Quadratec Q Series Setup guide

The Trusted Source
®
Q-Series Electric Winch
Assembly and Installation Manual
#92122.200X
RE UIRED TOOLS:
SAFETY GLASSES
GLOVES
TOR UE 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
NEEDLE NOSE PLIERS
READ ALL SAFETY MESSAGES AND UNDERSTAND ALL
INSTRUCTIONS AND PROCEDURE NOTICES BEFORE
ATTEMPTING TO INSTALL OR USE THIS PRODUCT.
HRM_92112_200X_Assembly_12P_Layout 1 2/8/12 4:51 PM Page 1

Winch Controller
Connected
to Solenoid
Assembly
Solenoid Assembly
Tie B r Clutch
H ndle
C ble Assembly
Winch B se
Winch Controller
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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.
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:
You CAN be KILLED or SERIOUSLY HURT
if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
Other important information regarding a safe assembly or
operation procedure may be emphasized by a NOTICE signal.
HRM_92112_200X_Assembly_12P_Layout 1 2/8/12 4:51 PM Page 2

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Assembly and Installation:
Solenoid (Side ount) Installation
Photo A. Carefully study the relationship
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.
Att ch the solenoid p ck to the side mount
solenoid br cket using fl t w sher, split
lock w sher nd nut for e ch
of the four studs. Tighten
using 10mm wrench.
Photo A
Photo B
Tighten both 6mm x 1mm x 12 mm
screws using 5mm hex key.
Photo C
Tighten the third 5mm x 8mm x 12mm
screw using P2 Phillips Screw Driver.
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 fe ture two mounting
positions to suit your individu l
pplic tions. The Above Side Mount
Inst ll tion fe tures He vy Duty
Solenoid Br cket (Shown Right). Some
bumpers with Grille Gu rds or Tubul r
Hoops require the Q-Series Winch to Be
inst lled using the Top Mount Solenoid
Br ckets. To inst ll Winch with Top Mount
Br cket, ple se refer to p ge 4 for
Inst ll tion.
HRM_92112_200X_Assembly_12P_Layout 1 2/8/12 4:51 PM Page 3

Tie B r
Be Sure to Keep
Power C bles From
Coming into Cont ct with
C ble Assembly
C ble
Assembly
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4
T pped holes to the re r tie b r.
Tighten using
10mm wrench.
Tighten using
P2 phillips he d
screw driver.
Att ch solenoid p ck to the top mount br ckets
using fl t w sher, split lock w sher nd nut for
e ch of the four studs.
Photo D
Photo E
Att ch the solenoid p ck with mount br ckets to
tie b rs using phillips he d screw with split lock
w sher.
Assembly and Installation (Continued)
When the solenoid is mounted to the top of the tie b rs, the winch power c bles MUST
be PROPERLY pl ced to the OUTSIDE of the re r tie b r s shown. Power c bles MUST
NOT come in cont ct with rot ting winch c ble ssembly or power c ble insul tion
MAY be compromised nd short circuit. Improper pl cement of power c bles MAY
result in d m ge to the winch or the vehicle.
Photo D. Note the relationship between
the solenoid pack an d 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 (Top ount) Installation
HRM_92112_200X_Assembly_12P_Layout 1 2/8/12 4:51 PM Page 4

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Assembly and Installation (Continued)
Yellow Motor St tor C ble
Green Motor St tor C ble
Red Motor Rot tor C ble
Bl ck Thermo Rel y Wire
Bl ck Neg tive Ground C ble
Red Positive C ble
(To Positive Termin l on B ttery) Bl ck Neg tive Ground C ble
(To Neg tive Termin l on B ttery)
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 ter-
minal and black thermo relay wire with
brass bolt. Tighten brass bolt onto termi-
nal using a 14mm wrench. DO NOT
OVER TIGHTEN.
Fire/Electrical Spark/Chemical Burn Hazards:
Connecting winch to b ttery nd winch oper tion m y c use electric l rcs. Never inst ll
or use winch where g soline le ks, v pors or other fl mm bles re present. Always
we r eye protection & remove jewelr y when working with b tter y or inst lling winch
electric l c bles. Pl n connections to void fuel lines, hot or rot ting p rts. Never route
electric l c ble or winch controller cross sh rp edges, doors or other pinch points.
Always use supplied termin l boots, insul te ny other exposed connections ne tly
support ll wiring. Depending on your level of knowledge reg rding electric l wiring, you
m y wish to h ve this procedure performed by qu lified technici n.
Electric Cable Connection
HRM_92112_200X_Assembly_12P_Layout 1 2/8/12 4:51 PM Page 5

