Industry News & New Products

Keep the cable on your winch drum neat and tight through a weekly maintenance procedure known as power wrapping. This exercise will prolong the life of your winch line by preventing weak points caused by unnecessary kinks and flat spots.

“You should power wrap your winch at least once a week,” recommends Rene Jimenez, a technical advisor at Zip’s AW Direct. “You want to keep your wire rope tight on the spool so it doesn’t dive or kink and start what I call the paper clip effect, where the more it bends, the weaker it gets before eventually failing.”

Power wrapping works in tandem with the cable tensioner. As illustrated in this video from Miller Industries, the procedure is performed by free-spooling the winch line out and then winding it back up under a load by attaching the hook to another vehicle or deadman.

“As you pull the wire rope out, you want to keep at least seven wraps on that last layer so you don’t pull all of the wire rope out of the drum. That would create quite a mess,” explains Miller’s Billy Drane in the video.

Experts say power wrapping should be done regardless of the size of the winch: from car carriers to heavy-duty recovery vehicles. The procedure is effective for both wire and synthetic rope. In fact, according to Jimenez, power wrapping helps “set the braid” on a new synthetic line.

Power wrapping is “something that is very important to do,” Drane said. “What can tend to happen (when you don’t) is the loose wire rope going around the drum will cause the top layers to bury down (or dive) into the inner layers.”

“Once you get in the habit of doing this regularly, it really doesn’t take very long to do,” Jimenez said. “Take a few minutes each week to prevent a headache down the road.”

Be prepared the next time your car won’t start with a jump pack from Zip’s AW Direct. We stock handheld chargers for the consumer, and powerful jump packs for the professional. In today’s blog, we are going to review a few of the models we currently have in stock.

The first item to consider when purchasing a new jump pack is safety. Look for models with reverse polarity protection. This safeguard prevents usage when the cables are not connected correctly. You should also keep an eye out for battery packs that won’t function when the voltage setting is wrong.

Another factor to look at is cable length, especially with a larger jump pack. Be sure to account for adequate clamp reach so the jump pack can rest safely on the ground. This prevents the pack from teetering on engine components or fenders when the hood is open on the disabled vehicle. 

Cable length is also important when connecting to terminals located inside of a vehicle. This keeps the power pack away from interior upholstery and prevents an unnecessary mess. Let’s face it. Jump packs only look new and clean once.

Cranking amps and battery ratings are also important items to research when purchasing a jump pack. Handheld models typically have lithium ion batteries. Their ratings are based on engine size. Larger jump packs with internal lead-acid batteries normally list cranking amps for capacity. 

Based on size, here are some of the jump packs Zip’s AW Direct has to offer. Be sure to click on each name to link back to its respective product page for complete details. 

• On the smaller scale is one of our newest models, the NOCO GB150 Boost Pro. This 4000-amp unit weighs just 7.5 pounds and can handle up to 80 starts per charge. The USB port can also charge personal electronic devices. 

• Next up is the Weego Crankenstein. The lithium-ion battery here can last up to 30 hours and can recharge in just six hours. The Crankenstein includes an LED flashlight and can hold a charge for one year. The built-in voltmeter also comes in handy.

• Perhaps one of our more popular models is the Jump-N-Carry JNC660 jump starter. This low-cost model features 425 cranking amps and 1700 peak amps. The unit weighs 18 pounds and features a DC outlet to power 12V accessories.

• A close cousin to the JNC660 is the JNCAIR, which offers the same capacity as the JNC660 but includes an internal air compressor. You can fill one flat tire under eight minutes and up to four tires on a single charge. The coiled air hose stretches to 12 feet and delivers on-demand air. 

• Two 12V heavy-duty sealed AGM batteries provide "Best in Class" performance for Associated Equipment's 6296 jump starter. This unit features 720 CCA of power and has a three-position "On/Off" switch with Easy-to-read LED battery status indicators.

• The last battery pack we’re going to look at is the Rescue 2100 from Quick Cable. This commercial-grade model offers 900 12V cranking amps and includes a 15-amp circuit breaker, worklight, and warning flasher. The Rescue 2100 does weigh a little bit more but delivers enough charging power for most applications. 

