KFI Products AS-50wx Assault Series Synthetic Cable UTV-SxS Winch User Manual
- October 27, 2023
- KFi PRODUCTS
Table of Contents
AS-50wx Assault Series Synthetic Cable UTV-SxS Winch
Place serial label here for reference.
OPERATOR’S MANUAL
ASSAULT SERIES SYNTHETIC CABLE UTV/SxS WINCH
MODEL #AS-50wx
5,000 LB. (2268 KG)
READ AND SAVE THIS MANUAL. This manual contains important safety precautions which should be read and understood before operating the product. Failure to do so could result in serious injury. This manual should remain with the product. Specifications, descriptions, and illustrations in this manual are as accurate as known at the time of publication, but are subject to change without notice.
SERIAL NO. LABEL Suppor t:
or visit www.kfiproducts.com
Made in China – REV 20220817
KFI Products – Kappers Fabricating, Inc., Spring Valley, MN USA
MODEL #AS-50wx 5,000LB (2268KG) WINCH
TABLE Of CONTENTS
Table of ConTenTs
Introduction………………………………. 1 Maintenance …………………………… 13
Accessories………………………………………..1 Motor ………………………………………………13
This Manual………………………………………..1
Safety Definitions………………………. 1
Lubrication ……………………………………….13 Synthetic Cable Inspection …………………..13
Important Safety Instructions ……… 2 Cable Assembly Replacement ………………14
Controls and Features………………… 4 Specifications …………………………. 15
Installation ……………………………….. 5 Performance:…………………………………….15
Mount the Winch …………………………………5 Parts Diagram……………………………………16
Winch Assembly – Generic Install ……………5 Mount the Contactor …………………………….6 Install UTV Dash Mounted Rocker Switch …6
Parts List………………………………………….17
Troubleshooting ………………………. 18 Warranty ………………………………… 19
Mount the Hand Remote Socket ……………..6 Contact Information ……………………………20
Wiring the Winch …………………………………7
Winch Wiring Diagram ………………………….8
Motor End Terminal Rotation ………………….8
Controller Wiring Diagram ……………………..9
Cable Hook Stopper Installation and Use ….9
General Tips for Safe Operation …………….10
Self Recovery ……………………………………10
Winching Techniques …………………………11
Synthetic Cable Usage ………………………..12
Snow Plow Usage………………………………12
Protective Sheath……………………………….12
MODEL #AS-50wx 5,000LB (2268KG) WINCH
INTRODUCTION
InTroduCTIon
safeTy defInITIons
Congratulations on your purchase of a KFI winch. KFI researches and develops
winches to strict specifications. With proper use and maintenance, this winch
will bring years of satisfying service.
Accessories
Kappers Fabricating, Inc. manufactures, purchases, and sells accessories
designed to help you get the most from your purchase. To find out more about
our products, visit our web site at:
www.kfiproducts.com
This Manual
The purpose of safety symbols is to attract your attention to possible
dangers. The safety symbols, and their explanations, deserve your careful
attentions and understanding. The safety warnings do not by themselves
eliminate any danger. The instructions or warnings they give are not
substitutes for proper accident prevention measures.
danGer DANGER indicates a hazardous
situation which, if not avoided, will result in death or serious injury.
Every effort has been made to ensure the accuracy and completeness of information in this manual. We reserve the right to change, alter, and or improve the product and this document at any time without prior notice.
WarnInG WARNING indicates a hazardous
situation which, if not avoided, could result in death
or serious injury.
Record the model as well as date and place of purchase for future reference.
Have this information available when ordering parts and when making technical
or warranty inquiries.
KFI TECHNICAL SUPPORT TEAM 1-877-346-2050 MODEL NUMBER AS-50wx SERIAL NUMBER
CauTIon CAUTION indicates a hazardous
situation which, if not avoided, could result in minor or moderate injury.
noTICe NOTICE indicates information
considered important, but not hazard-related (e.g. messages relating to
property damage or physical injury).
DATE OF PURCHASE
PURCHASE LOCATION
1
MODEL #AS-50wx 5,000LB (2268KG) WINCH
IMPORTANT SAfETy INSTRUCTIONS
ImporTanT safeTy InsTruCTIons
WarnInG Pull only on area of the vehicle as
specified by the vehicle manufacturer.
WarnInG Cancer and Reproductive Harm –
www.P65Warnings.ca.gov
WarnInG Read this manual thoroughly before
operating the winch. Failure to follow instructions could result in serious
injury or death.
WarnInG Do not use the winch to secure or
hold a vehicle for a long period of time. Do not use the winch to secure a
vehicle for transport.
WarnInG Disconnect the remote control and
battery leads when not in use for extended periods.
WarnInG Do not exceed the rated capacity.
danGer Do not use this winch for lifting or
moving people or animals.
danGer Keep yourself and others a safe
distance to the side of the cable when under tension.
danGer Never step over a cable or near a
cable under load.
WarnInG Avoid “shock loads” by using the
control switch intermittently to take up slack in the cable. “Shock loads” can
far exceed the rated capacity for the winch cable and drum.
Do not accelerate your vehicle while winching. Loss of traction can cause a
shock load on the cable. Do not use cable as a pull strap.
