Quadratec Q-Performance Stealth Series, 92122.4011, 92122.4021 Assembly And Installation Manual
The Trusted Source
®
Q-Performance Stealth
Series Winch
with Integrated Solenoid
& Synthetic Winch Line
Assembly and Installation Manual
#
92122.4011 & #92122.4021
REQUIRED TOOLS:
Safety Glasses
Safety Gloves
Torque Wrench
13 MM Wrench
15 MM Socket
16 MM Wrench
2.5 MM Hex (Allen
®
) Key
4 MM Hex (Allen®) Key
#1 Phillips Head Screwdriver
READ ALL SAFETY MESSAGES AND UNDERSTAND ALL
INSTRUCTIONS AND PROCEDURE NOTICES BEFORE
ATTEMPTING TO INSTALL OR USE THIS PRODUCT.
US PATENT PENDING
2
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.
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-Performance 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 hazar dous situation which, if not avoided, could result in minor or
moderate injur y. You CAN be moderately HURT and also may suffer
property damage if you do not follow instr uctions.
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.
Winch Assembly
Clutch
Handle
Winch Power Button
Hawse
Fairlead
Chafe
Guard
Fairlead
Hardware
Winch
Mounting
Hardware
Remote
Controller
Remote
Cable
Winch Hook
Winch Hook Strap
Remote Control
Plug Cover
Winch
Line
3
The Trusted Source
®
Assembly and Installation
Motor Stator
Cable Yellow
Motor Stator
Cable Green
Motor Rotator
Cable Red
Solenoid Ground
Wire (See below)
Positive Cable
Red Tip
(To Positive Battery Terminal)
Negative Ground Cable
Black Tip (To Negative
Terminal on Battery)
Electric Cable Connection
Attach the black (negative) ground
cable to motor terminal and black
solenoid ground wire with brass bolt.
Tighten the brass bolt onto terminal
using a 13mm wrench. Then attach
positive and negative cables to their
corresponding battery terminals.
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 r oute 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.
Motor
& Solenoid
Ground Wires
4
The Trusted Source
®
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 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. Using a 15mm socket, 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 Pre-Tensioning
The winch line must be pre-tensioned
prior to use. Do NOT use winch line without pre-tensioning it.
First, place clutch in Free 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 the line to the winch
drum. You now need to pre-stretch winch
line to ensure even stretching. To stretch
winch line, begin with 5 or 6 snug wraps
around the drum and set up a secure
Assembly and Installation (Continued)
Flange
Head Nut
(10mm x
1.5mm)
Flange Head Whiz Bolt
(10mm x 1.5mm x 35mm)
Winch Mount
Plate or Bumper
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.
The Trusted Source
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5
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.
Attach the Winch Hook to Synthetic
Winch Line:
Attach as shown using the
included cotter pin through the clevis pin.
Spread the cotter pin ends to secure the
hook. Be sure to keep the safety latch
clean and lubricated at all times.
Assembly and Installation (Continued)
Cotter Pin
Winch Hook
Winch Line
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.
CAREFULLY STUDY WINCH USER GUIDE SUPPLIED WITH YOUR WINCH.
The Trusted Source
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6
For Wired Operation:
Unscrew the remote
plug cap. Plug the 12’ long remote cord
into the handheld remote controller.
Make sure that you align the cord with
the three indexing notches in the remote
handle. Thread the securing collar onto
the remote handle to ensure a proper
connection.
Next, loosen the Rubber Plug Cover on
the right hand side of the winch. Plug the
“D” shaped end of the Remote Cord into
the corresponding receptacle on the right
hand side of the winch. Be sure that the
plug is fully engaged onto the winch as
shown.
Your winch will automatically power up
and be fully functional once the controller
is connected to the winch. The amber
LED Winch Drum light will illuminate
along with the blue “wired” indicator
light on the remote. There is NO need to
activate the power button on either the
winch or the controller when using
“wired” mode. Test both the OUT and IN
functions of the winch using the red
rocker switch on the remote with a short
press of the switch. The winch will stay
on as long as the remote is plugged in.
The winch will automatically shut off as
soon as the cord is unplugged.
For Wireless Operation:
First, loosen the
rubber Power Button Cover on the left
hand side of the winch to expose the
power button. Press the power button
once. The power button will illuminate
along with the amber winch drum lights.
Now press the Remote Control power
button once. The red “WIRELESS” light
will illuminate on the controller. This red
Remote Controller Setup
Remote
Handle
Plug cap
Securing Collar
Cord
Rubber remote
plug cover
“D” Shaped
Remote
Plug End
Blue “Wired”
Indicator Light
Red
Rocker
Switch
Rubber Power
Button Cover
Winch Power
Button
WIRED
MODE
WIRELESS
MODE
The Trusted Source
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7
light will remain lit while it is connected
to the winch. If the red light on the controller begins blinking while operating
the winch, the controller is out of range.
Move the controller closer to the winch
until the light stops blinking. Test both
the “OUT” and “IN” functions of the
winch using the rocker switch. The
winch is now ready for use.
