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INVESTIGATIVE REPORT ATS File No. B05507 Date 03 April, 2001 Title: Warn XD9000i 4.6 hp Winch Testing Date: 03 April, 2(X)1 ATS File No.: Bo5507 File Prepared: Mr. Richard Aho MileMarker Inc 1450 S.W. 13th Court 么Prepared ByReviewed BJeffrey D. Hyall 么 Prepared By Reviewed B Jeffrey D. Hyall Forensic Engineering Staff Dave M. Paul Forensic Engineering Manager Professional Engineers Design Consulting Testing and Inspection Members in AAFS, ACS, ASM, ASME, ASNT, ASQC, AWS, FSCT, IAAI, NCSL, NFPA, SAFSGEORGIA SOCIETY OF PROFESS IONAI. ENGINEERS, NATIONAL SOCIETY OF PROFESSIONAL ENGINEERS Mr. Richard Aho Mile Marker, Inc. 1450 S.W. 13th Court Pompano Beach, Fiori da 33069 Re: Warn Winch Testing Subject Testing of the Warn XD9000i 4. 6 hp winch under laboratory and field condi tions Background Mr. Richard Aho of Mile Marker, Inc. (Mile Marker) contacted Applied Technical Services, Inc. (ATS) on 24 August 1999. Mr. Aho requested that ATS conduct testing of the productio门 model XD90001 winch manufactured by Warn Industries, Inc. (Warn). Mr. Aho made arrangements to have a new XD9000i winch as well as several spare motors and steel wire ropes shipped from Warn resellers directly to ATS in October 2000. Mr. Aho shipped a Warn HS9500i winch to ATS as well so that limited testing could be performed on that winch as well. Objective Test the Warn XD9000i and determi ne its mechanical and electri cal operating limits, also the unloaded stopping distance required by the XD9000i and HS9500i? Conclusions When pulling at or near 让s advertised rated capacity of 9000 lb., the Warn XD9000i winches wire ropes failed consistently. The wire rope failures on the XD90(X)i winch occurred at loads ranging from 72% to 103% of its advertised capacity. Based on standard industry calculation methods, the design breaking strength of the wire rope supplied with the Warn XD9000i winch was approximately 10% less than the winchs advertised rated capacity. The recoil from a sudden and unexpected wi