WarnInG Batteries contain acid and produce
explosive gases. Keep sparks, flames and cigarettes away from batteries at all
times. Wear safety glasses and protect the eyes at all times. Do not lean over
the batteries during operation.
WarnInG The cable may break before the
motor stalls. For heavy loads at or near rated capacity, use a pulley
block/snatch block to reduce the load on the cable.
WarnInG Do not use as a hoist. Do not use
for overhead lifting.
WarnInG Do not move the vehicle to pull a
load (towing) on the winch cable. This could result
in cable breakage.
2
MODEL #AS-50wx 5,000LB (2268KG) WINCH
IMPORTANT SAfETy INSTRUCTIONS
WarnInG When re-spooling the cable, ensure
that the cable spools in the under-wind position with the cable entering the
drum from the bottom, not the top.
To re-spool correctly, and while wearing gloves, keep a slight load on the
cable while pushing the remote button to draw in the cable. Walk toward the
winch not allowing the cable to slide through your hands. Do not let your
hands get within 12 in. of the winch while re-spooling. Turn off the winch and
repeat the procedure until a few feet of cable are left. Disconnect the remote
control and finish spooling by rotating the drum by hand with the clutch
disengaged. Keep hands clear of the fairlead and drum while the winch is under
power.
CauTIon If the motor stalls, do not maintain
power to the winch.
Electric winches are designed and made for intermittent use and should not be
used in constant duty applications.
CauTIon Never release the free spool clutch
when there is a load on the winch.
CauTIon
Use the Hand-Saver strap when handling the winch hook for spooling or unspooling the cable.
CauTIon
Use gloves to protect hands when handling the cable. Never let the cable slide through your hands.
CauTIon Do not wrap the cable around any
object and hook it back onto itself.
CauTIon Apply blocks to the wheels of the
vehicle when on an incline.
CauTIon Duration of winching pulls should
be kept as short as possible.
If the motor becomes uncomfortably hot to the touch, stop winching immediately
and let it cool down for a few minutes. Do not pull for more than one minute
at or near the rated load.
3
MODEL #AS-50wx 5,000LB (2268KG) WINCH
CONTROLS AND fEATURES
ConTrols and feaTures
Read this operator’s manual before operating your winch. Familiarize yourself with the location and function of the control features. Save this manual for future reference.
Winch
6
2
7
6 1
4
5
12
14
11
10
3
13 9
8
1. Motor 1.22 HP 12V DC motor provides power to the planetary gear
mechanism.
2. Winch Drum The winch drum is the cylinder on which the cable is stored.
It can feed or wind the cable depending on the switch assembly.
3. Synthetic Cable 15/64 in. x 50 ft. Synthetic cable designed specifically
for load capacity of 5,000 lbs. (47 usable feet with five wraps on the drum).
The synthetic cable feeds onto the drum in the “under wind” position through
the roller fairlead (4) and is looped at the end to accept the clevis hook pin
(12).
4. Roller Fairlead When using the winch at an angle the roller fairlead
acts to guide the synthetic cable onto the drum and minimize damage to the
cable from abrasion on the winch mount or bumper.
5. Free Spooling Clutch The clutch allows the operator to manually
disengage (“Release”) the spooling drum from the gear train. Engaging the
clutch (“Engage”) locks the winch into the gear system.
6. Braking System Braking action is automatically applied to the winch drum
when the winch motor is stopped or there is a load on the cable.
7. Planetary Gear System The reduction gears convert the winch motor power
into extreme pulling forces. This system allows high torque while maintaining
compact size and light weight.
8. UTV Dash Mounted Rocker Switch Premium look & quality dash mounted
switch for easy access.
9. Hand Held Remote Hand held switch with a remote socket for powering the
cable in or out of your winch drum.
4
MODEL #AS-50wx 5,000LB (2268KG) WINCH
CONTROLS AND fEATURES
10. Fairlead Mount Adapter to mount the winch and fairlead for utility
applications.
11. Contactor Power from the vehicle battery flows through the weather
sealed solenoid switch before being directed to the winch motor.
InsTallaTIon
This KFI 5,000 lb winch is designed with a bolt pattern that is standard for
this class of winch. Many winch mounting kits are available that utilize this
bolt pattern for the most popular ATVs and UTVs. You can find most of the
ATV/UTV winch mounts on our website (www.kfiproducts.com).
Mount the Winch
WarnInG Before starting to install this winch,
disconnect the vehicle ground and positive leads from the battery.
1. Install the winch and fairlead with the supplied hardware per the
instructions provided with the model specific winch mounting kit or prepare a
flat, secure mounting location for the winch.
CauTIon Mounting bolts must be SAE Grade
5 or better and torqued to 17 ft. lbs.
12. Clevis Hook Provides a means for connecting the looped ends of cables
to an anchor.
13. Cable Hook Stopper Protects the rollers, motors, and gears.
14. Hand Saver Strap Used to assist cable feed.
noTICe This kit includes mounting bolts
with different lengths for fastening the winch (M8 x 20, 25, and 30mm long).
Use the length that best fits your mounting application. Refer to vehicle
specific mount instructions for more information.
