimited responsibility for the safety and protection of both people and material during all rescue and recovery operations. - Page 55 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED When using snatch blocks, the load multiplication effect depends on the rope angle. The pulling force (F) increases when the rope angle decrease. The required pulling force (F) decreases when using snatch blocks.
- Page 56 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 1. Winch 2. Snatch block 3. Recovery object 4. Anchor point Use double rope to increase the pulling capacity by attaching the free end of the wire rope to a fixed point on the vehicle or another fixed point. Attach the snatch block to the load that shall be recovered and winch in the rope.
- Page 57 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 1. Winch 2. Snatch block 3. Recovery object 4. Anchor point Use a snatch block to reduce the required pulling force and if there is no straight line between the winch and the recovery object. This will also enable better control of the recovery.
- Page 58 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 1. Winch 2. Double snatch blocks 3. Recovery object A relatively small winch can frequently manage to pull significantly heavier loads due to the multiple increase of its power with the use of snatch blocks.
- Page 59 WORLD CLASS WINCHES Winch basics RELIABLE - DEPENDABLE - UNCOMPLICATED 1. Pulling winch 2. Anchor point 3. Snatch block 4. Recovery object 5. Holding winch A complicated location of the object to be recovered can require the use of more than one recovery vehicle.
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Page 60: Operating Instructions
WORLD CLASS WINCHES Operating instructions RELIABLE - DEPENDABLE - UNCOMPLICATED 5 Operating instructions Operation of the winch requires a skilled operator. For how to handle the remote control see additional instructions. WARNING Keep hands clear of the rope and all attaching devices during installation, pulling operations and when spooling the rope in. - Page 61 WORLD CLASS WINCHES Operating instructions RELIABLE - DEPENDABLE - UNCOMPLICATED With heavy loads, always work with the bottom wire rope layer on the drum to avoid loaded rope pushing onto underlying rope layers and causing damage. Never overload the wire rope. The minimum breaking load applies only to a new and unused rope and remember also that the securing devices may not be designed to withstand the maximum pulling power of the winch.
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Page 62: Pull Out Rope
WORLD CLASS WINCHES Operating instructions RELIABLE - DEPENDABLE - UNCOMPLICATED 5.2 Pull out rope WARNING Always handle the rope in the hook when spooling in or out by hand. Be careful not to place hands in the rope eye or the attaching hook. 1. - Page 63 WORLD CLASS WINCHES Operating instructions RELIABLE - DEPENDABLE - UNCOMPLICATED The different manual handles for the Sepson winch groups are shown below. 1. Pull 2. Turn Art. No. Art. No. 60.08- 73.08- 60.15- 73.09- 60.16- 73.06- 73.07- 0058-01 0057-01 63.01- 63.31-...
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Page 64: Attaching The Load
WORLD CLASS WINCHES Operating instructions RELIABLE - DEPENDABLE - UNCOMPLICATED 5.3 Attaching the load WARNING Always use adequate equipment that is designed to withstand the maximum pulling force for the winch. Attach the rope to a secure point on the recovery object. Never hook the wire rope on to itself, it may damage the wire. -
Page 65: Engage The Rope Drum
WORLD CLASS WINCHES Operating instructions RELIABLE - DEPENDABLE - UNCOMPLICATED 5.4 Engage the rope drum WARNING Make sure nobody is inside or close to the danger zone of the winch during operation. Disengage the free-spool Manual free-spool control - Release the handle for the free-spool control. Pneumatic or hydraulic free-spool control. -
Page 66: Pull The Load
WORLD CLASS WINCHES Operating instructions RELIABLE - DEPENDABLE - UNCOMPLICATED 5.5 Pull the load 0009-01 1. Activate the control valve and continue pulling until the object is secured. 2. Stop the winch by releasing the control valve. The spring loaded brake and the double over centre valves will automatically hold the load in place. -
Page 67: Unhook The Load
WORLD CLASS WINCHES Operating instructions RELIABLE - DEPENDABLE - UNCOMPLICATED 5.6 Unhook the load 0009-02 WARNING Before unhooking the rope after pulling, make sure it is slack; otherwise there is a significant risk of injury from an uncontrolled rope rotation. 1. -
Page 68: Spool The Rope Back On The Drum
WORLD CLASS WINCHES Operating instructions RELIABLE - DEPENDABLE - UNCOMPLICATED 5.7 Spool the rope back on the drum 0009-01 WARNING Always keep a pull on the rope when spooling it back on the drum otherwise it will not spool correctly. 1. -
Page 69: Maintenance
6.1 Gear drive For most Sepson winches, the gear drive is placed inside a closed container filled with grease. If the gear drive needs to be repaired use grease of NLGI 2 grade that has lithium complex soap as thickener. Sepson recommends Mobil Grease XHP 222 or similar. -
Page 70: Drum Brake
WORLD CLASS WINCHES Maintenance RELIABLE - DEPENDABLE - UNCOMPLICATED 6.2 Drum brake Schedule a regular check of the friction drum brake components. The purpose of this brake is to avoid and prevent the drum from continuing to turn when unwinding the rope in a free spooling operation. - Page 71 WORLD CLASS WINCHES Maintenance RELIABLE - DEPENDABLE - UNCOMPLICATED To increase the brake effect, follow these steps: 1. Loosen the locking nut. 2. Turn the adjusting screws clockwise. 3. Tighten the locking nut. To reduce the brake effect, follow these steps: 1.
