Quadratec 92122.203 series Setup guide

The Trusted Source

Q-Series Winch

with Synthetic Winch Line

Assembly and Installation Manual

#92122.203X

REQUIRED TOOLS:

SAFETY GLASSES

GLOVES

TORQUE WRENCH

10 MM SOCKET

10 MM WRENCH

13 MM WRENCH

14 MM WRENCH

4 MM HEX (ALLEN®) KEY

5 MM HEX (ALLEN®) KEY

P2 PHILLIPS HEAD SCREW DRIVER

READ ALL SAFETY MESSAGES AND UNDERSTAND ALL

INSTRUCTIONS AND PROCEDURE NOTICES BEFORE

ATTEMPTING TO INSTALL OR USE THIS PRODUCT.

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Solenoid Assembly Tie

Bar

Controller

The Trusted Source

Unpacking:

When unpacking, check to make sure all parts are included. If any part is missing or

broken, please call Quadratec Customer Service at 800-745-6037 as soon as possible.

Note About Photos in this Installation Guide:

Some of the graphics in this manual may not exactly match your winch model.

All information and instructions given applies to all models except where noted.

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 man-

ual 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:

a hazardous situation which, if not avoided, could result in death or

serious injury. You CAN be KILLED or SERIOUSLY HURT if you do not

follow instructions.

a hazardous situation which, if not avoided, could result in minor or

moderate injury. You CAN be moderately HURT and also may suffer

property damage if you do not follow instructions.

Careful attention is required to this instruction or operation but does

not generally relate to personal injury. Damage to your Quadratec®

product or other property may result if you do not follow instructions.

Clutch Control

Synthetic

Winch Line

with Chafe

Guard

Hawse

Fairlead

Winch Hook Strap

Mounting

Hardware

Winch

Hook

Fairlead

Hardware

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The Trusted Source

Assembly and Installation:

Solenoid Installation (as Side Mount)

Photo A. Carefully study the relation-

ship between the solenoid pack and the

side mount bracket. Run the four cables

and black thermal relay ground wire

through the bracket along with the four

mounting studs as shown. Place a flat

washer, lock washer and nut onto each

stud and tighten with a 10mm wrench.

Photo B. Fasten two socket cap screws

with split lock washer and flat washer

to attach the bracket to the winch base.

There are tapped holes on each side of

the motor mount. Do not tighten until

the third fastener is in place.

Attach the solenoid pack to the side mount

solenoid bracket using a flat washer, split

lock washer and nut for each

of the four studs. Tighten

using a 10mm wrench.

Photo A

Photo B

Tighten both 6mm x 1mm x 12 mm

screws using a 5mm hex key.

Photo C

Tighten the 6mm x 1mm x 12 mm

screw using a 5mm hex key.

Photo C. Fasten a machine screw with a

split lock washer followed by a flat

washer. Tighten all three solenoid

mount fasteners now.

Q-Series Winches feature two

mounting positions to suit your

individual application. The Above Side

Mount Installation features a Heavy

Duty Solenoid Bracket (Shown Right).

Some bumpers with Grille Guards or

Tubular Hoops require the Q-Series

Winch to Be installed using the Top

Mount Solenoid Brackets. To install

Winch with Top Mount Bracket, please

refer to page 4 for Installation.

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Tie Bar

Be Sure to Keep

Power Cables From

Coming into Contact with

Cable Assembly

Cable

Assembly

The Trusted Source

Tapped holes to the rear tie bar.

Tighten using

a 10mm wrench.

Tighten using a

P2 phillips head

screw driver.

Attach solenoid pack to the top mount brackets

using a flat washer, split lock washer and nut for

each of the four studs.

Photo D

Photo E

Attach the solenoid pack with mount brackets to

tie bars using a phillips head screw with split lock

washer.

Assembly and Installation (Continued)

When the solenoid is mounted to the top of the tie bars, the winch

power cables MUST be PROPERLY placed to the OUTSIDE of the rear tie

bar as shown. Power cables MUST NOT come in contact with a rotating

winch cable assembly or power cable insulation MAY be compromised

and short circuit. Improper placement of power cables MAY result in

damage to the winch or the vehicle.