We hope you find this quick overview of jump packs at Zip’s AW Direct useful. To view our entire lineup, click on ‘Jump Start Equipment’ under ‘Roadside Assistance’ under our ‘Products’ section at zips.com.

Randy Wickman joined Zip’s AW Direct five years ago as a service writer and warranty rep. He was named service manager for our used truck division about a year ago. He now oversees repairs and reconditioning of used truck trade-ins and helps determine what repairs need to be made before resale.

Given his “intimate knowledge” of each used truck, Randy said he can offer support to the sales staff here and can also be a resource for the customer after the purchase. “I am always available to assist with each potential sale and provide advice on the unit’s representation,” he said.

In addition to sales and shop personnel, Randy said he works with several other departments at Zip's AW Direct, including the body shop, car carrier plant, finance, marketing and shipping and receiving. He described his co-workers as an “amazing team of people.”

“I work with each department to make sure our jobs get completed and out to our customers,” he said. “I enjoy my position in the service department because I get to interact with almost every department here.”

Randy said he is proud of the trucks Zip’s produces and enjoys seeing all of the Zip’s-built trucks on the road, making recoveries and taking care of customers. That pride motivates him to make sure every job he takes on is “done right” and to the best of his ability.

“At the end of the day, I drive home knowing that I did the best job possible with each project I take on,” he explained.

Home is now an acreage he and his wife recently purchased. When he is not busy settling in and making improvements, Randy said he enjoys racing motocross in his free time and rebuilding dirt bikes in his shop at home.

 

There are numerous factors to contemplate when buying a brand new tow dolly. Zip’s AW Direct offers a variety of Collins and In The Ditch dollies. We carry nine different models with capacities listed at either 3,040 pounds or 4,280 pounds, depending on tire size.

Today we break down the components of a tow dolly sets and explore how they relate to durability and maintenance. The blog post and video provide more information on the topic. The blog post provides a detailed outline of the key points.

Each featured part of a dolly offers benefits and limitations, both of which can affect the price range of $1,485 to more than $2,000 per set.

Tow dollies have 8” utility tires, allowing them to have a maximum road speed of 60 mph. Making them a good choice for short and medium distance travel. However, most operators prefer to stay at or below 50 mph for safety.

Based on your use cases, choose from 5.70 or 4.80 tire sizes with steel or aluminum wheels. Besides speed, tire sizes also affect load capacity: the larger the tire, the greater the load it can handle. Be sure to check tire pressures regularly on your tow dolly tires, for maximum safety and efficiency.

Dolly assemblies are made from steel and are available with aluminum or steel axles. Aluminum axles offer a weight savings that your operators will appreciate. Steel components can be zinc-plated or powder-coated with each offering its own level of durability.

Another item to consider is maintenance, especially this time of year. Tow dollies can often be neglected, and replacing a set may be the reason you’ve landed here. Zip’s AW Direct offers dollies with easy-to-lube grease zerks or with maintenance-free hubs. Featuring automotive sealed hubs and bearings, the latter can save you time and money and extend the life of your dolly. Choose what best fits your operation.

You can compare options and learn more by visiting our tow dolly section online at www.zips.com/towing-accessories. Here you will find detailed product descriptions as well as tables identifying which features accompany each model.

Also, don’t forget to check out our replacement dolly parts as well as our deck mounts and storage racks for your dollies when they are not in use.

Nancy joined Zip’s AW Direct one year ago as a Customer Service Representative. She was recently promoted as one of three new Key Accounts Representatives here. In her new role, she is looking to maintain “high levels” of customer service in ‘Rigging and Recovery’ parts and accessories.

“My motivation comes from addressing problems and obstacles and helping customers overcome them,” she said. “I want to empower my clients with the knowledge of parts and accessories in the industry. I look forward to becoming a leader within the rigging and recovery business and finding what motivates others.”

Nancy said she plans to cultivate relationships with current and prospective customers and will be relying on social media to achieve that goal. Her hard work and dedication have already garnered the attention of several of her customers, including Brandon Davis, owner of ABBA Towing & Recovery, Pawlsey Island, S.C.

