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
READ ALL SAFETY MESSAGES AND UNDERSTAND ALL
INSTRUCTIONS AND PROCEDURE NOTICES BEFORE
ATTEMPTING TO INSTALL OR USE THIS PRODUCT.
13 MM WRENCH
14 MM WRENCH
4 MM HEX (ALLEN®) KEY
5 MM HEX (ALLEN®) KEY
P2 PHILLIPS HEAD SCREW DRIVER
®
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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
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 proper ty may result if you do not follow instructions.
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:
®
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.
Solenoid Assembly
Tie
Bar
Mounting
Hardware
Controller
Clutch Control
Synthetic
Winch Line
with Chafe
Guard
Hawse
Fairlead
Fairlead
Hardware
Winch Hook Strap
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.
Winch
Hook
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2
Assembly and Installation:
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
Solenoid Installation (as Side Mount)
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
Tighten both 6mm x 1mm x 12 mm
screws using a 5mm hex key.
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.
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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Photo C
Tighten the 6mm x 1mm x 12 mm
screw using a 5mm hex key.
®
3
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.
Solenoid Installation (as Top Mount)
Tapped holes to the rear tie bar.
Tighten using
a 10mm wrench.
Photo D
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.
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.
Tie Bar
Photo E
Tighten using a
P2 phillips head
screw driver.
Attach the solenoid pack with mount brackets to
tie bars using a phillips head screw with split lock
washer.
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.
Cable
Assembly
Be Sure to Keep
Power Cables From
Coming into Contact with
Cable Assembly
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4
Assembly and Installation (Continued)
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 per formed by a qualified technician.
Electric Cable Connection
Red Positive Cable
(To Positive 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.
Yellow Motor Stator Cable
Green Motor Stator Cable
Red Motor Rotator Cable
Black Thermo Relay Wire
Black Negative Ground Cable
Black Negative Ground Cable
(To Negative Terminal on Battery)
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.
®
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5
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 thr ough the bumper or
any other part of the vehicle, make sure to install a rubber grommet (not included) in the hole to prevent fraying of the battery cables at that point. The use of at least a 650 Cold Cranking Amps
(CCA) battery is highly recommended.
Flange
Head Whiz
Nut (10mm
x 1.5mm)
Winch Mount
Flange Head Whiz Bolt
(10mm x 1.5mm x 35mm)
Plate or Bumper
Winch Mounting
Mount the supplied Hawse Fairlead to
the Mounting Frame (not included) using
supplied Bolts and Nuts.
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 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
The winch hook is not removable and will
not fit through the hawse fairlead. Therefore, 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-tensioning it. First, place clutch in Free
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6
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 anchor 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 operation. 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.
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
#
1 rated website at quadratec.com
our
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
Guide Manual
and also by learning from
Winch Operator’s
4mm HEX Key
Shown:
Clocked at
Zero Degrees
from Factory
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.
®
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7
SPECIFICATIONS
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
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)
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)
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8
TROUBLESHOOTING
Symptom Possible Cause Suggested Remedy
Motor does not
turn on
Motor runs
too hot
Motor runs slow
or lacking power
Switch assembly not
connected properly
Loose battery cable
connection
Solenoid
malfunctioning
Defective switch
assembly
Defective motor
Water has
entered motor
long period of
operation
battery run down Recharge battery by running vehicle engine.
Insert switch assembly firmly to the
connector.
Tighten nuts on cable
connectors.
Tap Solenoid to free contact, applying 12V
(for 12V motor) or 24V(for 24V motor) to coil
terminal directly. Solenoid will make an audible clicking when activating.
Replace switch assembly.
Check voltage at armature port with switch
pressed. If voltage present, replace motor.
Drain and dry. Run in short bursts without
load until completely dry.
Let winch cool down periodically.
Insufficient current
or voltage
Motor runs but
cable does not turn
Motor runs in one
direction only
Clutch not engaged
Defective or stuck
solenoid
Defective switch
assembly
Clean, tighten or replace connector.
Push clutch handle into IN position, if that
does not work, seek professional assistance.
Tap solenoid to free contacts.
Repair or replace solenoid if needed.
Replace switch assembly.
®
The Trusted Source
9
INSTALLATION NOTES
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®
The Trusted Source
10
Quadratec® Limited Warranty
for Q-Series Self-Recovery Winches
Your Q-series self-recovery winch is covered by the
following
by Quadratec, Inc., 1028 Saunders Lane
West Chester PA 19380.
This
in connection with purchase. Quadratec
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
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
tial retail purchaser only that your Q-series winch
shall be free of defects in material and workmanship:
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).
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 invoice or other proof your winch is
within the terms of this
condition of warranty service and, (b.) make future
revisions to this product and
without prior notice or obligation to upgrade your
winch.
What is Not Covered:
our Quadratec
Y
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.
Limited Warranty
Limited Warranty
Limited Warranty.
(a.) for so long as your Q-Series winch is
All other warranties are hereby
®
Limited Warranty
provided exclusively
is the only warranty made
®
warrants to the ini-
Limited Warranty
Limited Warranty
®
neither
as a
does not cover
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.
consideration on Q-series self-recovery winches
should first contact Quadratec
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
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 product purchased. Your exclusive remedy hereunder for
covered parts is repair/replacement as described
above.
Limited Warranty
This
may also have other rights that vary from state to
state. For example, some states do not allow limitations of how long an implied warranty 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 the above
warranty information is supplied on a separate
5” x 7” printed card. Please retain for your records.
Instructions Part# 12999.2022
©Quadratec, Inc. 2012. All Rights Reserved.
Version 09.25.12
Customers requesting warranty
®
to obtain a RGA
®
nor any independent
gives you specific rights. You
®
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11
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