Red Winches HORNET2Q User manual

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Hornet 2q
HIGH MOUNT |QUAD MOTOR
THE ULTIMATE COMPETITION WINCH
USER MANUAL
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Contents
About ....................................p3
Safety ....................................p5
Winch Dimensions .......................p8
Winch Overview ........................p10
Winch Connections ......................p11
Winch Motor ............................p12
Winch Gearbox .........................p13
Winch Gears ............................p14
Drive Shaft & Freespool .................p15
Air Brake ................................p16
General Winch Maintenance ............p17
Winch Operation .......................p18

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>High Mount (Motor) Competition Winch
>QUAD Motor
>12v dc
>Air brake fitted on all models
>Freespool, Air Operated
>XL Drum length
>Gearboxes Available: Standard, Overdrive
>Rated pulls: From 2,200kg - 4,500kg (model specific)
>Ox motor fitted on all options for the ultimate power
behind your winching
This 4 MOTOR ultimate competition winch is the flagship RED Winches designed
product, whose design has undergone extensive testing, worldwide. The end user
can enjoy a professional highly engineered, precision, high performance competition
electric winch capable of operating in the most demanding of situations all over the
world.
The CNC billet housings combined with its amazing speed and pulling power make it an
ideal winch for maximum impact when connected to competition rated power source.
Hornet 2q
HIGH MOUNT | QUAD MOTOR
ULTIMATE COMPETITION ELECTRIC WINCH

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>The Hornet 2 QUAD Winch
The H2Q is the ultimate choice when it comes to
the very best competition electric winch for your
vehicle. The RED Winch engineers have designed
and developed this high-performance QUAD
motor electric winch for the 4×4 competition and
Motorsport markets.
It has been designed with competition in mind and
has many features ideally suited to high-performance
Motorsport oroad events.
The winch body is CNC machined from high-grade
heat-treated aerospace aluminium from solid billets.
We only use the best machine tools and machining
processes to ensure stress in the material is kept to a
minimum and strength to its maximum. With its air free
spool and air brake system, the Hornet oers control
and reliability previously unavailable on a winch to the
o-road and motorsport sectors.
This H2Q like all our engineered winches has the
famous RED Winch air brake system, meaning the
winch stops instantly when you take your finger o the
winch button.
>RED Winch Air Brake System
Springs apply pressure to a steel disc which then
applies pressure to the brake disc and its material when
the winch is not in use. This applies the brake and stops
the winch drum from moving under load and from
spooling out the rope.
An air solenoid for the air brake is fitted next to the
motors at the top of the winch. This is fed by an air
supply from the vehcile on-board compressor.
When you winch in or out you energise your motor
solenoid, this also energises the air solenoid valve for
the brake on top of the winch. This then allows air to
go into a specially designed chamber that releases the
brake instantly.
When you remove your winching finger from the
controls the air solenoid dumps the air and the springs
apply the brake disc onto the brake pads.
This means compared to normal winching you do not
get overrun of excess rope causing snatching and
jerking as the vehicle takes up the slack rope that has
been spooled out. It also means when spooling the rope
back onto the drum and you stop winching, the rope
stops and doesn’t continue spooling in. A safety feature
many find important when looking after the operators
hands.
The high power Albright motor solenoid is used to
switch direction of the motor and at the same time
provide an electrical feed to the air brake air solenoid
via its signal terminals.
>Gearbox
The gearbox has been specifically designed for
strength, power and ease of service.
The gears are manufactured from chromium
molybdenum steel and case hardened to give strengths
(Up to 1230 N/mm2) and excellent durability.
The gearbox runs in high load, high temperature grease
not oil making it much easier to service in the field.
Hornet 2q
>Quick Start Guide
1Check winch connections are correctly fitted
and are not loose
2Switch winch isolator on
3Switch Compressor on
4Connect Wireless Controller with base unit
(if used)
5Winch is now ready to be used