“I started in the towing industry about the same time as Nancy did at Zip's AW Direct,” Brandon said in a review. “The first time I called looking for products for the tow company that I was working for, I was connected with Nancy.  I was unsure of exactly what I needed, but I had a customer service rep who was extremely knowledgeable on the phone to guide me.

“Her first priority has always been finding the best solution for my needs rather than being an ‘order- taker’ that just cares about making a sale,” Brandon added. “She, alone, has made me a Zip’s customer for life. She is second to none and goes out of her way to make me feel the same way.”

In between her phone calls, Nancy took some time recently to respond to a few questions for today’s employee profile. Her responses now follow:

Q. What do you enjoy most about working here?

A. The family environment. We all work together to ensure each and every truck and parts order is done to the highest standard.

Q. Is the glass half full or half empty?

A. I've always been an opportunist. Instead of the normal half full, half empty look, I like to think there's an opportunity to keep the glass full at all times.

Q. What do you like to do in your spare time?

A. As a mom of three boys, my spare time involves going to football games. I also enjoy rebuilding and racing muscle cars. My current project is a ‘78 Camaro. I also love cross-country traveling and camping.

If you have any ‘Rigging and Recovery’ needs or questions, Nancy is eager to help. You can reach her at 800-222-6047x142.

Brothers Steve (left) and Sam McGuire drove 12 hours straight through from eastern Kentucky to New Hampton, IA, last month to pick up their new LCG 21-foot steel car carrier from Zip’s AW Direct. The Century 12 Series rollback was the family’s first purchase from us.

The brothers said they spared no expense on the exterior of the red 2020 Peterbilt and were planning to dress up the interior as well. The polished aluminum bed rails, stainless steel toolbox doors, shiny wide bumper, chrome bug shield and chrome visor were just a start, they said.

“We’re shooting to make it back home in one day, but we have to stop by the chrome shop first,” explained Sam, who described himself as the “older and prettier” of the two siblings.

“The interior is just too plain for us,” Steve joked, confirming their first stop of the return trip will be the famous Iowa 80 Truckstop two and a half hours away.

The brothers hail from McGuires Towing, a 32-year-old towing and recovery company that is now well into its second generation. They operate out of Ashland, KY, and serve the tri-state area of Kentucky, West Virginia and Ohio.

“Dad started out with just one truck in 1987 with a homebuilt bed, and we’ve kind of grown from there,” Steve said. “We’re just the next generation to keep it going.”

“It has definitely evolved over years,” Sam added. “Dad has stepped back and given us the reins.”

Their latest truck purchase joins a fleet that includes a Miller 1150 rotator, a heavy-duty straight stick, three car carriers, two tractor-trailers and other light-duty wreckers.

Besides all of the exterior jewelry on this newest addition, the lighting package--highlighted by an LED message board--is sure to grab your attention as well. There’s also an SP9000 Sidepuller, GoJaks, storage trays and synthetic winch line.

“We went a little overboard with this one,” Sam admitted. “We figured it’s just easier to do it now when it’s being built.”

The brothers said they put together their shopping list for their custom car carrier by attending various tow shows and by researching Zip’s options online. “We’ve been following your trucks on social media and on your website for a long time now,” Sam said.

Both Sam and Steve said their first time working with the staff at Zip’s AW Direct has exceeded their expectations. They were able to stay at the company’s complimentary on-site hotel suite and were very appreciative of the red-carpet treatment they received during their overnight stay here.

“This has been a great experience for us,” Steve said. “You come to a place, and you usually don’t know where to stay, where to eat or anything like that. It’s nice to come here and meet all these nice people. They treat you like family here.”

“We want to thank you guys for the hospitality,” Sam said. “We’re very grateful, and we’re definitely looking forward to doing business with you guys again.”

To see the custom truck in person, visit our booth at the Tennessee Tow Show in Chattanooga Oct. 10-12.

Carrick Johnson serves as our equipment sales order entry manager at Zip’s AW Direct in New Hampton, IA. He has served in his role at Zip’s for the past three years. His primary responsibility is to take equipment sales quotes and then transfer them to a production order to initiate the build process. He orders all of our chassis and truck bodies and ensures the compatibility of the parts sold.

