The Trusted Source ® Q-Series Electric Winch Assembly and Installation Manual # 92122.200X 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 NEEDLE NOSE PLIERS READ ALL SAFETY MESSAGES AND UNDERSTAND ALL INSTRUCTIONS AND PROCEDURE NOTICES BEFORE ATTEMPTING TO INSTALL OR USE THIS PRODUCT.
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The Trusted Source
®
Q-Series Electric WinchAssembly and Installation Manual
#92122.200X
REQUIRED TOOLS:SAFETY GLASSESGLOVESTORQUE WRENCH10 MM SOCKET10 MM WRENCH
13 MM WRENCH14 MM WRENCH4 MM HEX (ALLEN®) KEY5 MM HEX (ALLEN®) KEYP2 PHILLIPS HEAD SCREW DRIVERNEEDLE NOSE PLIERS
READ ALL SAFETY MESSAGES AND UNDERSTAND ALL INSTRUCTIONS AND PROCEDURE NOTICES BEFORE ATTEMPTING TO INSTALL OR USE THIS PRODUCT.
Attach the solenoid pack to the side mountsolenoid bracket using a flat washer, splitlock 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 mmscrews using a 5mm hex key.
Photo C
Tighten the third 5mm x 8mm x 12mmscrew using a 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 feature two mountingpositions to suit your individual applications. The Above Side Mount Installation features a Heavy Duty Solenoid Bracket (Shown Right). Somebumpers with Grille Guards or TubularHoops require the Q-Series Winch to Beinstalled using the Top Mount SolenoidBrackets. To install Winch with Top MountBracket, please refer to page 4 for Installation.
Attach solenoid pack to the top mount bracketsusing a flat washer, split lock washer and nut foreach of the four studs.
Photo D
Photo E
Attach the solenoid pack with mount brackets totie bars using a phillips head screw with split lockwasher.
Assembly and Installation (Continued)
When the solenoid is mounted to the top of the tie bars, the winch power cables MUSTbe PROPERLY placed to the OUTSIDE of the rear tie bar as shown. Power cables MUSTNOT come in contact with a rotating winch cable assembly or power cable insulationMAY be compromised and short circuit. Improper placement of power cables MAY result in damage to the winch or the vehicle.
Red Positive Cable (To Positive Terminal on Battery) Black Negative Ground Cable
(To Negative Terminal on Battery)
Attach red, yellow and green short cablesto motor terminals as shown. Note: Thethree copper terminal stud ends are colorcoded. Tighten all three brass nuts ontoterminals using a 13mm wrench. DONOT OVER TIGHTEN.
Attach black ground cable to motor ter-minal and black thermo relay wire withbrass bolt. Tighten brass bolt onto termi-nal using a 14mm wrench. DO NOTOVER TIGHTEN.
Fire/Electrical Spark/Chemical Burn Hazards: Connecting winch to battery and winch operation may cause electrical arcs. Never installor use winch where gasoline leaks, vapors or other flammables are present. Alwayswear eye protection & remove jewelry when working with battery or installing winch electrical cables. Plan connections to avoid fuel lines, hot or rotating parts. Never routeelectrical cable or winch controller across sharp edges, doors or other pinch points. Always use supplied terminal boots, insulate any other exposed connections neatlysupport all wiring. Depending on your level of knowledge regarding electrical wiring, youmay wish to have this procedure performed by a qualified technician.
Battery cables SHOULD NOT be drawn taut. Leave slack for some cable movement. Thebattery cables SHOULD BE secure, out of the way of moving parts, road debris, or anypossibility of being damaged by operation or maintenance of the vehicle. For example,the battery cables may be routed under the vehicle, attaching them to the frame usingsuitable fasteners such as cable ties (not included). DO NOT attach the Battery Cablesto the exhaust system, drive shaft, emergency brake cable, fuel line, or any other com-ponents which may cause damage to the battery cables through heat or motion, or cre-ate a fire hazard. If a hole is drilled through the bumper or any other part of the vehicle,make sure to install a rubber grommet (not included) in the hole to prevent fraying ofthe battery cables at that point. The use of at least a 650 Cold Cranking Amps (CCA)battery is highly recommended.