DIY auto winch repair

In detail: do-it-yourself auto winch repair from a real master for the site my.housecope.com.

We repair the electric winch ourselves
1. The principle of operation of the electric winch
2. Malfunction of the electric winch
3. How to repair an electric winch yourself

A winch for a motorist is an almost irreplaceable thing. This is especially true for those motorists who are used to driving not on highways and highways, but on off-road and mountains, those who like to overcome all kinds of obstacles and obstacles to achieve their goal. Thus, this device is intended for real men. However, many motorists who love this kind of extreme are afraid of winches.

Of course, they do not run away from a taut cable and are not afraid to use such a necessary mechanism, this is not the point here. The fear of a winch in a motorist arises at the moment when the winch ceases to function normally or completely ceases to function. Most of the car enthusiasts will seek help in such situations, which, of course, cannot but be upsetting. With all this, most of them do not even think that this kind of device can be repaired and brought into working order, if only in order to return to camp or continue the race.

The main components of a standard automotive electric winch are: gearbox, main and auxiliary drum, starting equipment and the electric motor itself. The device of the main drum is the leading working element. The whole principle of operation of an electric winch boils down to the following: when the shaft rotates directly clockwise, the cam clutch will be activated, through which torque is transmitted through the gearbox to the main drum. Thus, the rope will be wound and the load will be lifted.

When the drum is directly rotated counterclockwise, it keeps the direction of its movement in the opposite direction, as a result of which the cam clutch device will be disconnected, and all contacts of the switch will close. During this kind of contact closure, voltage will be applied directly to an electric magnet - part of the auxiliary drum.

Under the influence of a magnet, the main drum clutch device will turn on, and rotation will be transmitted to the drum itself. An auxiliary cycle of twisting the main drum to the starting position will also take place. The main drum device will rotate under the influence of the auxiliary mechanism.

If you do not take into account that there are many serious differences between mechanisms from different manufacturers, all the main details and layout of the vast majority of modern electric winches will be very similar. Like all other traction mechanisms, the winch will have two unequal parts. The mechanical part will consist of a motor, a gearbox and a shaft that connects them, a brake device, a drum with a cable and a housing.

The on-board network of the car, the control unit, the remote control and the electric motor will relate directly to the electrical part of the winch. Any of the above elements may fail. Nevertheless, if the motorist has at least a minimal idea of their structure, then most of the faults will be very easily eliminated on their own, without the need to resort to the help of specialists.

Video (click to play).

So how can you identify a broken piece of machinery? For example, in the event that, due to the activation of the winding mode, the winch does not work, many motorists will assume that the electrical part has not worked. But at the same time, they will not check if the wires are connected to the battery, if it was accidentally planted. If everything is fine here, then it will be necessary to check the entire electrical circuit, and you should start directly from the remote control.

Regardless of the appearance of the console, it will be a low-current three-position switch to which three separate wires will be connected. Two wires will be routed to the contacts in the control unit to the power relay, and the third will supply "plus". If the switch is out of order, then the non-positive wire should be closed, one of the controllers, after which the work can be continued.

All radio consoles will have rather complex designs, nevertheless, even such a detail can be duplicated by means of a conventional remote control. In the absence of a tester, the operability of the remote control device is checked by closing the contacts in the located connector on the solenoid block. However, only two of the three contacts need to be closed. In order for the winch device to work in different modes, you just need to swap the contacts. In cases where the check of the control panel will show that it has a working state, it will be necessary to proceed with the power control unit.

Before the motorist starts work, you need to figure out how exactly you can connect the winch. It is important to do this without fail to study all the diagrams of its connection, after which it will be necessary to connect all the wires of the device in accordance with these diagrams. If the connection is to an electronic network, the voltage of which is 220 V, then three wires will be connected to the mounting block. If the connection is carried out to a three-phase network, then four wires will be connected.

In the event that the motorist has connected the winch, and its drum starts rotating in the wrong direction at all, the two extreme wires to which the "phase" is connected will need to be reversed. It is the correct connection that will play an important role in the normalized and reliable operation of the winch. Any motorist will be able to independently disassemble the connection diagram, if it did not work out, then you should contact a specialist.

