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Offline Gunna Do

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Winch Failure (Tell us yours!)
« on: July 25, 2011, 01:24:14 PM »
This series of pics came up on another forum, and I thought a few on here may be interested.  They show a Superwinch X9 winch which has had the gearbox housing sheer in half whilst in operation.  My first observation about the pics below, was what appears to be a complete lack of grease in and around the gear set and housing.

If you have a winch which has let you down at some time, give us a bit of a description of the failure, and what the end cause was, as well as the cure.  Don't forget to include the brand of the winch so we can get some idea if each problem is specific to a particular brand, and to help potential and present owners to narrow down any inherent problems, and maybe be a little proactive in reducing the risk of it happening to their winch, and leaving them stranded.  
« Last Edit: July 25, 2011, 01:26:11 PM by Gunna Do »
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Offline Red Dog 4x4

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Re: Winch Failure (Tell us yours!)
« Reply #1 on: July 25, 2011, 02:18:25 PM »
I fitted a cheaper winch that had a wireless remote system, to my uncles truck a few years back ( 2-2.5 ) not long after fitting it he parked his car at work, came out at the end of the day, Flat battery...WTF called RACQ new battery put in off he gos.

We went round there for tea one night and I noticed the fairlead was out of shape, I went a spoke to him, and he knew nothing about it. what had harped was the remote system for the gate to get into the work car park had a very similar radio feq as the winch did. So as some one went into the gate the winch would wind in killing the main battery and twisting the winch, bullbar and fairlead and burning the winch motor out.

Long story he was given a new winch and a new bar, so when it came time to fit it all again we removed the wireless system out of the control box.

Red Dog
PS- I will get a photo of the free spool system, I had a busy weekend.
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Offline welchygq

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Re: Winch Failure (Tell us yours!)
« Reply #2 on: July 25, 2011, 02:55:25 PM »
Warn High Mount winch - does not come factory with the rear "tie bars" that you get on a low mount.

Loose wrap on the drum and the cable hooked up around the end plate.

Destroyed the end plate, brake shaft and one of the itermediate gears.

$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$

Welchy
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Offline Gunna Do

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Re: Winch Failure (Tell us yours!)
« Reply #3 on: July 25, 2011, 03:44:50 PM »
Red Dog, what was the brand of your Uncle's winch.  With remotes for just about everything these days, you've got to wonder what frequencies are close on all these things. (Can't wait for the pics of your freespool setup either)

Wireless remote on a winch, to me, just complicates things, and is just something else to cause grief just when you need it.  I've fitted winch controls on the console of my Patrol, and have found them brilliant, and don't need any extra setting up to use.

 
« Last Edit: July 25, 2011, 03:57:49 PM by Gunna Do »
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Offline Red Dog 4x4

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Re: Winch Failure (Tell us yours!)
« Reply #4 on: July 25, 2011, 03:59:02 PM »
It was one of the Aldi winchs, for him I don't think he has even unwound the cable off the drum yet. But your not wrong about about the wireless systems!!!!

All though my system isn't a simple system anyway.
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Offline Strider

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Re: Winch Failure (Tell us yours!)
« Reply #5 on: July 25, 2011, 04:14:08 PM »
I have to disagree with the wireless systems being an extra complication. To me they give you the freedom to operate without any chance of the wired remote cable getting tangled or damaged. And if the wireless remote fails you have a wired remote (now where di I put that) to back you up.

One positive to getting my winch proffesionaly installed by Ash at Coastl 4x 4 Hervey Bay was that he put in a isolator switch. Why? so other remotes don't activate it. Good thinking Ashley!

Cheers
Alan
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Offline Jon

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Re: Winch Failure (Tell us yours!)
« Reply #6 on: July 25, 2011, 05:03:22 PM »
Quote from: Gunna Do on July 25, 2011, 01:24:14 PM
 Don't forget to include the brand of the winch  

This might turn into a winch hunt. ;D
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Offline RWS

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Re: Winch Failure (Tell us yours!)
« Reply #7 on: July 25, 2011, 05:10:19 PM »
Tigerz11 has a inline isolator switch which cuts all power with the turn of a knob...http://www.tigerz11.com.au/isolator_cable.html
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Offline Gunna Do

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Re: Winch Failure (Tell us yours!)
« Reply #8 on: July 25, 2011, 05:18:19 PM »
RWS,  I think TigerZ introduced the inline isolator switches after a few problems with winches activating accidentally in their earlier models.
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Offline MR MAC GU

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Re: Winch Failure (Tell us yours!)
« Reply #9 on: July 25, 2011, 07:35:36 PM »
While winching with my TJM OX 10000lb electric winch too much cable wound up on one end of the drum jamming against the tie rods causing the housing to crack.

TJM repaired it at no charge even though it was my fault.
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Offline savanahkelpy

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Re: Winch Failure (Tell us yours!)
« Reply #10 on: July 25, 2011, 08:07:45 PM »
Even Tirfor type hand winches can have problems. Don,t ever lend your winch to a mate, who ends up using the cable for something else whereby he ties a knot in the cable,, >:( >:(,,even if the knot is undone,,the cable will never be the same and there will be a dead spot on your wire rope that the jaws won,t grip properly. >:( >:(
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Offline Silvo

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Re: Winch Failure (Tell us yours!)
« Reply #11 on: July 25, 2011, 08:12:22 PM »
Quote from: Gunna Do on July 25, 2011, 05:18:19 PM
RWS,  I think TigerZ introduced the inline isolator switches after a few problems with winches activating accidentally in their earlier models.

yes mine doesn't have the isolator..

also, i had winch failure on the weekend. it looks to be the solenoid, which i believe is fairly common in the tigerz winches.
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Offline Black Diamond

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Re: Winch Failure (Tell us yours!)
« Reply #12 on: July 25, 2011, 08:18:48 PM »
Quote from: Gunna Do on July 25, 2011, 05:18:19 PM
RWS,  I think TigerZ introduced the inline isolator switches after a few problems with winches activating accidentally in their earlier models.
Yep i just helped a mate fit one and it has one, a good feature.
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Offline BigJules

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Re: Winch Failure (Tell us yours!)
« Reply #13 on: July 25, 2011, 08:27:58 PM »
I've had the dodgy three position switch on my Tigerz11 fail. Initially thought is was the solenoid, ordered and fitted a new one, still no go. The wireless controller also gave up the ghost.

