Quadratec Q9500i Manual

The Trusted Source
®
Q9500i
Self-Recovery Winch
Operator’s Guide
Instruction and Operation Manual
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 1
07262012164235

2
Q-Series Winch
Record this data for your records as shown below:
Date of Purchase: ____________________________________
Model Number: _______________________________________
Serial Number on Gearbox Leg: ________________________
Serial Number on Motor Leg: ___________________________
On the Gearbox Leg: Find the 11 digit number
beginning with “QD”
On the Motor Leg: Find the 12 digit number
beginning with “S”
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 2
07262012164251

Table of Contents
Section I: Q-Series Winch Operation and Care
Defining: Warning, Caution and Notice ........................5
Symbol Index ..............................................................6
General Safety Precautions .....................................7-15
Winch Anatomy (the parts of the winch) ..................16-17
Clutch Operation ........................................................18
Remote Control Switch...............................................19
Cleaning ...................................................................20
Battery Recommendations.........................................21
Maintenance .............................................................21
Troubleshooting ........................................................22
Section II: Q-Series Winching Guide
Winching Guide Introduction ......................................23
Part 1 - Before you use your Q Series Winch
Prepare winch cable before you use your winch..........23
Practice, practice, practice ........................................24
Plan your pull and pull to the plan ..............................24
Winching guidelines to always remember ...................25
Part 2 - Essential Winch Accessories & Equipment
Leather Gloves..........................................................26
Winch Hook Strap .....................................................27
Tree Trunk Protector..................................................27
3
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 3
07262012164251

Heavy Duty D -Ring....................................................28
Snatch Block ............................................................28
Shovel & Hand Tools .................................................29
Other Useful Off Road Accessories........................29-31
Part 3 - Setting up the pull
How to choose an anchor point .................................32
Steps 1 -5: Setting up the pull ...............................33-35
Anchoring to a live tree..............................................35
Anchoring to a dead tree, rock or stump ....................35
Anchoring to another vehicle......................................35
Steps 6-11: Setting up the pull...............................35-37
Part 4 - Engaging your Winch for the pull
Steps 12-16: ..........................................................38-41
Part 5 - Vehicle Recovery Winch Rigging Options
Creating a Straight Pull..............................................42
Increasing winching power with a Snatch Block ..........43
Double Line Pull........................................................44
Triple Line Pull ..........................................................45
Buried Object Anchor.................................................45
Conclusion ...............................................................45
4
The Trusted Source
®
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 4
07262012164251

A Few Words About Product Safety:
Your safety and the safety of others is very important.
To help you avoid risks and make informed decisions this
manual contains safety messages about your Q-Series
self-recovery winch. Individual safety messages and
sections of this manual may be preceded by the safety alert
symbol ! [in triangle] and one of three signal words:
Pay careful attention to all WARNINGS,
CAUTIONS AND NOTICES throughout this
user guide and ALWAYS WORK SAFELY.
5
AVOID RISK OF SERIOUS INJURY BY
READING ALL SAFETY MESSAGES AND
PROCEDURE NOTICES CONTAINED IN
THIS OPERATORS GUIDE AND THE AC-
COMPANYING INSTALLATION MANUAL
BEFORE ATTEMPTING TO INSTALL OR
USE YOUR WINCH
You CAN be KILLED or
SERIOUSLY HURT if you
DO NOT follow instructions.
You CAN be HURT if you
do not follow instructions.
Other important information
regarding a safe assembly
or operation procedure
may be emphasized by
a NOTICE signal.
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 5
07262012164251

Explanation of Symbols:
Your safety and the safety of others is very important.
To help you avoid risks and make informed decisions.
6
Read the Instruction
Manual
Always Wear Hearing
and Eye Protection
Keep Fingers Clear o
f
Fairlead Pinch Point
Never Use Winch
as a Hoist
Never Apply Load to
Hook Tip or Latch
Wind Rope on Bottom
of Drum
Moving Parts Hazard
Hot Surface Hazard
Finger/Fairlead
Crushing Hazard
Always Use Supplied
Hook Strap
Properly Seat Load in
Throat of Hook
Do Not Move
People
Never Wind Rope
Over Top of Drum
Sharp Edge Hazard
Hand Piercing/
Cutting Hazard
Fire and Burn Hazard
Explosion/
Bursting Hazard
Always Wear
Leather Gloves
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 6
07262012164251