Read also: DIY tennis table repair

The electric winch will be powered from an alternating current network with a voltage of 380 V and 220 V. In addition, the equipment used can have 360 V. It is the last winches that are most often used on cars, since other analogues cannot be connected to the vehicle's on-board network. After the motorist has figured out the principle of operation and with the winch device, you can proceed to the next stage of the description. Sometimes situations arise when the motorist needs to completely disassemble the winch for troubleshooting or cleaning.

Repair of an electric winch can be done by hand if the motorist knows exactly how to disassemble the device. Thus, the analysis of the apparatus will proceed as follows. First, it is necessary to disconnect the cable by unscrewing the retainer and the bolts of the tie rods directly on the gearbox. Further, the gearbox is disconnected from the housing.

In order to disassemble the gearbox itself, it is necessary to remove the brake cover. After that, you also need to remove the brake drive clutch. Standing on a bearing, it rotates with the shaft. Next, you need to remove the drive shaft and, using round-nose pliers, remove the brake shaft and brake drum. Next, you simply need to unscrew all the bolts of the gearbox and disconnect it.

It is important to note that all certified winches should not be disassembled and repaired by hand, but rather they should be handed over to a workshop. That's it, the disassembly is complete and now you can fix the damage that has arisen. After completing all the above work, the assembly will take place strictly in the reverse order. In addition, partial disassembly of the winch can be done in order to carry out preventive work: removal of dust, dirt, lubrication renewal. It is important to do this in accordance with the operating instructions for this unit, as this will allow you to use the device, avoiding all sorts of failures.

Using a car starter is the most popular and effective way to make a homemade winch. The device is distinguished by a powerful traction electric motor, the supply voltage of which is 12 volts. These characteristics make it possible to use the manufactured winch on an off-road vehicle. How is a do-it-yourself winch made from a starter, and what needs to be done for this?

The winch is the most demanded hoisting device. Its purpose is to move the load horizontally. Drivers of off-road vehicles need this mechanism first of all, since such vehicles are used to move on roads without asphalt coverage and urban comfort. Such conditions lead to the fact that the machine can get stuck in sand or mud, and will fail when climbing a hill. For such situations, SUVs are equipped with a winch on the front bumper, but if it is not there, you can do it yourself. How is a do-it-yourself winch made from a starter, and what recommendations should you follow?

Depending on the situation, different types of winches can be used, which differ in the energies driving the mechanism. The principle of operation in this case is the same - a steel cable is wound on a drum, which can be rotated manually or by means of a motor reducer. Both a factory and a home-made winch from a starter can be manual, hydraulic or electric. Let's consider them:

So, how to make a homemade winch, what restrictions need to be taken into account? Here they are:

The automobile starter is started by means of a solenoid relay with a bendix. There is no need for a solenoid, but a contact starter will not be superfluous. This will provide more current to the contacts. It is better to leave the switching circuit as standard. The fixation of the bendix is carried out by welding in the position of maximum adhesion, but, depending on the gearbox used, it can be removed from the solenoid relay.
Starter operation cannot be continuous. But this does not mean that prolonged loads will lead to its immediate combustion. However, the motor housing will not provide sufficient cooling to the winding. Regular operation of the winch, taking into account long periods of operation, should provide the mechanism with additional cooling. Aluminum corners welded onto the body are suitable as cooling fins.
It is allowed to independently manufacture a gearbox for a winch, but you can choose a suitable one from an electric tool, taking into account the required load.
To prevent overheating, make sure that the supply wires are of large cross-section.

The following is a detailed instruction on how to make a winch with your own hands, using a starter from "Zhiguli". The choice of this starter is due to the fact that it is as compact as possible and has a high degree of reliability. An additional advantage is the ability to purchase it practically for a song in any spontaneous automotive market.

The long operational life of a home-made winch directly depends on the observance of the following conditions:

high-quality bearing lubrication;
reliable fixation of the mechanism on the foundation;
installation of chain pairs in one plane;
checking parts before starting;
watch the load and do not exceed the permissible limits;
control the movement of cargo;
do not touch the cable if it is under load;
watch the turns as the cable is wound around the drum.

A driver with basic car repair skills will be able to make a winch on his own and not worry about the vehicle's cross-country ability in off-road conditions. Use only proven and high-quality consumables, since the reliability of the mechanism and the duration of the winch's operating life directly depend on them.