CauTIon If you choose not to use a model
specific mounting kit, you will need to drill holes in the structural support
of the vehicle. Be certain that your structural support is sufficient for the
pulling forces of this winch.
2. Attach the winch using supplied M8 x 25mm or 30mm bolts and washers thru
the fairlead bracket or model specific winch mount and into the winch.
3. Disengage the clutch by rotating the clutch cap to the RELEASE position.
Release the synthetic cable and pull through the roller fairlead.
4. Attach the clevis hook to the cable and the hand saver strap to the clevis
hook.
Split Cable Hook
Stopper (If included)
Cable
Clevis & Cotter Pin
Note: Cable must exit between spool and mounting surface!
Roller Fairlead Hook
Winch Assembly – Generic Install
5
Winch Body
Mount Plate () Generic plate shown (Fairlead Mount) . Use vehicle specific
mounting application and assembly instructions for most installs. Bolts – M10
x 20mm, Fairlead
Winch Bolts M8 x 20, 25, or 30mm See Notice above. Use longer bolts with
multiple plates. Do not over tighten or strip threads!
MODEL #AS-50wx 5,000LB (2268KG) WINCH
ASSEMBLy
Mount the Contactor
5. Find a location for the contactor. If the model specific mounting kit does
not indicate a recommended contactor location, then it is recommended that the
contactor be mounted close to the battery in a clean dry location. Be certain
the location you choose allows for sufficient clearance form all metal
components. Drill mounting holes if required. Once a location is found, do not
install until all wiring is completed.
Install UTV Dash Mounted Rocker Switch
6. Most UTV’s & SxS’s have a predefined switch location that is scored or
marked for mounting and requires finish cutting with a knife.
9. Splice the end of the red wire to an ignition controlled (keyed) power
source using the supplied wire splice. You may need to use a test light or
multimeter to locate a suitable wire. The wire should only have power when the
key is in the ON position.
Mount the Hand Remote Socket
(optional)
10. Determine a mounting location for the Hand Remote socket. Be certain the
area behind the selection location is clear.
11. Drill three holes as shown in the following figure and install using
supplied hardware. You can also use the rubber cap attached to the remote
socket as a template.
1.0 in. [25 mm]
1.69 in. [42.5mm]
3/16 in. [5 mm]
.84 in. [21.3 mm]
Not to Scale DO NOT Use as a template.
7. Use the cut-out dimensions shown below to cut the switch location pattern if your dash doesn’t have a predefined knockout or area.
8. Once your switch is mounted you can route wires back to the contactor location.
12. Once your remote socket is mounted, you may route wires back to the
contactor location.
13. Splice the end of the red wire to an ignition controlled (keyed) power
source using the supplied wire splice. You may need to use a test light or
multimeter to locate a suitable wire. The wire should only have power when the
key is in the ON position.
14. Secure the wires with supplied cable ties.
6
MODEL #AS-50wx 5,000LB (2268KG) WINCH
ASSEMBLy
Wiring the Winch
CauTIon Never route electrical wires across
any sharp edges, through or near moving parts, or near parts that become hot.
15. Connect the yellow and blue wires to the motor terminals on the winch.
Torque the nuts on the motor to 5.7 N-m (50 in lbs) Route the opposite ends to
the contactor location. (See diagram on page 8).
16. Connect the yellow and blue wires to the contactor block (yellow to
yellow, blue to blue). DO NOT tighten nuts. (See diagram page 8).
17. Connect the red and black wires to your contactor block (red to red,
black to black). DO NOT tighten nuts. Route the opposite ends to the battery
location (See diagram page 8).
18. Connect the mini rocker switch to the contactor block (black to black,
green to green). (See diagram on page 9).
19. Once all wiring is connected to the contactor, finish mounting it to the
contactor location using supplied M6 hardware (See diagram page 8).
WarnInG Failure to follow specific wiring
instructions may result in damage to your wiring system or equipment.
noTICe If you are installing the hand
remote along with the mini rocker switch, you will need to connect the remote
socket to the contactor and then the mini rocker switch to the remote socket
(see diagram on page 9).
22. Connect the battery leads from the contactor to the vehicle’s battery
(black to black, and red to red, see diagram on page 8).
23. Check for proper drum rotation. Turn the clutch cap to the RELEASE
position. Pull out some cable from the drum and then turn the clutch cap to
the ENGAGE position to engage the gears. Make sure your vehicle is running and
press the cable out button on the switch. If the spool is turning and
releasing more cable, then your connections are accurate. If the spool is
turning and collecting more cable, then reverse the leads on the motor. Repeat
and check rotation.
CauTIon Battery cables should not be drawn
taut. Leave some slack for cable movement.
noTICe Always hold the bottom nut with
a wrench while tightening motor wire terminals. Do not allow the bottom nut to
spin, else you may damage the end cap.
noTICe Depending on the location of the
contactor, you may need to use an alternate winch wiring configuration. Please
see the “Alternate Winch Wiring Diagram” available on: www.kfiproducts.com
20. Torque the contactor terminal nuts to 4.5 N-m (40 in lbs) Do NOT over
tighten.
21. Place all terminal boots over terminals and secure all cables with zip
ties or electrical tape.