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SYMBOL EXPLANATION
Read all product literature
Always wear leather gloves
Always wear hearing & eye protection
Fairlead pinch point
Always use suitable hook or recovery hoop
Properly seat load in throat hook
Never apply load to hook tip or latch
Never hook back on rope
SYMBOL EXPLANATION
Explosion/Bursting Hazard
Fire and burn hazard
Never route electrical cables across sharp
edges
Never route electrical cables through or
near moving parts
Avoid installing electrical cables around
pinch and wear/abrasion points
Never use winch as a hoist
Do not move people
Wind rope on bottom of drum
SYMBOL EXPLANATION
Never wind rope over top drum
Hand piercing/cutting hazard
Hot surface hazard
Finger/Fairlead crushing Hazard
Exposed wiring hazard insulate exposed
wiring and terminals
Clutch disengaged
Avoid side pulls
Never hook the wire rope back onto itself
Every winching / recovery situation has the potential
for personal injury. In order to minimize that risk, it
is important to read this guide carefully before using
the winch.
Please familiarize yourself with the operation of your
winch before using it and be constantly safety oriented.
In this guide we provide important safety information
and instructions on how to install your winch.
SAVE THIS MANUAL and other product literature
found in this kit for future reference and review
frequently for continuing safe operation.
Instruct all users of this winch product to review this
manual before operating the winch.
>Symbol Index for winch
WINCHING SAFETY GUIDELINES

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>WARNING >WARNING
>Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to serious injury or death.
Winching Safety:
• Always Know Your Winch. Take time to fully read the Instructions
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 or approved gloves when handling
winch rope.
• 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 you are under 16 years of age.
Installation Safety:
• Always choose a mounting location that is suciently strong to
withstand the maximum pulling capacity of your winch.
• Always use class 8.8 metric( grade 5) or better fasteners
• Never weld mounting bolts.
• Always use factory approved mounting hardware, components,
and accessories.
• Never use bolts that are too long.
• Always confirm required bolt length to ensure proper thread
engagement.
• 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 slot so rope does not rub on it during
normal straight line recovery operations.
• Always pre-stretch rope and freespool under load before use.
Tightly wound rope reduces chances of ‘binding’, which can
damage the rope.
>Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to serious injury or death.
General Safety:
• 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 or spliced loop whenever spooling
winch rope in or out, during installation and during operation.
• Always require operators and bystanders to be aware of vehicle
and or load.
• Always be aware of stability of vehicle and load during winching,
keep others away. Alert all bystanders of an unstable condition.
• Always unspool as much winch 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 freespool lever if winch is under
load, the rope line is securing an object, winch rope is in tension
or drum is moving.
• Never touch winch rope or hook while under tension or
under load.
• Always stand clear of winch rope and load and keep others away
while winching.
• Never use vehicle to pull load on winch rope. Combined load or
shock load can damage, over load and break rope and winch.
• Never wrap winch rope back onto itself. Use a choker chain or
tree trunk protector on the anchor.
• Never use remote when vehicle is not in line of sight of operator.
• Never pair more than one winch and one remote
together at the same time.
>Warnings and Cautions
As you read these instructions, you will see WARNINGS,
CAUTIONS, NOTICES and NOTES.
Each message has a specific Purpose. WARNINGS are safety
messages that indicate a potentially hazardous situation, which, if
not avoided could result in serious injury or death. CAUTIONS are
safety messages that indicate a potentially hazardous situation,
which, if not avoided, could result in minor or moderate injury.
A CAUTION may also be used to alert against unsafe practice.
CAUTIONS and WARNINGS identify the hazard, indicate how to
avoid the hazard, and advise of the probable consequence of not
avoiding the hazard. NOTICES are messages to avoid property
damage. NOTES are additional information to help you complete a
procedure. PLEASE WORK SAFELY!
>EMC Regulation
This device complies EMC regulations. Operation is subject to the
following two conditions:
• This device may not cause harmful interference.
• This device must accept any interference received, including
interference that may cause undesired operation.
This equipment has been tested and found to comply. See
separate CE certificate. These approvals are designed to provide
reasonable protection against harmful interference in a residential
installation. This equipment generates, uses and can radiate radio
frequency energy, and if not installed and used in accordance
with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference
will not occur in a particular installation. If this equipment does
cause harmful interference to radio or television reception, which
can be determined by turning the equipment o and on, the user is
encouraged to try to correct the interference by one or more of the
following measures:
• Reorient or relocate the receiving antenna (if installed)
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit dierent from
that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.