Homemade winch from a starter: drawings of an electric winch, a photo of making a homemade product with your own hands.

For the manufacture of a home-made winch, the author used a starter from a VAZ 21015. The engine from a car starter is designed for short-term operation and quickly overheats, but it is quite suitable for making an electric winch.

We also need a reduction gearbox from a perforator, you can find a gearbox on the flea market, in this homemade product the author took a gearbox from an old Soviet-made drill with a gear ratio of 1 x 20.

The motor shaft must be connected to the gearbox shaft; this can be done using an adapter coupling and cotter pins, or simply welded by welding.

Now let's make a drum for the winch from a piece of metal tube and sheet metal - 3 mm thick.

A bolt is fixed in the pipe for fastening the cable.

Cut out two circles from the metal with a hole in the middle and weld them to the pipe.

A gear with a shaft must be welded to the drum. In this homemade product, the gear shaft is taken from a decommissioned oil pipeline valve mechanism.

The drum rotates on two bearings which are welded to the winch frame covers.

Drum with gear assembly.

Alternatively, you can take the drawings of the manual winch drum.

To prevent the cable from flying off the drum, we weld the guide lug to the winch body.

The gearbox is fixed on the winch frame, the author attached the gearbox using a pipe die for threading.

We compare the gear of the gearbox shaft with the gear of the drum. Gear ratio 1 x 5.

Reverse connection diagram on the winch.

We wind the cable onto the drum, the thickness of the cable is 6 - 10 mm.

Advice! Do not connect the electric winch to the car battery with the engine off, the battery will be discharged in a few minutes.

Also, you cannot cling to a metal cable a car from which the electric winch is powered, as an option, you can use a fabric cable or redo the brush assembly on the electric motor, isolate the mass on the winch itself.

A homemade winch from the starter will calmly pull a passenger car out of the mud, including the UAZ "loaf".

Homemade author: Nikolay Evdokimov.

Interesting video: the author shows his homemade winch from the VAZ 21010 starter

Judging by the fact that leading SUV manufacturers include electric winches in the basic configurations of their vehicles, it can be concluded that the interest of buyers in this accessory has reached a boiling point, and installation of a winch the SUV has become a must.On the basis of the 4x4 Club, a Department was opened for the repair of electric winches.Before starting the repair, the Club's specialists will perform diagnostics, determine the malfunction and the cost of the repair. It may turn out that repairs will not be required, but it will be enough just to clean the collector, bearings and their lubrication, which should be done regularly. 4x4 specialists are ready to advise you on the repair of winches.The production base of the 4x4 Club has all the necessary equipment and spare parts for the repair and maintenance of winches.Additional information by phone: (499) 922 4444 ext. 237

Winch diagnostics on a car, from 765 to 2500 rub. (depends on installation option)

ATV winch diagnostics, from 765 to 1225 p. Automotive winch diagnostics, from 765 to 1530 rub. Replacing the winch cable 765 p. Diagnostics, repair and maintenance of an automobile winch 4590 p. Diagnostics, repair and maintenance of ATV winches 3060 p. Replacing email car winch motor 1530 p. Replacing email ATV motor winch 765 p. Replacing the drum brake 3060 p. Replacing the drum 3060 p. Sidewall replacement 2300 RUB Replacing the sidewall ties 612 p. Replacing the winch motor control unit 1225 p.Replacing solenoids in the engine control unit 1225 p.* All prices are indicated taking into account the availability of a 4x4 discount CardHomemade winches from starters with your own hands: options and principle of operation, tips for assembly and operationHomemade winches from starters Image - DIY auto winch repair

Any car enthusiast, before setting off on a journey, must make sure that he takes everything he needs with him. But, if ordinary drivers do not need to take a lot of equipment, then off-road conquerors gather with special zeal. Any car enthusiast who prefers driving on the most extreme and difficult sections and roads takes with him the most necessary and necessary equipment that can help and facilitate movement, as well as provide a way out of the most difficult situations.

One piece of equipment that will help the extreme car enthusiast is the winch. An experienced driver who is ready for all the twists and turns of a road adventure will definitely take this important device with him. In difficult conditions, in which there is a high probability of the vehicle falling into a ditch or getting stuck in mud, the winch will help the driver pull his vehicle out of such road obstacles.