Photo D. Note the relationship between

the solenoid pack and the top mount

brackets. Place a flat washer, lock washer

and nut onto each stud and tighten with

a10mm wrench.

Photo E. Center the solenoid pack onto

the winch tie bars and fasten with two

phillips head machine screws with split

lock washers to attach the brackets.

There is a tapped hole on each of the

brackets. Tighten both screws using a P2

phillips head screwdriver.

Solenoid Installation (as Top Mount)

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The Trusted Source

Assembly and Installation (Continued)

Yellow Motor Stator Cable

Green Motor Stator Cable

Red Motor Rotator Cable

Black Thermo Relay Wire

Black Negative Ground Cable

Red Positive Cable

(To Positive Terminal on Battery) Black Negative Ground Cable

(To Negative Terminal on Battery)

Attach red, yellow and green short cables

to motor terminals as shown. Note: The

three copper terminal stud ends are color

coded. Tighten all three brass nuts onto

terminals using a 13mm wrench.

DO NOT OVER TIGHTEN.

Attach black ground cable to motor

terminal and black thermo relay wire

with brass bolt. Tighten brass bolt onto

terminal using a 14mm wrench.

DO NOT OVER TIGHTEN.

Fire/Electrical Spark/Chemical Burn Hazards:

Connecting winch to battery and winch operation may cause

electrical arcs. Never install or use winch where gasoline leaks,

vapors or other flammables are present.

Always wear eye protection & remove jewelry when working with

battery or installing winch electrical cables. Plan connections to

avoid fuel lines, hot or rotating parts. Never route electrical cable

or winch controller across sharp edges, doors or other pinch

points.

Always use supplied terminal boots, insulate any other exposed

connections neatly support all wiring. Depending on your level of

knowledge regarding electrical wiring, you may wish to have this

procedure performed by a qualified technician.

Electric Cable Connection

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The Trusted Source

Assembly and Installation (Continued)

Battery cables SHOULD NOT be drawn taut. Leave slack for some

cable movement. The battery cables SHOULD BE secure, out of

the way of moving parts, road debris, or any possibility of being

damaged by operation or maintenance of vehicle. For example,

the battery cables may be routed under the vehicle, attaching

them to the frame using suitable fasteners such as cable ties

(not included).

DO NOT attach Battery Cables to the exhaust system, drive shaft,

emergency brake cable, fuel line, or any other components which

may cause damage to the battery cables through heat or motion,

or create a fire hazard. If a hole is drilled through the bumper or

any other part of the vehicle, make sure to install a rubber grom-

met (not included) in the hole to prevent fraying of the battery ca-

bles at that point. The use of at least a 650 Cold Cranking Amps

(CCA) battery is highly recommended.

Winch Mounting

Mount the supplied Hawse Fairlead to

the Mounting Frame (not included) using

supplied Bolts and Nuts.

The winch MUST be properly secured to

a winch mount bumper or an approved

winch mount plate with the included

10mm nuts and bolts (qty 4/each). There

are machined pockets at each of the four

inside winch base corners that fit a flange

head whiz nut. Place a nut into each

pocket and center the winch over the

mounting base holes. Tip: a touch of

bearing grease can hold the 4 nuts in

place prior to fastening the flange head

whiz bolts. In some rare mounting

situations drilling for bolt holes may be

required. Thread the four 10mm x 1.5 x

35mm bolts through the bottom of the

winch mount plate or bumper and into

the whiz nuts. Use a torque wrench and

10mm socket and torque each mounting

bolt to 50 Ft-lbs.

Synthetic Winch Line Installation

Your winch has been shipped to you with

the synthetic winch line wound on its

drum for shipping purposes only. Prior to

winch installation, it is necessary to

completely remove and detach the winch

line and re-install it.

The winch hook is not removable and will

not fit through the hawse fairlead. There-

fore, the winch line needs to be threaded

through the fairlead and attached to the

drum once the winch and fairlead are

mounted to the vehicle. The winch line

must then be pre-tensioned.