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>WARNING >WARNING >CAUTION
>NOTICE
>NOTICE
>WARNING >CAUTION
>WARNING
>Falling Or Crushing Hazard
Failure to observe these instructions could lead to serious injury or death.
• Always stand clear, keep hands clear, keep others away.
• Never operate winch with less than 6 wraps of synthetic 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, its a winch not
a hoist.
• Always be certain anchor will withstand load, use appropriate
rigging and take time to rig correctly.
• Never use winch to lift or move people.
• Never use excessive eort to free spool winch rope.
• Always use proper posture/lifting technique or get lifting
assistance while handling and installing product.
• Always wind the winch rope on bottom (mount side) of drum.
• Never wind rope over top of drum.
• Always spool the winch rope onto the drum in the direction
specified by the drum rotation labels on the winch and/or in the
documentation. This is required for the automatic brake (if so
equipped )to function properly.
>Cut And Burn Hazard
Failure to observe these instructions could lead to minor or moderate
injury.
• Never let winch rope slip through your hands. Always use
recommended gloves / hand protection.
>Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to serious injury or death.
To avoid injury to hands and fingers:
• Never leave winch remote control where it can be activated
during free spooling, rigging, or when the winch is not being used.
• Never leave the wireless winch remote control turned on or
connected to winch controls when installing, free spooling,
rigging or servicing winch, or when the winch is not being used.
AVOID WINCH AND EQUIPMENT DAMAGE
• Always avoid side pulls which can pile up winch rope at one end
of the drum, this can damage winch rope or winch.
• Always ensure the freespool 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, if not IP68 rated.
• Always store the remote control in a protected, clean dry area.
• Never hook the synthetic rope back onto itself because you
could damage the synthetic rope .Use a strap.
• Avoid continuous pulls from extreme angles as this will cause the
rope to pile up on one end of the drum. This can jam the rope
and cause the rope to dive down through other rope layers.
This manual provides instructions on how to install and operate your winch and operating your Wireless Remote Control.
When installing your winch system, read and follow all mounting and safety instructions. Always use caution when working with electricity and
remember to verify that no exposed electrical connections can accidentally be touched before energizing your winch circuit. For specifications
and performance data, refer to the specification sheets and the RED Winches website.
>Chemical And Fire Hazard
Failure to observe these instructions could lead to serious injury or death.
• Always remove loose jewellery 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
batter terminals with metal objects.
• Always consult operator’s manual for proper wiring details.
• Always insulate and protect all exposed wiring and electrical
terminals.
• Always connect red(+) power cable ONLY to the positive(+)
terminal of the battery.
• Always connect black ground(-) power cable ONLY to the
negative(-)terminal of the battery.
• Never connect red(+) power cable to the negative(-) terminal of
the battery.
>Moving Parts Entanglement Hazard
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
centre of hook.
• Never use a hook whose throat opening has increased, 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. Never hook back on rope.

