Kfi Se45-r2 Stealth Series Synthetic Cable Atv Utv Winch User Manual

Kfi Se45-r2 Stealth Series Synthetic Cable Atv Utv Winch User Manual

KFi LOGOSTEALTH SERIES
SYNTHETIC CABLE
ATV/UTV WINCH
MODEL #SE45-R2
4,500 LB. (2041 KG)KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv WinchOPERATOR’S MANUALKFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - Warrenty

SE45-R2 Stealth Series Synthetic Cable Atv Utv Winch

READ AND SAVE THIS MANUAL.
warning 2Danger iconThis 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.

INTRODUCTION

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
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.
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
SE45-R2
SERIAL NUMBER
………………….
DATE OF PURCHASE
………………….
PURCHASE LOCATION
………………….

SAFETY DEFINITIONS

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.
Warning-icon.png DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Warning-icon.png WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Warning-icon.png CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - ICON NOTICE
NOTICE indicates information considered important, but not hazard-related (e.g. messages relating to property damage or physical injury).

IMPORTANT SAFETY INSTRUCTIONS

Warning-icon.png WARNING
Cancer and Reproductive Harm – www.P65Warnings.ca.gov
Warning-icon.png WARNING
Read this manual thoroughly before operating the winch. Failure to follow instructions could result in serious injury or death.
Warning-icon.png WARNING
Do not exceed the rated capacity.
Warning-icon.png DANGER
Do not use this winch for lifting or moving people or animals.
Warning-icon.png DANGER
Keep yourself and others a safe distance to the side of the cable when under tension.
Warning-icon.png DANGER
Never step over a cable or near a cable under load.
Warning-icon.png 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-icon.png WARNING
Do not move the vehicle to pull a load (towing) on the winch cable. This could result in cable breakage.
Warning-icon.png WARNING
Pull only on area of the vehicle as specified by the vehicle manufacturer.
Warning-icon.png 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-icon.png WARNING
Disconnect the remote control and battery leads when not in use for extended periods.
Warning-icon.png 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-icon.png 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-icon.png WARNING
Do not use as a hoist. Do not use for overhead lifting.
Warning-icon.png 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.
Warning-icon.png CAUTION
Use gloves to protect hands when handling the cable. Never let the cable slide through your hands.
Warning-icon.png CAUTION
Do not wrap the cable around any object and hook it back onto itself.
Warning-icon.png CAUTION
Apply blocks to the wheels of the vehicle when on an incline.
Warning-icon.png 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.
Warning-icon.png 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.
Warning-icon.png CAUTION
Never release the free spool clutch when there is a load on the winch.
Warning-icon.png CAUTION
Use the Hand-Saver strap when handling the winch hook for spooling or unspooling the cable.

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

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - Winch

  1. Motor – 1.70 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 38 ft. Synthetic cable designed specifically for load capacity of 4,500 lbs. (35 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.
  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.
  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.

INSTALLATION

This KFI 4,500 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-icon.png 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.
    Warning-icon.png CAUTION
    Mounting bolts must be SAE Grade  5 or better and torqued to 17 ft. lbs.
    KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - ICON 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.
    Warning-icon.png 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.KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - InstallationMount 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.KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - Rocker Switch
  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.KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - predefined knockout
  8. Once your switch is mounted you can route wires back to the contactor location.
  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.KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - Hand Remote Socket
  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.
  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.
    Wiring the Winch
    Warning-icon.png 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-icon.png WARNING
    Failure to follow specific wiring instructions may result in damage to your wiring system or equipment.
    KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - ICON 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.
    KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - ICON NOTICE 
    If you are installing the remote socket 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.
    Warning-icon.png CAUTION
    Battery cables should not be drawn taut. Leave some slack for cable movement.
    KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - ICON 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.

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - nut

Winch Wiring Diagram

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - Wiring Diagram

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.

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - Terminal Rotation

Controller Wiring Diagram

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - Controller Wiring Diagram

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.

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - Cable Hook Stopper

General Tips for Safe Operation
Your SE45-R2 winch is rated at 4,500 lbs. capacity in first layer (max) when spooling the first cable layer on the drum. Overloads can damage the winch, motor and/ or cable.
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.
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.
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.
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.
Self Recovery
Locate a suitable anchor such as a strong tree trunk or boulder. Always use a sling as an anchor point.