When not at work, Carrick describes himself as an avid hunter, fisher and trapper. He said he also likes to “tinker” in his shop with metal and woodworking. Let’s see what else makes Carrick tick:

Q. What do you enjoy most about working at Zip’s AW Direct?

A. The people and work environment make Zip’s a great place to work.

Q. What motivates you professionally and personally?

A. I always try to improve upon a process using the skills I’ve acquired in my career. It motivates me to also help others with their professional roadblocks. I tend to see if there is a “simple” answer to a complex problem.

Q. Is the glass half-full or half-empty?

A. Half full, if you made me choose. But I feel I am more of an optimistic realist. I see the best in people but have realistic expectations of situations based on my experience.

 
Jeremy and Alicia Ray of Cozy Corner Towing drove 12 hours from Colorado to New Hampton, IA, last week to pick up a light-duty wrecker from Zip’s AW Direct. The new Chevrolet was the couple’s fourth purchase from Zip’s in the last year and a half.

The timing of the Aug. 16 delivery was especially fitting for Alicia, coming the day after her late grandfather’s birthday. Bob Swaney founded the Lafayette, CO-based company more than 30 years ago, and Alicia is now a third-generation owner of the business.

Inducted in October of 2003, Swaney is a member of the International Towing and Recovery Hall of Fame in Chattanooga, TN. He was instrumental in organizing the Widows and Orphans Relief Fund in their state, and with their latest purchase, the Rays are planning to pay homage to the company founder.

“Everybody has their own story to tell, but this is a pretty big deal to us,” Jeremy said. “I was never able to meet my wife’s grandfather, but our newest truck will be an ode to the person who started all of this…who started our company.”

Swaney passed away 10 years ago. He was an active member and past president of the Towing and Recovery Professionals of Colorado. The Rays said they plan to keep the truck primarily white in honor of Swaney’s original company colors and will name it ‘Bobbie Joe’.

The decision to minimize the decals on this latest truck purchase is in stark contrast to the rest of their fleet. Their other three trucks feature full decal wraps, displaying their support for various causes which are “personal to us and our families.”

One truck features ‘Slow Down. Move Over’ decals and is dedicated to the Widows and Orphans Fund and the Wall of the Fallen tow truck operators' memorial. Another is decaled in support of breast cancer research, and a third calls attention to autism awareness.

In addition to their moving billboards, they also donate a percentage of the revenue from each truck to its respective charity. They said it’s a way to promote the organizations they care about and to help improve the image of tow truck operators to the motoring public.

“We just want to give back,” Jeremy said. “We don’t come from rich families. What we got is what we got. But being able to do something like this is one small thing we can do for others.”

Having started nearly two decades ago, Kevin Einck has seen Zip’s with only 60 people grow into what we now know as Zip’s AW Direct, which now employs 260+ people. He’s gone from being a car carrier installation tech to a manager of 17 mechanics in 7 crews, plus an off-site crew in Charles City. He’s seen how much the company has grown just by looking up from his work.

Working as a car carrier installation tech for ten years, he learned the trade and the business. He began working under a manager who taught him the ropes. He worked under him for “6 to 8 months” before Kevin ended up in his own stall with his own crew. For him, it’s been a major sign of growth that the people he’s trained have gone on to train more crews.  

Nowadays, Kevin ensures “the techs are doing a proper job of installing the carriers … in a timely manner.” He also schedules the jobs that come into the shop, double-checks that they have the right parts from Miller to build the carriers, fields calls from the service department on issues that might come up and does what he can “to solve any issues that may arise during a build.” He has one goal in mind, and that is “to assure the customer is getting the best product that Zip’s can provide.”

In his position he doesn’t “see an end … anytime soon for car carrier builds.” He sees them as Zip’s bread and butter. It’s what we do best, and in his eyes, we make them the best. We put out a quality product because that’s what gets people coming back. That’s what the business is, customer satisfaction. Whether it be “the minimal builds” or “the tricked-out, flashy builds” they have to be the best. It’s a point of pride for Kevin to watch “top-notch trucks going out to customers daily.”