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Page 72: Service And Maintenance
WORLD CLASS WINCHES Maintenance RELIABLE - DEPENDABLE - UNCOMPLICATED 6.3 Service and maintenance Item or Assembly Notes Daily service Minor Medium Major Lubricant After every use service service service Every 2 12 mths 36 mths mths Winch, wire rope, rope gui- des and other accessories Emergency stop Wire rope... - Page 73 WORLD CLASS WINCHES Maintenance RELIABLE - DEPENDABLE - UNCOMPLICATED Item or Assembly Notes Daily service Minor Medium Major Lubricant After every use service service service Every 2 12 mths 36 mths mths Automatic rope spooling Mobil device (gear drive) Grease XHP (optional) 222 or eq.
- Page 74 WORLD CLASS WINCHES Maintenance RELIABLE - DEPENDABLE - UNCOMPLICATED Notes: 1. Always clean the winch and the accessories after use. 2. Check the emergency stop function. 3. Pull out the rope and inspect for deformation, damage and wear in accordance with 6.5 Wire rope.
- Page 75 WORLD CLASS WINCHES Maintenance RELIABLE - DEPENDABLE - UNCOMPLICATED 18. Inspect the gear drive and grease winches with grease nipple. 19. Check the gear oil level. Drain and refill the gear oil. 20. Check all fixation bolts. If necessary tighten up. Note: Ensure that tightening torques are in accordance with the table below or with the manufacturer’s specifications.
- Page 76 WORLD CLASS WINCHES Maintenance RELIABLE - DEPENDABLE - UNCOMPLICATED Winch drum and rope wedge Audio visual 4-wrap rope warning Spooling device rope guide Winch gear drive Winch gear drain Spooling device gear drive Spooling device Spooling device helix Constant force device screw and bellow roller fairlead Keep the shaft dry and clean...
- Page 77 WORLD CLASS WINCHES Maintenance RELIABLE - DEPENDABLE - UNCOMPLICATED WARNING Do not run the winch without oil! Some winches are delivered with no oil in the gearbox. Before using fill the winch with oil. For Sepgain H40 and H70 we recommend SAE 80W/90 or similar. Fill the gear box up to the oil level plug.
- Page 78 WORLD CLASS WINCHES Maintenance RELIABLE - DEPENDABLE - UNCOMPLICATED Example of winch grease nipple Example of snatch block grease nipple VANSBRO, Sweden Example of fairlead grease nipple Equipment with grease nipple should be greased regulary.
- Page 79 WORLD CLASS WINCHES Maintenance RELIABLE - DEPENDABLE - UNCOMPLICATED Tightening torques According to DIN 912, DIN931, DIN933 etc Bolt Spec. 10.9 12.9 Dimension Tightening torque [Nm] 10.4 10.4 15.3 17.9 M 10 M 10 x 1.25 M 12 M 12 x 1.25 M 14 M 14 x 1.5 M 16...