Section I: SAFETY CONSIDERATIONS
In order to be useful as a vehicle self-recovery tool, your Q
series winch uses a powerful electric motor to develop a
cable pull of roughly 9500 lbs. In order to avoid risk of
injuries, all users and bystanders to winch operations
should acquaint themselves with the following important
safety considerations.
MOVING PARTS ENTANGLEMENT HAZARDS
Failure to observe these instructions could lead
to serious injury or death.
ALWAYS ensure hook latch is closed
and not supporting load.
NEVER apply load to hook tip or latch.
Apply load only to the center of hook.
NEVER use a hook whose throat opening has
enlarged, or whose tip is bent or twisted.
ALWAYS use a hook with a latch.
ALWAYS ensure the operator and bystanders are
aware of the stability of the vehicle and/or load.
ALWAYS keep wired remote control lead and
power cord clear of the drum, rope, & rigging.
Inspect for cracks, pinches, frayed wires or loose
connections. Damaged components must be
replaced before operation.
7
Never Apply Load to
Hook Tip or Latch
Properly Seat Load in
Throat of Hook
MOVING PARTS
ENTANGLEMENT HAZARDS LIST
Always Wear Hearing
and Eye Protection
Always Wear
Leather Gloves
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 7
07262012164251

Installation Safety continued:
ALWAYS pass remote lead thru window (and not through
pinch point of the door) when used in vehicle
ALWAYS Know Your Winch. Take time to fully read the
Instructions and/or Operations Guide, and/or Basic
Guide to Winching Techniques, in order to understand
your winch and its operations.
NEVER exceed winch or winch rope rated capacity.
Double line using a snatch block to reduce winch load.
ALWAYS wear heavy leather gloves when handling
winch rope to avoid injury from burrs.
NEVER use winch or winch rope for towing.
Shock loads can damage, overload and break rope.
NEVER use a winch to secure a load.
NEVER operate this winch when under the influence
of drugs, alcohol or medication.
NEVER operate this winch if under 16 years of age.
Installation Safety:
ALWAYS use an approved mounting system that
exceeds the capacity of your winch.
ALWAYS use grade 5 (grade 8.8 metric) or better
hardware. Never weld mounting bolts.
ALWAYS use factory approved mounting hardware,
components, and accessories.
NEVER use bolts that are too long.
8
MOVING PARTS
ENTANGLEMENT HAZARDS LIST
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 8
07262012164251

Installation Safety continued:
ALWAYS complete the winch installation and hook
attachment before installing the wiring.
ALWAYS keep hands clear of winch rope, hook loop,
hook and fairlead opening during installation, operation,
and when spooling in or out.
ALWAYS position fairlead with printed warning
readily visible on top.
ALWAYS prestretch rope and re-spool under load before
use. Tightly wound rope reduces chances of “binding”,
which can damage the rope.
Winching Safety:
ALWAYS ensure the clutch is fully engaged
or disengaged.
ALWAYS inspect winch rope, hook, and slings before
operating winch. Frayed, kinked or damaged winch rope
must be replaced immediately. Damaged components
must be replaced before operation.
Protect parts from damage.
ALWAYS remove any element or obstacle that may
interfere with safe operation of the winch.
ALWAYS be certain the anchor you select will withstand
the load and the strap or chain will not slip.
ALWAYS use supplied hook strap whenever spooling
winch rope in or out, during installation and operation.
9
MOVING PARTS
ENTANGLEMENT HAZARDS LIST
Never Apply Load to
Hook Tip or Latch
Properly Seat Load in
Throat of Hook
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 9
07262012164252

