KFI SE45w Manual

Model#: SE45w
Owner’s Manual and Operating Instructions
4500lb.WIDE
UTVWINCH
Revision Date: 2016-07-19

Table of Contents
Introduction......................................1
Accessories................................................ 1
This Booklet.............................................. 1
Manual Conventions......................... 2
Safety Rules...................................... 3
Controls and Features ...................... 5
Winch........................................................5
Installation....................................... 6
Step 1-Mount the Winch...........................6
Step 2-Mount the Contactor.....................6
Step 3-Mount the Mini-Rocker Switch....6
Step 4-Mount the Hand Remote Socket
(Optional) .................................................7
Step 5-Wiring the Winch..........................7
Winch Wiring Diagram .................... 8
Switch Wiring Diagram .................... 9
Cable Hook Stopper Installation and
Use ................................................... 9
Operation ........................................10
General Tips for Safe Operation.............10
Self Recovery ..........................................10
Winching Techniques A-Z.......................11
Maintenance.................................... 12
Lubrication .....................................12
Cable Assembly Replacement ................ 12
SE45w Specifications....................... 13
Performance Specifications.................... 13
Winch Diagram....................................... 14
Model: #SE45w ...................................... 14
Winch Parts List ..................................... 15
Troubleshooting ..............................16
PLOWING ALERT.................................. 16
Warranty......................................... 17
Warranty Qualifications..........................17
Repair/Replacement Warranty...............17
Do not return the unit to the place of
purchase...................................................17
Warranty Exclusions ...............................17
Normal Wear........................................17
Installation, Use and Maintenance .....17
Other Exclusions..................................17
Limits of Implied Warranty and
Consequential Damage............................17
Contact Information............................... 18
Address................................................ 18
Corporate ............................................ 18
Customer Service................................ 18
Technical Service ................................ 18
Agreement.......................................18
Synthetic Cable................................19
Revision Date: 2016-07-19

Introduction
SE45w 1
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 Booklet
Every effort has been made to ensure the
accuracy and completeness of the
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.
Kappers Fabricating Inc. Support
1-877-346-2050
Model Number
SE45w
Date of Purchase
Purchase Location
Serial Number

Manual Conventions
2 SE45w
Manual Conventions
This manual uses the following symbols to
help differentiate between different kinds of
information. The safety symbol is used with
a key word to alert you to potential hazards
in operating and owning a winch.
Follow all safety messages to avoid or reduce
the risk of serious injury or death.
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
CAUTION
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
NOTE
If you have questions regarding your winch, we
can help. Please call our help line at 1-877-346-
2050.

Manual Conventions
SE45w 3
Safety Rules
WARNING
Read this manual thoroughly before operating
your winch. Failure to follow instructions could
result in serious injury or death.
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
The wire rope 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 wire rope.
WARNING
Do not move the vehicle to pull a load (towing)
on the winch cable. This could result in cable
breakage.
WARNING
Pull only on areas of the vehicle as specified by
the vehicle manufacturer
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
Avoid “shock loads” by using the control switch
intermittently to take up the slack in the wire
rope. “Shock loads” can far exceed the rate
capacity for the wire rope 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.

Safety Rules
4 SE45w
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
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”
of the winch while re-spooling. Turn off the
winch and repeat the procedure until a few feet
of cable is 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
Do not use as a hoist. Do not use for overhead
lifting.
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.
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 hook strap when handling the hook for
spooling or unspooling the wire rope.

SE45w 5
Controls and Features
Read this owner’s manual before operating your winch. Familiarize yourself with the location and
function of the controls and features. Save this manual for future reference.
Winch
Motor (1): 1.7 HP 12V DC motor provides power
to the planetary gear mechanism.
Winch Drum (2): The winch drum is the
cylinder on which the wire rope is stored. It can
feed or wind the rope depending on the remote
winch switch.
Synthetic Cable (3): 15/64” x 50’ Synthetic
cable designed specifically for load capacity of
7,000lbs. (47 useable feet with five wraps on the
drum). The wire rope 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).
Roller Fairlead (4): When using the winch at
an angle the roller fairlead acts to guide the wire
rope onto the drum and minimizes damage to the
wire rope from abrasion on the winch mount or
bumper.
Free spooling Clutch (5): The clutch allows
the operator to manually disengage
(“FREESPOOL”) the spooling drum from the gear
train. Engaging the clutch (“ENGAGE”) locks the
winch into the gear system.
Braking System (6): Braking action is
automatically applied to the winch drum when
the winch motor is stopped and there is a load on
the wire rope.
Planetary Gear System (7): The reduction
gears convert the winch motor power into
extreme pulling forces. This system allows high
torque while maintaining compact size and light
weight.
Rocker Switch (8): Rocker switch with
handlebar mount for powering the rope in or out
of your winch drum.
Hand Held Switch (9): Hand held switch with
a remote socket for powering the rope in or out of
your winch drum.
Fairlead Mount (10): Adapter to mount the
winch and fairlead for utility applications.
Contactor (11): Power from the vehicle battery
flows through the weather sealed solenoid switch
before being directed to the winch motor.
Clevis Hook (12): Provides a means for
connecting the looped ends of cables to an
anchor.
Cable Hook Stopper (13): Protects the
Rollers, motor and gears

