101 now called 102 ?

[101 Ron]

I found the limits of a 101 winch on Sunday.
I also anchored the front of the vehicle with the front pintle hook and winched out the rear and the vehicle may have been longer than before.




The cable has been broken at the 30 mtr mark and is stuffed.
Any one got 65 mtrs of special 9mm cable with a specail thimble swage on the end of it ?
What would be the breaking strain of a 9mm cable with IWRC......?
the winch should be rated at 6000lb and I naturally exceeded this.
The winch its self appears OK
The POMs always thought the winch breaks before the cable did if the overload clutch is screwed up.
It is interesting in that it broke at the capstain.

[101RRS]

My guess you either had a fault in your cable or more likely the clutch on the winch itself was out of adjustment. The clutch is designed to slip at 2100 - 2000 Kg pull so you should have just lost pull rather than breaking the cable.

[101 Ron]

Fiction overload clutch.
I have been a bad boy and screwed it up just a little bit too high.......or the over load clutch was sticky.
I was giving the thing a hard time too.

[Blknight.aus]

depending on the construction of the rope it should have a WLL of about 2.3T (average figure of the most common constructions) you probabley want a 2.5T version..

Conveniently I might just happen to still have a roll of that grade FSWR from a crane that would be more than the 60m you need. Its not long before I go for a recycling run.... so I'll check then, swaging and adapting will be something you need to sort.

[101 Ron]

Thanks for the offer,but at this stage I have to check lots of things.
I am told the cable on the 101 is 9mm and is IWRC.
The winch on the 101 is not normal in its design and operation.
The winch drum only stores the cable.
The pulling effect of the winch via two turn capstan and the cable must be correct diameter and construction for the winch to work correctly.
Interestingly the cable parted company not on its weakest point up near a worn section near the hook, but on the capstan drum and the break was over a 10cm lenght of the cable.
Later this week I will do some home work on what is needed.
My greatest concern is not the cable , but trying to replace the special swage fitting on the hook end of the cable.
The fitting I am thinking of making in the lathe.
The crimping and securing of it to the cable is the problem.
The other problem I can not really at this stage see any crimping marks on this special fitting on the end of the cable for the hook.......more study needed.

[Blknight.aus]

the constuction isnt all that Special its Independant Wire Rope Core.
without getting stupidly technical it was special in its day because of its resistance to flattening, kinking and its flexability.

theres a couple of other styles of rope that will work just as well as the IWRC stuff.

in order for a dual capstan winch to work the key factors of the rope you need to have it work properly (aside from the correct nominal diameter)are its resistance to flattening and its flexabilty. If its too stiff it wont bend around the capstans and if it doesnt resist flattening it will chaff and bunch on the capstans pullys which dramatically shortens the life of both the capstan and the rope.

got some pics of the swage?

[abaddonxi]

A. Noble & Son Ltd
Is iwrc the same as tirfor wire rope?

Edit:
http://www.nobles.com.au/overview.as...ink_id=64.html
wire rope descriptions including iwrc.

[101 Ron]

Sorry like most of my pics they are out of focus.
This fitting is a must on the end of the cable.........sort of like a needle when the hook is removed so the cable can be threaded though the pulleys for transfer front or rear of the vehicle.

1.photobucke
t.com/albums/p299/101Ron/BILD0080.jpg[/IMG]

[101RRS]

When I got a hard eye put in my cable the rope guy took a sample and there is nothing special about the wire. I no longer have the specs - but it is something like - 9mm with solid wire core - four strand with something like 10 wires in each strand. It was listed in his wire catalogue so with a sample can be easily matched.

The ends are an issue - the ones the wire rope company had in their catalogue for the size wire were too large in diameter where the hook goes on to fit down the holes in the 101. They suggested getting a engineering shop to make one up - they didn't seem to have issues but it concerned me a little - the rope guy was happy to test the end product to determine SWL for $50. (non destructive testing)

An option is to go for a large soft eye which will fit down the holes but there will be increased wear on the cable where the hook joins - though most electric winches have this set up.

The cable on the capstan and around the rest of the winch is quite convoluted (I had to re-thread mine a few weeks back - job is a PITA) so maybe something happened there - whatever, the winch needs to be reset up.

PS - as an edit - my wire guy was Nobles in Newcastle

Garry

[Blknight.aus]

thats a fairly common fitting for stays but its still a compression fitting.

I think its available as a screw compression fitting.