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Page 80: Free-Spool Clutch
Note It is extremely important that the winch is not used if the free-spool function is not working properly. Contact an authorized repair centre of SEPSON immediately. Manual free-spool Lubricate moving components with thin moisture-absorbing oil. Check that the free-spool clutch has an unrestricted full movement annually or if suspected to not work properly. - Page 81 WORLD CLASS WINCHES Maintenance RELIABLE - DEPENDABLE - UNCOMPLICATED Minimum allowed movement of the free-spool clutch Art. No. Art. No. 73.06- 73.07- 73.08- 73.09- 60.08- 60.15- 60.16- 63.01- 63.02- 63.53- 63.35- 62.56- 63.31- 63.34-...
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Page 82: Wire Rope
WORLD CLASS WINCHES Maintenance RELIABLE - DEPENDABLE - UNCOMPLICATED 6.5 Wire rope WARNING A damaged or worn wire rope must be replaced. The design of the winch does not allow unlimited use of the wire rope. For ropes with 6 or 8 strands the most common wear is superficial thread breakage. Internal thread breakage is most common for rotation-resistant ropes, and this cannot be seen from the outside. -
Page 83: Troubleshooting
WORLD CLASS WINCHES Maintenance RELIABLE - DEPENDABLE - UNCOMPLICATED 7 Troubleshooting Symptom Probable cause Action 1. Winch does not 1. No oil flow to winch – Check hydraulic oil function level – Check all hydraulic lines, fittings and components for leaks 2. - Page 84 WORLD CLASS WINCHES Troubleshooting RELIABLE - DEPENDABLE - UNCOMPLICATED Symptom Probable cause Action 2. Winch drum 1. The drive train is not – Disengage the does not turn aligned and the free- free-spool clutch and spool clutch can not rotate the drum till the connect the winch drum drive chain engages to the drive chain...
- Page 85 WORLD CLASS WINCHES Troubleshooting RELIABLE - DEPENDABLE - UNCOMPLICATED Symptom Probable cause Action 4. The winch jerks 1. Hydraulic pump is – Replace pump or or is noisy during defective contact authorized operation repair service 2. Defective hydraulic motor – Replace motor or contact authorized repair service 3.
- Page 86 WORLD CLASS WINCHES Troubleshooting RELIABLE - DEPENDABLE - UNCOMPLICATED Symptom Probable cause Action 5. The winch will not 1. Engine rpm too low – Increase engine rpm reach required rope speed 2. Hydraulic oil filter dirty – Clean or replace filter 3.
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Page 87: Technical Information
WORLD CLASS WINCHES Technical information RELIABLE - DEPENDABLE - UNCOMPLICATED Technical information General 8.1.1 Noise The A-weighted sound pressure level at the winch operation place depends on the placement of the winch controls on the vehicle and type of vehicle. The noise level for the winch is ≤... -
Page 88: Design Standard
WORLD CLASS WINCHES Technical information RELIABLE - DEPENDABLE - UNCOMPLICATED 8.2 Design standard Sepson’s VEHICLE RECOVERY WINCHES are designed according to the following standards Directive 2006/42/EC Machinery (Harmonised C-standard) EN 14492-1:2006 + A1:2009 Cranes – Power driven winches and hoists... - Page 89 WORLD CLASS WINCHES Technical information RELIABLE - DEPENDABLE - UNCOMPLICATED Sepson’s ELECTRICAL CONTROL SYSTEM and CABLE REMOTE CONTROLS are designed according to the following standards. Directive 99/5/EC Radio and telecommunications terminal equipment. (Supporting safety standards) EN 301489-1:2001 EMC and radio spectrum matters (ERM)
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Page 90: Ec Declaration Of Conformity
Sepson AB SE-780 50 Vansbro, Sweden, declare under our sole responsibility that the products: Hydraulic winches in model series SEPDURANCE, SEPMATIC, FORCEMATIC, SEPGAIN and SEPTRAC from year of manufacturing 2010 and onwards conforms with the following provisions of Directives: 2006/42/EC, Machinery... - Page 91 WORLD CLASS WINCHES RELIABLE - DEPENDABLE - UNCOMPLICATED Sepson AB SE-780 50 Vansbro, Sweden, phone: +46 281 758 40, fax: +46 281 710 09 info@sepson.se www.sepson.se...
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