Installation
6 SE45w
Installation
This KFI 4,500 lb winch is designed with a
bolt pattern that is standard in this class of
winch. Many winch mounting kits are
available that utilize this bolt pattern for the
most popular ATV’s and UTV’s. You can find
most of the ATV/UTV winch mounts on our
Website www.kfiproducts.com
Step 1-Mount the Winch
WARNING
Before you start 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
mounting kit or prepare a flat, secure
mounting location for the winch.
NOTE
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 will
stand up to the pulling forces of this winch.
CAUTION
Mounting bolts must be SAE grade 5 or better
and torque to 17 ft. lbs.
2. Attach the winch using the M8 x 25 or
30 bolts and washers through the
fairlead bracket or model specific mount
and then into the winch.
3. Disengage the clutch by rotating the
clutch cap to the “FREESPOOL”
position. Release the wire rope and pull
through the roller fairlead.
4. Attach the clevis hook and hand strap to
the cable.
Step 2-Mount the Contactor
1. 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. Make
sure the location you chose allows
sufficient clearance from all metal
components. Drill mounting holes if
required. Once location is found do not
install until all wiring is completed.
Step 3-Mount the Mini-Rocker
Switch
1. The switch is usually installed on the left
handlebar on ATV’s. If you are
installing on a UTV or SxS you can use
the supplied Bracket and hardware as
shown above. This bracket can be
placed in any location that is convenient
for you.
2. If mounting to the handle bars of an
ATV use a piece of electrical tape around
the handlebar to help prevent rotation of
the mount on the handlebar. Do NOT
tighten over any hoses or cables.
3. Once your switch is mounted you can
route the wires back to where your
contactor is located.
4. Splice the end of the red wire to an
ignition (keyed) controlled power source
using the supplied wire splice. You may
need to use a test light to locate a
suitable wire. The wire should only have
power when the key is in the ON
position.
5. If mounting to the handle bars of an
ATV make sure the handlebars have full
range of motion and then secure the
switch’s cable with the supplied cable
ties.
Not to scale. Do NOT use as a template
UTV Mounting Bracket
ATV Mounting Location

Installation
SE45w 7
Step 4-Mount the Hand
Remote Socket (Optional)
1. Determine a mounting location for the
hand remote socket. Make sure the area
behind your selected location is clear.
2. Drill the three holes as shown in the
figure on page 6 and install using the
supplied hardware. You can use the
rubber cap as a template.
3. Once your remote socket is mounted you
can route the wires back to where your
contactor is located.
4. Splice the end of the red wire to an
ignition (keyed) controlled power source
using the supplied wire splice. You may
need to use a test light to locate a
suitable wire. The wire should only have
power when the key is in the ON
position.
5. Secure the cable with the supplied cable
ties
Step 5-Wiring the Winch
CAUTION
Never route electrical cables across any sharp
edges, through or near moving parts, or near
parts that become hot
1. Connect the yellow and blue cables to
the motor terminals on the winch.
Torque the terminal nuts on the motor
to 5.7 N-m (50 lb-in). Route the other
ends to the contactor location.
(See diagram on page 8)
2. Connect the yellow and blue cables to
the contactor (yellow to yellow and blue
to blue). Do NOT tighten nuts.
(See diagram on page 8)
3. Connect the red and black cables to your
contactor (red to red and black to black).
Do NOT tighten nuts. Route the other
ends to your battery location.
(See diagram on page 8)
NOTE
Depending on the location of the contactor, you
may need to use the black and red cables in
place of the yellow and blue, and the yellow and
blue in place of the red and black. Just
remember that this also changes the diagram.
4. Connect the Handle bar switch to the
contactor. (black to black and green to
green) (See diagram on page 9)
NOTE
If you are installing the remote socket along with
the handlebar switch you will need to connect
the remote socket to the contactor and then the
handlebar switch to the remote socket.
(See diagram on page 9)
5. Once all wiring is connected to the
contactor you can then mount it using
the supplied M6 hardware.
6. Torque the contactor terminal nuts to
4.5 N-m (40 lb-in). Do NOT over
tighten.
7. Place all terminal boots over terminals
and secure all cables with zip ties or
electrical tape.
8. Connect the battery leads from the
contactor to the ATV’s Battery (red to
red and black to black)
(See diagram on page 8)
NOTE
Depending on the location of the contactor, you
may need to use the black and red cables in
place of the yellow and blue, and the yellow and
blue in place of the red and black. Just
remember that this also changes the diagram.
CAUTION
Battery cables should not be drawn taut. Leave
some slack for cable movement.
9. Check for proper drum rotation. Turn
the clutch cap to the “FREESPOOL”
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 machine is
running and press the cable out button
on the switch. If the drum is turning and
releasing more cable, then your
connections are accurate. If the drum is
turning and collecting more cable, then
reverse the leads on the motor. Repeat
and check rotation.

