INSTALLATION AND

INSTALLATION AND
ATV/UTV RECOVERY WINCHES
INSTALLATION AND
OPERATION MANUAL
Read manual carefully and understand all warnings and instructions before use.
Model RP25
2,500 lbs. Capacity
*Cable winch shown.
Also available with Dyneema® rope.
Model RP35
3,500 lbs. Capacity
*Cable winch shown.
Also available with Dyneema® rope.
Model RP50
5,000 lbs. Capacity
*Cable winch shown.
Also available with Dyneema® rope.
ISO/TS16949:2009
ZL 2008 3 0166399.6
Due to continuing improvement, the actual product may differ slightly from item described herein.
QUADBOSS WINCH MODEL RP25
Features:
•2-stage planetary gear system for fast line speed
•Automatic load-holding brake
•Free spooling
•Power-in and power-out
•3Hp (2.25Kw) heavy-duty electric permanent magnetic motor
•Low electric current
•Protected against dust and water-resistant (rated IP67)
Specifications:
Rated line pull (Single line)
2,500 lbs./1,135kgs
Gear reduction ratio
241:1
Motor (permanent)
3Hp (2.25Kw), 12-Volt DC
Drum
Diameter 2” x Length 3.15”
Cable (min. break force 4,200 lbs.) 3/16” 39’
3/16” x 50
Dyneema® rope option
Overall dimension
13.1” x 4.6” x 4.5”
Net weight
15 lbs./6.8kg
Mounting bolt pattern
3” x 4.88”
Performance of 1st layer
Line Pull
Line Speed
Lbs Kgs
Fpm Mpm
0
0
19.7
6.0
1000 454
18.4
5.6
2000 907
14.8
4.5
2500 1135
13.5
4.1
2
Motor
Current
Amp
31
105
145
195
Line Pull & Cable Capacity by Layer
Cable Rated Line
Cable
Dyneema®
Layer
Pull
Capacity
rope Capacity
Lbs Kgs Feet Meters Feet Meters
1
2500 1135
9.2
2.8
9.2
2.8
2
2130 967 20.3 6.2
20.3
6.2
3
1855 842 33.1
10.1
33.1
10.1
4
1643 746 39.4 12.0
47.6 14.5
5
1475 669
—
—
50.0 15.2
QUADBOSS WINCH MODEL RP35
Features:
•2-stage planetary gear system for fast line speed
•Automatic load-holding brake
•Free spooling
•Power-in and power-out
•3.5Hp (2.6Kw) heavy-duty electric permanent magnetic motor
•Low electric current
•Protected against dust and water-resistant (rated IP67)
Specifications:
Rated line pull (single line)
3,500 lbs./1,589kgs
Gear reduction ratio
241:1
Motor (permanent)
3.5Hp (2.6Kw), 12-Volt DC
Drum
Diameter 2” x Length 3.15”
Cable (min. break force 5,600 lbs.)
7/32” x 39’
Dyneema® rope option
Overall dimension
13.5” x 4.5” x 4.3”
Net weight
18 lbs./8.16kg
Mounting bolt pattern
1.89” x 3”
Performance of 1st layer
Line Pull
Line Speed
Lbs Kgs
Fpm Mpm
0
0
18.4
5.6
1000 454
15.0
4.6
2000 907
13.1
4.0
3500 1589
9.8
3.0
Motor
Current
Amp
30
86
136
230
Line Pull and Cable Capacity by Layer
Cable Rated Line
Cable
Dyneema®
Layer
Pull
Capacity
rope Capacity
Lbs Kgs Feet Meters Feet Meters
1
3500 1589 8.2
2.5
9.2
2.8
2
2900 1317 18.0
5.5
20.3
6.2
3
2500 1135 29.2 8.9
33.1
10.1
4
2200 1000 42.0 12.8
47.6 14.5
5
1900 863
45
13.7
50.0 15.2
3
QUADBOSS WINCH MODEL RP50
Features:
•2-stage planetary gear system for fast line speed
•Automatic load-holding brake
•Free spooling
•Power-in and power-out
•3Hp (2.25Kw) heavy-duty electric permanent magnetic motor
•Low electric current
•Protected against dust and water-resistant (rated IP67)
Specifications:
Rated line pull (Single line)
5,000 lbs./2,267kgs
Gear reduction ratio
165:1
Motor (permanent)
3.8Hp (2.8Kw), 12-Volt DC
Drum
Diameter 2.01” x Length 5.4”
Cable (min. break force 4,200 lbs.) 1/4” x 50’
Dyneema® rope option
1/4” x 50’
Overall dimension
15.62” x 4.61” x 4.72”
Net weight
23 lbs./10.43kg
Mounting bolt pattern
3” x 6.61”
Performance of 1st layer
Line Pull
Line Speed
Lbs Kgs
Fpm Mpm
0
0
20.7
6.3
2000 908
15.1
4.6
3000 1360
11.5
4.0
4000 1810
10.5
3.2
5000 2270
9.2
2.8
4
Motor
Current
Amp
34
135
155
190
230
Line Pull & Cable Capacity by Layer
Cable Rated Line
Cable
Dyneema®
Layer
Pull
Capacity
rope Capacity
Lbs Kgs Feet Meters Feet Meters
1
5000 2270
–
–
–
–
2
4080 1852
–
–
–
–
3
3446 1565
–
–
–
–
4
2983 1354
–
–
–
–
5
2629 1194
–
–
–
–
INSTALLATION INSTRUCTIONS
For winch installation video, see QUADBOSS.COM
Included with your winch:
- Winch 2,500/3,500 lbs.