Of course, such a device can be purchased already in the form of a ready-made device, which, of course, cannot but rejoice. But, if the car enthusiast does not really want to go shopping and spend money on this device, moreover, if he has all the necessary components, he can make the winch himself.

The winch will be needed primarily for drivers of off-road vehicles. It is no secret that such cars are used just for trips on those roads where there is no longer urban comfort and asphalt. Country roads can be a problem for the untrained driver. But the presence of a winch can help out and overcome the most difficult sections of the path. Some off-road vehicle models are already equipped with a winch that is installed on the front bumper.

If the car is not equipped with such a device, then it can be purchased and installed on your vehicle. But it is quite possible to make a winch with your own hands. Many car enthusiasts already use homemade starter winches. By the way, most people argue that homemade winches are even more reliable. than their factory counterparts.

There are several types of such a device. These types differ depending on the energy that drives the actuator. It is impossible to immediately take and say which of the existing types of winches can be called preferable and best, since they are used in different situations.

As it was written just above, there are only three types of winches. They come in handy in different situations and also differ from the energy that drives the mechanism. But they are similar in one thing: in the principle of work. It consists in the fact that a steel cable is wound around the drum. The drum can be rotated, thanks to the motor reducer, or by using its forces, manually.

Homemade car winches can be:

A hydraulic winch is considered a more complex mechanism, since it has some additional elements, namely: a hydraulic drive, an oil tank and an oil pump. The device itself is rather cumbersome and is more difficult to assemble than other types of devices.But a hydraulic winch has two big advantages. it consumes less electricity, but at the same time has more power than other mechanisms. Usually winches of this type are mounted on very cool off-road vehicles, as well as on tractors and walk-behind tractors.

As a rule, an electrically driven winch can be found much more often, as it is the most popular option among craftsmen who assemble these devices by hand. Such a high popularity can be explained by the high efficiency and simplicity of the entire design. As a drive, you can use both an electric motor and a tractor or car generator. The generator must be connected in such a way that it subsequently functions as an engine. If a starter is used in the winch device, then the device itself will turn out to be more compact.

A very important requirement for an electric drive is that it must have a high torque. To prevent the battery from discharging too quickly, care must be taken that the drive does not consume too much power. but at the same time it worked with sufficient power. By the way, this type of homemade winch is easier to build with your own hands.

The device with this drive works according to the same principle of operation by which other design options of this device work. The main disadvantage of the mechanical drive is its size - it is rather bulky. By the way, this is the largest drive of the other device options.

The main difference between a device using a mechanical drive from other options is that instead of an electric motor, a direct physical effect is used. That is, in order to bring the mechanism into action, you will have to make some efforts. In principle, if you use a winch of this type, then you can note its main advantage, which is that such a winch can always be used in the absence of energy sources.

In order to make a homemade winch, you should first familiarize yourself with the list of the main parts that are used to make it. The main elements of hand-made devices include the following details:

Before starting the assembly, you should prepare everything for this. To begin with, it is recommended to understand all the necessary drawings and electrical diagrams. In this case, it is better not to rely on your memory or let all the work go by itself. Then you need to prepare the workplace and all the tools. which will be needed in the process.

If the master assembles the entire structure with his own hands, then he will understand it much better than in the purchased device. In addition, many motorists are inclined to believe that homemade winches are of better quality and reliability. If you assemble such a device from a starter, then the whole procedure will take about an hour, but on condition that everything you need is prepared ahead of time.

The main working unit of the winch is a drum with a cable. If the user already has one, then the work will take much less time. But not everyone is the happy owner of such a useful device. If there is no ready-made drum, then you can make it yourself using a thick pipe and sheet metal with a thickness of 3 to 5 mm. The cheeks should simply be welded to the pipe on both sides. The gear is attached to one of them. This gear will subsequently be energized by the gearbox.

By the way, if there is no ready-made drum, then it can also be made from Zhiguli hubs. who have already completed their term. This is not very difficult to do. You just need to weld them on the thin side. In order to ensure the alignment of the parts, you need to do this on a mandrel.