Paul Rottinghaus, President of Zip’s AW Direct, has told Kevin many times, “You can and you will figure it out, there is no I can’t figure it out.” It’s a sentence that Kevin has taken to heart. Kevin does everything he can to get the job done while ensuring he has given the best he has because to him, what he does is more than just for a paycheck. He views Zip’s as part of his family.

 

Keeping wreckers clean and professional looking is part of maintaining a good business reputation. An important part of lightbar maintenance is keeping it clean.

However, the cleaning methods used will vary depending on the components used on our wreckers. For instance, lightbar lenses have specific cleaning requirements depending on the manufacturer. The general steps for cleaning your lightbar are as follows:

1. Wet lightbar with gently running water

2. Use a mild, soapy detergent with a soft cloth to wipe lightbar clean

3. Rinse lightbar with running water and use your soft cloth to remove water spots

Below are excerpts from the owner’s manuals of several of our lightbar manufacturers.

Whelen: Clean the outer lenses of a Whelen lightbar with only soap and water. Do not use any other cleaning products. Using any other cleaning products or solvents, may cause damage to the lenses.

When cleaning, use a soft cloth or sponge to gently scrub away any dirt or debris from the lenses. Rinse the lenses with clean water and then dry completely with a soft, lint-free cloth. Use of other chemicals could result in premature lens cracking (crazing) and discoloration.

Lenses in this condition have significantly reduced effectiveness and should be replaced immediately. After cleaning, inspect and operate this product regularly to confirm its proper operation and mounting. Do not use a pressure washer to clean this product, as it can damage or scratch the lens.

PSE Amber: Clean your lenses with clean water and a soft cloth. Alternatively, use Code 3® lens polish and very soft paper towels or facial tissue. Because plastic scratches easily, cleaning is recommended only when necessary (about every six months). Do not subject the lenses to car washes that use brushes as these will scratch and damage the lenses.

Federal Signal: Crazing (cracking) of the lenses will cause reduced effectiveness of the light. Do not use cleaning agents (which will cause crazing) such as strong detergents, solvents or petroleum products. If crazing of lenses does occur, reliability of the light may be reduced until the lenses are replaced.

Ordinary cleaning of the plastic lenses can be accomplished by using mild soap and a soft rag. Should fine scratches or haze appear on the lens, they can be removed. Remove with a non-abrasive, high-quality, one-step automotive paste cleaner/wax and a soft cloth.

ECCO: Occasional cleaning of the lenses will ensure optimum light output. Take care when cleaning lenses – although tough, polycarbonate scratches easily. Clean the lens and base with soap and water or a lens polish using a soft cloth.

Do not use solvents as they may damage the polycarbonate lens. Do not subject the lightbar to high-pressure washers or automatic car washers.

Snatch blocks are a common tool on almost every tow truck for good reason. Snatch blocks are useful in difficult recovery scenarios as they can increase the pulling force of a winch line.

A snatch block is a type of pulley block. It features a swing-open plate. This makes it suitable for short winch line runs and servicing.

When selecting snatch blocks for your truck, verify that the working load limit (WLL) of the winch line and snatch block are compatible. The snatch block must be at least as strong as your winch line.

Verify that the groove in the snatch block’s sheave wheel is sized for the diameter of your winch line. A groove that is too large won’t fully support the winch line and could cause damaging flat spots. A winch line that’s too large can crack the block.

To determine the proper size sheave wheel, use a 12:1 ratio. For example, a 3/8" winch line dia. multiplied by 12 yields 4.5" which is the ideal sheave diameter for a 3/8" wire rope.

Changing Directions.

Another primary use of a snatch block is to change the direction of pull. Blocks are anchored in a fixed position. The wider the angle at the block, the less force the recovery point has to withstand. One of the most common direction changes is attaching a snatch block to your bed. This allows the wire rope to feed straight into the winch. This ensures that it winds properly on the drum, rather than winding to one side.

Snatch blocks are also used as anchor points to change the winch line direction. Allowing the disabled vehicle or tow truck to increase pulling power. Multiple snatch blocks can even be used for self-extraction. This can be achieved by routing the winch line from the back of the tow truck to several anchored blocks to the front of the tow truck.