Winching Safety continued:
ALWAYS require operators and bystanders to be aware
of vehicle and or load and stay clear of cable and vehicle
path in case winch line fails or vehicle rolls.
ALWAYS be aware of stability of vehicle and load during
winching, keep others away. Alert all bystanders of
an unstable condition.
ALWAYS while assuring at least five wraps remain on
drum, unspool as much wire rope as possible when
rigging. Double line or pick distant anchor point.
Always take time to use appropriate rigging
techniques for a winch pull.
NEVER touch winch rope or hook while someone else is
at the control switch or during winching operation.
NEVER engage or disengage clutch if winch is under
load, winch rope is in tension or drum is moving.
NEVER touch winch rope or hook while under tension
or under load.
ALWAYS stand well clear of winch rope and load
and keep others away while winching.
NEVER use vehicle use vehicle power to increase load on
winch cable. Combined load or shock load can damage,
overload and break winch rope.
NEVER wrap winch rope back onto itself.
ALWAYS Use a choker chain or tree trunk protector
on the anchor.
10
MOVING PARTS
ENTANGLEMENT HAZARDS LIST
Never Apply Load to
Hook Tip or Latch
Properly Seat Load in
Throat of Hook
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 10
07262012164252

FALLING OR CRUSHING HAZARDS:
ALWAYS stand clear, keep hands clear,
keep others away.
NEVER operate winch with less than 5 wraps of rope
around the drum. Rope could come loose from the drum,
as the rope attachment to the drum is not designed to
hold a load.
NEVER use winch as a hoist or to suspend a load.
ALWAYS be certain anchor will withstand load, use
appropriate rigging and take time to rig correctly.
NEVER use winch to lift or move persons.
ALWAYS spool the rope onto the drum in the direction
specified by the winch warning label on the winch and/or
documentation.
11
FALLING OR CRUSHING
HAZARDS LIST
Never Use Winch
as a Hoist
Wind Rope on Bottom
of Drum
Do Not Move
People
Never Wind Rope
Over Top of Drum
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 11
07262012164252

CUT AND BURN INJURY HAZARDS
ALWAYS wear heavy leather gloves when
handling winch rope to protect from burrs.
ALWAYS be aware of possible hot surfaces at
winch motor, drum or rope during or after winch use.
CHEMICAL AND FIRE HAZARDS
ALWAYS remove jewelry and wear eye protection.
NEVER route electrical cables across sharp edges.
Never route electrical cables near parts that get hot.
NEVER route electrical cables through or near
moving parts.
ALWAYS place the supplied terminal boots on wires
and terminals as directed by the installation instructions.
NEVER lean over battery while making connections.
NEVER route electrical cables over battery terminals.
NEVER short battery terminals with metal objects.
12
CUT AND BURN INJURY
HAZARDS LIST
Hot Surface Hazard
Hand Piercing/
Cutting Hazard
CHEMICAL AND FIRE
HAZARDS LIST
Moving Parts Hazard
Sharp Edge Hazard
Fire and Burn Hazard Explosion/
Bursting Hazard
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 12
07262012164252

CHEMICAL AND FIRE HAZARDS continued
ALWAYS verify area is clear of fuel lines, fuel tank,
brake lines, electrical wires, etc., when drilling.
ALWAYS consult installation manual for proper
wiring details.
ALWAYS insulate and protect all exposed wiring
and electrical terminals.
CUT AND BURN INJURY HAZARDS
NEVER let winch rope slip through your hands.
ALWAYS wear heavy leather gloves when
handling winch rope.
13
CHEMICAL AND FIRE
HAZARDS LIST
CUT AND BURN INJURY
HAZARD LIST
Hot Surface Hazard
Hand Piercing/
Cutting Hazard
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 13
07262012164252

MOVING PARTS ENTANGLEMENT HAZARDS
NEVER leave remote control where it can be activated
during free spooling, rigging, or when the winch is not
being used.
NEVER leave the winch remote control plugged in when
installing, freespooling, rigging, servicing or when the
winch is not being used.
ALWAYS avoid side pulls which can pile up wire
rope at one end of the drum.
This can damage the wire rope or winch.
ALWAYS ensure the clutch is fully engaged
or disengaged.
ALWAYS use care to not damage the vehicle frame when
anchoring to a vehicle during a winching operation.
NEVER submerge winch in water.
ALWAYS store the remote control in a protected,
clean and dry area.
14
MOVING PARTS ENTANGLEMENT
HAZARD LIST
Keep Fingers Clear o
f
Fairlead Pinch Point
Finger/Fairlead
Crushing Hazard
AVOID WINCH AND
EQUIPMENT DAMAGE
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 14
07262012164252