Proper Terminal Tightening
7
MODEL #AS-50wx 5,000LB (2268KG) WINCH
Winch Wiring Diagram
POS(+)
NEG(-)
ASSEMBLy
Note: Some batteries may require the use of longer bolts to fasten both the
winch wire ends and the stock vehicle wiring. Use two M6 x 20mm Bolts
(included) if required.
BLUE
53.5 53.3
YELLOW
NEG(-)
53.4 53.2
Assembly
BLACK RED
POS(+)
These two posts must be wired to the battery!
CONTACTOR
TO WINCH (+) (YELLOW POST)
TO BATTERY (-) (BLACK POST)
TO BATTERY (+) (RED POST)
TO WINCH (-) (BLUE POST)
Motor End Terminal Rotation
With some applications, the motor terminals may need to be rotated to avoid
interference with other components. If rotation is required please give us a
call at 1-877-346-2050 for instructions or visit our website at
www.kfiproducts.com and look in the support section.
STANDARD
45° ROTATION
90° ROTATION
Note: Motor casing rotates with End Cap 8
MODEL #AS-50wx 5,000LB (2268KG) WINCH
Controller Wiring Diagram
ATV-HR
Remote Socket
ATV-HR
Handheld Corded Remote
ASSEMBLy
ATV-CONT or #AS-CONT
Contactor Block
NOTE: WHITE WIRE MUST BE CONNECTED TO NEGATIVE (TYPICALLY BLACK POST) or
VEHICLE GROUND.
UTV-DRS-K
Dash Rocker Switch
Cable Hook Stopper Installation and Use
1. Release winch and pull out approximately 2 feet of cable.
2. Assemble cable hook stopper as shown in diagram with the flat portion of
the two halves resting against your fairlead. Tighten fasteners.
3. To stow hook, engage clutch and retract cable onto winch spool until hook
is snug against the hook stopper and fairlead.
4. Position cable hook stopper at approx. 3/4 of the total line distance
towards the hook while using your winch to help reduce whip back in the event
of cable breakage.
9
IGNITION fED WIRE VOLTAGE MUST ONLY BE SUPPLIED WHEN THE KEY IS TURNED ON.
+12VDC
MODEL #AS-50wx 5,000LB (2268KG) WINCH
OPERATION
General Tips for Safe Operation
Self Recovery
Your AS-50wx winch is rated at 5,000 lbs. capacity in first layer (max) when spooling the first cable layer on the drum. Overloads can damage the winch, motor and/ or cable.
Locate a suitable anchor such as a strong tree trunk or boulder. Always use a sling as an anchor point.
The vehicle engine should be kept running during operation of the winch to minimize battery drain and maximize power and speed of the winch. If the winch is used for a considerable time with the engine off the battery may be drained and too weak to restart the engine.
Your winch is equipped with a roller fairlead to help guide the cable and to reduce binding on short side pulls.
Get to know your winch before you actually need to use it. We recommend that you set up a few test runs to familiarize yourself with rigging techniques, the sounds your winch makes under various loads, the way the cable spools on the drum, etc.
Do not winch from an acute angle as the cable will pile up on one side of the drum causing damage to cable and the winch.
Inspect the cable and equipment before each use. A frayed or damaged cable should be replaced immediately. Use only manufacturer’s identical replacement cable with the exact specifications.
Inspect the winch installation and bolts to ensure that all bolts are tight
before each operation.
Store the remote control inside your vehicle in a place that it will not be
damaged.
Short pulls from an angle can be used to straighten the vehicle. Long pulls should be done with the cable straight out from the winch/vehicle.
Any winch that appears to be damaged in any way, is found to be worn, or operates abnormally MUST BE REMOVED FROM SERVICE UNTIL REPAIRED. It is recommended that the necessary repairs be made by a manufacturer’s authorized repair facility.
Pull only on areas of the vehicle as specified by the vehicle manufacturer.
Only attachments and/or adapters supplied by the manufacturer are to be used.
When pulling a heavy load, place a cable hook stopper, blanket or jacket over
the cable five or six feet from the hook.
In the event of a cable snap it will dampen the snap back. For additional
protection open the hood of the vehicle.
10
MODEL #AS-50wx 5,000LB (2268KG) WINCH
OPERATION
Winching Techniques
1. Take time to assess your situation and plan your pull.
2. Put on gloves to protect your hands.
3. Release the clutch and free-spool the winch; it’s faster than using the
switch and saves battery power.
4. Attach the hook strap to the clevis hook.
5. Pull out the cable to your desired anchor point using the hook strap.
6. Secure the clevis hook to the anchor point: Sling, chain or snatch block.
Do not attach the hook back onto the cable.
7. Engage the clutch.
8. Start your engine to ensure power is being replenished to the battery.
9. Power in the cable guiding the cable under tension to draw up the slack in
the cable. Once the cable is under tension, stand clear. Never step over the
cable.
10. Double check your anchors and make sure all connections are secure.
11. Inspect the cable. Make sure there are at least 5 wraps of cable around
the winch drum.
15. The vehicle to be winched should be placed in neutral and the parking
brake released. Only release the loads to the winch. This can damage the
winch, cable and vehicle.
16. The winch is meant for intermittent use. Under full load with a single
line rig do not power in for more than a minute without letting the motor cool
down for a few minutes and then resume the winching operation.
