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WORLD CLASS WINCHES

RELIABLE - DEPENDABLE - UNCOMPLICATED

6.5 Wire rope

A damaged or worn wire rope must be replaced.

WARNING

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.

Discard criteria (examples)

Strand jerk

Snarl

Basketing

Flattening

Maintenance

Summary of Contents for FORCEMATIC

Page 1: ...Original User Manual SEPDURANCE SEPMATIC FORCEMATIC SEPGAIN WORLD CLASS WINCHES RELIABLE DEPENDABLE UNCOMPLICATED Vehicle Recovery Winch hydraulically driven ...

Page 2: ...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 Afte...

Page 3: ...ve 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 ...

Page 4: ...ual 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 significantly increases the useful life of the rope and reduces operating expenses The SEPMA...

Page 5: ...EPSON 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 Introducti...

Page 6: ... 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 eq...

Page 7: ... 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 ...

Page 8: ...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 ...

Page 9: ...WORLD CLASS WINCHES RELIABLE DEPENDABLE UNCOMPLICATED 8 2 3 Winch markings Machine plate See 2 4 Machine plate The placement of the markings varies between different winch models 0078 01 Safety ...

Page 10: ...ive pulling force If the pressure is higher than our specification the warranty is not valid 4 Maximum allowed oil flow to the winch A higher oil flow 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 manuf...

Page 11: ...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 specified wire rope does not comply with EU standards and the winch is delivered for use in countries outside the European Union with o...

Page 12: ...ons 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 identifications and risk assessment of all activities associated with the use ...

Page 13: ...t 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 G...

Page 14: ...ersonnel 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 ...

Page 15: ...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 ...

Page 16: ...er power Caution Never hook the wire rope on to itself it will cause damage Caution Never fill 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 re...

Page 17: ...d 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 replace...

Page 18: ... 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 win...

Page 19: ...l 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 ...

Page 20: ...ection 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 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 ...

Page 21: ...on page 21 If the winch has a pneumatic free spooling control the air pressure shall be 6 10 bar If the winch has a hydraulic free spooling control the oil pressure must not exceed 40 bar Check free spool clutch 0018 01 1 2 3 1 Air oil supply 2 Control valve 3 Free spooling valve Art No mm Art No mm 73 06 73 07 73 08 60 08 60 15 60 16 16 73 09 9 63 01 63 02 21 63 53 10 63 35 11 62 56 12 63 31 9 63...

Page 22: ...w points at the connection point Art No Art No 73 06 73 07 60 08 60 15 60 16 0049 01 73 09 63 01 63 02 63 53 63 31 63 34 63 35 62 54 62 56 63 31 63 34 73 08 Installation Pne 1 8 Hyd G 3 8 Pne 1 4 Hyd G 1 2 Pne 1 8 0053 01 Hyd G 1 4 Pne M 12x1 5 or 1 4 Pne 1 8 Pne 1 4 0050 01 0052 01 Pne 1 4 0054 01 Pne 1 4 Hyd G 1 4 Pne 3 8 Hyd G 3 8 0051 01 ...

Page 23: ...tallation Always wear protective gloves when handling the rope Caution 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 Installation ...

Page 24: ...ld the rope firmly inside the pocket and pull firmly to insert the rope key and rope loop inside the slot on the drum 6 Make certain that both the rope key and the loop are entirely inserted into the rope pocket on the drum 7 Now wind the rope carefully on the drum while maintaining a pull on the rope itself Make certain that the rope ends wind up close together 0026 01 Installation Always keep a ...

Page 25: ...nge by hand as tightly as possible 3 Pass the free end through the hole nearest to the flange and make sure it goes right to the end of the hole 4 Secure the end of the rope in this hole by tightening the locking screw 5 Now wind the rope carefully on the drum while maintaining a pull on the rope itself Make certain that the rope ends wind up close together Wind the rope on the drum to exit either...

