Troubleshooting - KFI U45-R2 Operator's Manual

MODEL #U45-R2 – 4,500LB (2041KG) WINCH

TroubleshooTInG

Problem
Motor does not run,
Contactor makes a click
sound.
Motor does not run, NO
click sound from Contactor.
Motor runs, Spool turns in
one direction only.
Motor runs, Spool does
NOT turn.
Spool turns, but no
movement from Cable
Motor runs slowly or
without normal power.
Motor overheating
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
Cause
Incorrect Wiring
Incorrect Wiring
Loose battery cable connections
Motor Issue
Water has entered motor
Brake Spring installed backwards
Incorrect Wiring
Switch Ignition Wire
Contactor malfunctioning
Switch malfunctioning
Incorrect Wiring
Defective or stuck Contactor
Defective Switch assembly
Contactor malfunctioning
Clutch not engaged
Broken Coupler / stripped Shaft
Cable not attached to Spool
Insufficient current or voltage.
Loose or corroded battery cable
connections
Worn Brushes
Winch running time too long
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 (#SE-A-CAPKIT)
Contact KFI Technical Support.
Allow winch to cool down periodically.
KFI Products Website Support:
Common installation, maintenance, and troubleshooting
guides are available on our website.
https://www.kfiproducts.com/support.html
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TROUBLESHOOTING