17. The winching operation is complete once the vehicle is on stable ground
and is able to drive under its own power.
18. Secure the vehicle. Be sure to set the brakes and place the vehicle in
park.
19. Release the tension on the cable. The winch is not meant to hold the
vehicle for long periods of time.
20. Disconnect the cable from the anchor.
21. Rewind the cable. Make sure that any cable already on the drum has
spooled tightly and neatly. If not, draw out the cable and re-spool from the
point where the cable is tight.
22. Keep your hands clear of the winch drum and fairlead as the cable is
being drawn in.
23. Secure the hook and hook strap.
12. Place a Cable Hook Stopper over the cable approximately 5 to 6 feet from the hook.
24. Disconnect the remote control and store in a clean, dry place.
13. Clear the area. Make sure all spectators stand clear and that no one is
directly in front or behind the vehicle or anchor point.
14. Begin winching. Be sure that the cable is winding evenly and tightly
around the drum. The vehicle that is being winched can be slowly driven to add
assistance to the winching process. Avoid shock loads; keep the cable under
tension.
25. Clean and inspect connections and mounting hardware for next winching
operation.
26. Never use the winch as a tie down.
27. Use brake pedal when under full tension.
11
MODEL #AS-50wx 5,000LB (2268KG) WINCH
OPERATION
Synthetic Cable Usage
Exercising proper care to prolong the usable life of a Synthetic Cable is your
responsibility.
1. Minimize Cable Abrasion Use the supplied protective sheath when the
cable comes in contact with trees, rocks, or other sharp abrasive objects. The
sheath is design to stay in position while the cable slips through it during
use.
2. Keep the Cable Clean Dirt, sand, and debris will cause abrasion. Use the
protective sheath to cover the cable on the spool once the cable is in the
stowed position.
3. Avoid Sharp Bends If the cable is positioned at a sharp angle, the
strength under load will decrease and cable damage or failure may result.
4. Correct Spool Winding When re-spooling cable without a load, it is
always better to have someone apply a load to the line while you reel in
evenly. Re-spool the cable evenly and tightly on the drum. If cable is wound
loosely, it may become wedged under adjacent layers and bind.
5. DO NOT Grease or Oil Do not lubricate synthetic cable with greases or
oils. Keep grease and oil away at all times.
Snow Plow Usage
Winches are commonly used to lift a Snow Plow System, but precautions and
correct usage are required to prevent costly damage.
noTICe Winch damage such as stripped
gears, broken housings and bent or damaged parts caused by exceeding your
plow’s lift height are not covered under warranty.
2. Do not continue to hold the Spool In button to power the winch while
reversing your vehicle or other instances where the operator may become
distracted while plowing.
Protective Sheath
3. Repeated spooling of a short length of cable will increase heat and
friction where the rollers contact the synthetic cable. Minimize wear and the
possibility of premature failure by SLIDING THE PROTECTIVE SHEATH BACK UP THE
SPOOL.
4. When the plow system is the in the DOWN position, freespool out enough
additional cable that you can slide the sheath back up the spool (approx 7-8
ft more). Push the sheath back up thru the optional Cable Hook Stopper and the
rollers. Re-spool the winch.
5. Be sure that the sheath completely clears the roller fairlead once spooled
tightly onto the winch. The sheath will wrap around several layers on the
spool. Reposition the sheath back near the hook when not used for plowing.
SPOOL
ROLLERS
noTICe Follow these precautions before
using your Winch to lift a Plow. Failure to do so may result in damage to your
winch or vehicle frame.
1. Stop the plow before full lift height – failure to do so will cause the
winch to pull against itself (i.e. “bottom out”) and will cause damage to the
winch components, your plow frame and your vehicle frame.
BARE SYNTHETIC
PROTECTIVE SHEATH
(ATV-SCHS)
Note: Sheath must fully clear rollers when plow system is all the way down and touching the ground.
PLOW LIFT POINT
12
MODEL #AS-50wx 5,000LB (2268KG) WINCH
OPERATION
maInTenanCe
The owner/operator is responsible for all periodic maintenance.
Complete all scheduled maintenance in a timely manner. Correct any issue
before operating the winch.
Synthetic Cable Inspection
Periodically, inspect the synthetic cable for wear. When new, it will have a
smooth finish (see Figure A).
WarnInG Never operate a damaged or
defective winch.
WarnInG Improper maintenance will void
your warranty.
noTICe
For service or parts assistance, contact our help line at 1-877-346-2050.
(A) New Cable
After normal use, the outer surface will appear slightly fuzzy (see Figure B).
This is expected and protects the underlaying fibers.
Motor
Periodically when not used very often, or after wet / damp conditions. Be sure
to run the motor in free spool until the motor is warm. This helps dry out any
moisture and condensation trapped inside the housing.
(B) Slight Fuzz
Once approximately 25% of the outer fibers show wear (see Figure C), the cable
must be replaced.
Lubrication
All moving parts within the Electric Winch have been Lubricated using high
temperature lithium grease at the factory. No internal lubrication is required
under normal conditions.
If the winch is subjected to extreme conditions lubrication may be required
using a high temperature lithium grease. Retract Cable Assembly onto drum
being careful not to allow kinking or over heating of the winch.