Page 26: ...w The rope must be fitted underwound Note This instruction is only valid when the spooling device is out of range and not working properly Installation 1 Turn the winch drum until the rope fixation hole or rope wedge pocket is in the rear vertical position Rope fixation hole Rope wedge pocket 2 Remove the cover from the rope guide Cover Helix screw Rope guide Top view Side view ...

Page 27: ...ing device 4 Remove the bolt washer key and gear Key Bolt Cover Washer Gear 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 Front view Rope guide to the outmost position Helix screw Top view Turn by hand Installation ...

Page 28: ... be pointing to the centre spot Note The location of the punched marks can be different between different winch models 6 Refit the gear and the cover secure the center bolt with Loctite 7 Refit the cover on the rope guide 8 Attach the rope in accordance to the instruction Rope installation Follower Rope guide Installation ...

Page 29: ...ation station and working lights 3 8 Electrical installation The emergency stop shall cut out the power supply to the winches WARNING 3 9 After installation Test all functions to see if they work properly before using the winch Check Control moves easily Emergency stop function Wire rope and attached devices free from damages Hydraulic system no oil leakage Level of hydraulic oil in the oil tank t...

Page 30: ...mechanical properties of liquids 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 This means that maximum pulling force and maximum rope speed cannot occur at the same time Winch basic...

Page 31: ...ontrol optional 2 Connection box optional 3 Switch for pneumatic or hydraulic free spool clutch 4 Connection for pneumatic or hydraulic free spool clutch 5 Winch 6 Hydraulic pipe Ø 16 mm or hydraulic hose 7 Hydraulic pipe Ø 16 mm or hydraulic hose 8 Return hose 1 9 Hydraulic tank with return filter and air filter Winch basics ...

Page 32: ...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 If a cable remote control is used the valve must be electro pneumatically or electrically controlled and with Hirschman or Deutsch contact 15 Ball valve assembly Winch ba...

Page 33: ... drive chain and run the winch for 5 10 minutes Viscosity The viscosity for the oil should be between 20 mm2 s and 75 mm2 s 100 and 370 SUS when the operating temperature of the system has become stabilised We recommend the use of an oil type having a viscosity of 35 mm2 s 165 SUS at the actual operating temperature Filtering It is necessary to keep the level of oil contamination at an acceptable ...

Page 34: ...increase in pressure or flow will increase the power and might damage the winch 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 The hydraulic oil must be of good quality and clean The oil tank must have a capacity adequate for the conditions under ...

Page 35: ... permits oil flow to measuring point E and to the brake F which releases when the pressure exceeds 30 bar The pilot line G leads oil to the Over Centre Valve D This valve opens at approximately 60 bar so that oil from the motor can return to the tank The oil drives the motor M1 and passes through the Over Centre Valve D and to V2 Red lines in the circuit diagrams oil flow Green lines only pressure...

Page 36: ...ceeds 30 bar The pilot line G leads oil to the Over Centre Valve D This valve opens at approximately 60 bar so that oil from the motor can return to the tank The oil drives the motor M1 and passes through the Over Centre Valve D and to V2 When the oil pressure exceeds approx 90 bar the sequence valve H opens and permits oil flow to all motors Red lines in the circuit diagrams oil flow Green lines ...

Page 37: ...rake F which releases when the pressure exceeds 30 bar The pilot line K leads oil to the Over Centre Valve L This valve opens at approximately 70 bar so that oil from the motor can return to the tank The oil flows to all motors M1 3 and passes through Over Centre Valve L and out through V1 Red lines in the circuit diagrams oil flow Green lines only pressure Winch basics ...

Page 38: ...ic block Combining sequence valve 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 They both have R 3 4 thread 1 1 1 Sequence valve This automatically regulates the rope speed and pulling force of the winch It is adjusted and se...

Page 39: ... is put in the neutral position or if the oil pressure is lost 2 Control valve unit 2 1 Directional control valve 4 way 3 position with spring centred motorised spool and built in pressure reducing valve The ports A and B must have at least R 1 2 threaded connections and the ports P and T at least R 3 4 2 2 Pressure reducing valve Must be pilot controlled set to maximum allowed pressure for the wi...

