New Warn AIR COOLED Endurance 12.0 winch

[4WD Toyota Owner Magazine]

4WD Toyota Owner was invited to Warn HQ to test out their new Endurance 12.0 winch! It's actually air cooled via a remotely mounted fan. When the winch motor reaches a certain temp, the fan switches on. You can also activate it manually. The winch has the universal "D" connector (thankfully!) and many parts are stainless steel. It was mounted on a Tacoma and did very well in the mud bog. The fan is under the hood, plumbed via hoses to the intake area, to the winch itself, and egress spot. The air fan moves quite a lot of air, I forget the exact number but maybe 200 feet per minute? 2000? Not sure, don't quote me, can't recall just now.

Warn really has an amazing engineering dept; they gave me the full tour. Full on physics dudes testing these things under heat duress, amp loss, you name it. Heat kills motors and winches and this is an innovative setup. I predict it will become quite popular, especially with the hot weather overland enthusiasts. Here's a few pics.

 

[Rexsname]

OK, I see the fan......I see the winch........I dont see how the fan gets its air to the winch motor. Is it ducted?

REX

 

[cruiseroutfit]

...The winch has the universal "D" connector (thankfully!)...

What is the universal D connector? Are you referring to the controller junction plug at the solenoids? That different than any previous warn models, can't see how that is an improvement? What is universal about it?

 

[ntsqd]

We Engineers do come up with all sorts of really cool contraptions. Most of which should have been vetted by marketing before going into production. IMO a non-integral fan wasn't worth pursuing. Put me in the unimpressed box.
I sort of see why a mfg might want to use a proprietary plug & socket for the remote, but they are too easily changed by someone down the line. Better to come up with an industry standard plug & socket. Then create a market for upgraded remotes.

 

[4WD Toyota Owner Magazine]

OK, I see the fan......I see the winch........I dont see how the fan gets its air to the winch motor. Is it ducted?

REX

There is 1.5" hose that takes in air (you can just see it in one pic, it is on the left side of the water bottle and thus is the intake hose), brings it to the motor, then is egressed out of the motor via another hose. The fan does all of the air moving of course. The fan is watertight, so it's where you place the end of the air intake hose that matters. The winch comes with 4 feet of hose, and one of the trucks had a snorkel and the air intake was up, inside the snorkel. Even in the engine bay wheel well it's high or higher than say the axle and t-case breathers.

 

[4WD Toyota Owner Magazine]

What is the universal D connector? Are you referring to the controller junction plug at the solenoids? That different than any previous warn models, can't see how that is an improvement? What is universal about it?

I just got an M12000 about four months ago and it still had a round plug at the end of the remote. That meant you always had to study the underside of the plug, then study the winch control box, to make sure it was lined up right. The D plug means you don't have to study anything; it's clear from any angle or at night how the remote attaches to the solenoid box.

 

[4WD Toyota Owner Magazine]

We Engineers do come up with all sorts of really cool contraptions. Most of which should have been vetted by marketing before going into production. IMO a non-integral fan wasn't worth pursuing. Put me in the unimpressed box.
I sort of see why a mfg might want to use a proprietary plug & socket for the remote, but they are too easily changed by someone down the line. Better to come up with an industry standard plug & socket. Then create a market for upgraded remotes.

Winches get hot fast under steady load. IIRC heat causes a certain amount of degradation of amperage levels to the winch, along with generally being hard on electrical components. I know I have had winches shut down on me after hard sessions because they were overheated. There was something else they mentioned. If near water or in water, as the winch heats up it's good at keeping its seal, but as it cools and if in water it will suction in. I'd posit for those who know they'll be doing a lot of gnarly winching it will come in quite handy. Not arguing with you here, btw.

 

[ntsqd]

A fan cooled winch motor is a good idea. One that's been sorely needed for years.
It's this execution that I find lacking. Yet another gadget to find a place for, wire, and plumb.

 

[Willman]

Thanks David for sharing!

Sweet winch!


:26_7_2:

 

[madizell]

The only winch motor failures I have ever had were a result of brush burn out or solenoid failure. Never had one "shut down" due to heat even after 30 minute long marathon winch sessions up a quarter mile 40 degree incline, and that was in the Outback in hot racing conditions. Personally, I see the external fan concept as a solution to a problem that scarcely exists. The majority of winches in use are sportsman class, and are not used enough to get hot enough often enough to warrant a cooling system, especially an ancillary system.