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WARNING:
MOUNTING PLATE THICKNESS IS IMPORTANT
FOR RELIABLE SAFE OPERATION THE
MOUNTING PLATE THICKNESS SHOULD NOT BE
LESS THAN 8MM (STEEL)
IT MAY DAMAGE WINCH DURING OPERATION
AND VOID ANY WARRANTY IF NOT THE
CORRECT THICKNESS
WINCH WEIGHT: 88KG (NO ROPE OR HOOK)
GENERAL INSTALL DIMENSIONS
Hornet 2q

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Hornet 2q
FEATURES
THE ORIGINAL AND BEST RED WINCH
AIR BRAKE SYSTEM. STOPS YOUR
WINCH INSTANTLY. FAIL SAFE AND
RELIABLE
ALBRIGHT SOLENOIDS
AND AIR SOLENOID
FOR AIR BRAKE
DRUM AIR FREESPOOL
6MM AIR TUBE REQUIRED
COVER CAN BE
REMOVED EASILY
TO SERVICE THE
FREESPOOL ASSEMBLY
ENGINEERED BILLET FAIRLEAD
TO GIVE THE SYNTHETIC ROPE THE
BEND RADIUS IT NEEDS AND TO
EXTEND ROPE LIFE
STAINLESS STEEL
FASTENERS
ENGINEERED DRUM
SUPPORTED BY PRECISION
SEALED BEARINGS
ADDED PROTECTION
FROM 2 x DRUM END SEALS
THE MIGHTY OX MOTOR IS A
VERY POWERFUL MOTOR
PROVIDING HIGH SPEED
AND HIGH TORQUE AND
IS THE POWER BEHIND
YOUR WINCH AND ITS
PERFORMANCE
COPPER BUS BARS
FOR THE ULTIMATE
EFFICIENT TRANSFER
OF POWER
AIR BRAKE CONNECTION
6MM AIR PIPE COMING
DIRECTLY FROM YOUR
ON-BOARD VEHICLE AIR
COMPRESSOR
PRECISION ENGINEERED
BILLET MACHINED HOUSINGS
AND DRUM ENDS, THE ULTIMATE
IN STRENGTH AND DESIGN
(+) POWER CONNECTION STUDS
M8 THREAD
FOR OPTIMAL PERFORMANCE:
2 x 70MM (SECTIONAL AREA) CABLE
ON CONNECTING BUS BAR
SUPPLIED DIRECT FROM YOUR
BATTERIES
(-) POWER CONNECTION M8 FEMALE THREAD
FOR OPTIMAL PERFORMANCE:
70MM (SECTIONAL AREA) CABLE
ON EACH STUD, SUPPLIED DIRECT FROM YOUR
BATTERY

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WINCH CONNECTIONS
Hornet 2q
WINCH IN & OUT
SWITCH CONNECTOR
SUPPLIED WITH
FLYING LEAD TO
WIRE TO A ROCKER
SWITCH IN YOUR
VEHICLE
Ø6mm AIRLINE
FROM ON-BOARD COMPRESSOR
NEEDS TO BE CONNECTED DIRECTLY
HERE, MINIMUM AIR PRESSURE:
4.5 BAR (60 PSI)
WARNING
ENSURE POSITIVE CABLE
CONNECTION AND LUG
USED IS INSULATED FROM
ACCIDENTAL TOUCHING
AND DOES NOT TOUCH
ANY SURROUNDING PARTS
OR MOTOR BUZZ BARS
(-) POWER CONNECTION M8 FEMALE
THREAD IN 2 x POSITIONS
FOR OPTIMAL PERFORMANCE:
70MM (SECTIONAL AREA) CABLE
ON EACH CONNECTION, SUPPLIED DIRECT
FROM
AIR BRAKE
SOLENOID
(SUPPLIED FITTED)
OUR MIGHTY
OX MOTORS
+12V SIGNAL WIRES TO
YOUR VEHICLE. WINCH IN
& OUT SWITCH
+12V SIGNAL TO RED WIRE:
WINCH IN,
+12V TO BROWN WIRE:
WINCH OUT.
BLACK IS EARTH /
NEGATIVE
(+) POWER CONNECTION BUS BAR
M8 THREADS FOR 2 x CONNECTIONS
FOR OPTIMAL PERFORMANCE:
70MM (SECTIONAL AREA) CABLE
ON EACH POSITION,
SUPPLIED DIRECT FROM YOUR
BATTERIES
AIR FREESPOOL
6MM AIR TUBE REQUIRED
COMING FROM A
CONTROL TOGGLE SWITCH
OR ELECTRICAL AIR
SOLENOID SWITCH THAT
IS CONNECTED TO YOUR
VEHICLE AIR COMPRESSOR
BUS BAR COVERS
REMOVED FOR
CLARITY OF NOTES
THIS QUAD WINCH HAS THE ABILITY TO DRAW
OVER 1000A 12V DC FROM YOUR VEHICLE
BATTERIES WHEN WINCHING HARD, AT NEARLY
FULL CAPACITY.
MAKE SURE THERE IS ENOUGH POWER
AVAILABLE TO SUPPLY IT