Page 40: ...er to 10 microns or better and accept required oil flow 3 4 Pipe hoses and connectors Must be approved for min 25 MPa 250 bar working pressure and have the following dimensions Pump inlet line min 1 1 4 Return line min 1 Pressure lines hose 1 2 3 4 pipes min Ø16 x 2 mm Pilot line pipe min Ø8 x 1 mm Winch basics ...

Page 41: ...releases when the pressure exceeds 30 bar The pilot line G leads oil to the Over Centre Valve D This valve opens at approximately 60 bar so that oil from the motor can return to the tank The oil drives the motor M1 and passes through the Over Centre Valve D and to V2 Red lines in the circuit diagrams oil flow Green lines only pressure Single Speed Winches with one motor Winch basics ...

Page 42: ... brake F which releases when the pressure exceeds 30 bar The pilot line K leads oil to the Over Centre Valve L This valve opens at approximately 70 bar so that oil from the motor can return to the tank The oil flows to the motor M1 and passes through Over Centre Valve L and out through V1 Red lines in the circuit diagrams oil flow Green lines only pressure Winch basics ...

Page 43: ...the vehicle s hydraulic system They both have R 1 2 or 3 4 thread 1 1 2 Double overcentre valve This allows the load to be spooled out at a controlled rate It also provides burst hose pro tection It is adjusted and sealed in our factory 1 1 3 Shuttle valve Supplies pressure for the spring loaded 1 1 4 Pressure gauge outlet R 1 4 female threaded connection Not on all winch models 0003 01 1 1 4 V1 V...

Page 44: ...controlled set to maximum allowed pressure for the winch and be sealed at installation 3 Hydraulic oil supply unit 3 1 Hydraulic pump The pump must be able to deliver required oil flow and oil pressure for the winch The pump is direct mounted to the vehicle PTO Fixed pump and load sen sing or variable pump requires different directional control valve 3 2 Hydraulic oil tank 3 3 Return oil filter Mu...

Page 45: ...emove 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 3 Pay out the rope to the first rope layer Connect the wire rope to a fixed object via a load cell Pull until the winch stalls Compare the load cell value to the winch maximum pulling force according to the technical data 4 To increase the oil pressure t...

Page 46: ...WORLD CLASS WINCHES RELIABLE DEPENDABLE UNCOMPLICATED 45 Winch basics 7503175 P T LS M A B Hydraulic circuit for control valve PVG 32 ...

Page 47: ...f g 1 000 Firm road 0 050 Grass 0 175 Gravel 0 250 Sand 0 325 Shallow mud 0 425 Deep mud 0 625 α 10 18 sinα 0 17 α 15 27 sinα 0 26 α 20 36 sinα 0 34 α 25 47 sinα 0 42 α 30 58 sinα 0 50 Rr The roll resistance for wheeled and tracked vehicles on different surfaces If a tracked vehicle has immobilized tracks you should increase the values below by 40 Ff The friction factor depends on the number of ro...

Page 48: ... is stuck in sand in a slope with an inclination of 15 The Vehicle weight is 10 000 kg RPF M sinα Rr 1 Ff g 1 000 10 000 0 26 0 325 1 0 05 10 1 000 61 4 kN A pulling force of 61 4 kN 6 1 T is required Winch basics The required pulling force increases if the gradient increases ...

Page 49: ...han 8 times it will be impossible to get a good rope spooling If the distance is less than 8 times the drum width W rope spooling problems may occur 4 3 How to improve rope spooling When installing a drum winch mount the winch as far as possible from the first rope sheave or roller fairlead Choose a winch with a drum width that allows you to have the smallest possible fleet angle Observe that a na...

Page 50: ...e appropriate wire rope becomes an important safety precaution The wire rope s minimum breaking load must be at least twice the load capacity of the winch itself unless national standards and requirements demand a different ratio of rope capacity vs the winch s load limits The wire rope will spool on to the winch drum To lessen the probability of an ac cident and to minimize the premature wear of ...