Installation
8 SE45w
With some applications the motor leads 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 Instructions section.
Winch Wiring Diagram

Installation
SE45w 9
1. Freespool winch and pull out approx. 2 feet of cable.
2. Pull Hairpin and release clevis pin from winch hook.
3. Safely pull your winch line loop through the hole in the
hook stopper, position mid-way down winch line. It can
help to use a zip tie or string to pull through.
4. Re-attach hook to cable end.
5. To stow hook, engage clutch and retract cable onto
winch spool until hook is snug against the hook stopper
and fairlead
6. Position hook stopper at approx. ¾ of the total line distance towards hook while using your winch to
help reduce whip back in the event of cable breakage.
Switch Wiring Diagram
Cable Hook Stopper Installation and Use

Operation
10 SE45w
Operation
General Tips for Safe
Operation
Your SE45w winch is rated at 4,500 lbs.
capacity in first layer (max) when spooling
the first rope 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 rope should be
replaced immediately. Use only
manufacturer’s identical replacement rope
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.
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.
Short pulls from an angle can be used to
straighten the vehicle. Long pulls should be
done with the wire rope at a 90° angle to the
winch/vehicle.
When pulling a heavy load, place a winch
saver, blanket or jacket over the cable five or
six feet from the hook.
In the event of a broken cable it will dampen
the snap back. For additional protection
open the hood of the vehicle.

Operation
SE45w 11
Winching Techniques A-Z
a. Take time to assess your situation and
plan your pull.
b. Put on gloves to protect your hands.
c. Disengage the clutch to allow free-
spooling and also save battery power.
d. Attach the hook strap to the clevis hook.
e. Pull out the cable to your desired anchor
point using the hook strap.
f. Secure the clevis hook to the anchor
point: Sling, chain or snatch block. Do
not attach the hook back onto the cable.
g. Engage the clutch.
h. Start your engine to ensure power is
being replenished to the battery.
i. 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.
j. Double check your anchors and make
sure all connections are secure.
k. Inspect the cable. Make sure there are at
least 5 wraps of cable around the winch
drum.
l. Drape a blanket or jacket over the cable
approximately 5 to 6 feet from the hook.
m. Clear the area. Make sure all spectators
stand clear and that no one is directly in
front or behind the vehicle or anchor
point.
n. 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.
o. The vehicle to be winched should be
placed in neutral and the parking brake
released. Only release the brake pedal
when under full tension. Avoid shock
loads to the winch. This can damage the
winch, cable and vehicle.
p. 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.
q. The winching operation is complete
once the vehicle is on stable ground and
is able to drive under its own power.
r. Secure the vehicle. Be sure to set the
brakes and place the vehicle in park.
s. Release the tension on the cable. The
winch is not meant to hold the vehicle
for long periods of time.
t. Disconnect the cable from the anchor.
u. 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.
v. Keep your hands clear of the winch
drum and fairlead as the cable is being
drawn in.
w. Secure the hook and hook strap.
x. Disconnect the remote control and store
in a clean, dry place.
y. Clean and inspect connections and
mounting hardware for next winching
operation.
z. Never use the winch as a tie down.