I now think I erred in not fitting the TPS I was generously given, thinking that the wireless system made this redundant. The thing about winches is that they live in the toughest positon on the vehicle, getting wet and dirty whenever the conditions are poor, dusty when it's dry and hot when you use it.

I am planning to fit an in-cab TPS and re-wire the control box for greater reliability. I also carry a spare solenoid.
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Offline Gunna Do

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Re: Winch Failure (Tell us yours!)
« Reply #14 on: July 25, 2011, 08:29:01 PM »
Silvo, I think solenoid problems may be the cause of many winch failures, regardless of brand.  Add to this the added complication of the new range of wireless remotes, and plenty of exposure to the elements, and its a recipe for failure.
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Offline dno

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Re: Winch Failure (Tell us yours!)
« Reply #15 on: July 25, 2011, 08:29:29 PM »
Quote from: Gunna Do on July 25, 2011, 05:18:19 PM
RWS,  I think TigerZ introduced the inline isolator switches after a few problems with winches activating accidentally in their earlier models.
I'm wondering if these in line isolators are going to have long term reliability issues, Has anyone had one apart ?
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Offline BigJules

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Re: Winch Failure (Tell us yours!)
« Reply #16 on: July 25, 2011, 08:29:46 PM »
Quote from: Red Dog 4x4 on July 25, 2011, 02:18:25 PM
what had harped was the remote system for the gate to get into the work car park had a very similar radio feq as the winch did. So as some one went into the gate the winch would wind in killing the main battery and twisting the winch, bullbar and fairlead and burning the winch motor out.

Fark. Must go out and use the isolator that came with the winch.

Wouldn't that really give you the shytes; your own wireless system might not work but whenever Aunty changes the channel with her old TV remote the winch twitches.

Quote from: dno on July 25, 2011, 08:29:29 PM
I'm wondering if these in line isolators are going to have long term reliability issues, Has anyone had one apart ?
They're a simple twist mechanism that closes the contacts, could fail, low probability.
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Offline Gunna Do

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Re: Winch Failure (Tell us yours!)
« Reply #17 on: July 25, 2011, 08:32:17 PM »
Probably just something else to go wrong Dean.
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Offline Black Diamond

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Re: Winch Failure (Tell us yours!)
« Reply #18 on: July 25, 2011, 08:36:34 PM »
Quote from: dno on July 25, 2011, 08:29:29 PM
I'm wondering if these in line isolators are going to have long term reliability issues, Has anyone had one apart ?
Funny you say ask that Deano as i spoke to my mate before and the connecting spring inside the isolator bent after a few times and broke connection.....
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Offline baldheadedgit

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Re: Winch Failure (Tell us yours!)
« Reply #19 on: July 25, 2011, 08:37:24 PM »
Just use a Anderson plug & socket.! fool proof,,, unless you forget to unplug it,,,  but then you could forget to turn the isolator switch too.??? so,,, whats the answer.??

BHG
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Offline Gunna Do

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Re: Winch Failure (Tell us yours!)
« Reply #20 on: July 25, 2011, 08:43:33 PM »
Don't think an Anderson plug would carry the sort of current which a fully loaded up winch can draw.
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Offline Silvo

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Re: Winch Failure (Tell us yours!)
« Reply #21 on: July 25, 2011, 08:49:31 PM »
just put an inline switch on the negative switching wire running to the control box/solenoid..


i ran that into my cabin, so unless that is on the winch doesn't work
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Offline Gunna Do

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Re: Winch Failure (Tell us yours!)
« Reply #22 on: July 25, 2011, 08:57:26 PM »
I have something similar with a switch on the positive feed wire to the in cab control switch which then runs through to the socket for the hand control on the bulbar.  I used a missile type switch cover to avoid the switch being turned on by accident.  I still worry about those heavy wires running through to the winch though.
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Offline dno

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Re: Winch Failure (Tell us yours!)
« Reply #23 on: July 25, 2011, 08:59:50 PM »
I've got a 12000lb tigerz and was worried about that inline isolator, First thing was that the switch was exposed. So i pulled that lead and swapped it end for end, so now the switch is under the bonnet up near the battery but still have my reservations about it's life span. Know about our old mate Murphy and how he like's to catch us out ;D
BD how'd the fix go with your mates ?
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Offline Black Diamond

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Re: Winch Failure (Tell us yours!)
« Reply #24 on: July 25, 2011, 09:05:17 PM »
Quote from: dno on July 25, 2011, 08:59:50 PM
I've got a 12000lb tigerz and was worried about that inline isolator, First thing was that the switch was exposed. So i pulled that lead and swapped it end for end, so now the switch is under the bonnet up near the battery but still have my reservations about it's life span. Know about our old mate Murphy and how he like's to catch us out ;D
BD how'd the fix go with your mates ?
I have not checked it out but it was as easy as bending it back. But took a bit of head scratching when his winch wasnt getting power before he found the problem - maybe he cocked it a bit when screwing it together  ;D or he screwed the cock not sure......;D
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