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F1 (M8)
BRUSH PACK AT
THE FRONT OF THE
MOTOR HERE
F2 (M8)
A (M8)
BUS BAR COVER
“A”
BAR
OX MOTOR OVERVIEW
125mm DIA BODY
AIR SOLENOID
POSITION VARIES
BETWEEN WINCHES
(SHOWN FOR ILLUSTRATION)
Hornet 2q
GENERIC FEATURES
EARTH CONNECTION
FROM BATTERY CAN GO
ON EITHER ONE OF THREE
M8 THREADED HOLES
SOLID COPPER BUS BARS
TRANSFER ALL THE POWER
EFFICIENTLY TO THE MOTOR
SMALL ZIP TIE USED
TO HOLD COVER IN PLACE
WARNING
OVERVOLTING (NOT UNDER WARRANTY)
(24v POWER ONTO A 12v RATED MOTOR)
NEVER ALLOW THE OX MOTOR TO ‘OVER SPEED’ OR RUN WHEN THE
WINCH IS NOT UNDER LOAD OR HAVE TENSION / WEIGHT IN THE
WINCH LINE. THIS SITUATION CAN DAMAGE THE ARMATURE AND CAUSE
THE MOTOR TO FAIL - THIS IS NOT COVERED UNDER WARRANTY
AIR SOLENOID FOR
AIR BRAKE. SUPPLIED FITTED
AUTOMATICALLY WORKS
WITH ‘WINCH IN’ OR ‘WINCH
OUT’ SIGNALS FROM YOUR
VEHICLE
DIODE FOR AIR
SOLENOID BI-DIRECTION
OPERATION FITTED IN CAP
WARNING
ENSURE POSITIVE CABLE CONNECTION AND LUG USED
IS INSULATED FROM ACCIDENTAL TOUCHING AND DOES
NOT TOUCH ANY SURROUNDING PARTS OR MOTOR
BUZZ BARS
SPLINED DRIVE

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MOUNTING BOLTS
M12 X 12 CAP HEADS ARE FITTED FOR OUR
ASSY PROCESS ONLY.
THESE BOLTS ARE TO BE REMOVED PRIOR
TO INSTALLATION
WINCH GEARBOX
FASTENERS
ENSURE ALL FASTENERS ARE TORQUED TO THE CORRECT
VALUES. LOCTITE 234 (THREADLOCK) TO BE APPLIED ON
ALL FASTENERS
UNLESS SPECIFIED
FASTENER TORQUE
M6 10 Nm
M8 24 Nm
M10 45 Nm
M12 80 Nm
M16 160 Nm
M20 200 Nm
ANY RESIDUE FOUND IN THE
BOTTOM OF THE CASE CAN BE
REMOVED. REPLACE WITH FRESH
GREASE AS REQUIRED
GREASE APPLIED TO ALL GEARS
AND THEIR TEETH. CASE DOES NOT
NEED TO BE FILLED WITH GREASE.
GREASE SPECIFICATION
CASTROL SPHEROL L-EP2
BP ENERGREASE LS-EP2 WINCH IN
MOTOR DIRECTION
WINCH IN
DRUM DIRECTION
WINCH IN
Hornet 2q