Maintenance
12 SE45w
Maintenance
The owner/operator is responsible for all
periodic maintenance.
WARNING
Never operate a damaged or defective winch.
WARNING
Improper maintenance will void your warranty.
Complete all scheduled maintenance in a
timely manner. Correct any issue before
operating the winch.
NOTE
For service or parts assistance, contact our help
line at 1-877-346-2050.
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.
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 “Free Spool”
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.
5. Retract Cable Assembly onto drum
being careful not to allow kinking or
over heating of the winch.

SE45w Specifications
SE45w 13
SE45w Specifications
Performance Specifications
Rated Pull 4,500 lbs (2041 kg)
Gear Reduction Ratio 166:1
Motor Permanent Magnet
1.7 HP (DC 12V)
Drum Size 2.0” (D) x 4.9” (L)
50.8 mm (D) x 125.0 mm (L)
Synthetic Cable 15/64” (D) x 50.0’ (L)
6 mm (D) x 15.2 m (L)
(47 useable feet with five
wraps on the winch drum)
Weight 35.3 lbs. (complete kit)
Height 4.82 inches (122.5 mm)
Width 4.55 inches (115.5 mm)
Length 16.3 inches (415 mm)
Bolt Pattern 6.60” x 3” (168mm x 76 mm)
Line speed and Motor Current (First layer)
Line pull Max
lbs
0
1000
2000
3000
4500
kgs
0
454
907
1361
2041
Line speed
(12VDC)
FPM
12.8
9.8
8.5
6.9
4.6
MPM
3.9
3.0
2.6
2.1
1.4
Max Current
amps
28
80
130
180
280
Cooling Time
minutes
5
5
5
5
5
Line pull and cable capacity
Layers of cable on drum
1
2
3
4
Max pulling capacity per
layer
lbs
4500
3715
3163
2754
kgs
2041
1687
1436
1250
Cable capacity
per layer
ft
12.2
26.2
41.9
50
m
3.7
8.0
12.8
15.2

SE45w Specifications
14 SE45w
Winch Diagram
Model: #SE45w

SE45w Specifications
SE45w 15
Winch Parts List
No.
Part #
Description
Qty
1
450100-C
Motor Assembly
1
2
450001
Coupling, 1
1
3
450002
Spring, Coupling
1
4
450003
Coupling, 2
1
5
450200A-BF
Drum Assembly
Black Flat
1
6
450004-BF
Gear Housing / End
Bearing Black Flat
1
7
450005-A
Gear Ring
1
8
450006
Gear Carrier Assembly,
Output
1
9
450007
Gear Carrier Assembly,
Intermediate
1
10
450008
Gear Carrier Assembly,
Input
1
11
450009
Gear-Input, Sun
1
12
450010
Gear, Fixed
1
13
250021
Clutch Bushing
1
14
250002-B
Washer Φ6, Flat
Black Zinc
6
15
450011-B
Bolt M6x25 Black Zinc
4
16
450012-B
Bolt M6x100 Black Zinc
2
17
450013
Seal
2
18
450014
Friction Washer
2
19
450015
Retaining Ring
1
20
450016
O-Ring Seal
1
21
450017
Drum Bushing
2
22
400018
Hexagonal Shaft
1
23
400008-B
Tie Bar Φ10 Black Zinc
2
24
451000
Synthetic Cable 15/64”
x 50ft
1
25
SE-HOOK
¼” Clevis Hook Black Zinc
1
26
250030-B
Strap-Black
1
27
250032-B
Bolt M8x25 Black Zinc
4
28
250063-B
Washer Φ8, Locking
Black Zinc
4
29
250070-B
Washer Φ8, Flat
Black Zinc
4
30
100695
Wide Fairlead Bracket
Black Flat
1
31
250033-B
Bolt M10x20 Black Zinc
2
32
250036-B
Locking Nut M10
Black Zinc
2
33
SE-WRF
Roller Fairlead
Black Flat & POM Rollers
1
34
400015-B
Winch Wires
2
35
450016-B
Battery Wires
2
36
400010-BF
Tie Bar Φ8 Black Flat
1
37
450026-B
Bolt M4x25 Black Zinc
2
38
450027-B
Washer Φ4, Flat Black Zinc
2
39
ATV-MR
Handle Bar Remote
1
40
250062
Wire Tap
2
No.
Part #
Description
Qty
41
250061
Terminal Protector
8
42
250045-BF
Handlebar Switch Clamp
Black Flat
2
43
250046-BF
Handlebar Switch
Extender Black Flat
1
44
250047-BF
Handlebar Switch
Mounting Angle Black Flat
1
45
250048-B
Bolt M5x25 Black Zinc
4
46
250049-B
Washer Φ5, Flat Black Zinc
5
47
250050-B
Washer Φ5, Locking
Black Zinc
3
48
250051-B
Bolt M5x18 Black Zinc
1
49
250052-B
Nut M5 Black Zinc
3
50
250053-B
Screw #6-32x9/32”
Black Zinc
4
51
250054-B
Washer Φ6, Locking
Black Zinc
2
52
ATV-CONT
Contactor
1
53
ATV-SCHS
Split Cable Hook Stopper
1
54
250065-B
Screw M6x25 Black Zinc
4
55
250066-B
Washer Φ6, Flat Black Zinc
4
56
250067-B
Washer Φ6, Locking
Black Zinc
4
57
250068-B
Locking Nut M6
Black Zinc
6
58
250069-B
Screw m6x1.0x20
Black Zinc
2
59
250071-B
Nut M5 Black Zinc
2
60
250059-B
Hand Remote Assembly
Black
1
61
250064
Hand Remote 3-Pin
Connector
1
62
450028-B
Bolt M8x30 Black Zinc
4
63
250035-B
Washer Φ10, Locking
Black Zinc
2
64
400032-BF
UTV Switch Bracket Black
1
65
400033-B
Bolt M6x16 Black Zinc
2
66
400034-B
Threading Screw M4x12
Black Zinc
2
67
450030-B
Washer Φ4, Flat Black Zinc
2
68
450031
Cross Recess Pan Head
Screw M6 x 8
1
69
450029
Spring
1
70
GB2760BB06
002-SS
Radial Ball Bearing 6002
Sealed
1
71
250019
Axis Support Bushing
1
72
450032
Cam Clutch Gear
1
73
250012
Spring
1
74
450033-BF
Clutch Cover Black Flat
1
75
GB2760BB16
002-SS
Radial Ball Bearing 16002
Sealed
1
76
250016-BF
Clutch Cap Black Flat
1
77
250011
Retaining Ring Clip
1
78
250017
Locking Washer Φ6
1
79
250018
Cap Screw M6 x 16
1