Increased Pulling Power

Snatch Blocks can increase pulling power by having a moving vs. fixed snatch block. In this situation, attach a snatch block to the load so it moves with the load as the winch is operated.

The amount of line angle at the moving block determines how much mechanical advantage is gained. Maximum gain is when the input wire rope is parallel, or zero degrees, to the output wire rope. This is called a double line pull.

It comes in handy when your winch is not rated for the amount of weight of your casualty. This setup effectively doubles the capacity of your winch by distributing the load over two lines.

Another situation is when the casualty is heavier than your recovery vehicle. In this instance, the tow truck’s wire rope goes through the snatch block attached to the casualty and back to another fixed snatch block then back to the load. This is a triple line pull and gains a 3:1 advantage. The more lines ran between the tow truck and the casualty, the more the pulling power increases.

Lubrication

When lubricating snatch blocks, use either sodium- or lithium-based grease. Bronze bushed blocks and sheaves generally need to be lubricated after 8 hours of continuous usage or at least every 14 days with intermittent use.

Roller bearing blocks and sheaves can be used for 24 hours continuously before needing lubrication. The same guideline of 14 days applies for intermittent use. Swivels follow the roller bearing lubrication schedule. Always follow your particular manufacturer’s lubrication timeline.

Snatch Block Inspection

Wear is a fact of life and will eventually affect the load a snatch block can handle. This means that regular and frequent inspection is needed. During inspection, keep the following in mind:

• Deformation of any part is an indication of overload and the snatch block must be replaced immediately.

• Swivel end-play of more than 1/16" is a danger sign. Replace the snatch block immediately.

• Spreading side plates are caused by overload and must be repaired or replaced.

• Looseness in the side plates are a sign of loose retaining nuts.

• Sheave alignment issues such as wobbly sheaves are caused by bearing wear.

• Groove wear in the sheave is caused by cable wear and can prematurely reduce wire rope life. Replace grooved sheaves immediately.

• Hook latches are designed to hold loose rigging under slack conditions. Replace any damaged latches.

• Any hook deformation, crack, gouge or distortion needs to be replaced immediately.

Having several snatch blocks on your tow truck can provide options when faced with challenging recoveries. Keeping them in proper working order will ensure they are ready when you need them most.

Before using any equipment described; be sure to read, understand and follow all manufacturers instructions and guidelines.

You’ve all experienced road service calls where someone simply runs out of gas. The solution seems as simple as filling and pouring using a gas can, right? Well, maybe not. The choice of which container used to bring fuel is actually not so simple.

There are three basic types of containers: Safety can, portable can and D.O.T. compliant can. Here’s the difference.

• Safety Can: Safety cans are approved by a third party safety company such as UL or FM. Safety cans must meet certain requirements set by OSHA 29 CFR 1926.155(l).

• They must be five gallons or less in size. They must have a flash-arresting screen, a spring-closing lid and spout cover. The design must safely relieve internal pressure when subject to fire exposure.

• This type of can is required when used by any business or commercial enterprise for storing or transferring gasoline and other flammable liquids. These cans meet OSHA requirements and are available in steel or plastic. These cans be used to transfer or store gas and other flammable liquids.

Eagle Type I Red Safety Can

• Portable Fuel Can: A portable fuel can is a container designed for use by consumers. These cans are used to receive, transport, store, and dispense gasoline, diesel fuel, or kerosene. Equipped with a spigot allows for no spilling and easy pouring.

• Cans are color coded in red for gasoline, yellow for diesel or blue for kerosene. They are deemed to be portable fuel containers regardless of how they are labeled per EPA 40 CFR 59.680.

• Portable fuel cans are designed with several features in mind. They help to control evaporative emissions and reduce spillage. These cans are often referred to as CARB (California Air Resource Board) compliant cans.

• These models are also designed with child-resistant features to meet the Children’s Gasoline Burn Prevention Act. These cans may meet EPA requirements, but not OSHA or DOT requirements. These cans are generally made of plastic, but there are some metal cans on the market.