(C) 25% Frayed
Inspect the inner and outer fibers by compressing the cable (see Figure D).
noTICe Do NOT attempt to lubricate or
grease the synthetic cable. Grease and oil will
attract dirt and debris which cause abrasion.
13
MODEL #AS-50wx 5,000LB (2268KG) WINCH
MAINTENANCE
(D) Compressed
Look for powdered fiber or abrasion (signs of internal wear). Consider the
amount of wear on the internal fibers when determining the percent of wear for
replacement.
Cable Assembly Replacement
It is recommended that any modifications be performed by a manufacturer’s
authorized repair facility, and that only manufacturer-supplied parts be used
1. Rotate the clutch cap to the “Release” position.
2. Extend Cable Assembly to its full length. Note how the existing cable is
connected to the inside of the drum.
3. Remove old Cable Assembly and attach new one.
4. Rotate the clutch cap to the “Engage” position.
(E) Glazed
Glossy or glazed sections (see Figure E) in the cable are usually caused by
compression, such as the cable being wound on the drum or through a pulley
block. This is considered normal.
noTICe Inspect cable before and after each
use. If cable becomes frayed it must be replaced.
noTICe If you compress (see Figure D) a
glazed section of cable (see Figure E) and it remains hardened, then the cable
has suffered heat damage and must be replaced.
WarnInG Sharp edges and rough surfaces
will shorten cable life. Inspect the cable and protective sheath before use.
Replace cable immediately if it has cut strands, fused or melted fibers, odd
stiff sections, chemical contamination, flat areas, or lumps that cannot be
eliminated after flexing the cable.
14
MODEL #AS-50wx 5,000LB (2268KG) WINCH
SPECIfICATIONS
speCIfICaTIons
Performance:
Rated Pull ………………………………….. 5,000 lb (2268 kg) Gear Reduction Ratio
…………………………………….. 180:1 Motor……………….Permanent Magnet, 1.22 HP (DC 12V) Drum
Size………………… 1.75 x 4.88 in. (44.5 x 81 mm) Cable Dimensions .. 15/64 in. x 50
ft. (6.0mm x 15.24m) Net Weight …………………………………… 27.8 lb. (12.6 kg)
Mounting Bolt Pattern……………………………………………… 6.6 in. x 3.00 in. (16.8 cm x 7.6 cm)
Overall Dimensions ………………………………………………… 15.63 in. (L) x 4.45 in. (W) x 4.76 in.
(H) (39.7 cm x 11.3 cm x 12.1 cm)
Line Pull
Line Speed (12 VDC) Max Current Run Time * Cooling Time **
Line Speed and Motor Current (First Layer)
LB
0
1500
2500
3500
KG
0
680
1134
1588
FPM
12.46
9.8
8.2
6.8
MPM
3.8
3.0
2.5
2.1
A
30
75
105
140
Minutes
1
1
1
1
Minutes
5
5
5
5
4500 2041 4.5 1.4 200
1 5
5000 2268 3.0 0.9 240
1 5
- If the motor becomes uncomfortably hot to the touch, stop winching immediately and let it cool down for 5 minutes. Do not pull for more than one minute at or near the rated load.
** Electric winches are designed and made for intermittent use and should not be used in constant duty applications.
Line Pull and Cable Capacity Per Layer
Layers of Cable on Drum
1
2
Rated Line Pull
LB
5000
4040
KG
2268
1833
Cable Capacity
FT
10.9
24.4
M
3.3
7.4
3 3389 1537 40.6 12.3
4 2919 1324
50 12.3
15
MODEL #AS-50wx 5,000LB (2268KG) WINCH
Parts Diagram
41
52
20
21
35
36
34
29
40
53
46
33
32
31
30
29
28
45 42 53
43 53 51
27
53
26
25
24
23
22
36
35
49
21
38
50
19
47 48
18 44
16
SPECIfICATIONS
1
2 3 4 5
6 7 6 8 9
10
11 12 13 39 14
37 15 16 17
MODEL #AS-50wx 5,000LB (2268KG) WINCH
Parts List
SPECIfICATIONS
Part Number
Description
Qty
Part Number
Description
Qty
1 MOTOR-AS50 Motor Assembly 2 HW-0023-B Screw M5 x 16 Socket
1 2
41
SE-WIRESUTV-BAT
Wiring, Battery, UTV
1
3 WP-0026
Coupling, I
1
41.1 WP-0092
Terminal Protector
4
4 WP-0055
Coupling, II
1
42 100695
Bracket, Fairlead, Wide
1
5 WP-0079
Spring, Shaft
1
43 SE-WRF
Roller Fairlead, Wide, Stealth 1
6 WP-0061
Delf-seal Packing
2
44 ATV-SCHS Split Cable Hook Stopper
1
7 WP-0080
Tie Bar Ø10 x 129
2
45 UTV-DRS-K UTV Dash Rocker Switch Kit 1