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - Self Recovery

Your winch is equipped with a roller fairlead to help guide the cable and to reduce binding on short side pulls.
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.

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - damage cable

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.

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - winch vehicle

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.

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.
  12. Place a Cable Hook Stopper over the cable approximately 5 to 6 feet from the hook.
  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.
  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.
  24. Disconnect the remote control and store in a clean, dry place.
  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.

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.
KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - ICON 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.
    KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - ICON 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.

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - wrap around

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.
Warning-icon.png WARNING
Never operate a damaged or defective winch.
Warning-icon.png WARNING
Improper maintenance will void your warranty.
KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - ICON NOTICE 
For service or parts assistance, contact our help line at 1-877-346-2050.
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.
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.
KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - ICON NOTICE 
Do NOT attempt to lubricate or grease the synthetic cable. Grease and oil will attract dirt and debris which cause abrasion.

Synthetic Cable Inspection
Periodically, inspect the synthetic cable for wear. When new, it will have a smooth finish (see Figure A).

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - New Cable

After normal use, the outer surface will appear slightly fuzzy (see Figure B). This is expected and protects the underlaying fibers.

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - Slight Fuzz

Once approximately 25% of the outer fibers show wear (see Figure C), the cable must be replaced.

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - Frayed

Inspect the inner and outer fibers by compressing the cable (see Figure D).

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - 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.

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - 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.
KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - ICON 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-icon.png 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.
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.

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - ICON NOTICE
Inspect cable before and after each use. If cable becomes frayed it must be replaced.

SPECIFICATIONS

Performance:
Rated Pull ………………………………….. 4,500 lb (2041 kg)
Gear Reduction Ratio …………………………………….. 166:1
Motor ……………….Permanent Magnet, 1.70 HP (DC 12V)
Drum Size ………………… 2.00 x 3.18 in. (50.8 x 81 mm)
Cable Dimensions …. 15/64 in. x 38 ft. (6.0mm x 11.6m)
Net Weight …………………………………… 33.5 lb. (15.2 kg)
Mounting Bolt Pattern ………………….. 4.88 in. x 3.00 in. (12.4 cm x 7.6 cm)
Overall Dimensions ………………………. 14.6 in. (L) x 4.55 in. (W) x 4.82 in. (H)
(37.1 cm x 11.6 cm x 12.3 cm)

Line Speed and Motor Current (First Layer)
Line PullLB01000200030004500
KG045490713612041
Line Speed (12 VDC)FPM12.89.88.56.94.6
MPM3.93.02.62.11.4
Max CurrentA2880130180280
Run Time *Minutes11111
Cooling Time **Minutes55555

* 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 Drum1234
Rated Line PullLB4500371531632754
KG2041168514351249
Cable CapacityFT7.616.827.638
M2.35.18.411.6

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - Electric winche.