Page 51: ...ds 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 0064 01 1 2 1 2 00064 02 1 1 2 2 1 Core 2 Strands 1 Conventional 2 Compacted 00064 02 1 1 2 2 00064 02 1 1 2 2 00064 02 1 1 2 2 A compacted rope will have a longer useful life since damage will be avoided because of the rope s sm...

Page 52: ...uent cleaning and lubrication will contribute to good wire rope economy Corrosion reduces the rope life Winch basics 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 Synthetic rope should have the following characteristics Elongat...

Page 53: ...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 If the change of rope direction is small the ratio can be much smaller but note that the rope will get damaged if the ratio is too small For dimensioning of rope sheaves diameters see DIN 15020 4 5 Dimensioning of rope sheaves Winch basics ...

Page 54: ...ilar situations 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 WARNING Block the recovery area acco...

Page 55: ...NCOMPLICATED 54 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 F F 2 F 3 Winch basics ...

Page 56: ...ease 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 4 1 2 3 1 Winch 2 Snatch block 3 Recovery object 4 Anchor point Winch basics ...

Page 57: ...se 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 4 1 2 3 1 Winch 2 Snatch block 3 Recovery object 4 Anchor point Winch basics ...

Page 58: ... UNCOMPLICATED 57 1 2 3 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 Winch basics ...

Page 59: ...ENDABLE UNCOMPLICATED 58 A complicated location of the object to be recovered can require the use of more than one recovery vehicle 1 2 3 1 Pulling winch 2 Anchor point 3 Snatch block 4 Recovery object 5 Holding winch 5 4 Winch basics ...

Page 60: ...neral Before a recovery operation is begun be sure that you have read and understood this manual Check Control moves easily Emergency stop function Wire rope and attached devices free from damages Hydraulic system no oil leakage Level of hydraulic oil in the oil tank tank filled to 80 Illumination of the working area if dark That long wire ropes are marked with flag s That roads are blocked accord...

Page 61: ...ring devices may not be designed to withstand the maximum pulling power of the winch Operating instructions 15 15 Never pull at an angle of more than 15 degrees on either side of the drum Place the winch in a straight line in front of the load if possible or use snatch blocks Also always use snatch blocks if you are not certain about the weight of the load about to be pulled This will reduce the p...

Page 62: ...ontrol Free spool the drum by using the electrical control switch 2 Pull out the rope manually Always pull out the rope manually with the drum disengaged Never run the rope while under power Always leave enough rope on the drum for at least four revolutions Check the drum brake before attempting to use it If it does not respond correctly please refer to the information in the chapter entitled Drum...

Page 63: ...t No 60 08 60 15 60 16 73 06 73 07 0057 01 1 2 73 08 73 09 0058 01 1 2 63 01 63 02 0060 01 1 2 63 31 63 34 0059 01 1 2 63 35 63 53 0061 01 62 52 62 56 0062 01 The different manual handles for the Sepson winch groups are shown below 1 Pull 2 Turn Operating instructions ...

Page 64: ...taching the load Attach the rope to a secure point on the recovery object Never hook the wire rope on to itself it may damage the wire Always use adequate equipment that is designed to withstand the maximum pulling force for the winch WARNING Operating instructions ...

Page 65: ...ol Engage the drum by using the electrical control switch Activate the control valve and rotate the drum slightly until it is fully engaged Make sure that the free spool clutch is fully engaged To avoid jamming the free spool cylinder regular maintenance is required See the chapter entitled Maintenance Make sure nobody is inside or close to the danger zone of the winch during operation WARNING Ope...

Page 66: ...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 A worm gear winch will hold the load without a brake and over centre valves as it is self braking Note The rope speed varies depending on the load and rope layer on the winch drum 0009 01 Operating instructions ...

Page 67: ...ut the rope and make sure it is slack before unhooking it from the load 2 Unhook the rope from the load 0009 02 Before unhooking the rope after pulling make sure it is slack otherwise there is a significant risk of injury from an uncontrolled rope rotation WARNING Operating instructions ...