- 250-Amp contactor
- .25” Hook w/ pull strap
- Roller hawse for cable winch
or aluminum fairlead for Dyneema rope
- Handlebar rocker switch w/ handlebar mount
- Hand held rocker remote control
- Red positive battery cable 92” length
- Black ground battery cable 92” length
- Red positive winch cable 36” length
w/ blue color ends
- Black ground winch cable 36” length
w/ yellow color ends
Tools Required:
-#1 Phillips Head Screw Driver
-#3 Phillips Head Screw Driver
-4mm Allen Key
-8mm Socket
-15mm Wrench
- 4–pin harness
- M10 - 1.50 X 25mm (2 pc.)
- M10 - 1.50 Flange nut (2 pc.)
- M8 - 1.25 X 20mm (4 pc.)
- M8 split lock washer (4 pc.)
- M8 x 16mm od flat washer (4 pc.)
- M6 - 12mm od flat washer (4 pc.)
- M6 - 1.0 Flange nut (4 pc.)
- M6 - 1.0 X 50mm Phillips head screws (4 pc.)
- Rubber winch terminal boot cover
(2 pc.) 1 red and 1 black
-15mm Socket
-10mm Socket
-13mm Socket
-Wire Strippers
-Quick Splice Connector(s)
CONTACTOR
4-PIN HARNESS
4-PIN TO CONTACTOR
HANDLEBAR AND WIRELESS REMOTE
WIRELESS REMOTE
HANDLEBAR AND HAND REMOTE
BEFORE WINCH INSTALLATION:
- Disconnect the vehicle’s negative (-) battery cable first and then the positive (+) cable from the battery
- Install the winch mount (sold separately) that is specified for your ATV/UTV. Sequence may vary per application
HANDLEBAR ONLY
MOUNTING THE WINCH
- Place the QuadBoss Winch in the winch mount and secure using the M8 split lock washers and M8 bolts
- Next place the roller fairlead/hawse fairlead in front of the winch mount, pulling the rope through the opening
- Remove the cotter pin and clevis pin from the .25” hook to attach to the cable/rope
- Reinstall the clevis pin and cotter pin to secure the hook to the cable/rope
MOUNTING THE CONTACTOR
- When mounting the winch contactor, it is recommended to mount in a suitable, clean and dry location (verify that you have sufficient clearance)
- If drilling is required for mounting holes, making sure electrical wires and/or components will not be damaged when drilling
- Use the supplied hardware, (M6 Phillip head screws, washers and corresponding nuts) to properly mount the contactor to your ATV/UTV
WIRING THE CONTACTOR
Note: Ground cable should NOT be connected to battery terminal until installation is complete!
- Using the 92” positive (RED) cable, connect one end to the RED terminal on the contactor
- Connect the other end of the RED cable to the positive terminal of the battery
- Using the 92” negative (BLACK) cable, connect one end to the BLACK terminal on the contactor. Leave the other end of cable disconnected
until installation is complete (connecting the ground cable to the battery should be the last step in the installation)
- Using the 36” Positive (RED) cable with blue heat shrink, connect one end to the BLUE terminal on the contactor
- Using the red terminal boot protector, slide it over the opposite end of the cable and then to the positive terminal on the winch
- Using the 36” Negative (BLACK) cable with the yellow heat shrink, connecting one end to the contactor that has been colored YELLOW
- Using the black terminal boot protector, slide it over the opposite end of the cable and then connect cable to the negative terminal on winch
Note: Depending on location of the contactor, you may need to use the shorter black/red cables in place of the longer red/black cables. In this case, the wiring
configuration of the color coded terminals will change.