NOTE: Wireless handheld remote controller will automatically shut off after 2
minutes of inactivity and the red indicator light will no longer be lit. The power
button must be pressed once again to reactivate the wireless controller. Also, the
wireless receiver on the winch is designed
to automatically shut off after 10 minutes
of inactivity and the power button will no
longer be lit. The power button on the
winch will need to be pressed once again
to reactivate the winch.
NOTE: The wireless remote will work
within a range of 10 feet from the winch
but may work farther distances depending on physical obstructions and other
conditions. We do not recommend using
the wireless feature from the cab of your
Jeep. If you choose to winch from the
cab, please use the wired option for
safety and consistency.
Clearing and Pairing a Wireless Remote
to your Winch:
The wireless controller
that comes with your winch is paired
from the factory and ready to use. This
pairing procedure is ONLY necessary
when replacing the original remote due
to loss or damage.
To clear a previously paired remote, make
sure your new replacement wireless remote control is off. Press and hold the
winch power button and continue to
hold the button in until the button begins
to blink. Continue holding the power button in until the light shuts off and comes
back on. At this point the old remote is
erased from the system. If the light begins
to blink again the clearing has failed.
Repeat the previous step.
To pair a new remote, press and continue
to hold both the power button on the
winch and the power button on the remote controller. The winch power button
and the red “WIRELESS” Indicator Light
on the controller will both blink and then
stay lit for approximately 10 seconds. At
this point the controller is paired. Test the
winch “OUT” and “IN” functions on the
remote to ensure that the remote is functioning properly. If the controller is not
working repeat the pairing procedure
from the beginning.
Remote
Control
Power Button
Rocker Switch
Red “Wireless”
Indicator Light
Remote Controller Setup
WIRELESS
MODE
The Trusted Source
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8
NOTE: The presence of a battery is NOT
required whenever using a “WIRED”
remote controller. But, a charged battery
is necessary when using a “WIRELESS”
remote controller. If the wireless mode is
not functioning properly, the battery may
need replacement.
Battery Replacement Procedure:
Remove the three (#1 size) Phillips head
screws that attach the winch controller
halves.
Remote Controller Battery Replacement
Carefully remove the old CR123A or
CR123 Lithium battery and replace with
new. Gently align and position the winch
controller halves together and fasten the
three Phillips head screws. Do not over
tighten! Test the winch “OUT” and “IN”
functions on the remote to ensure that
the remote is functioning properly.
Remove 3 Phillips
Head Screws
+ Positive
Battery End
CR123A
Lithium
Battery
The Trusted Source
®
9
There are two positions of the clutch handle. The Clutch is either “engaged” or
“free spooling”. Clutch allows operator to
manually engage or disengage the spooling drum from the gearset using the
clutch lever.
Winch Clutch Operation Details
NEVER ENGAGE OR DISENGAGE CLUTCH IF THE WINCH IS
UNDER LOAD, THE WINCH ROPE IS UNDER TENSION OR
THE SPOOL IS MOVING IN ANY WAY.
Engaged Free Spool
The Trusted Source
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10
NOTE: Our Patent Pending removable
Clutch Handle doubles as a “key” that
can be temporarily removed to deter
winch line theft, vandalism and
pranksters.
Once the Clutch Handle is removed, it
can be stored in the vehicles glove box or
console and used only when winching.
Clutch handle removal is optional.
Rotate Clutch Handle to the “FREE
SPOOL” position to reveal the set screw
that holds the handle in place. Using a 2.5
MM Allen wrench, back out the set screw
until the Clutch Handle lifts off but do
not remove the handle at this time.
Rotate the clutch selector to the “ENGAGED” position. You may remove the
Clutch Handle now and keep it in a safe
place. We suggest keeping the Clutch
Handle somewhere in the vehicle,
Note: If the handle is not present when
winching is needed, a standard 3/8” drive
socket wrench extension can be used to
rotate the clutch selector mechanism.
Do not keep the clutch handle on the
winch unless the set screw if fully
engaged to secure the handle in place.
US PATENT PENDING
Clutch Handle Removal (Optional)
The Trusted Source
®
11
Battery Requirements:
Our powerful series
wound motors and
class-leading low gear
ratios give fast line speeds with a “Battery Friendly” low current draw that will
get the most winching time from your
battery's available charge state. A fully
charged battery and good connections
are essential to the proper operation of
your winch. The minimum requirement
for a 12 volt automotive DC battery is 650
Cold Cranking Amps. Ask your
Quadratec sales representative for details
about heavy-duty batteries and terminals
for your vehicle.
General Maintenance:
All moving parts within the winch have
been lubricated at the factory using high
temperature lithium grease. No internal
lubrication is required. Check battery cables and electrical connections at regular
3 month intervals to be certain they are
clean and tight at all connection points.
Inspect winch line before & after each
winching operation.
Winch Care and Cleaning:
Do not direct very high-pressure water at
your winch. Use low-pressure (normal)
car wash soap and water to clean your
winch. With the remote control disconnected and the protective boots covering
the remote control socket and power button sockets, wash normally with your vehicle. During winter exposure to road
salt, wash the winch as soon as possible
to avoid corrosion. Always wash per the
recommendations above.