8 WP-0054
Clutch Cover, Assault
1
46 AS-CONT
Contactor, Assault
1
9 WP-0068
Gear Ring, I
1
10 WP-0065
Gear Carrier Asm, Output
1
47 SYN25-S50
Cable, Synthetic, 15/64″ x 50ft
1
11 WP-0064 12 WP-0078 13 WP-0077 14 WP-0085 15 HW-0024 16 WP-0002 17 HW-0007-B
Gear Carrier Asm, Input Bearing 606 Sealed O-Ring Ø19 x 2.4 Spring, Clutch Washer SS Ø16 Clutch Cap, Assault Screw M6 x 16 Phillips
1 1 1 1 1
48 UTV-RPS
Protective Sheath, Replacment
49 SE-HOOK
Clevis Hook, 1/4″
50 WP-0030-BLK Hand Saver Strap, Black
51 ATV-HR
Hand Remote Asm
1
1 1 1
1
52 AS-CAPKIT Motor End Cap Assembly
1
1
53 HK-500
Hardware Kit, Black
1
18 HW-0006-B Washer Ø6 Lock
1
53.01 HW-0001
Wire Tap
2
19 HW-0004 Circlip Ø15
1
53.02 HW-0014-B Nut M6 Nylock
4
20 HW-0025-B Screw M4 x 20 Socket
1
53.03 HW-0006-B Washer Ø6 Lock
4
21 HW-0020-B Lock Washer Ø4
2
53.04 HW-0003-B Washer Ø6
4
22 WP-0067
Gear Housing
1
53.05 HW-0013-B Bolt M6 x 25
4
23 WP-0053
Cam, Clutch Gear
1
53.06 HW-0015-B Bolt M6 x 20
2
24 WP-0052
Bushing, Axis Support
1
53.07 HW-0010-B Bolt M10 x 20
2
25 WP-0084
Gear, Input, Sun
1
53.08 HW-0011-B Washer Ø10 Lock
2
26 WP-0063
Gear Carrier Asm
1
53.09 HW-0012-B Nut M10 Nylock
2
27 WP-0069
Gear Ring, II
1
53.10 HW-0016-B Washer Ø8
8
28 WP-0075
O-Ring Ø100 x 1.9
1
53.11 HW-0009-B Washer Ø8 Lock
4
29 WP-0062
Bushing, Drum
2
53.12 HW-0008-B Bolt M8 x 25
4
30 WP-0073
Hex Tie Bar 6 x 131
1
53.13 HW-0018-B Bolt M8 x 20
4
31 WP-0025
Set Screw M5 x 8
1
53.14 HW-0017-B Bolt M8 x 30
4
32 WP-0057
Drum, Steel, Wide
1
33 WP-0071
Shaft, Hexagon, H6 x 187
1
34 WP-0027
Spring, Coupling
1
35 WP-0049
Square Nut
4
36 WP-0050
Pin, Spring, Ø3 x 14
4
37 HW-0026-B Screw M5 x 18 Socket
2
38 HW-0019-B Screw M4 x 25 Socket
1
39 WP-0076
O-Ring Ø13 x 2
2
40
SE-WIRESUTV-WIN
Wiring, Winch, UTV
1
40.1 WP-0092
Terminal Protector
4
17
MODEL #AS-50wx 5,000LB (2268KG) WINCH
TroubleshooTInG
Problem
Cause
Incorrect Wiring
Motor does not run, Contactor makes a click sound.
Incorrect Wiring Loose battery cable connections Motor Issue Water has entered motor Brake Spring installed backwards Incorrect Wiring
Motor does not run, NO
Switch Ignition Wire
click sound from Contactor.
Contactor malfunctioning
Switch malfunctioning
Motor runs, Spool turns in one direction only.
Motor runs, Spool does NOT turn. Spool turns, but no movement from Cable
Incorrect Wiring
Defective or stuck Contactor Defective Switch assembly Contactor
malfunctioning Clutch not engaged Broken Coupler / stripped Shaft
Cable not attached to Spool
Motor runs slowly or without normal power.
Motor overheating
Insufficient current or voltage.
Loose or corroded battery cable connections Worn Brushes Winch running time
too long
TROUBLESHOOTING
Solution Check Winch Wiring Diagram, make sure all wires are correctly
connected. Hand Remote / Mini Rocker Switch wires must be connected green to
green and black to black. Hand tighten nuts on all cable connections. Contact
KFI Technical Support Allow to drain and dry. Run in short burst with load
until completely dry. Contact KFI Technical Support. Check Winch Wiring
Diagram, make sure all wires are correctly connected. Check connection to an
ignition fed source. Must supply 12V with the key on and vehicle running.
Contact KFI Technical Support. Contact KFI Technical Support. Check wiring
diagram, verify switch wires (black/ green) are properly connected and making
good contact. Tap contactor to loosen plungers. Replace Switch assembly.
Contact KFI Technical Support. Rotate Clutch Cap to Engage. Replace Coupler or
Shaft
Contact KFI Technical Support.
The battery is weak, recharge. Run winch with vehicle motor running (battery
should have a strong charge).
Clean, tighten, or replace.
Replace with End-Cap Kit (#AS-CAPKIT) Contact KFI Technical Support. Allow
winch to cool down periodically.