Page 68: ... drum 0009 01 1 Spool back the rope on the drum 2 Keep a sufficient load in the rope to keep it stretched 3 Check that the rope spools properly on the drum Always keep a pull on the rope when spooling it back on the drum otherwise it will not spool correctly WARNING Operating instructions ...

Page 69: ...ar may leak some oil The seal between the rope drum and gear housing is a V ring to allow the rope drum to rotate A small amount of oil will leak out from the V ring seal Note that all grease consists of oil and a thickener If the winch is not used for a long time the grease will bleed and seperate the oil and thickener The bleeding temperature for Mobil Grease XHP 222 is 30 C 40 C On some winches...

Page 70: ...s 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 The brake lining shall be replaced when the thickness is less than 1 mm Art No Art No 63 31 0068 01 63 31 63 34 0069 01 62 54 62 56 63 02 63 53 0073 01 63 35 0074 01 73 07 73 08 0076 01 Maintenance ...

Page 71: ...fect 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 Loosen the locking nut 2 Turn the adjusting screws counter clockwise a quarter turn 3 Tighten the locking nut Maintenance ...

Page 72: ...pe wedge 4 I IN IN Winch drum brake 5 I IAN IANG Winch pressure roller pressure plate 6 I IN IN Rope guides rope trumpets and roller fairleads 7 I INL INL Mobil Grease XHP 222 or eq Winch drum seal V ring 8 I IN IN Free spool clutch 9 I IL ILY Moisture absorbing oil Winch gear drain 10 E E Winch floating wheel optional 11 IN IN IN Audio visual 4 wrap rope warning optional 12 I IN IN Automatic rope...

Page 73: ...ope sheave optional 17 IN IN IN Mobil Grease XHP 222 or eq Winch gear drive 18 L INL Mobil Grease XHP 222 or eq 150g Winch gear oil on some winches 19 U E 6254 6256 SAE 80W 90 or eq Hor 2 litres Vert 3 litres 6353 SAE 10W 30 or eq 26 litres Winch rope guides and other accessories fixation points 20 Y Hydraulic tubes pipes and fittings 21 N I Electrical cables and connectors 22 N I Painting and cor...

Page 74: ...m 6 Inspect the pressure roller for deformation damage and wear 7 Inspect the rope guides for deformation damage and wear Lubricate 8 Check that the drum seal ring is in place and in good condition 9 Check that the free spool clutch has an unrestricted full movement in accordance with 6 4 Free spool clutch Lubricate moving components 10 Drain the winch gear from moisture 11 Inspect the rope sheave...

Page 75: ...ion bolts If necessary tighten up Note Ensure that tightening torques are in accordance with the table below or with the manufacturer s specifications 21 Inspect the hydraulic tubes pipes and fittings for leakage deformation damage and wear 22 Inspect the electrical cables and connectors for damage and wear 23 Inspect the equipment for corrosion and paint removal repaint if necessary Maintenance ...

Page 76: ...vice gear drive Spooling device Spooling device helix screw and bellow Constant force device roller fairlead Winch gear drain Winch gear drive Winch drum and rope wedge Audio visual 4 wrap rope warning Spooling device rope guide Maintenance Keep the shaft dry and clean ...

Page 77: ...the winch without oil WARNING 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 Oil filling Oil level Oil draining For Sepdurance H300 we recommend SAE 10W 30 or similar Fill the gear box with approx 26 litres up to the oil level plug Maintenance ...

Page 78: ...BLE DEPENDABLE UNCOMPLICATED 77 VANSBRO Sweden 1 7 MSK 6 Example of winch grease nipple Example of snatch block grease nipple Example of fairlead grease nipple Maintenance Equipment with grease nipple should be greased regulary ...

Page 79: ...Dimension Tightening torque Nm M 4 3 1 4 5 5 3 M 5 6 1 8 9 10 4 M 6 10 4 15 3 17 9 M 8 27 40 47 M 10 50 73 86 M 10 x 1 25 53 78 91 M 12 86 127 148 M 12 x 1 25 95 139 163 M 14 137 201 235 M 14 x 1 5 150 220 257 M 16 214 314 369 M 16 x 1 5 229 336 393 M 18 306 435 509 M 18 x 1 5 345 491 575 M 20 432 615 719 M 20 x 1 5 482 687 804 Maintenance ...