As far as water intrusion due to rapid heating and cooling, while it does occur, I have yet to see anything other than a maintenance issue arise from the fact of it. That is, the water or condensation that does get into the internals does not cause shut down or failure. If left in a "sealed" motor, moisture will cause corrosion. Oddly, if the motor is "vented" or not completely sealed, it is as likely to shed condensation through use as it is to take it on. I am more concerned with dust infiltration in the motor than I am with moisture, and have never had a problem due to submersion coincident with hard use of the winch. For reference, mine is the 8274-50.

 

[I Leak Oil]

There's no doubt that electric winches get hot and in some cases quit. In such extreme use I'm not sure how much good a fan is going to do. If I were having an issue with heat or the motor quitting I wouldn't go for this Warn option, I'd look at a hydraulic winch or on my series truck, a PTO driven unit. both of these will go all day long without issue and are only slightly more complex than the Warn unit. Since I haven't had any issues with it I'll stick with my XD9000i.....
Jason T.

 

[Antichrist]

I just got an M12000 about four months ago and it still had a round plug at the end of the remote. That meant you always had to study the underside of the plug, then study the winch control box, to make sure it was lined up right.

Huh? So you're saying Warn took a good design from many years ago, screwed it up on the M12000, now say this one is "improved"? Definitely sounds like marketing people were involved.
My 8274 which I bought in '74 or '75 has a 4-pole round connector, just a trailer connector. It has a little protrusion on the plug that fits in a recess on the cover for the socket. It was easy to feel it, even with gloves on, and I never have had a problem getting it in right on the first go. Even in the dark.

There's no doubt that electric winches get hot and in some cases quit. In such extreme use I'm not sure how much good a fan is going to do. If I were having an issue with heat or the motor quitting I wouldn't go for this Warn option, I'd look at a hydraulic winch or on my series truck, a PTO driven unit. both of these will go all day long without issue and are only slightly more complex than the Warn unit.

x2. Never have had an issue with my Koenig PTO packing up.
Same with hydraulics I've used.

 

[madizell]

Definitely sounds like marketing people were involved.
My 8274 which I bought in '74 or '75 has a 4-pole round connector, just a trailer connector. It has a little protrusion on the plug that fits in a recess on the cover for the socket. It was easy to feel it, even with gloves on, and I never have had a problem getting it in right on the first go. Even in the dark.

Personally I agree. However, Warn has public relations and liability concerns to consider as well. An acquaintance of mine in Alaska, using the old round 4-pin connector, lost a finger when the connector was plugged in wrong causing a reversal of electrical direction commands to the winch. While I do not believe that the reversal of the plug was the proximate cause of the accident (operator error and a failure to communicate were more directly related) still Warn saw this situation as potentially expensive and changed the plug design in an attempt to make it idiot proof. I suppose this could be seen as "marketing" but at bottom, it was a change made toward additional safety and to avoid potential liability. You can't really fault Warn for taking this step. The old round connectors can easily be forced together incorrectly. A "D" plug can't be misaligned.

 

[DaveInDenver]

An old thread with some relevance to this discussion. I do think hydraulic makes sense, but in reality I'd expect to have to upgrade pumps and add a cooler to make it really more reliable than a good electric system. Certainly would want something better than stock PS pump. A PTO would be nice, but in their infinite wisdom most manufacturers stopped making them easily installed after the era of the FJ40, Jeep J30, early Broncos and the like.

https://expeditionportal.com/xenforo_live/index.php?threads/6673/

 

[Antichrist]

You can't really fault Warn for taking this step. The old round connectors can easily be forced together incorrectly. A "D" plug can't be misaligned.

Well, I guess yes, I can't fault them for wanting to protect themselves from careless people who wouldn't take responsibility for their own actions.. But they could have just gone to a commonly available 4 pole connector with a keyway that prevents you from accidentally installing them wrong. Still no need for anything exotic.

An old thread with some relevance to this discussion. I do think hydraulic makes sense,

If I wanted the highest comfort level it would be hydraulic with an electric motor driven pump as backup.