5
INSTALLATION INSTRUCTIONS CONTINUED
MOUNTING THE HANDLEBAR SWITCH
- The handlebar switch is usually mounted on the left side of the handlebar, but can be mounted on either side
TIP: A piece of electrical tape wrapped around the handlebar where the switch will be mounted can help prevent rotation
of the mount on the handlebar.
- Once the switch is mounted, route the wires to the location of the contactor (check for handlebar range of motion when routing wires)
- The brown and blue wires from the switch should then be connected directly to the brown and blue leads on the contactor
- The red wire will need to be connected to a keyed power source (a test light may be needed to locate a suitable source of power)
- The red wire should only have power when the key is in the “ON” position
- Verify that you have full range of motion of the handlebars with no binding issues
- Secure all wiring to prevent from coming loose in the future
MOUNTING THE 4–PIN HARNESS (OPTIONAL)
- The 4-pin harness is required when connecting the handheld controller and/or wireless controller (sold separately); it is also required
when using two controllers at the same time; it is recommended to find a location near the contactor to drill a 22mm hole to securely
mount the 4-pin harness into your body work
- Insert the harness into the drilled hole to connect to the brown and blue leads coming out of the contactor
- The brown and blue wires have a splitter on each end that can be connected to the handlebar switch for the using two controllers simultaneously
- Using the base of the 4–pin harness connector as a template, drill two 5mm holes on either side of your 22mm hole and secure using the
fasteners supplied with the harness; the black wire with the ring connector needs to be connected to a ground; the red wire would need
to be connected to a keyed power source (a test light may be needed to locate a suitable source of power)
- The red wire should only have power when the key is in the “ON” position
- Connect the remaining 92” negative (BLACK) cable end to your battery ground
WINCH OPERATION
Clutch Operation:
The clutch is operated by turning the Clutch Knob clockwise about 45-90° to the“DISENGAGE” position.
This will allow you to free spool the winch.
Turn the Clutch Knob counter-clockwise to “ENGAGE” position until it pops back into place, allowing it to go into gear.
CAUTION: Never release the wire rope while under tension. Doing this can badly damage the winch, cause property damage and/or
serious injury.
Wire Rope Handling:
Grab the hook using the Hand Saver Strap and pull the wire rope to the desired length. Then attach the hook to item being pulled. Make sure the
hook spring-loaded latch is set.
CAUTION: Always leave at least five turns of wire rope on the drum. Review Winch Safety Warnings and Precautions before continuing.
Winching loads:
While standing aside of the tow path, press and hold the push button on the remote control to pull the load. If the load will not move, release
pull switch and check for obstacles blocking the load or check to see if load is too heavy for winch capacity.
CAUTION: This winch is designed for intermittent use only, and should not be used in a constant duty application. The duration of the
pulling job should be kept as short as possible. If the winch motor becomes very hot to touch, stop the winch and let it cool down for several
minutes. Never pull for more than one minute at or near the rated load. Do not maintain power to the winch if the motor stalls as it can
damage the motor or gear.
Note: A fully charged battery will give best service. The engine should be kept running during operation.
6
INSTALLATION PRECAUTIONS
- If you choose not to use an ATV mounting kit,
you may be required to drill holes into a structural support
- Be sure the location will be strong enough to support
the rated pulling force of the winch
- Do not drill into wiring or fuel tank - If mounting requires bolts different than the length supplied,
use a bolt of equal or better quality
- Torque the kits 5/16” Grade 8 mounting bolts to 12 lbs.-ft.(1.7kgm)
- Make sure the winch mounting bolts and winch hardware
has been checked for proper torque
- When attaching wires to the motor terminals, hold the inner nut
with a second wrench to keep the terminal from rotating in the
housing; this will help avoid internal wire breakage (image A)
- Always use the Hand Saver strap when the hook
is near the fairlead or winch drum
- Before testing the winch, set the clutch to free spool position
by turning the Clutch Knob clockwise (image B); pull about 2
feet of wire rope off the winch and set the Clutch Knob to
engaged position by turning it counter-clockwise (Image C)
- Always wear heavy gloves when handling heavy wire rope
SAFETY WARNINGS AND PRECAUTIONS
- Do not operate winch under influence of drugs or alcohol
- Read manual before using this winch
- Always use heavy gloves when handling wire rope
- Never hook the cable back upon itself
The cable can break under tension and cause injury and damage
- Stay clear of wire rope and keep others away when
in operation or with load on wire
- Inspect winch and wire rope before each use
- Do not use winch if wire rope or winch shows wear or damage
- Replace any parts as needed before using the winch
- Do not exceed the winch capacity
- Do not place hands near the fairlead when winch is in operation
- Always use the protective hand-saving belt when spooling
- Do not use the winch as a hoist or to move people
- Do not use winch to secure a load or tow vehicles
Image A
Image B
Image C
PROPER WINCHING TECHNIQUE
BE SAFE
Take all precautions and use common sense to avoid injury and property
damage before operating winch. Electric winch is for intermittent use only.