Q
Safety Summary:
As you can see, winching must be taken seriously.
The preceeding Warnings, Cautions and Notices may seem
like a lot to absorb, but in summary we think you will agree
that these Warnings, Cautions and Notices are fairly
straight forward and sensible.
After careful consideration of the various potential
hazards associated with improper use, the operator can
move forward to utilize this powerful and reliable piece
of equipment to enhance the off-road experience.
In the next section of this guide, we will illustrate the
primary components and features of your Q Series winch,
and discuss care and maintenance of the product.
15
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 15
07262012164252

Section I: Winch Anatomy
This section will familiarize you with the name and
purpose of the major Q Series Winch parts & components.
1. Controller:
Sends the flow of electrical power to the winch motor to
tell the winch what you want it to do. The remote switch
has three positions: Power In, Power Out and Off. Long
cord allows operator to stand clear of the wire rope.
2. Winch Cable:
Q-Series wire cables are 100’ in length and 3/8” in diameter.
The cable is wrapped around winch drum and fed through
the roller fairlead and attached to the clevis hook.
3. Safety Latch:
The safety latch is a spring loaded mechanism to assist in
keeping rigging apparatuses in place. Be sure the safety
latch is free of debris and check the clevis hook periodically
to ensure safety latch is functioning properly.
16
1
2
35
9
10
6
7
8
4
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 16
07262012164253

4. Clevis Hook:
The clevis hook connects your vehicle to a recovery point.
Ensure that the hook is securely fastened to the winch
cable with the clevis and cotter pin.
5. Nylon Hook Strap:
A 12” long strap that holds the clevis hook. Made to keep
fingers away from the roller fairlead while winch cable is
being spooled in. Winches have tremendous force and can
remove fingers or limbs within a pinch point. Place the
hook into the loop end of the strap and hold the strap
between the thumb and the forefinger.
6. Roller Fairlead (Zinc Plated):
The fairlead guides the wire rope onto the winch drum and
minimizes wear and tear to the winch cable as it goes
through the winch mount or bumper.
7. Clutch Control:
Clutch Lever allows manual engagement/disengagement
from the gear train. Clutch must be fully engaged or in free
spool. Never attempt to shift lever when cable under
load (see WARNINGS section).
8. Solenoid Pack:
The solenoid pack is an electromechanical switch that
transfers power from the car battery to the winch motor
enabling the winch operator to change direction of the
winch drum rotation.
9. Winch Drum: (Spool)
The hardened metal cylinder core around which the wire
rope is wound. Driven by the Winch Motor.
10. Winch Electric Motor:
Winch motor is powered by the vehicle battery. The winch
motor provides the power and motion to the gear
mechanism, which turns drum to wind the wire rope.
17
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 17
07262012164253

Battery Friendly Product:
Our powerful 4.8 HP series wound
motor and class leading low gear
ratios give fast line speeds with a
“Battery Friendly” low current
draw that will get the most
winching time from your battery's
available charge state.
Clutch Operation:
There are two positions of the clutch handle. The Clutch is
either “engaged” or “free spooling”. Clutch allows
operator to manually engage or disengage the spooling
drum from the gearset using the clutch lever.
NEVER engage or disengage clutch
if the winch is under load, the winch
rope is under tension or the spool
is moving in any way.
18
Engaged Free Spool
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 18
07262012164253

Remote Control:
The remote control plugs into the winch
control box, allowing the operator to
control the winch direction, as well as stand well clear of
the wire rope while operating the winch.
Remote Control
Switch Positions:
Switch Up = Winch Out
Switch Down = Winch In
Switch Center = Motor Off
Always use extreme
caution when remote
is connected.
19
NEVER leave the winch remote
control plugged in when not in use.
NEVER allow remote to activate
winch during free spooling or rigging.
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 19
07262012164253

Winch Care and Cleaning:
Do not direct very high-pressure water at your winch. Use
low-pressure (normal) car wash soap and water to clean
your winch. With the remote control disconnected and the
protective boot covering the remote control socket, wash
normally with your vehicle. You can also secure winch with
an optional waterproof cover.
Wintertime Care:
When exposed to winter road salt, wash the winch as soon
as possible to avoid corrosion. Always wash per
recommendations above.
20
Q_WINCH_GUIDE_BLACK_9500i_GLOVEBOX 7/26/12 4:39 PM Page 20
07262012164253