Page 80: ...s each time the vehicle is being washed 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 P...

Page 81: ...ELIABLE DEPENDABLE UNCOMPLICATED 80 Art No mm Art No mm 73 06 73 07 73 08 60 08 60 15 60 16 16 73 09 9 63 01 63 02 21 63 53 10 63 35 11 62 56 12 63 31 9 63 34 13 Minimum allowed movement of the free spool clutch Maintenance ...

Page 82: ...sign 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 Discard criteria examples Strand jerk Snarl Basketing Flattening Maintenance ...

Page 83: ...engaged 7 Hydraulic brake is not releasing 8 Defect hydraulic pump Check hydraulic oil level Check all hydraulic lines fittings and components for leaks Engage PTO Replace motor or contact authorized service shop Release the emergency stop Inspect and repair electrical system Disengage the free spool clutch Check oil pressure at the inlet to the brake 30 bar Replace the hydraulic brake Replace pum...

Page 84: ...pool housing 1 If pneumatic free spool clutch is used insufficient air supply can be reason 2 If hydraulic free spool clutch is used insufficient air supply can be reason 3 The winch is under load 4 The free spool clutch is damaged Disengage the free spool clutch and rotate the drum till the drive chain engages Dismantle the free spool clutch or for some models the winch and replace the return spr...

Page 85: ... flow 4 Hydraulic oil filter is dirty 5 Air in hydraulic system 6 Control valve dirty 7 Hydraulic brake is malfunctioning Replace pump or contact authorized repair service Replace motor or contact authorized repair service Increase engine rpm Clean or replace filter Ventilate hydraulic oil system Clean control valve Check oil pressure at the inlet to the brake 30 bar Replace the hydraulic brake Tr...

Page 86: ...ontrol valve defect 1 Suction channel sucks air 2 Oil return line ends over the oil surface in tank 3 Ambient temperature too high for the hydraulic oil 1 System relief valve set too low Increase engine rpm Clean or replace filter Replace motor or contact authorized repair service Let the oil cool down Replace pump or contact authorized repair service Clean or replace valve Check connections Exten...

Page 87: ...re 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 70 dB A The vibration total value in the winch controls depends on the placement of the controls on the vehicle The value is less than 2 5 m s2 8 1 2 Vibration Technical information ...

Page 88: ...isk assessment and risk reduction EN ISO 4413 2010 Hydraulic EN ISO 4414 2010 Pneumatics EN 60204 1 2006 Electrical equipment of machines Part 1 general requirement DIN 15020 1 Strength of gear transmissions EN 60529 A1 2013 Degrees of protection provided by enclosures IP code EN 13732 1 2008 Methods for the assessment of human responses to contact with surfaces Part 1 Hot surfaces EN 13857 2008 S...

Page 89: ... telecommunications terminal equipment Supporting safety standards EN 301489 1 2001 EMC and radio spectrum matters ERM EN 301489 3 2001 EMC and radio spectrum matters ERM EN 300220 3 2000 EMC and radio spectrum matters ERM EN 61000 6 2 2005 EMC immunity EN ISO 13849 1 2006 Safety related parts of control systems Military applications Applicable defence standards on request Technical information ...

Page 90: ...ovisions of Directives 2006 42 EC Machinery 2014 30 EU Electromagnetic compatibility to which this declaration relates is in conformity with the following standards and other normative documents EN ISO 12100 2010 EN ISO 4413 2010 EN ISO 4414 2010 EN 14492 1 2006 A1 2009 EN 60204 32 2008 EN 301489 1 2001 EN 301489 3 2001 This declaration relates exclusively to the machinery in the state in which it...

Page 91: ...Sepson AB SE 780 50 Vansbro Sweden phone 46 281 758 40 fax 46 281 710 09 info sepson se www sepson se WORLD CLASS WINCHES RELIABLE DEPENDABLE UNCOMPLICATED 2018 03 ...

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