A guide to inspecting wire winches on transporters, trailers and off-road vehicles

Winch wires and ropes are critical components for trucks, trailers and off-road vehicles fitted with winches, yet they are susceptible to damage if not properly handled and maintained. Understanding the common causes of damage and implementing comprehensive inspection routines can significantly enhance their longevity and safety. Winch wire or rope damage is important to pick up as part of pre-trip inspections.

Common causes of winch wire or rope damage

1. Excessive force: Applying force beyond the rated capacity of the winch wire or rope can cause irreversible damage. It is crucial to adhere to the manufacturer’s specifications to avoid overloading.
2. Kinking or knots: Kinking or tying knots in the wire or rope can weaken its structural integrity. Even a slight kink can reduce the strength of the wire or rope significantly, making it more prone to breakage. Kinks are caused by trapping or bending.
3. Surface abrasion: Rubbing the wire or rope against abrasive surfaces can cause fraying and cuts. Continuous friction can lead to the wire or rope deteriorating faster than expected.

Key considerations for transporters and trailers fitted with winches

When climbing onto a flat deck or trailer to inspect the winch, use three points of contact and watch out for slippery surfaces.

1. Clear display of maximum capacity: Every winch should have its maximum capacity in kilograms (KG) clearly displayed. This ensures users are aware of the limits and helps prevent overloading.
2. Safety margin in ratings: The winch, along with its wire/rope and fittings, should have a safety factor of at least 1.5 times the displayed rating. For instance, if a winch is rated for 3000kg, the displayed rating should not exceed 2000kg.
3. Manufacturer’s recommendations: The quantity of winch wire or rope should comply with the manufacturer’s guidelines and should not extend beyond the trailer or its fitted ramps to minimize damage and misuse.

Comprehensive pre-trip inspections

• A thorough pre-trip inspection should include checks for:
  • Expiry dates: if there are expiry dates for any components, these should not be past due
  • Wire strands and strap/rope integrity: Look for broken strands, frays, rips, or cuts.
  • Heat marks: Check for any discolouration or heat marks that indicate excessive heating.
  • Excessive stretching: Mark the full extent of the wire or rope on the trailer or truck body and ensure it does not exceed this mark, indicating stretching.
  • Sharp kinks and knots: Identify any sharp kinks or knots, as these weaken the wire or rope.
  • Hook and clip/keeper condition: Inspect for any stretching or cracks.
  • Crimp ferrules: Ensure the crimp ferrules are intact with sufficient tail length.
  • Fittings condition: Check for any deformities or cracks in splices, bends, loops, eyes, shackles, and other fittings.
  • Winch mechanism: Ensure the mechanism is clean, lubricated, and free from dirt or excessive buildup. Remove any deformed or damaged mechanisms.
  • Corrosion protection: Spray the winch wire with a lubricant to protect against corrosion. Check that the wire and hook are not corroded
  • Winch operation: check that the winch itself is not straining or making unusual noises.
  • Cleanliness: winches used in muddy areas can pick up all kinds of dirt which they then transport into the mechanism, degrading it over time. Keep the winch clean.

By adhering to these guidelines, you can enhance the safety and operational efficiency of winches on your trailers. Regular inspections and proper handling are paramount to preventing damage and ensuring the longevity of winch wires and ropes.