Winching and Setup Tips

These hints and tips will help you get the most from your vehicle winch set up.

1.  The largest battery with the highest "Cold Cranking Amp" (or CCA), capacity will provide the most brutal initial pull.  With series wound motors found in most quality winches, more battery power means the more the winch will pull...to a point, of course.  An excellent choice in batteries would be the interstate brand "31 series" commercial grade battery, providing a whopping 950 CCA's and an incredible 195 Minute Reserve Capacity (or MRC).  It's only slightly larger than the typical series 27 batteries found in many full sized trucks, and cost only a few dollars more while nearly doubling the average batteries performance.

Reserve power of a battery is also a major consideration, since that's what makes the winch pull for a determined amount of time before either the alternator can't keep up with the demand, the winch performance starts to fall off or the battery goes dead.

Say for instance, the Interstate 31 series battery which is rated at a reserve capacity rated at 195 minutes at a 25 amp draw, can be calculated to how long your winch can operate before the battery must be restored to it's full charge.  As an example, say your engine has stopped in a deep water hole, and the started is inoperable.  With 12,000 lbs Warn winch pulling at it's full capacity (400 amp draw), you will be able to winch with your vehicle for about 12 minutes before the engine MUST be started to charge the battery.  And at a line speed of 3 fps, you'll move your vehicle about 36 feet, well out of the 'midst of your keeper'.  This can be calculated by this formula....

W = Winch amp draw at rated pull (amps)

T = Reserve Capacity Time of battery (minutes)

A = Reserve Cap. rated @ what amps (usually 25)

TIME DURATION OF PULL = (A/W) x T   (the "/" means divide)

2.  The alternator should also have the largest possible capacity, although not 'critical' to winch performance.  This will just recharge the battery that much faster after or between usage's.

3.  The cables from the battery are also extremely important in the winch's performance.  Number "00 welding" cable should be used for both the positive AND the ground cables.  Run the shortest length of cable directly from the battery to the winch.  DO NOT ground the cable from the winch to the vehicle's bumper or frame.  Run it directly to the battery.  Any resistance in the current' path will extremely hamper the power needed by the winch motor during the initial surge of current required for a heavy pull.  Also insuring secure electrical connections are as equally important.

4.  When beginning a pull, remember that the more cable that is off the drum (up to one layer left on), the more pulling power the winch has, due to the ration reduction by the lack of diameter the effect the thickness of cable has on the drum.  So if possible, get the most distance between your vehicle and the hook location.  This will also increase the safety factor in case of breakage.  Using a tackle block to double line the winch also dramatically increases pulling capacity, by about 50% increase, NOT double.

5.  Remember not to pull a continuous extreme load for more than 1-1/2 minutes at a time before stopping and letting the winch motor cool down and the battery recharge.  Also periodically throughout the season check your battery's charge capacity and condition for top performance.  Recharge your battery on a charger every 3 months for optimum performance!

6.  Before using a new winch or cable, it is necessary to "break in" the new cable.  This is required to eliminate the possibility of the cable stretching at certain spots and not at others, thus causing weak points.  To "break in" the cable, spool out all of the cable, except for 6 wraps remaining on the drum.  Connect the hooked end of the cable to a stationary object, and begin to draw the vehicle in along a flat, hard surface.  Only a moderate resistance of brake load on the vehicle need be applied.  This will prestretch the cable out to it's maximum possible stretch uniformly along the entire length of cable.

7.  Any time you have the chance (after using your winch) to respool up the cable nice and tightly, DO SO!  Unravel the entire length of cable and draw it back up again with moderate resistance, while neatly spooling the cable into even and tight rows.  This will prevent the upper layers of cable from sliding down into the inner layers (underneath, thus creating such a snarl, whereas it may then be necessary to disassemble the winch in order to unravel it. 

8.  The use a pulley block, or "tackle block", is intended to increase a winch's pulling power, but also reduces the line speed about 40% at the same time.  Although the line speed is nearly cut in half, the actual pulling power of the winch is not in fact doubled.  This is due to the inherent power loss in the internal resistance of the cable being forced to make a 90 degree turnaround, as well as bearing friction of the pulley.  The tighter the pulley radius, the more pulling power loss.  The approximate power multiplication of most pulley blocks are about 150% of the winch's power (as opposed to the theoretical 200% figure).  This make a 8,000 pound winch look like a 12,000 pound pull, but also sacrificing half the line speed.  Also remember it will also take TWICE as much cable to go the same distance!  Multiple pulley blocks can also be used for triple lining, but remember not to exceed the capacity of the cable, or pulley blocks. 

OTHER NOTES:

1.  Drum diameter & Gear Ratio have a direct effect on pulling power while affecting line speed at the same time.  Motor horsepower has a direct effect on both line speed & pulling power with no compromise.

2. A magnetic motor will pull the same as a series wound motor, at at less of an amperage draw.  However, as the magnetic motor gets warmer, the power will drop as the amperage draw will increase.  A series wound motor pretty much stays the same throughout the duty cycle. 

3.  The width of the drum determines the inevitable loss of pulling power as the cable spools in, the layers on the drum increase and the effective gear ration ultimately drops.  The narrower the drum, the quicker the cable spools up and therefore, looses it's pulling power quicker as compared to a wider drum. 

4.  Worm drives are generally stronger and simpler than other drives such a planetary's due to the lack of the need for a braking system as well as the extreme gear reductions possible.  The primary drawback is the noticeable reduction in overall line speed, especially in a 'no load' cable reel-up situation.  Here, the planetary has an advantage.  

5.  Most winch ratings are generally limited by the maximum amperage draw, with right around 400 being the cut-off point.  Anymore than that would most likely damage the power source or charging system.  In order to reduce the amperage usually the gear ration will need to be increased numerically, to relive the motor from the increasing stress, however, this will also reduce the line speed at the same time. 

Maintenance Tips

• Inspect the wire rope before and after each winching operation. If the wire rope has become kinked or frayed, the wire rope needs to be replaced. Be sure to also inspect the winch hook and hook pin for signs of wear or damage. Replace if necessary.
   

• Keep winch, wire rope, and switch control free from contaminants. Use a clean rag or towel to remove any dirt and debris. If necessary, unwind winch completely (leaving a minimum of 5 wraps on spooling drum), wipe clean, and rewind properly before storage. Using a light oil on the wire rope and winch hook can keep rust and corrosion from forming.
   

• Operating your winch for a long period of time places an extra burden on your vehicle’s battery. Be sure to check and maintain your battery and battery cables according to manufacturer guidelines. Also inspect switch control and all electrical connections to be certain they are clean and tight fitting.
   

• Inspect the remote control for damage, if so equipped. Be sure to cap the remote socket to prevent dirt and debris from entering the connections. Store remote control in a protected, clean, dry area.
   

• Many winches require no lubrication for the life of the winch.  However check with your manufacturer's instructional manual for specific maintenance and lubrication requirements.