Introduction
This manual provides essential instructions for the safe and effective installation, operation, and maintenance of your KFI Products AS-50 5000lb Assault Winch. Please read this manual thoroughly before using the winch to ensure proper function and to prevent injury or damage. Keep this manual for future reference.
Safety Information
WARNING: Failure to follow these safety instructions can result in serious injury or death.
- Always wear heavy-duty gloves when handling winch cable.
- Never exceed the rated line pull of the winch.
- Keep hands and clothing clear of the cable, hook, and fairlead during operation.
- Do not operate the winch if the cable is frayed, kinked, or damaged.
- Ensure the vehicle's engine is running during winching to maintain battery power.
- Never use the winch to lift people or objects over people.
- Always use a tree saver strap or anchor point that can withstand the load.
- Disengage the clutch when not in use and ensure the remote control is stored safely to prevent accidental operation.
- Inspect the winch and all components before and after each use.
Product Overview
The KFI Products AS-50 5000lb Assault Winch is designed for reliable pulling power in various applications. Key components include the winch motor, gear housing, drum with synthetic cable, fairlead, clutch, and remote control.
An image showing the KFI Products AS-50 5000lb Assault Winch. The winch unit is black with 'KFI ASSAULT AS-50' branding. It features a synthetic cable spooled around the drum, a clutch mechanism on the right side labeled 'ENGAGE' and 'RELEASE', and a mounting bracket. To the left, a wired remote control with 'IN' and 'OUT' buttons is visible. Below the winch, a black strap with 'KFI WINCH' in white lettering is attached to the hook.
Specifications
- Rated Line Pull: 5000 lbs
- Motor: 12V DC, 1.22 HP permanent magnet
- Gear Ratio: 180:1
- Synthetic Cable: 15/64" D x 38' L (Smoke Color)
- Winch Dimensions: 13.9" L x 4.45" D x 4.76" H
- Item Weight: 6 pounds
- Product Dimensions: 17.3 x 13 x 7 inches (packaging/overall)
- Model: AS-50
- Manufacturer: KFI Products
Setup and Installation
Installation should be performed by individuals with mechanical aptitude. Refer to your vehicle's specific mounting instructions if available. The winch features a standard 4-hole mounting design.
General Installation Steps:
- Mounting: Securely attach the winch to a suitable mounting plate or bumper using appropriate hardware. Ensure the mounting surface can support the winch's maximum pulling force.
- Electrical Connections:
- Connect the winch motor leads to the solenoid/contactor.
- Connect the solenoid/contactor to the vehicle's battery (positive and negative terminals) using heavy-gauge cables. Ensure all connections are tight and corrosion-free.
- Install the remote control wiring according to the provided diagram, typically connecting to the solenoid/contactor.
- Fairlead Installation: Mount the fairlead to the winch mounting plate, ensuring the cable can pass through smoothly without obstruction.
- Cable Spooling: Carefully spool the synthetic cable onto the drum under light tension. Ensure the cable is wound evenly and tightly.
- Test Operation: After installation, perform a brief test run of the winch (in and out) to confirm all connections are correct and the winch operates smoothly.
Operating Instructions
Before Operation:
- Ensure the vehicle's engine is running to provide adequate power.
- Inspect the winch cable, hook, and anchor point for damage or wear.
- Clear the winching area of bystanders and obstacles.
Engaging the Clutch:
To free-spool the cable, rotate the clutch knob to the "RELEASE" position. This disengages the gear train, allowing the drum to rotate freely. To engage the clutch for winching, rotate the knob to the "ENGAGE" position. Ensure the clutch is fully engaged before applying load.
Winching Operation:
- Prepare the Cable: With the clutch in "RELEASE", pull out the desired length of synthetic cable and attach the hook to a secure anchor point using a tree saver strap or shackle.
- Engage Clutch: Rotate the clutch knob to "ENGAGE".
- Operate Remote: Use the wired remote control to spool the cable "IN" or "OUT". Apply power in short bursts to control the load smoothly.
- Monitor: Continuously monitor the cable, hook, and anchor point during winching. Stop if any component shows signs of stress or failure.
- Respool: Once the winching operation is complete, carefully respool the cable onto the drum under light tension, ensuring it winds evenly.
Maintenance
- Cable Inspection: Regularly inspect the synthetic cable for fraying, cuts, or damage. Replace damaged cable immediately.
- Electrical Connections: Check all electrical connections for tightness and corrosion. Clean terminals as needed.
- Winch Housing: Keep the winch housing clean and free of dirt and debris.
- Lubrication: The winch is designed with sealed components. Consult KFI Products for specific lubrication requirements if any.
- Storage: When not in use, ensure the cable is fully spooled, the clutch is disengaged, and the remote control is disconnected or stored to prevent accidental activation.
Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| Winch does not operate. | No power, loose electrical connections, faulty remote, solenoid issue. | Check battery connections, ensure vehicle engine is running, test remote, inspect solenoid wiring. |
| Winch operates slowly or weakly. | Low battery voltage, undersized wiring, excessive load. | Ensure battery is fully charged, check for proper wire gauge, reduce load if possible. |
| Cable does not free-spool. | Clutch not fully disengaged, mechanical obstruction. | Ensure clutch is in "RELEASE" position, check for debris around the drum. |
| Winch makes grinding noise. | Damaged gears, motor issue. | Discontinue use immediately. Contact KFI Products support for inspection and repair. |
Warranty and Support
For warranty information, technical support, or replacement parts, please contact KFI Products directly. Refer to the official KFI Products website or your purchase documentation for the most current warranty terms and contact details.
KFI Products Contact Information: (Please refer to official KFI Products resources for current contact details.)
