DIY electric winch repair

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

Any foreman will tell you that winch repair always starts with diagnostics. Small firms may lack skilled craftsmen and sophisticated equipment. If the cause of the breakdown is difficult to establish, it is better to contact the place where the part will be checked in production.

Shaft displacement due to loose bolts in the side of the mechanism. Tighten and secure the bolts.

2... There is no grip on the ratchet wheel, the toe of the dog has shifted. The spare part is coupled to the wheel and fixed.

3... The braking system does not work. Most likely, the dog is jammed, which needs to be cleaned and lubricated.

4... Problems with the gear teeth, when they can jam, won't work. There can be two reasons for the breakdown. Either the teeth of the wheels are dirty, or the side parts of the assembly are skewed. It is necessary to pull off the sidewalls, clean the teeth.

Speaking of a manual winch, we also remember that sometimes there is such a problem as heavy turning of the handle, on which it is more and more difficult to push. This is not considered a malfunction, but the work still needs to be made easier. In this case, you will need fresh lubricants for the bearings, as well as the sidewall screed.

Unlike manual devices, an electric winch is a much more complex device that can fail at any time due to operator negligence or improper handling of the unit.

Depending on the nature of the malfunction, repair or replacement of the winch part may be required. Let's list the main types of breakdowns.

The gearbox is noisy. The reason is bearing wear. It is necessary to replace the components and flush the mechanism.

The electromagnetic brake hums and overheats, there are extraneous sounds. This is caused by incorrect spring tension or the appearance of a gap between the core and the armature of the magnet. Also, the electric winch can make noise due to power surges or low voltage.

Video (click to play).

Excessive heating of the gear bearings. This means that the old lubricants need to be replaced, having previously flushed the gearbox with kerosene.

Overheating of the brake pads. It is worth trying to change the clamping force of the pads. Since the malfunction may have deeper causes, it is better to immediately contact the craftsmen who repair the winches and guarantee the accuracy of the diagnosis.

As soon as the winch is disconnected, the load is lowered. Probably, the pads of the brake unit are not tightened enough or these elements are oiled. Just in case, the mechanism is washed with kerosene, and the worn out parts are replaced.

The electric winch does not lift the load. This is due to the fact that the voltage in the network has dropped, the cable is overtightened, or the oil in the gearbox is too thick. Release the brake, change the lubricants and eliminate surges in the power supply.

If you follow the rules for the operation of electric and manual winches, then most of the malfunctions do not cause huge problems. Any sensible master will cope with such work pretty quickly. However, there are situations when a major breakdown occurs. Here are some examples.

1... Brake clutch repair. The pulley consists of two half-couplings worn on the shafts of the motor and gearbox. Both elements are connected by so-called pins with rubber bushings. On average, the bushings need to be changed every 5-6 months. In addition, it may be necessary to replace the clutch or make pins.

2... Repair or replacement of a part such as an electric motor. There may also be trouble with the starting equipment. Most often, the motor breaks down due to problems with the train.Network jumps, phase loss, acidification of contacts and errors in operation play a role.

It happens that it takes a long time to start an electric winch. The issue can be resolved only by calling the wizard. After finding out the cause of the breakdown, the electrician will repair the motor, starters or replace the power cable.

Repair of the brake mechanism. Although this issue has been partially discussed above, some points should be clarified. The fact is that the brake mechanism is a very complex element in which anything can fail: a pusher, pads, brake, electromagnet.

After repairing the winches, it is advisable to call a specialist again after a while to observe the device and evaluate its work.

In addition to the listed works, the craftsmen replace the drum stands, beds, make gears, paint winches. It is not recommended to repair the mechanisms yourself. If a manual winch can still be brought to life on its own, then it is better not to joke with an electric one.

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

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 fixing 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.

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 stops functioning 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.

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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 console 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 having to resort to the help of specialists.

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 remote control, 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.

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, a 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.

A hand-made winch will always be a wonderful help, both during construction, repair, and in many other situations that require moving or lifting loads to a height.

The brilliant artist, scientist, inventor is also known as the author of original solutions in the creation of weapons.So, a catapult with a winch made Leonardo famous and was an effective means of deterring enemies. A winch is a machine for moving loads by means of a moving working body (rope, chain). The simplest of them - a gate, a block - have been known since ancient times.

In Russia, winches have been used since the eleventh century for the extraction of brine. In the fourteenth and fifteenth centuries, they were used for drainage, in ore mines, in construction work. They are described in the works of M.V. Lomonosov. Theoretically, it is possible to build a winch to the moon, there were such fantastic projects. You just need to make the right calculations.

You can familiarize yourself with real devices, including a homemade hand winch, by watching the video.

If you happen to lift a bucket of water from a deep well by rotating the gate, you already have an idea of how the winch works. A winch is a machine for lifting or moving loads. It consists of a drum or pulley for a load rope, a drive mechanism with intermediate gears, a brake device and a support frame. Depending on the purpose, these mechanisms are divided into traction (moving loads horizontally) and lifting.Nowadays, it is difficult to imagine loading and unloading, construction, repair, warehouse work, car service without these simple and reliable devices that have been tested over the centuries and are constantly being improved. Along with mechanisms for mooring ships, lifting anchors, winches as part of a large number of machines, a homemade hand winch is successfully functioning - the best option for building a country house. Image - DIY electric winch repair

A few words about the classification of winches. Depending on the installation method, there are

stationary,
portable (placed on a temporary basis),
mobile (with stands with road rollers).