Troubleshooting
16 SE45w
Troubleshooting
Problem
Cause
Solution
Motor does not turn on
Switch Assembly not connected properly
Insert Switch Assembly all the way into
the connector.
Loose battery cable connections
Tighten nuts on all cable connections.
Contactor malfunctioning
Tap Contactor to loosen contacts. Apply
12 volts to coil terminals directly. A
clicking indicates proper activation.
Defective Switch Assembly
Replace Switch Assembly.
Broken Motor Leads. Over tightened
leads and broke internal wire connection.
May have also broken Isolator
Pull End-Cap off and check terminal solder
joint and plastic isolator. Get a
replacement End-Cap #A-CAPKIT
Defective motor
Check for voltage at armature port with
Switch pressed. If voltage is present,
Replace motor.
Water has entered motor
Allow to drain and dry. Run in short bursts
without load until completely dry.
Motor runs but Cable drum
does not turn
Clutch not engaged
Rotate clutch cap to the "Engage"
position. If problem persists, a qualified
technician needs to check and repair.
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
connections.
Clean, Tighten, or replace.
Worn Brushes
Replace Worn Brushes
Motor overheating
winch running time too long
Allow winch to cool down periodically.
Motor runs in one direction
only
Defective or stuck Contactor
Tap Contactor to loosen contacts.
Repair or Replace Contactor.
Over tightened leads and broke internal
wire connection. May have also broken
Isolator.
Pull End-Cap off and check terminal solder
joint and plastic isolator. Get a
replacement End-Cap #A-CAPKIT
Defective Wire Crimp or Bad connection
Check all connections
Defective Switch Assembly
Replace Switch Assembly.
WARNING
PLOWING ALERT
READ BEFORE USING YOUR WINCH TO LIFT A PLOW
ATV winches are one of the most widely used methods of lifting a plow. When used properly they are a
perfect match to any plow system but proper precautions and correct usage are required to prevent costly
damage.
When lifting a plow using a winch it is very important to stop the plow before its full lift height is reached.
Failure to do so will cause the winch to pull against itself and can, and most likely will, cause damage to the
winch, your plow frame and your ATV.
Please remember that winch damage such as stripped gears, broken housings and bent and damaged parts
caused by exceeding your plows lift height are not covered by warranty.
Special precautions should be taken when backing up or other instances where you may be distracted and
forget your finger is still on the power-in switch.
A little practice and common sense will ensure a trouble free plow season and prolong the life of your
equipment.