Parts Diagram

KFi SE45 R2 Stealth Series Synthetic Cable Atv Utv Winch - Parts Diagram

Parts List

#Part NumberDescriptionQty
1MOTOR-45-BLMotor Assembly1
2HW-0019-BScrew M4 x 25 Socket2
3HW-0020-BLock Washer Ø42
4WP-0026Coupling, I1
5WP-0027Spring, Coupling1
6WP-0028Coupling, II1
7WP-0029-BTie Bar Ø8 x 861
8WP-0051Drum, Steel, Standard1
9WP-0031Gear Housing1
10WP-0032Gear Ring1
11WP-0033Gear Carrier Asm, Output1
12WP-0034Gear Carrier Asm, Inter1
13WP-0035Gear Carrier Asm, Input1
14WP-0036Gear, Input, Sun1
15WP-0037Gear, Fixed1
16WP-0038Bushing, Clutch1
17HW-0004Circlip Ø151
18HW-0006-BWasher Ø6 Lock1
19HW-0007-BScrew M6 x 16 Phillips1
20HW-0003-BWasher Ø66
21HW-0021-BScrew M6 x 25 Socket4
22HW-0022-BScrew M6 x 100 Socket2
23WP-0001Clutch Cap1
24WP-0015Bearing 16002 Sealed1
25WP-0039Clutch Cover1
26WP-0013Spring, Clutch1
27WP-0040Cam, Clutch Gear1
28WP-0016Bushing, Axis Support1
29WP-0017Bearing 6002 Sealed1
30WP-0041Seal2
31WP-0042Washer, Friction2
32WP-0043Retaining Ring1
33WP-0044O-Ring Seal1
34WP-0045Bushing, Drum2
35WP-0025Set Screw M5 x 81
36WP-0046Shaft, Hexagon, H8 x 1501
37WP-0047Spring, Shaft1
38WP-0048-BTie Bar Ø10 x 862
39WP-0049Square Nut4
40WP-0050Pin, Spring, Ø3 x 144
41ATV-CONTContactor1
42UTV-DRS-KUTV Dash Rocker Switch Kit1
#Part NumberDescriptionQty
43ATV-SCHSSplit Cable Hook Stopper1
44ATV-HRHand Remote Asm1
45100495Bracket, Fairlead, Standard1
46SE-RFRoller Fairlead, Stealth1
47SE-WIRES- UTV-WINWiring, Winch, UTV1
47.1WP-0092Terminal Protector4
48SE-WIRES- UTV-BATWiring, Battery, UTV1
48.1WP-0092Terminal Protector4
49SYN23-S38Cable, Synthetic, 15/64″ x 38ft1
50UTV-RPSProtective Sheath, Replacment1
51SE-HOOKClevis Hook, 1/4″1
52WP-0030-BLKHand Saver Strap, Black1
53SE-U-CAPKITMotor End Cap Assembly1
54HK-500Hardware Kit, Black1
54.01HW-0001Wire Tap2
54.02HW-0014-BNut M6 Nylock4
54.03HW-0006-BWasher Ø6 Lock4
54.04HW-0003-BWasher Ø64
54.05HW-0013-BBolt M6 x 254
54.06HW-0015-BBolt M6 x 202
54.07HW-0010-BBolt M10 x 202
54.08HW-0011-BWasher Ø10 Lock2
54.09HW-0012-BNut M10 Nylock2
54.10HW-0016-BWasher Ø88
54.11HW-0009-BWasher Ø8 Lock4
54.12HW-0008-BBolt M8 x 254
54.13HW-0018-BBolt M8 x 204
54.14HW-0017-BBolt M8 x 304

TROUBLESHOOTING

ProblemCauseSolution
Motor does not run, Contactor makes a click sound.Incorrect WiringCheck Winch Wiring Diagram, make sure all wires are correctly connected.
Incorrect WiringHand Remote / Mini Rocker Switch wires must be connected green to green and black to black.
Loose battery cable connectionsHand tighten nuts on all cable connections.
Motor IssueContact KFI Technical Support
Water has entered motorAllow to drain and dry. Run in short burst with load until completely dry.
Brake Spring installed backwardsContact KFI Technical Support.
Motor does not run, NO click sound from Contactor.Incorrect WiringCheck Winch Wiring Diagram, make sure all wires are correctly connected.
Switch Ignition WireCheck connection to an ignition fed source. Must supply 12V with the key on and vehicle running.
Contactor malfunctioningContact KFI Technical Support.
Switch malfunctioningContact KFI Technical Support.
Motor runs, Spool turns in one direction only.Incorrect WiringCheck wiring diagram, verify switch wires (black/ green) are properly connected and making good contact.
Defective or stuck ContactorTap contactor to loosen plungers.
Defective Switch assemblyReplace Switch assembly.
Contactor malfunctioningContact KFI Technical Support.
Motor runs, Spool does NOT turn.Clutch not engagedRotate Clutch Cap to Engage.
Broken Coupler / stripped ShaftReplace Coupler or Shaft
Spool turns, but no movement from CableCable not attached to SpoolContact KFI Technical Support.
Motor runs slowly or without normal power.Insufficient current or voltage.The battery is weak, recharge. Run winch with vehicle motor running (battery should have a strong charge).
Loose or corroded battery cable connectionsClean, tighten, or replace.
Worn BrushesReplace with End-Cap Kit (#SE-U-CAPKIT) Contact KFI Technical Support.
Motor overheatingWinch running time too longAllow 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
[email protected]
KFI Products Website Support:
Common installation, maintenance, and troubleshooting guides are available on our website.
https://www.kfiproducts.com/support.html

WARRANTY

KAPPERS FABRICATING, INC.
1 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 (90 days for commercial use); and electrical components will be free of defects in material and workmanship for (1) years (90 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.
  2. 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.

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: [email protected]
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: [email protected]
Website
https://www.kfiproducts.com

KFi LOGO 21-877-346-2050
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

Documents / Resouces

Download manual
Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.


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