Do NOT use winch line without pre-ten-

sioning it. First, place clutch in Free

Flange

Head Whiz

Nut (10mm

x 1.5mm)

Flange Head Whiz Bolt

(10mm x 1.5mm x 35mm)

Winch Mount

Plate or Bumper

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The Trusted Source

Synthetic Line Installation (continued)

Spool position and slowly pull all of the

winch line from the drum. Remove the

line fastener at the drum using a 4mm

allen key at the drum and remove the

line. Thread the winch line through the

fairlead and re-attach to the line to the

winch drum. You now need to pre-stretch

winch line to ensure even stretching and

to eliminate any weak points. To stretch

winch line, begin with 5 or 6 snug wraps

around the drum and set up a secure an-

chor point. Pull vehicle (in neutral gear)

with the winch up a slight flat incline.

See your glovebox sized “Self-Recovery

Winch Operator’s Guide” to properly set

up this pull with full understanding of all

safety precautions. To fully stretch the

winch line, you will need about 500 lbs.

of tension on the cable during the opera-

tion. Once you have completed the pull,

be sure to rewind cable in tight rows not

allowing upper rows to intertwine with

lower rows. Review Operator’s Guide for

this extremely important procedure.

Learn to Winch Properly

Your winch should add greater utility and

enjoyment to your off-road adventures.

Keep in mind, however, the weight of

your vehicle and the forces required to

move it create certain hazards. Self

recovery that is safe for you, bystanders

and the environment requires product

knowledge, planning and practice.

Be aware there are specific techniques

and hazards associated with recovery

winching. Begin by understanding ALL

Safety Information found in this winch

installation manual and then supplement

your knowledge by studying the supplied

glovebox-sized Q Series Winch Operator’s

Guide Manual and also by learning from

more experienced off-road enthusiasts.

The broad conditions where winch-based

self-recovery are required are discussed in

the supplied glovebox sized guidebook.

Keep the supplied booklet in the winch

installed vehicle glovebox after winch

installation as a handy reference.

Develop and rely on your own good

judgment at all times. If you have a

question specific to your purchase, our

customer service staff is standing by.

Call or toll free: (800) 745-6037 or visit

our #1 rated website at quadratec.com

Clocking Instructions

For some winch installations, it may be

necessary to rotate the gear housing to

make room for clutch handle operation.

To rotate the gear housing, remove all the

11 socket cap screws using a 4mm allen

key. Rotate the gear housing to the

desired location and reinstall the 11

fasteners. Note: There are 12 different

positions at 30° increments allowing a

full 360° rotation.

4mm HEX Key

Shown:

Clocked at

Zero Degrees

from Factory

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The Trusted Source

SPECIFICATIONS

Rated Line Pull (Single Line)

Gear Reduction Ratio

Motor (Series Wound)

Drum Size

Dyneema®Synthetic Winch Line

Winch Line Capacity

Overall Dimension

Net Weight

Mounting Bolt Pattern

9000 lbs (4090 kgs)

212:1

12 Volt / 4.8 Hp (3.6 Kw)

2.64” x 9” (67mm x 228mm)

3/8” x 85’

Minimum Break Force 17,000 lbs.

22.44” x 6.6” 11.22” (570mm x 168mm x 285mm)

63.5 lbs. (28.8 kgs)

10” x 4.5” (254mm x 114.3mm)

Q9000 Winch with Synthetic Winch Line

Rated Line Pull (Single Line)

Gear Reduction Ratio

Motor (Series Wound)

Drum Size

Dyneema®Synthetic Winch Line

Winch Line Capacity

Overall Dimension

Net Weight

Mounting Bolt Pattern

Q11000 Winch with Synthetic Winch Line

11000 lbs (5000 kgs)

295.75:1

12 Volt / 4.8 Hp (3.6 Kw)

2.64” x 9” (67mm x 228mm)

3/8” x 85’

Minimum Break Force 17,000 lbs.

22.44” x 6.6” 11.22” (570mm x 168mm x 285mm)

65.3 lbs. (29.6 kgs)

10” x 4.5” (254mm x 114.3mm)

QSERIES_92112_203X_INSTALL_Layout 1 9/25/12 11:23 AM Page 8

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The Trusted Source

Symptom Possible Cause Suggested Remedy

Motor does not

turn on

Switch assembly not

connected properly

Insert switch assembly firmly to the

connector.

Loose battery cable

connection

Tighten nuts on cable

connectors.

