Sepson SEPMATIC Manuel utilisateur
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
WORLD CLASS WINCHES
RELIABLE - DEPENDABLE - UNCOMPLICATED
2
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 signicantly
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
WORLD CLASS WINCHES
RELIABLE - DEPENDABLE - UNCOMPLICATED
4
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.
WORLD CLASS WINCHES
RELIABLE - DEPENDABLE - UNCOMPLICATED
5
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
WORLD CLASS WINCHES
RELIABLE - DEPENDABLE - UNCOMPLICATED
6
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
WORLD CLASS WINCHES
RELIABLE - DEPENDABLE - UNCOMPLICATED
7
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
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
WORLD CLASS WINCHES
RELIABLE - DEPENDABLE - UNCOMPLICATED
9
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 specication 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
Ce manuel convient aux modèles suivants
3
Table des matières