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HORNET2-MD-20
MOTOR GEAR
(15 TOOTH - STD)
HORNET2-MD-21
INTERMEDIATE GEAR
(50 TOOTH - STD)
DRIVE GEAR
SHAFT GEAR
GREASE SPECIFICATION
CASTROL SPHEROL L-EP2
BP ENERGREASE LS-EP2
HORNET 2 - STANDARD GEARS (STD)
RATIO: 45:1
HORNET 2 - OVERDRIVE GEARS (OD)
RATIO: 38:1
HORNET2-MD-25
MOTOR GEAR
(17 TOOTH - OD)
HORNET2-MD-26
INTERMEDIATE GEAR
(48 TOOTH - OD)
Hornet 2q
STD GEARSET SHOWN
GEARSETS
UNLESS SPECIFIED
FASTENER TORQUE
M6 10 Nm
M8 24 Nm
M10 45 Nm
M12 80 Nm
M16 160 Nm
M20 200 Nm
GEARBOX RATED PULLING CAPACITY
Overdrive 2,200kg (4,000 lbs)
Standard 4,500kg (10,000 lbs)

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DRIVE SHAFT & FREESPOOL SYSTEM
GREASE SPECIFICATION
CASTROL SPHEROL L-EP2
BP ENERGREASE LS-EP2
UNLESS SPECIFIED
FASTENER TORQUE
M6 10 Nm
M8 24 Nm
M10 45 Nm
M12 80 Nm
M16 160 Nm
M20 200 Nm
PISTON FITTED WITH O-RINGS,
INTERNAL & EXTERNAL
PISTON
PISTON
SPINDLE
TO REMOVE CLUTCH
PLATE, FIRST REMOVE
THESE PINS CLUTCH PLATE
PISTON SPINDLE AND PISTON TO BE
LIGHTLY OILED WITH WD40 PRIOR TO
ASSEMBLY.
SWIVEL 90DEG
AIR FEED FITTING
TO REMOVE PINS
REMOVE FASTENERS
SPRING - ENGAGE DRIVE
LOCTITE 234
(THREADLOCKER
TO BE USED ON ALL
FASTENERS
GREASE SPLINE PRIOR
TO ASSEMBLY
DRIVE SHAFT
3 X DRIVING DOWELS
SLOTS USED TO
DRIVE DRUM
Hornet 2q

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AIR BRAKE HOUSING
6MM AIR PIPE
90DEG FITTING
BREATHER
PISTON BODY
PISTON SEALING CAP
BRAKE REACTION
PLATE LOWER
PISTON O-RING
PISTON SEALING CAP
O-RING
PISTON SEALING CAP
CIRCLIP
BRAKE REACTION PLATE
UPPER
BRAKE DISC
BRAKE PAD LOWER
BRASS DRIVE PINS
BRAKE PAD
UPPER
REACTION PLATE
PILLARS
GUIDE BEARING
BRAKE
SPRINGS
AIR BRAKE ASSEMBLY
FASTENERS
ENSURE ALL FASTENERS ARE TORQUED TO THE CORRECT
VALUES. LOCTITE 234 (THREADLOCK) TO BE APPLIED ON
ALL FASTENERS
AIR FEED COMES FROM AIR BRAKE SOLENOID
OEM SUPPLIED AND BUILT ONTO THE WINCH
SPRINGS
8 - SPRINGS ARE FITTED AS STANDARD AND WILL WORK FOR
95% OF VEHICLES. IF YOU WANT A STRONGER BRAKE , YOU CAN
FIT UP TO 12 SPRINGS.
IF YOU HAVE A HEAVY TRUCK ABOVE 3,OO0KG, IT WOULD BE
WORTH CONSIDERING MORE SPRINGS.
UNLESS SPECIFIED
FASTENER TORQUE
M6 10 Nm
M8 24 Nm
M10 45 Nm
M12 80 Nm
M16 160 Nm
M20 200 Nm

