To secure the right choice of winch we recommend you to read this information.
If you miss to find the right winch and uses the wrong the lifetime of the winch will most probably be reduced and the winch will stop functioning to early.
Winches used in special conditions (rescue/off road) has higher demands for capacity compared to a winch which is used less.
As an example:
If your winch is mounted on a 4 x 4 vehicle you must secure the winch is powerful enough to pull your vehicle through streaming water, up hills, in mud, snow or sand.
The pulling force declines with each layer on the drum. The maximum pulling force of the winch is between the 2: and the 5: round.
Always multiply the weight to be pullet by factor 1.5.
This way the winch has sufficient power to compensate for small declines in the surface as well as lost power because of “final layer effect”.
The electric motor is powered by the battery on your vehicle or an external battery 12-or 24V
The drum: is the cylinder where the wire is placed. The drum is driven by the motor and the gearbox. The direction of the drum (in or out) can be changed on the gearbox.
The wire: The dimensions of the wire are determined by the capacity and form of the winch. Change the wire if the Ø has been reduced by more than 10%. If fibers in the wire are broken. If you find flat or clumpy areas on the wire. If the wire looks old and used.
Roller Fairleads: have the function to make sure the wire is placed correct on the drum. Normally the Roller Fairleads are not used, if the winch is placed in a position which gives the correct angle for the wire on the drum (90°)
The gearbox: is changing the effect of the motor to a big pulling/lifting force. The composition of the gearbox is important for the weight of the winch and the space needed to mount the winch.
Breaks: is functioning automatically, when the motor is stopped and the wire has a load. The break effect can be carried out by the motor or a separate mechanical break.
Clutch: is used to connect the drum to the gearbox/transmission. This means the drum can rotate free if the clutch has not been engaged. The clutch is activated by the handle on top of the gearbox.
This is how the winch is functioning:
Heat: it is very important to understand the relation between the use of the winch and the generated heath: the longer the winch is used the warmer the motor. Make sure to free spool the winch when possible and be sure to do the necessary pauses for heating down the motor. (If you “burn” your fingers on the motor, it´s too hot and you need to let the motor cool down).
Battery: if you use the car battery be sure you don´t empty the battery. Start the engine and reload.
Capacity: The maximum capacity is on the first layer of the drum. If the limit for the winch capacity is ignored the winch may collapse in which situation the product guaranty doesn´t work.
Accessories: a winch as such is nothing more than a simple tool.If used together with accessories your winch will be a productive aid in your daily tasks.
Always read the manual which comes with the winch alternatively can be found on our web page.
First, it´s important to understand the information about pulling force of the winch. This is a combination of the mechanical capacity of the winch and the breaking force of the wire.
It is important to understand the pulling force of the winch is based on the first layer of the drum.
The first layer has the biggest pulling force and the slowest speed. The last layer of the winch has the lowest pulling force and the fastest pulling speed.
As rule no. 1, we recommend to multiply the weight to be pulled by factor 1.5.
This way you make sure to take in consideration the factor of the first and last layer.
Using double wire by the help of a pully block and reduce the size of the winch. By using double wire the pulling force of the winch will be double but the speed will be only 50%. Also the pulling length will be only 50%.
“Double wire” only means using the wire mounted on the winch and letting the wire go through a pully block and back to the winch.
Like this illustration:
The influence on the pulling effect from increasing terrain is very important.Some figures to illustrate:
It´s very important the wire is going right onto the drum. If not the wire will wind up in one side of the drum causing big damage to the winch:
The winch must be mounted on a firmly fixing point to avoid dangerous situations.
To do so first fix the winch to a mounting plate including the 4 way-roller. Mounting plates can be ordered for all winch models and up to 4500lbs (2041 kg) mounting is included in the price and deliverance.
Mounting plates can be found in at least 2 groups:
Ordinary mounting plates like this for a 12000lbs winch:
In the front of the mounting place, the 4-way roller fairlead or Aluminum fairlead is mounted.
The winch is placed in the plate in the 4 mounting holes seen.
The entire unit (mounting plate including 4-way roller fair-led/alu-fairlead and winch) is placed on a firm fix point on the car or elsewhere.
Portable mounting plates:
The advantage is you are able easily to move your winch to different places on your vehicle (front/bag) or other places you are in the need of a winch. So instead of buying 2 or more winches you can use the same winch simply by moving it.
This is needed:
Fixing points which can be like this iron pipe, which has been welded to the frame of the car:
The portable mounting plate on which the winch is fixed like this for small winches (2000-3500lbs):
Or this for a 4500 lbs. winch:
For bigger winches (8000-12000lbs, this portable mounting plate is needed:
For the past two decades, synthetic rope has been rising in the off-road industry as the preferred winching material. Still, the differences between steel cable and synthetic rope are much less concretely understood than they should be. Both have their pros and cons and it is important to understand them before making a choice between the two.