According to the type of traction power transmission, winches with winding drums and winches with friction drums or pulleys are distinguished. The use of a manual or machine drive defines two main types of winches. The horse-drawn drive - oxen or horses - remained in the distant past. So if you are not capable of pulling the equivalent of a pair of oxen, the electric winch is your choice, self-installed.

Hand winches are often used for various repair work, in individual construction, at bases and in stores selling building materials - in general, where it is necessary to lift or move rather large weights. A winch with a hand drive must necessarily have a brake and a ratchet stop or a safety handle that combines the functions of a drive handle, stop and brake. This is a guarantee of trouble-free work. Image - DIY electric winch repair

Yes, the winch undoubtedly makes the job easier. But do not forget that it requires, depending on the operation being performed, certain physical efforts, sometimes very significant. Only by correlating the amount of work to be done and their severity, you decide to make the construction winch yourself.

Traditionally, machine-driven winches are used to service simple construction cranes, scraper, drilling rigs, and elevators. They can have one, two or three reels. It is possible to use various drives - electric, diesel, pneumatic, steam. Image - DIY electric winch repair

More often, there are reversible winches, the drum of which is connected to the engine shaft by gears of the gearbox, less often - frictional ones using an appropriate clutch or split friction transmission. Electric winches are equipped with automatic braking systems.

A DIY construction winch is a tempting project. Having studied the issue, purchasing the necessary parts and assemblies, I hurried to the suburban area, where the walls of my future chorus began to grow. But on the outskirts of the farm, my "iron horse" was hopelessly stuck. As always, attempts to break free from the grip of the mud backfired.I knew that the only tractor driver Kostya had gone to a wedding in another village, and the summer residents had not yet appeared. The situation is called "Help yourself", similar to how Baron Munchausen pulled himself out of the swamp by the hair.And I pulled my car out. Because I managed to make a hand winch from scrap materials. Whoever has a hacienda in these blessed places always has a kit in the trunk in case of emergencies: a crowbar that plays the role of an axis of rotation, a piece of pipe, that is, a drum, well, and without a cable, who gets behind the wheel? I have a lever welded to the pipe. Force, of course, is needed to move the car. But it is still possible. Sweated, turned the pipe. Gradually the rope wound up, and we crawled out of the mud. The golden invention is the winch.

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You ask, how can you make such a winch with your own hands? Everything is very simple.

First, dig a crowbar or long sturdy stick deep enough into the ground. This will be our axis of rotation.
Then, on top of this axis, a piece of pipe should be put on. It is more convenient to use a pipe with some kind of indentation or welded "ears" for which the cable can be hooked. (You can use an electric pipe cutter or even a metal hacksaw to cut the pipe you want.)
We grab one end of a strong cable (sling) on a piece of pipe, and the other end to our load (in this case, it is a stuck car).
Using the lever, we begin to wind the cable around our pipe. It is important to take into account two points here: the longer the lever, the less force you will have to apply to achieve the result, but at the same time working with a very long lever is usually inconvenient. The optimal length will be 70–90 centimeters.

It remains to figure out how the lever will be fixed. There are several options: you can weld the lever to the pipe in advance, which is not always convenient; or make a loop of the cable and insert the lever into this loop.

When operating hoisting mechanisms, safety rules are of paramount importance. No person should be in the range of the winch. If for some reason it is difficult to ensure, it is necessary to set up an observer who will not allow situations that threaten to arise. The person who operates the mechanism must clearly see how the load is moving. Professionals know how important it is to securely fasten the winch and check that the rope is wound correctly on the drum. Ideally, the safety margin of the winch should be six times. Image - DIY electric winch repair

If you are using a winch to pull the vehicle out, make sure the cable is strong enough and not damaged. And for insurance, it will be useful to throw some old blanket or jacket over the cable, which you do not mind getting dirty. If the cable breaks, this will partially extinguish the force with which its pieces will "shoot", which can save you from injury.

Undoubtedly: the one who can did it long ago. Dealt with bearings, gears, crawling and stationary nuts, etc. Such people, first of all, specifically formulate a goal, start with accurate calculations, diagrams, sketches. And the matter is in their hands is arguing. But not everyone has such a calling. If you are not among those who are confident in their abilities, but would like to make an electric winch with your own hands, use the services of a qualified consultant. Image - DIY electric winch repair

And remember that you should take into account the fact that, without having suitable parts at hand, you will have to pay a decent amount for a homemade electric winch. And the amount will be comparable to the cost of buying a good used option. Then, perhaps, the best way for you is to successfully choose a reliable machine from the ones on sale for the planned work, correctly install this mechanism, and study the operation manual. The choice is yours!

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.6. And finally, make a remote control. For this, just one button is enough, which will close the contact. It must be spring-loaded so that its contact opens when released.7. Such a do-it-yourself car winch has one important nuance, namely, it cannot be fixed directly to the car.You will have to attach a fabric towing cable to the frame to act as an insulator. To get rid of this nuance, it is necessary to isolate the motor brushes from the mass.A do-it-yourself manual winch is structurally similar to an electric one, so you can follow the instructions described above, however, instead of an electric motor, you must attach a handle, which you have to rotate by hand. Thanks to the gearbox, it will be possible to significantly reduce the load on a person, however, the power of such a winch will still be determined precisely by muscular strength. This is worth considering if you own a full-size crossover or SUV.Now you know how to make a winch with your own hands. It has a fairly simple design and is easily made from common and cheap materials, which will allow you to make even a temporary solution without extra costs before buying a branded unit.