Solenoid

malfunctioning

Tap Solenoid to free contact, applying 12V

(for 12V motor) or 24V(for 24V motor) to coil

terminal directly. Solenoid will make an audi-

ble clicking when activating.

Defective switch

assembly Replace switch assembly.

Defective motor Check voltage at armature port with switch

pressed. If voltage 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 slow

or lacking power battery run down Recharge battery by running vehicle engine.

Insufficient current

or voltage Clean, tighten or replace connector.

Motor runs but

cable does not turn Clutch not engaged Push clutch handle into IN position, if that

does not work, seek professional assistance.

Motor runs in one

direction only

Defective or stuck

solenoid

Tap solenoid to free contacts.

Repair or replace solenoid if needed.

Defective switch

assembly Replace switch assembly.

TROUBLESHOOTING

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____________________________

The Trusted Source

INSTALLATION NOTES

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Your Q-series self-recovery winch is covered by the

following Limited Warranty provided exclusively

by Quadratec, Inc., 1028 Saunders Lane

West Chester PA 19380.

This Limited Warranty is the only warranty made

in connection with purchase. Quadratec®neither

assumes nor authorizes any vendor, retailer or other

person or entity to assume for it any other obliga-

tion or liability in connection with this

product or Limited Warranty.

What is Covered:

LIFETIME MECHANICAL & 1 Year Electrical

Subject to the terms, exclusions and limitations

herein and with respect only to winches first sold in

the United States, Quadratec®warrants to the ini-

tial retail purchaser only that your Q-series winch

shall be free of defects in material and workman-

ship: (a.) for so long as your Q-Series winch is

owned by the initial retail purchaser with respect

to mechanical and other non-electrical components

and (b.) for a period of 1 year from date of purchase

with respect to all electrical components (ex: motor,

solenoid & control). All other warranties are hereby

disclaimed, except to the extent prohibited by ap-

plicable law in which case any implied warranty of

merchantability or fitness for a particular purpose

on this product is limited to 1 year from date of ini-

tial retail sale. Quadratec® reserves the rights to:

(a.) require invoice or other proof your winch is

within the terms of this Limited Warranty as a

condition of warranty service and, (b.) make future

revisions to this product and Limited Warranty

without prior notice or obligation to upgrade your

winch.

What is Not Covered:

Your Quadratec®Limited Warranty does not cover

products or parts Quadratec® determines to have

been damaged by or subjected to: (a.) installation

damage, alteration, modification, failure to

maintain or attempted repair or service by anyone

not authorized by Quadratec®, (b.) normal wear &

tear, cosmetic damage or damage from moisture or

water immersion, (c.) Acts of God, accidents,

misuse (including overload & continuous pulls),

negligence, inadequate mounting or impact

with vehicle(s), obstacles or other aspects of the

environment, (d.) theft, vandalism or other

intentional damage.

Remedy Limited to Repair/Replacement:

The exclusive remedy provided hereunder shall,

upon Quadratec® inspection and at Quadratec’s

option, be either repair or replacement of product

or parts (new or refurbished) covered under this

Limited Warranty. Customers requesting warranty

consideration on Q-series self-recovery winches

should first contact Quadratec®to obtain a RGA

number (610-701-3336). All labor, removal, shipping

and installation costs are customer’s responsibility.

Other Limitations - Exclusion of Damages

- Your Rights Under State Law:

In consideration of the purchase price paid,

neither Quadratec®nor any independent

Quadratec®distributor/licensee are responsible

for any time loss, rental costs, or for any incidental,

consequential, punitive or other damages you may

have or incur in connection with any part or prod-

uct purchased. Your exclusive remedy hereunder for

covered parts is repair/replacement as described

above.

This Limited Warranty gives you specific rights. You

may also have other rights that vary from state to

state. For example, some states do not allow limita-

tions of how long an implied warranty lasts and/or

do not allow the exclusion or limitation of inciden-

tal or consequential damages, so the limitations and

exclusions herein may not apply to you.

Note: An extra glovebox copy of the above

warranty information is supplied on a separate

5” x 7” printed card. Please retain for your records.

Instructions Part# 12999.2022

Version 09.25.12

The Trusted Source

Quadratec® Limited Warranty

for Q-Series Self-Recovery Winches

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The Trusted Source

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