Perhaps the biggest difference between steel cable and synthetic rope is their inherent safety. Anyone who has ever been around a steel cable when it snaps or has watched a YouTube video of it happening knows there is a lot of dangerous energy stored in a steel winch cable. If the line breaks, that energy turns the cable into a violent projectile, capable of dismembering or even killing people.
For this reason, proper safety precautions are vital, no matter what sort of winch cable you have. When using steel cable:
When winching, no matter what material the line is, you must know your winch. All truck and Jeep parts have capacity limits: light truck tires can only handle so heavy a load, each vehicle has a maximum towing capacity and different grades of winch line are only designed to handle so much force. Know how much your winch can handle before trying to pull yourself out of a mess or you’ll just end up in a bigger one.
Steel cable is also prone to developing burrs, so gloves are required to operate a winch loaded with steel cable. It may develop kinks, making re-spooling the cable difficult and decreasing strength.
There are also many benefits to using a steel cable over synthetic rope. For instance, steel cable requires much less maintenance than synthetic rope does, as it is very durable and unlikely to fray. Winching around a rock or tree is not much of a concern with steel cable, as the tree or rock is more likely to wear down than the cable is. This makes steel cable great for tough winching in tight areas where friction can become a real problem. It is also less expensive than its synthetic counterpart.
On the other hand …
Synthetic ropes are much less likely to cause injury than steel cables in the event of a break, as they are lighter and lose tension rapidly, falling to the ground. If a break were to happen, synthetic rope can also be re-braided in the field using the proper technique. It is a temporary fix to get you out of a bind, but it’s more than you can do with a broken steel cable
Because it is so much safer than steel cable, many 4x4 clubs and competitions require that synthetic rope is used. It makes sense, as these group activities mean there are plenty of innocent bystanders and helpers who could be injured by someone else’s steel cable snapping.
Despite being much thinner and weighing only 1/7 of what steel cable does, synthetic rope is about 1.5 times stronger than steel cable. It is also highly flexible, easy to handle and floats – making it perfect for winching from mud or water.
On the downside, synthetic rope requires much more maintenance than steel cable does. While it is very strong, it is also more fragile than steel cable. Synthetic rope is susceptible to damage from UV light, high temperatures (150° F and higher), chemicals, friction and grit.
However, proper care and maintenance can negate all of those weaknesses. With Synthetic rope, it is important to:
There are also aluminum and roller fairlead options for synthetic rope, which insure the heat created from winching will not damage or melt the line.
Aside from maintenance concerns, synthetic rope’s greatest weakness is its ability to hold water. Not only does this mean it will absorb all sorts of abrasive grit which will need to be washed out, but in cold weather it can freeze solid. If off-roading in freezing temperatures, it is important to keep this in mind and try to keep the line dry.
On the flip side, synthetic rope comes in all sort of dazzling colors. I don’t see any steel cables out there capable of matching my seat covers.
Chose an ordinary 12V/24V 50 amp or 65 amp car battery for your winch.
The right fleet angel is very important to avoid wire jam. Use a sheave as shown in this illustration:
Tuse a strop, not the wire:
Tuse a strop, not the wire:
Figure 1 :(step 1)
To install the complete kit, you will need to mount the winch, contactor and handlebar mounted Mini-rocker switch. Mounting locations may vary depending on make and model of the ATV. Read and understand the following instructions to choose the appropriate mounting locations.
Figure 2 :(step 2)
Figure 3 :(step 3) Contactor Location
The contactor is a primary safety feature in your winch system. It disconnects your winch from its power source when the ATV is not in use.
The contactor must be correctly installed to work properly.
It´s recommended that the contractor be mounted close to the battery and in a location as clean and dry as possible. Usual locations include inside, on top or on the side of rear storage box, and on a few models, under the seat.
Steel wire 133 treads/galvanised
|AD||Artikelnr||Nominell diam. d mm||Nominell diam. d tol. %||Stålarea mm2||Vikt kg||Min. brottlast 1960 N/mm2||Min. brottlast 200 kp/mm2|
Never use the winch or the wire on the winch to fix a load. Always use strops, pulley and shackle.
Getting to know your winch: after receiving and mounting your winch start to test your new machine with just a small load.
To avoid damages from the wire always use gloves when working with the wire.
Many different steel wire compositions are available.
This scheme is showing the general braking points of a steel wire:
This is how to calculate the max wire length:
The maximal length is calculated like this: A x B x (A+C) x 3,143/x wire Ø2
If you are new to winches it´s easy to be cheated. In China alone more than 200 companies without own development department are trying to make cheap copy products without knowing the demands for a quality winch.
Even products from high profiled producers can be copies. It´s very difficult for consumers to see the difference between a copy and the original product. Every component is hidden inside the winch.
Winch Supply Ltd. has trusted producers also in China and many years of experience. We are visiting all our producers once every year to make sure production is according to our quality standards.
When you buy products from Winch Supply Ltd. you are sure to buy quality!