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GENERAL WINCH MAINTENANCE
>General Maintenance
• Check the battery regularly. Ensure that it is in good
condition and is fully charged.
• Check that all of the connections are clean and tight.
Corrosion on the battery connections can aect the
performance of the winch. Ensure that the battery
connections are tight.
• The winch is protected from water and rain, but
avoid submerging the winch for a prolonged time,
particularly if the winch casing is warm / hot.
• If it does become submerged, once clear, run the
winch in and out for about 10 meters of rope to
generate heat inside the winch to help dry the inside
of the casing.
• Only clean your winch with soap and water, then
rinse. DO NOT PRESSURE WASH THE WINCH. This
can force water past the seals and gaskets.
• If you were not the last person to use the winch,
always inspect the full length of the winch rope
before applying any load to it.
• Have the winch serviced regularly at an authorised
RED Winch centre / Partner / Distributor.
>Basic Trouble Shooting
Powers in only one direction
• Faulty Solenoid, damaged remote control or remote
control cable. Check remote control plug pins for
damage. Check remote correctly connected.
Completely Dead
• Burned motor, poor earth, discharged battery, faulty
isolator switch, damaged earth wire, damaged remote
control cable or switch. Check remote control pins for
damage. Check isolator switch is on. Check power is
getting to the winch.
Low Power
• Check the condition of the battery and if the
alternator is charging correctly, check the voltage to
the battery. Are the battery terminals corroded or the
cables damaged?
• Turn o any electrical items in the vehicle; Radio,
lights, heated seats etc.
Winch Will Not Free Spool
• Warped mount plate, winch rope bound up on one
side of the drum, bent drum flange or gear damage
inside the winch.
• Check freespool air solenoid if fitted.
• Check Air solenoid or Air switch is working
• Check freespool clutch plate is free to move and can
be both engaged & disengaged easily.
Winch Motor Gets Hot Very Quickly
• Overloaded or stalled during winching operation,
Poor earth to battery, worn motor, water or mud in
motor. Check the load is not heavier than the rated
load. Check all connections and cables.
• Connecting power cables are too small.
Winch Brake Will Not Hold
• Worn friction material or brake overheated from
extended period of powering out.
• Air solenoid controlling air brake can not exhaust
(holding brake o).

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USING YOUR
H2Q WINCH
A REFERENCE GUIDE
TO WINCHING

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WINCH HANDLING
>Estimating Winch Loads
Before attempting to move a rolling load with a winch,
an estimate of the load should be made to ensure
that the safe working load limits of the winch and any
supporting equipment is not exceeded.
If there is a solid resistance that prevents the load from
moving, the winch must not be allowed to operate
in a situation where it is overloaded; the forces and
electrical loading on the vehicle this creates may
become excessive. The load to be recovered must be
able to move as freely as possible. Before winching it
might be necessary to dig out a trapped wheel or dig
away any part of the terrain upon which is resting any
part of the load apart from its wheels.
There are two factors which should be added together
to arrive at a total load:
The maximum inclination of the ground, even if it is only
a short section; for instance a pot hole or a tree root.
On sloping ground a factor has to be allowed for the
gradient as follows:
Divide the gradient angle in degrees by 60, and multiply
that by the load being pulled. Therefore ascending a
30° gradient with a vehicle weighing 2,250 kg would be:
30° / 60 = 0.5 x 2250 = 1125 kg
The pull required to move a vehicle varies depending
upon the type of ground upon which it stands.
The required pull as a percentage of its weight is as
follows;
A 2250kg Vehicle in shallow mud would be:
2250 / 100 x 35 = 788kg
Therefore to calculate the true load when pulling up an
incline, add the previous calculation for the gradient to
the calculation for the ground condition:
Gradient 1125Kg + Ground 788kg = Total estimated
load 1913Kg
Hard Surface 5%
Grass 15%
Wet Sand 15-20%
Soft Dry Sand 25-30%
Shallow Mud 35%
Bog/Marsh where chassis is not grounded 50%