No-Spill CARB Gas 

• DOT Compliant Can:  These cans need to meet the Performance Oriented Packaging requirements of the Federal Hazardous Materials Regulations. For instance, a standard safety can does not meet the requirements for transport. However, Safety Transport Cans have a spring loaded hold-down bracket for the lid to protect the spout.

• Some portable fuel cans have DOT caps that replace the spout assembly during transport to make them compliant. Jerri cans with screw-in caps that replace the spout assembly can also meet DOT requirements. Only cans meeting DOT requirements can be used for transporting flammable liquids.

DOT Compliant Cap

Check the label or imprinting on your gas cans to see if they meet DOT requirements. You should look for a DOT approval stamp, or UN marking numbers like 1A1/T1.2/100.

The choice of which gas can you purchase depends on how the container will be used. Safety cans are great in maintenance shops or storage yards while DOT approved cans are best for road service vehicles See more Fuel Cans.

Before using any equipment described, be sure to read, understand and follow all manufacturers instructions and guidelines.

Understand the different pros and cons of different types of winch lines. Additionally, know how to take care of winch lines correctly.

Wire winch lines, commonly called steel wire rope, are the heart vehicle recovery operations. A damaged line is a serious safety issue and a broken one removes a recovery vehicle from service. This article will cover the basics of winch lines, winch line inspection, and how to select a new winch line.

Rope Cores: Rope cores serve as the foundation for the strands. They keep the rope round and strands properly positioned.

There are 3 different core types: fiber core, independent wire core (IWRC) and strand core. Fiber core offers the greatest flexibility. It is commonly made of polypropylene fibers, but natural fiber options are also available.

Independent wire rope core (IWRC) is available in bright, galvanized, and stainless steel configurations. It is the strongest type of core available and has 10-15% higher work load limit than fiber core.

Strand Core is made of stands of wires. It is least flexible of the three types discussed and is mostly used on utility cables.

Rope Grades: The most common rope today is extra improved plow steel (EIP or XIP). It is typically used on winch lines and generally has 15% stronger break strength than improved plow steel grade (IPS). Extra extra improved plow steel grade (EEIP or XXIP) is also available for added strength in higher rated equipment.

Rope Types: Bright wire is un-coated and is the most commonly used winch line. Another option is galvanized wire, which improves corrosion resistance. However, galvanization can reduce a wire’s strength up to 10% compared to bright wire unless the wire is drawn again. 

Stainless steel wire contains chromium and nickel. It is very corrosion resistant and used primarily on yachts or as control cables.

Construction: Construction determines how the wire rope performs. For instance, a 6 x 19 rope will have 6 strands of rope that have between 19 to 26 wires. Each added wire makes for better abrasion resistance. A 6 x 37 construction has 27 to 49 wires and is more flexible, while a 19 x 7 construction is rotation resistant.

Lay: There are two categories of lay, directional lay and lay orientation. Directional lay refers to what direction the strands of the rope face when you are looking down the rope, and lay orientation refers to the direction the wires within the strands are twisted.

Directional lay is either right or left. Lay orientation is either regular or lang. In regular lay, the wires are twisted in one direction while the strands are twisted in the opposite direction. In lang lay, the wires are laid in the same direction as the strand in the rope.

Regular lay ropes are less likely to untwist. They are also less likely to fail because of crushing and distortion; however, they are less flexible than lang lay ropes. Wire winch lines use right regular lay construction.

Design Factors: Design factors are safety factors required by government and industry organizations for wire rope. While they vary depending on application, typical towing winch lines have a 3:1 design factor, while lifting wire ropes have a 5:1 factor.

During a winch line’s “useful life” all wire rope will gradually lose strength due to surface wear and metal fatigue. Metal fatigue is caused by normal use of the winch line but is made worse by excessive bending, which can be caused by a sheave that is too small.

Inspecting your winch lines periodically for damage can save you many headaches on the road. Below is mechanical damage to look for when inspecting your winch line and determining whether to remove it from service.

• Hook damage: Look for any cracks or deformation of hooks. If the throat opening has been enlarged by 15% or twisted out of plane by 10%, it needs replacing.