When choosing a gearbox for a device, many professional craftsmen recommend taking gearboxes that are used in trolleybuses to open and close doors. If the user has the ability to get such a gearbox, then it is recommended to use it. But if there is no such device, then you need to make the winch differently, that is, using a starter. It is recommended to use a special starter equipped with a planetary gear. This starter is more compact and lightweight. which will subsequently be a positive factor.

Homemade winches are usually attached to the front bumpers of cars. But car enthusiasts also use portable versions of such devices. They are put in the trunk and taken out in the event that their use is needed in a certain situation. In principle, in any case, the winch should be made as compact as possible. Bulky devices can cause some inconvenience later, making them more difficult to use.

When assembling a homemade winch, you should carefully consider all the details. This will avoid possible unpleasant consequences that may occur due to poor-quality design.
In no case should you force the assembly process. As they say, hurry up - make people laugh. It is better to spend an extra hour to understand everything exactly than to reap the fruits of your haste later.
You need to pay attention to the switching and installation of electrical wiring. It is recommended to fix the winch control panel away from rotating parts. This will reduce the risk of injury, which can subsequently be sustained through negligence or hasty action.

Homemade winches are believed to be less safe. than factory counterparts. In addition, they are not suitable for lifting loads in any way. This is due to the fact that such devices have no stopper. But one of the main advantages of home-made winches is the fact that, when properly assembled, they can last even longer than factory-assembled winches.

Homemade starter winches are more compact, so when choosing an option before assembly, it is better to opt for these devices. The advantages of such winches will be noticed by the user immediately upon use.

The winch is an essential part of any true SUV. So, the winch for UAZ and cars like it is a real helper in bad weather. But, what if you just want a simple and cheap unit that will help out a passenger car on a country road? For this, a do-it-yourself winch, both electric and manual, is perfect. Let's take a look at the required materials and manufacturing process.

If you are interested in a do-it-yourself winch from a starter, you can get by with cheap and common options. As a power unit, a motor from a VAZ-2101 electric starter is well suited. They are quite common and are cheap, but they do not have much power, but for a small sedan or SUV, for example, GAZ 69, it will be enough.

Next, it is worth looking at the gearbox. You can also choose from an old Soviet drill. The main thing is that the gear ratio is about 1 to 20.

You also need a shaft with gears and bearings, a piece of pipe for the drum and two round metal plates. You will also need sheet metal, various rods, bolts and nuts.

A do-it-yourself electric winch is good because you can use a lot of lying and unnecessary materials for it.

Of the tools, you definitely need a grinder, a welding machine, and an adjustable wrench.

A winch is often needed on a long and demanding trip. If you are adventurous, you will also find it helpful to learn about building an expedition rack. Read this article.And for a fishing trip you will need a boat trailer. Read about making it yourself here.

In fact, the process of making a winch is quite simple, but it is worth adhering to the order so that you do not have to redo the same job several times.

1. The first step is to connect the electric motor to the gearbox. To do this, weld a tube to the engine gear. Drill the other end through and weld two nuts. Next, you put the tube on the gear of the reducer and screw in the nuts, which will serve as a lock. So that nothing is wound around the shaft, it is worth covering it with something. For example, you can peel off a piece of thin-walled plastic pipe.

Very important! Before fixing, be sure to check that the gearbox is decreasing, not increasing, the motor speed.

2. Now you need to make the second important part of the auto winch with your own hands, namely the drum.

To do this, we take a piece of pipe and weld two metal round plates to it on the sides, which I will limit the rope. The plates should have a through hole through which we pass the shaft with the gear and weld it.

It's important to be aligned, otherwise your shaft will wobble and cause unnecessary vibration.

3. Next, we take two metal square plates, which in length will be slightly larger than the diameter of the drum plates. We make a hole in the center and in each corner.

We weld two bearings on each plate (but not with the inner part). Next, we pass the drum shaft through the bearings. To assemble the entire structure, you need 4 bolts, which we pass through the hole in one and the other plate, and on the other side we screw the nut. As a result, we do this from 4 corners.

4. The reducer must be attached to one of the plates so that it meshes with the shaft gear with its gear.

5. Finally, you need to make a frame. To do this, you can make a rectangle from square profiles and weld square plates to it with one side, and also fix the motor and gearbox.