Place a towel or winch accessory bag over wire cable while winch is in use.
In case of a breakage, this will help disperse the kinetic energy of the cable,
keeping it closer to the ground to avoid injury.
WINCHING USING A
SNATCH/PULLEY BLOCK
WINCHING USING A TREE AS AN ANCHOR POINT
Use QuadBoss Winch Accessory Kit (P/N 608994 sold separately) when
using a tree as an anchor point for winching. Wrap the 1”x 8’ Tree Trunk
Protector strap around the tree to protect it from damage when winching.
WINCHING USING A SNATCH/PULLEY BLOCK
To double the pulling power of your winch, use the snatch/pulley block
included in the QuadBoss Winch Accessory Kit (P/N 608994 sold separately).
Pull the winch cable through the snatch block around the pulley.
Unscrew the pin on .25” D-Shackle. Slide both looped ends of the Tree Trunk
Protector strap and the open ends of the snatch block around the .25” D-Shackle.
Reinsert pin into the .25” D-Shackle to secure Tree Trunk Protector strap to the snatch/pulley block.
Use the Hand Saver strap to carefully pull the winch rope/cable back to your ATV/UTV.
With the open end of the hook facing upward, connect the hook to the frame or tow hook at a downward angle.
Caution: Keep hands clear of wire rope, hook and roller fairlead opening during winch operation.
Always use Hand Saver strap to hold the hook when spooling winch.
7
MAINTENANCE
LUBRICATION:
1.All moving parts within the winch have been lubricated using high-temp
lithium grease at the factory; no internal lubrication is required.
2.Lubricate wire rope periodically using a light penetrating oil.
CABLE ASSEMBLY REPLACEMENT (to be performed only by a qualified service tech.)
1.Move clutch knob to the OUT position.
2.Extend cable assembly to its full length;
note how the existing wire rope is connected to the inside of the drum.
3.Remove old cable assembly and attach new one.
4.Retract cable onto drum being careful not to allow kinking.
GENERAL
1.Keep vehicle battery in good condition.
2.Be sure that the winch battery cables are not drawn tight against any surfaces, which could possibly damage them.
3.Periodically remove and clean cable connections to the battery fuse box and chassis ground;
corrosion will reduce performance or may cause a short.
4.Cover the cables and winch when not in use.
TROUBLE SHOOTING
SYMPTOM
POSSIBLE CAUSE
SUGGESTED REMEDY
Switch assy. not connected properly
Insert switch assy. firmly to the connector
Loose battery cable connection
Tighten nuts on cable connectors
Contactor malfunctioning
Tap contactor to free contact, apply 12
volts to coil terminal directly
Defective motor
Check for voltage at armature port with
switch pressed. If voltage is present, replace
motor
Water has entered motor
Drain and dry; run in short bursts without
load until completely dry
Motor runs too hot
Long period of operation
Let winch cool down periodically
Motor runs slowly
or without normal
power
Battery run down
Recharge battery by running vehicle engine
Insufficient current or voltage
Clean, tighten or replace the connector
Motor runs but cable
drum does not turn
Clutch not engaged
Push Clutch Knob into IN position; if that
does not work, ask a qualified technician to
check and repair
Motor runs in one
direction only
Defective or stuck solenoid
Tap solenoid to free contacts
Repair or replace solenoid
Defective switch assy.
Replace switch assy.
Makes audible clicking
when activating
Defective switch assy.
Replace switch assy.
Motor does not
turn on
QuadBoss | 4900 Alliance Gateway Freeway, Fort Worth, TX 76177 | 877-847-1558 | QUADBOSS.COM
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