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>Operating Capacity
The maximum operating capacity of the winch is
aected by the number of wraps of rope around the
drum, and consequently whenever operating a winch
recovery, as much winch rope should be removed
from the drum as possible to maximise mechanical
advantage prior to applying the recovery load.
The pull rating of the winch is based on the rope being
on bottom layer, or 1st layer of wrap around the drum.
Please note maximum drum loads cannot be achieved
for long periods on most electric winches.
For operations requiring periods of prolonged use, the
load needs to be considerably below the winch rated
pulling figure on bottom layer.
This helps when deciding when to use a pulley system
(RED Winch Snatch Ring or Pulley Blocks) to improve
the mechanical advantage
of the winch.
Other types of winch e.g. mechanical or hydraulic
are able to sustain maximum rated load for longer
durations.
>Vehicle Electrical System
It is important to understand how much power is being
drawn from the battery by the winch.
It is important whatever winch you install, you find out
what the draw is from your winch and the maximum
draw the vehicle systems can deliver.
Always use the correct sized electrical power cable,
using cable too small will result in the winch motors
being starved of current, increased resistance and
potential motor failure.
Make sure your Earth / negative connections to the
winch are the same size as the positive connections.
A battery cannot recharge as quickly as it is discharged.
Increasing the engine revs while winching, and consider
increasing the revs between winches will help to
maintain the charge.
On most vehicles, maximum alternator output is
achieved at approximately 1800 rpm.
Winching without the engine running will discharge the
battery rapidly and is not recommended as you will end
up with a battery that can no longer start your vehicle
THE HORNET2Q WINCH
LOADING AND ELECTRICAL SUPPLY

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WINCH ROPE CARE AND INSPECTION
GUIDELINES – SYNTHETIC
The life of a synthetic rope can be increased through
good working practices and care. Synthetic ropes
must be regularly inspected for damage. RED
Winches recommend that winch ropes are always
checked before use.
Under PUWER (Provision and Use of Work Equipment
Regulations - UK only), work equipment should be
inspected every 6 months.
Always refer to the Manufacturers Guidelines.
>Handling Guidelines
• Do not over load or shock load the rope. This can
cause damage which is not visible, but could cause
the rope to break later. (A shock load is a load that
is 10 % greater than the recommended load, applied
suddenly.)
• Do not bend the rope through an angle that is less
than 6 times its diameter. (9mm x 6 = 54mm)
• Rope life can be prolonged by keeping it clean
and dry.
• Do not clean ropes using a pressurised hose. (This
can force abrasive material in to the fibres.) Remove
rope and wash in a container of cold water. Allow the
rope to dry before loading it back onto the drum.
• Synthetic ropes can be damaged by direct contact
with chemicals and in some instances, the fumes from
them.
• When the rope is not in use, protect it from UV light
by using a winch cover.
• Synthetic rope can be weakened if exposed to heat.
(Usually an overheated drum).
• Do not winch out under load if using an electric winch
that has an over run brake enclosed within the winch
drum.
• Where possible, do not allow the rope to come in to
contact with the ground. Do not tread on the rope.
This can lead to the ingress of abrasive material.
• Ropes should be marked with a unique number.
A history of rope use should be kept. This should
include inspection dates.
RED Winches recommends you inspect a winch rope
before using it.
In all commercial applications ropes must be
inspected under PUWER every 6 months. Always refer
to the Manufacturers Guidelines.
• Inspect the entire length of the rope. The outer fibres
of the rope will become fluy during normal use.
• Look for areas of inconsistency. These include lumps,
bumps or flat areas. These can be the result of shock
loading and the rope should be destroyed.
• Damaged ropes should always be destroyed to
prevent subsequent use.
• Generally if 25% or more of the fibres are broken, the
rope should be destroyed.
• 12 strand ropes should be destroyed if 2 or more
adjacent strands are cut.
• Rope can be damaged by direct heat, from the
drum for example, or from heat caused by excessive
friction. High temperatures can invisibly, reduce the
strength of the rope.
• Chemical contamination can cause areas of
discolouration, as can UV light. Determine the cause
of the discolouration and destroy the rope if it is
brittle or sti in these areas.