Winch ounting
ount the Roller Fairlead to the ount-
ing Frame (not included) using supplied
Bolts, Nuts.
The winch UST be properly secured to
a winch mount bumper or an approved
winch mount plate with the included
10m 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. Hint: a touch of
bearing grease can hold the 4 nuts in
place prior to fastening the flange head
whiz bolts. In some rare mounting situa-
tions drilling for bolt holes may be re-
quired. 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.
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Assembly and Installation (Continued)
Fl nge
He d Whiz
Nut (10mm
x 1.5mm)
Fl nge He d Whiz Bolt
(10mm x 1.5mm x 35mm)
Winch C ble
Cotter Pin
Winch
Hook
Winch Hook Str p
Winch Mount
Pl te or Bumper
Figure 1
B ttery c bles SHOULD NOT be dr wn t ut. Le ve sl ck for some c ble movement. The
b ttery c bles SHOULD BE secure, out of the w y of moving p rts, ro d debris, or ny
possibility of being d m ged by oper tion or m inten nce of the vehicle. For ex mple,
the b ttery c bles m y be routed under the vehicle, tt ching them to the fr me using
suit ble f steners such s c ble ties (not included). DO NOT tt ch the B tter y C bles
to the exh ust system, drive sh ft, emergency br ke c ble, fuel line, or ny other com-
ponents which m y c use d m ge to the b ttery c bles through he t or motion, or cre-
te fire h z rd. If hole is drilled through the bumper or ny other p rt of the vehicle,
m ke sure to inst ll rubber grommet (not included) in the hole to prevent fr ying of
the b ttery c bles t th t point. The use of t le st 650 Cold Cr nking Amps (CCA)
b ttery is highly recommended.
HRM_92112_200X_Assembly_12P_Layout 1 2/8/12 4:52 PM Page 6

Winch Hook Assembly
Pull the Cable through the Fairlead and
connect the Hook and Safety Pin. Attach
winch hook to the winch cable as shown
using the cotter pin. Spread the cotter pin
ends to secure the hook.
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.
Thank you for purchasing your
Quadratec®Q-Series self-recovery winch!
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. The
broad conditions where self-recovery is
required make it impractical for this
manual to advise you of all techniques or
hazards associated with winching. Start
with the Q-Series safety information
found in this manual and supplement
your knowledge by consulting off road
technique manuals or more experienced
Jeep®enthusiasts.
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 at
our #1 rated website quadratec.com or
toll free: [phone].
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7
Installation (Continued)
Congratulations!
Shown:
Clocked t
Zero Degrees
from F ctory
4mm HEX Key
HRM_92112_200X_Assembly_12P_Layout 1 2/8/12 4:52 PM Page 7

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SPECIFICATIONS
Rated Line Pull (Single Line)
Gear Reduction Ratio
otor (Series Wound)
Drum Size
Cable Supplied
Aircraft Cable
Overall Dimension
Net Weight
ounting 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 100’
inimum Break Force 14,400 lbs.
22.44” x 6.6” 11.22” (570mm x 168mm x 285mm)
94.8 lbs. (43 kgs)
10” x 4.5” (254mm x 114.3mm)
9000 Winch
Rated Line Pull (Single Line)
Gear Reduction Ratio
otor (Series Wound)
Drum Size
Cable Supplied
Aircraft Cable
Overall Dimension
Net Weight
ounting Bolt Pattern
11000 Winch
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 100’
inimum Break Force 14,400 lbs.
22.44” x 6.6” 11.22” (570mm x 168mm x 285mm)
94.8 lbs. (43 kgs)
10” x 4.5” (254mm x 114.3mm)
HRM_92112_200X_Assembly_12P_Layout 1 2/8/12 4:52 PM Page 8

The Trusted Source
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Revised 2 / 2012
Symptom Possible Cause Suggested Remedy
otor 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.
otor runs
too hot
long period of
operation Let winch cool down periodically.
otor runs slow
or lacking power battery run down Recharge battery by running vehicle engine.
Insufficient current
or voltage Clean, tighten or replace connector.
otor runs but
cable does not turn Clutch not engaged Push clutch handle into IN position, if that
does not work, seek professional assistance.
otor 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
HRM_92112_200X_Assembly_12P_Layout 1 2/8/12 4:52 PM Page 9

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The Trusted Source
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10
INSTALLATION NOTES
HRM_92112_200X_Assembly_12P_Layout 1 2/8/12 4:52 PM Page 10

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
obligation or liability in connection with this
product or Limited Warranty.
What is Covered:
LIFETI E ECHANICAL & 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
initial retail purchaser only that your Q-series
winch shall be free of defects in material and
workmanship: (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 com-
ponents (ex: motor, solenoid & control). All other
warranties are hereby disclaimed, except to the
extent prohibited by applicable 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 initial retail sale.
Quadratec® reserves the rights to: (a.) require in-
voice 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 main-
tain 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, mis-
use (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, nei-
ther Quadratec®nor any independent Quadratec®
distributor/licensee are responsible for any time
loss, rental costs, or for any incidental, consequen-
tial, punitive or other damages you may have or
incur in connection with any part or product pur-
chased. Your exclusive remedy hereunder for cov-
ered 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 Limitations of how long an implied war-
ranty lasts and /or do not allow the exclusion or
limitation of incidental or consequential damages,
so the limitations and exclusions herein may not
apply to you.
Note: An extra glovebox copy of above warranty
information is supplied on a separate 5” x 7” card.
Please retain for your records.
©Quadratec, Inc. 2012. All Rights Reserved.
The Trusted Source
®
11
Quadratec® Limited Warranty
for Q-Series Self-Recovery Winches
HRM_92112_200X_Assembly_12P_Layout 1 2/8/12 4:52 PM Page 11

The Trusted Source
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HRM_92112_200X_Assembly_12P_Layout 1 2/8/12 4:52 PM Page 12