Winch Care and Maintenance:
The Trusted Source
®
12
SPECIFICATIONS
Rated Line Pull (Single Line)
Gear Reduction Ratio
Motor (Series Wound)
Drum Size
Synthetic Winch Line
Overall Dimension
Net Weight
Mounting Bolt Pattern
Q10 Performance Stealth Winch with Synthetic Line
Rated Line Pull (Single Line)
Gear Reduction Ratio
Motor (Series Wound)
Drum Size
Synthetic Winch Line
Overall Dimension
Net Weight
Mounting Bolt Pattern
Q12 Performance Stealth Winch with Synthetic Line
10,000 lbs (4536 kgs)
210:1
12 Volt / 4.9 Hp (3.65 Kw)
2.64” x 8.35” (67mm x 212mm)
3/8” x 82’
21” x 6.375” x 10” (533.4 mm x 162 mm x 254 mm)
61.0 lbs. (27.67 kgs)
10” x 4.5” (254mm x 114.3mm)
12,000 lbs (5443 kgs)
294:1
12 Volt / 4.9 Hp (3.65 Kw)
2.64” x 8.35” (67mm x 212mm)
3/8” x 82’
21” x 6.375” x 10” (533.4 mm x 162 mm x 254 mm)
61.0 lbs. (27.67 kgs)
10” x 4.5” (254mm x 114.3mm)
The Trusted Source
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13
Problem Possible Cause Possible Solution
When remote
control switch is
activated, a click-
ing sound occurs
and winch does
not operate in
either the power
in or power
out mode.
Battery is inadequate
or defective.
Replace battery with 650 cold cranking amp
rating or greater.
Battery is not fully
charged
Charge the battery.
Faulty battery cable
or connections
Clean and tighten all battery connections.
Poor electrical
grounding of thermo
relay wire
Be sure connections are clean and tight.
Worn or damaged
motor brushes
Replace winch motor.
Vehicle not running Start vehicle & keep running during winching
Winch Lacks
Power, pulls
slower than
normal, stalls or
does not run at all.
Ground and power
cables are loosely
connected to battery
or winch terminals
Be sure connections are clean and tight.
Battery is not fully
charged
Charge the battery.
Battery is inadequate
or defective.
Replace battery with 650 cold cranking amp
rating or greater.
Battery terminals are
corroded.
Clean battery terminals.
Vehicle not running Start vehicle & keep running during winching
TROUBLESHOOTING
The Trusted Source
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14
Problem Possible Cause Possible Solution
When winch con-
trol is activated,
the winch oper-
ates only in one
direction.
Remote control
switch is damaged.
Check remote control switch and its cable.
Check all connections and replace if
necessary.
Ground and power
cables are loosely
connected to battery
or winch terminals
Be sure connections are clean and tight.
Battery is not fully
charged
Charge the battery.
Battery is inadequate
or defective.
Replace battery with 650 cold cranking amp
rating or greater.
Battery terminals are
corroded.
Clean battery terminals.
Solenoids inside the
control pack is stuck
or damaged
Replace Solenoid Module
Vehicle not running Start vehicle & keep running during winching
Winch does not
hold a load
Winch line is spooled
onto winch drum in
the wrong direction.
Winch line must exit from the bottom of the
drum. Re-Spool in the proper direction.
Load exceeds winch
rating.
Do Not exceed the line pull rating shown in
the ID label on the winch motor. Refer to the
winch operators manual for correct rating.
Brake inside the
winch drum is badly
worn or broken.
Replace entire drum and brake assembly.
TROUBLESHOOTING
The Trusted Source
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15
Problem Possible Cause Possible Solution
Winch line has
difficulty spooling
off the winch
drum by hand.
Bent drum side
flange.
Replace Drum.
Worn drum bearing
surfaces.
Replace motor sub-assembly and/or
clutch sub-assembly.
Free spool clutch is
damaged.
Remove and inspect gear carrier assembly.
Inspect output gear, intermediate gear, input
gear, sun gear ring and gear ring output.
Remove burrs with file.
Winch is not
mounted correctly or
square on the winch
plate.
Check mounting hole measurements for
consistency and squareness. Be sure that
mounting surface is flat and mounting
bolts are tight.
Internal damage
to ring gear.
Disassemble gear assembly, inspect for
damage, clean and grease or replace worn or
damaged parts.
TROUBLESHOOTING
The Trusted Source
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16
Your Q-Performance 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:
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 initial retail purchaser only that your winch shall be
free of defects in material and workmanship:
(a.) for
so long as your 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 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
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.
W
hat 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 refurbishe d) covered under this
Limited Warranty.
Customers requesting warranty
consideration on Q-Performance Series 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 product 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 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.
Instructions Part
#
12999.1051 A4
©Quadratec, Inc. 2018. All Rights Reserved.
Version 07.30.18
US PATENT PENDING
Quadratec® Limited Warranty
for Q-Performance Series Self-Recovery Winches
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