For further support, contact:
KFI Tech Support
Mon-Thr 8:00 AM – 5:00 PM (CST/CDT) Fri 7:00 AM – 1:00PM (CST/CDT) Toll Free:
1-877-346-2050 tech@kfiproducts.com
KFI Products Website Support:
Common installation, maintenance, and troubleshooting guides are available on
our website.
https://www.kfiproducts.com/suppor t.html
18
MODEL #AS-50wx 5,000LB (2268KG) WINCH
WARRANTy
WarranTy
KAPPERS FABRICATING, INC. 2 YEAR LIMITED LIFETIME WARRANTY
Warranty Qualifications
Kappers Fabricating Inc. (KFI) will register this warranty upon receipt of
your Warranty Registration Card and a copy of your sales receipt from one of
KFI’s resale locations as proof of purchase. Please submit your warranty
registration and your proof of purchase within Fifteen (15) days of the date
of purchase.
Repair/Replacement Warranty
KFI warrants to the original purchaser that mechanical components will be free
of defects in material and workmanship for the usable lifetime of the product
(180 days for commercial use); and electrical components will be free of
defects in material and workmanship for (2) years (180 days for commercial
use); from the original date of purchase. Transportation charges on product
submitted for repair or replacement under this warranty are the sole
responsibility of the purchaser. This warranty only applies to the original
purchaser and is not transferable.
Do Not Return The Unit To The Place Of Purchase
Contact KFI’s Technical Service and KFI will troubleshoot any issue via phone
or e-mail. If the problem is not corrected by this method, KFI will, at its
option, authorize evaluation, repair or replacement of the defective part or
component at a KFI Service Center. KFI will provide you with a case number for
warranty service. Please keep it for future reference. Repairs or replacements
without prior authorization, or at an unauthorized repair facility, will not
be covered by this warranty.
Warranty Exclusions
This warranty does not cover the following repairs and equipment:
Normal Wear
Winches need periodic parts and service to perform well. This warranty does
not cover repair when normal use has exhausted the life of a part or the
equipment as a whole.
Installation, Use and Maintenance
This warranty will not apply to parts and/or labor if this winch is deemed to
have been misused, neglected, involved in an accident, abused, loaded beyond
the winch’s limits, modified, installed improperly or wired incorrectly to any
electrical component. Normal maintenance is not covered by this warranty.
Other Exclusions
The winch cable or synthetic cable.
Cosmetic defects such as paint, decals, etc.
Accessory parts such as storage covers.
Misuse, abuse, neglect, acts of God, terrorism and causes beyond the control
of KFI.
Problems caused by parts that are not original Kappers Fabricating Inc.
parts.
Cable Stacking and Water Submersion or Damage Caused by Water.
Warranty Procedure
1. Contact KFI Technical support to acquire a Return Authorization (RA)
number.
2. KFI may request additional materials (such as original sales receipt, date
of purchase, technical details, or photos of Product condition) prior to
issuing an RA number.
3. At the discretion of KFI, Buyer shall mail, ship, or otherwise deliver to
KFI the Warrantied Product, at the address noted below.
Limits of Implied Warranty and Consequential Damage
Kappers Fabricating Inc. disclaims any obligation to cover any loss of time,
use of this product, freight, or any incidental or consequential claim by
anyone from using this winch. THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE
A unit provided as an exchange will be subject to the warranty of the original
unit. The length of the warranty governing the exchanged unit will remain
calculated by reference to the purchase date of the original unit.
This warranty gives you certain legal rights which may change from state to
state. Your state may also have other rights you may be entitled to that are
not listed within this warranty.
19
MODEL #AS-50wx 5,000LB (2268KG) WINCH
WARRANTy
Contact Information
Address
KFI Products Winch Customer Service P.O. BOX 32 721 SATA DRIVE SPRING VALLEY,
MN 55975
Corporate
KAPPERS FABRICATING, INC. P.O. BOX 32 1015 INDUSTRIAL DR. SPRING VALLEY, MN
55975
Customer Service
Mon – Thr 8:00 AM – 5:00 PM (CST/CDT) Fri – 7:00 AM – 1:00 PM (CST/CDT) Toll
Free: 1-877-346-2050 Opt 1 Fax No: 1-507-346-2010 E-mail:
sales@kfiproducts.com
Technical Service
Mon – Thr 8:00 AM – 5:00 PM (CST/CDT) Thr – 7:00 AM – 1:00 PM (CST/CDT) Toll
Free: 1-877-346-2050 Opt 2 E-mail: tech@kfiproducts.com
Website
https://www.kfiproducts.com
20
MODEL #AS-50wx 5,000LB (2268KG) WINCH
NOTES
1-877-346-2050
KFI PRODUCTS
P.O. BOX 32 721 SATA DRIVE SPRING VALLEY, MN 55975
WWW.KFIPRODUCTS.COM
CORPORATE OFFICE: KAPPERS FABRICATING, INC.
P.O. BOX 32 1015 INDUSTRIAL DR. SPRING VALLEY, MN 55975
USA
MADE IN CHINA ©2022 KAPPERS FABRICATING, INC.
References
- ATV winches, mounts and accessories for KFI Products - KFI ATV Winch, Mounts and Accessories
- P65Warnings.ca.gov
- ATV winches, mounts and accessories for KFI Products - KFI ATV Winch, Mounts and Accessories
- Support - KFI ATV Winch, Mounts and Accessories
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