Tips for Winch Identification and Safe Operation
Tips, tricks and important concepts that can help you identify and operate your winch.
By Don Kubly, AW Direct Technical Product Support
One of the most important tools needed daily in our industry is the winch. Here are a few basic winch tips.
Winch Identification
Most winches are left uncovered, leaving them exposed to the elements. They can also get nicked or scratched by tools, chains and daily use. After a time, the identification label or ID tag can become difficult to read or torn off all together. Without the label, it's difficult to know your winch specifications, and when necessary, how to find replacement parts or a new winch with the same capabilities.
When purchasing a new winch or a truck with a winch already installed, take pictures of the winch and all exposed labels and tags. Write down all of the information the labels include. When the time comes for any repairs or replacement, you’ll have a record of all specifications including pulling capacity, model number, manufacturer and serial number.
In addition, if your driver calls in needing winch parts or replacement parts, you have the information on file and don’t need access to the truck to get started on your search.
When you need replacement parts or need to replace the entire winch, all you will need to do is retrieve your pictures, which should include the manufacturer model number, part number and serial number and any other necessary information.
Common Winches and Their Primary Uses
Industrial-Grade Winches: Generally used for towing and recovery.
Consumer-Grade and Utility Winches: NOT for towing or recovery.
Planetary Gear Winch
Planetary Gear Winches: These include multiple gears, are lightweight and have fast line speeds. These winches require a brake system to operate.
Worm Gear Winch
Worm Gear Winches: These include just a worm and flat gear and do not require a secondary brake.
Winch Accessories
Roller Guides and Fairleads: These help promote even spooling. They also increase wire rope life and protect drum sidewalls.
Plate Tensioners: These help keep constant tension on the wire rope so it wraps tightly. Plate sizes should be the same size or slightly smaller than the drum.
Important Winch Specs and Concepts
Winch Speed Ratio: The lower the first number in the ratio, the greater the feet per minute speed (eg. 30:1 is about 32 fpm and a 46:1 is about 16 fpm).
Winch Maintenance: Check the owner’s manual that comes with your winch for daily, weekly and monthly inspection and maintenance information. Also consult it for repair or replacement information as needed. In general maintenance, check the mounting brackets and bolts to make sure the winch is securely mounted so winch components will stay properly aligned.
Safety Wrap: A minimum of five wraps of wire rope around the drum barrel is needed to support the load. The setscrew will not support a load.
Winch Pull Rating: Remember on most worm gear winches rated at 8,000-lb. with 3/8 wire rope, the rated line pull is:
8,000 lb. with one layer of wire rope on the drum
6,600 lb. with two layers of wire rope on the drum
5,600 lb. with three layers of wire rope on the drum
5,000 lb. with four layers of wire rope on the drum
4,400 lb. with five layers of wire rope on the drum
Check your winch manual for exact line pull ratings for your winch.
Operating Your Winch
The best way to get to know your winch is to read and understand the operator’s manual. After reading about your winch, listen to it. Learn to recognize the sounds of a light pull and heavy pull as well as the sounds of a load shifting or jerking. Then hook on to a few cars in the lot before actually heading out on the road for that first call.
Keep in mind the following two details when operating your winch:
Learn the correct procedure for disengaging and engaging the clutch to avoid future failure of components or loss of load.
To Disengage the Clutch: Run the winch in reverse (reel out) direction until the load is off the wire rope. Pull outward on the clutch handle and rotate to disengage the clutch. You can now pull the wire rope freely from the winch drum. If the winch is run forward and not in reverse, the pressure and speed of the drum rotation can catch the jaw clutch before it is fully engaged. This can cause only partial engagement, which exerts excessive pressure on the gears and can cause premature wear. If this procedure is constantly repeated, the winch may disengage at any time under load due to wear, causing the winch to jump into free spool. Your load will then go in reverse at excessive speed with no way to stop the load.
To Engage the Clutch: Release the handle and push inward to engage the clutch. Run the winch until the clutch handle snaps fully in or until the wire rope drum starts turning. Then run the winch in reverse for a fraction at slow speed. This will allow the clutch to fully engage. At this point make sure the clutch handle is all the way in and locked. After the clutch is fully engaged, the winch is ready for winching the load.
Using the winch and wire rope as the only means of tie-down to secure the front of the vehicle on the flatbed during transport is not DOT approved.
For information about choosing and caring for winch line, check out the article “The Heart of the Pull: Choosing and Caring for Winch Lines” on tech.awdirect.com.
For more information, contact AW Direct’s Technical Service Specialists Monday through Friday at 1-800-243-3194.
AW Direct | Answering the Call™ 1-800-243-3194 | awdirect.com
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