• Broken Wires: Pulling winch lines across edges, fatigue or overload can all break individual wires. If you find five or more broken wires in a single strand or 10 or more in one lay, the wire should be replaced.

• Wear: Dragging a winch line on the ground or loading over the winch line will cause flat areas on individual wires of the cable. If these wires have lost 1/3 or more of the original diameter the line needs to be taken out of service.

• Corrosion/Heat Damage: Any discoloration from rust or lack of lubrication promotes fatigue. If the wire rope is severely pitted or individual wires rusted through, replace the line. Fiber core slings need to stay below 180°F and steel core below 400°F. Exceeding these heats greatly reduce wire rope strength.

• Kinking: Shock loading or forcing the line against an edge causes bent strands. This prevents the rope from rotating properly and greatly reduces its strength, making it necessary to replace the rope. Use load pads to protect the line and prevent this.

• Crushing: A load set on top of a winch line can flatten the cable. This has the same effect as kinking, making it necessary to remove the line from service.

When you are inspecting your winch line and have not found any damage that would require replacement, it is an ideal opportunity to lubricate the line to get the maximum service life possible. Be sure to use a lubricant especially made for wire rope. Proper lubrication reduces internal friction within the wires and strands of the wire rope. In addition, it protects the rope from oxidation and corrosion.

When selecting a new winch line it should be based on the diameter, length and type recommended by the winch manufacturer for the model of winch you own. This information can be found on the winch nameplate, otherwise you can contact the winch manufacturer or local supplier.

Beyond making sure your rope is compatible with your winch, there are a few other things you may want to consider. First, swivel hooks will help relieve rotational tension as the rope moves, so you may want to invest in them. Also, keep in mind that imported ropes can provide substantial cost savings without sacrificing quality.

To reduce damage to whatever winch line you choose, use roller guides and tension plates. These aid in the proper winding of wire rope on the winch drum.

Periodic inspections and lubrication of your winch line will save your business money, but more importantly, keep your employees safe and your customers happy. That is the heart of our industry.

See all our Winch Line Products >>

Tips for Preserving the Life of Jump-Start Packs

Older car batteries show their age in the cold temperatures with dead batteries. Jump-start packs are an operator’s best friend in these types of conditions. A quick boost will get many customers back on the road and you off to the next call. In order to keep your jump packs working when you need them, here are a few tips.

• Keep the jump pack charged according to the manufacturer’s instructions. Yes, this seems like an easy one, but jump packs have different charging techniques.

• Some packs have built-in overcharge protection. This allows them to be plugged in constantly.

• Other packs require charging for a specific period. Afterwards, they must be disconnected from the power source. Constant charging will damage the battery on packs on units without overcharge protectors.

• Jump-start packs require cool-down periods between jumps. The high amperage needed to start a vehicle heats up the internal components of the jump pack. The timeframe varies depending on the manufacturer, but in general, after 6 seconds of trying to jump-start start a vehicle, a pack will need 3 minutes of cool down time.

• Cold temperatures reduce the capacity of the jump-start batteries. Keep the pack warm between uses.

• Train employees on the proper hook-up of the battery hand clamps per manufacturer instructions.

• Use to charge non-frozen lead-acid batteries only.

• Follow any other jump pack maintenance outlined in the owners manual.

• Following these tips will extend the life of your portable jump starters and allow them to operator at peak amps.

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The use of this recovery rope will drastically cut down on the overall weight of any truck.

AmSteel-Blue Synthetic Rope is an excellent alternative to steel winch cables! These synthetic winch lines and rope extensions are very durable with extremely low stretch, have superior flex fatigue and are wear resistant. Size-for-size, it is the same strength as steel - yet it floats in water! Learn more about AmSteel-Blue Synthetic Rope now! 

A dead car battery can leave you stranded. A dead phone battery can leave you without a way to call for help. The solution? Zip’s supplies portable power boosts small enough to carry in your purse or stow in your glove compartment—and strong enough to not only charge large electronics, but jump-start your engine. This means power when you need it most, without the time and trouble of calling for roadside assistance. Zip’s also carries other impressive power packs in a range of sizes and power voltages, perfect for any member of your family, any time a battery charge is needed. Learn more about them here.