Winch accessories, spare parts and safety controls

Here we offer two packages to do a small or large winch overhaul.

With this package you get

• a water- and dirtproof winch control solenoid for 12 or 24 Volts
• a 'small' roller fairlead, greasable

(for details look below)

To do all critical issues on your winch:

• a water- and dirtproof winch control solenoid for 12 or 24 Volts
• a 'small' roller fairlead, greasable and spring loaded for even rope layers on the drum
• 35meters of reinforced winch rope 9mm dia and 7.1tons capability, designed for 3.6-ton winches at double security
• our self developed security winch remote control with automatic mains solenoid 12 or 24 Volts and straight cable

(for details look below)

No winch-OEM parts included.

We (last!) designed an integrated Safety Winch-Control unit.

Key features:

• automatic battery disconnect switch (BDS) - water- and dustproofed (small model only)
• Emergency-STOP-pushbutton
• mechanically and electrically interlocked FWD/REV-pushbuttons
• Safety-function: without connected Control unit your winch is completely powered down - easy servicing
• waterproofed connectors w/ caps
• waterproofed and rugged control unit coloured signal-yellow, safety-level: commercial cranes!
• available for 12 and 24 volts

This Remote Control is designed according DIN EN/IEC 61508 and DIN 19250 and provides STOP category class 0.

Function:

As soon as you connect the control unit to the winch the BDS powers up the winch. From now on you may operate your winch as you are used to it. The Emergency-STOP pushbutton immediate opens the high-power-circuitry from battery to winch and stops the winch - even in case of sticked control relays! A ruptured or cut control cable also stops the winch immediately. The connectors can be screwed tight to the main unit to prevent unwanted disconnection.

All connectors are water- and dirtproof (IP68) similar to the control unit (IP65). The control cable is made of high-quality 'Oelflex' wiring and available in two variants:

• straight, length 5 meters (additional length per request)
• coil-spring-style 3m retracts to 1m

See for yourself the effects of a hanging solenoid and NOT having a safety solenoid. Luckily the vehicle didn't start to burn. (Video courtesy of SoLottaTech):

Watch the video on YouTube

Advantages:

• no more 'thinking' - connect the control, operate the winch.
• without control the winch is unpowered - no risc of short-circuits and electrical failure or even fire in case of accident or damaged wires!
• No abuse ever possible!
• BDS has no long wires and therefore no losses compared to a manual BDS located in the passenger cab
• Emergency-STOP ensures immediate safe and reliable stopping of your winch even when control relays are sticking.
• no erroneous operation anymore!
• complies with requirements for commercial usage and car insurance companies

Kit contains:

• BDS solenoid small or large (small mdl. water- & dustproof IP55)
• continuous current: 100A / 150A, 1 minute: 450A / 520A, peak 800A / 1000A
• high-power pigtail from BDS to vehicle battery
• mounting bracket for BDS
• control unit complete with wiring harness and waterproofed connector w/ cap
• winch socket w/ waterproofed cap
• control wiring harness
• installation and operation manual - schematic to be found HERE

Variants:

• control unit w/o BDS
• double BDS-unit for vehicle and winch
• 250A / 1050A / 1500A hardcore-BDS

Extra Heavy-Duty design

• very durable, zink-plated steel
• all Models are greasable
• fairlead is a heavy welded construction of massive steel
• all sizes can be delivered with spring-loaded top roller - your rope will lay much more even on the drum!
• Dimensions shown are for the opening for the rope - spring-loaded variants the minimum clearance between top and bottom roller

These roller fairleads are built for tough continuous use: solid material, galvanised, greasable and extremely durable.

To change the towing direction or to double the force.

• Material: galvanically zink plated.
• Hook can rotate, can be opened for winch-use.

These snatch blocks are also built for tough continuous use: solid material, galvanised, extremely durable and easy to handle.

Wire Forestry Ropes

Special reinforced forestry winch wire ropes - same strength, smaller diameter - to give you more length on the drum at equal safety!

These special ropes are being compressed after first stranding process. The diameter is reduced and the surface gets flat and even.

Major advantage of these forestry wire ropes

• smaller diameter at identical strength
• more length possible on winch drum
• better winding for each layer
• lowest dirt pickup
• identical strength at smaller diameter OR
• more strength at identical diameter

Please mind: use the available room for the rope supplied by your winch only up to 50-70%. This way you will have enough clearance for the rope on the drum even while winching at large angles.

Regarding the pulling power: Let's assume you have a 3.6ton winch on your 4WD it's always good to have the rope some two classes better i.e. 7.1ton breaking force - your winch never will break the rope but a mechanical hit might if it's too weak!

Dyneema Winch Ropes

Dyneema Winch Ropes Ultimate Strength

Those ropes do have some major advantages over standard wire ropes:

• -won't rust
• -triple lifetime compared to steel rope
• -low weight (10 to 15% of a steel rope, floats on water!)
• -33% and more capacity on the winch drum - more rope on the trail!
• -ultimate strength
• -doesn't store much energy - rope breakage almost harmless
• -samples available

We do offer a complete Rope with stainless security hook. We offer them ropes coloured blue (standard) and also white, black, red, green and yellow.

Please note: Winches with planetary gears like e.g. most of the WARNs (NOT the 8274!) may suffer from thermal insulation of the drum that integrates the break. Prolonged winching may overheat the break and render it useless!

Fixtures, Ratchets, Hooks...

Yes, we do have all those things. The assort is that big that we don't want to place everything on our page, but rather put together a package that suits your very special needs.

High-Power-Solenoids, protected according IP54, sealed and closed, 12 or 24V, 100 amps continuous rating. Complete integrated package for forward and reverse rotation of DC winch motors.

These units are European quality products.

Please state at order: 12 or 24 volts coil operation.

See our datasheet accordingly.

Together with a Bowmotor you can waterproof the most endangered parts of your winch to cope with water and mud.

This controller block DC88P is intended for normal use. Heavy winch usage is better equipped with model capable of 150 Amps and 250 Amps continuous rating. Sorry to say, these solenoids aren't available sealed and protected but only 'closed'.

Are available single, too. You can equip your existing winch with a waterproofed motor.

Suitable for:

• Superwinch X9, X9plus, E14P, Husky
• WARN
• Ramsey
• Goodwinch

These motors are available for 12 and 24Volts.

Additionally we have a wide variety of replacement motors for almost all brands!

Here we present you a high-Amp connector system you might know in a similar manner from forklifts.

This system is capable of 160Amps continuous current and wiring of AWG4 / 25qmm. Suits perfect applications like removable winches, chargers, generators a.s.o. as well as motorhome / camping cabins, solar power systems and so forth...

We enhanced this system:

In combination with our safety Winch-Remote-Control and Battery Disconnect Solenoid electrical power is being switched to the terminals only if the connectors have settled together. Without connector the plugs are absolutely safe!

Additionally you can enable this system with air adapters that might also be activated by connecting the system together. Finally, the housings withstand sulfuric (battery) acid.

We offer you customized wiring harness made of best quality from 10cm up to 25meters or more (measured hole-to-hole).

Colours available are Red and Black (others on request), wiring comes in AWG4 / 25qmm.

We use flexible wiring made of copper with a rugged insulation. Terminals and cable are double hexagon-crimped and are waterproofed by using an unique combination of shrinking tube and thermoplastics.