Keeper KW7.5RM Quick reference guide

Assembly & Operating Instructions
KW7.5RM
7500 lbs 12V DC Electric Winch
CAUTION!
READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION
AND OPERATION OF THIS PRODUCT.
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™
OWNER’S MANUAL

2 3
The Danger, Warnings, Cautions, and Instructions discussed in this instruction manual cannot cover all possible
conditions and situations that may occur. It must be understood by the operator that common sense and caution are
factors which cannot be built into this product, but must be supplied by the operator.
Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This notation is also used to alert against unsafe practices.
Note: Indicates additional information in the installation and operation procedures of your winch.
KW7.5RM 7500 lb 12V DC Electric Winch
PLEASE READ ALL SAFETY PRECAUTIONS AND WARNINGS BEFORE
INSTALLING AND USING THE WINCH!
You will need this manual for the safety warnings and cautions, assembly instructions, operating procedures,
maintenance procedures, trouble shooting, parts list, and diagram. Keep your invoice with this manual. Write the invoice
number on the inside of the front cover. Keep both this manual and your invoice in a safe, dry place for future reference.
THIS PRODUCT IS NOT INTENDED FOR LIFTING / HOISTING
Winch Dimensions and Mounting Bolt Pattern
FIGURE 1
THIS PRODUCT IS NOT INTENDED FOR LIFTING / HOISTING
KW7.5RM SPECIFICATIONS
Part Number:
Rated Line Pull:
Motor - Series Wound:
Control:
Switching:
Gear Train:
Gear Reduction:
Clutch (Freespooling):
Brake:
Wire Rope:
Drum Diameter/Length:
Fairleads:
Battery Leads:
Battery:
Application:
Finish:
Weight:
Warranty
KW75122 - with Wireless
7,500 lbs., 3,402 kg.
4.5 hp 12V DC
Handheld Pendant Switch on 15' Lead with Built-in High Density Light
High Duty Cycle Integrated Sealed Solenoid Pack and KTA14126 Wireless
High Efciency 3-Stage Planetary Gear Set
180:1
Lift and Turn
Mechanical Automatic
72' (22.00 m) of 5/16ths (8.0 mm) Diameter Galvanized Wire Rope with
Looped Thimble, Latched Clevis Hook and Red Warning Area.
Diameter - 2.5" (63.5 mm) / Length - 6.6" (152 mm)
4-way Roller
2 Gauge: Front Mount 2’ motor leads with Quick Connect and 6’harness with Quick Connect
Minimum 650 CCA
General Utility Load Recovery/Trailer, Truck, Tractor, Equipment
High-Gloss gray Powder Coat over Undercoating
76 lbs. / 35 kg.
Limited Lifetime: See Warranty
! !
WARNING
Thank you for purchasing your KEEPER®Winch.
PLEASE READ ALL INSTRUCTIONS, PAYING SPECIAL ATTENTION TO THE
SAFETY INSTRUCTIONS.
Your KEEPER®Winch has been designed and manufactured to provide years of trouble-free operation.
When requesting information in regard to this winch, please give the following information:
Winch Part #____________________ and Serial number___________________________________.
(Please write down this information here for future reference.) (Found on Motor Housing)
Please read and understand this Owner’s Manual prior to installing and operating this product.
PAY PARTICULAR ATTENTION TO THE GENERAL SAFETY INFORMATION.
Your Winch is a powerful machine. If used unsafely or improperly, there is a possibility that property damage and/or
personal injury can result. Your safety ultimately depends on your caution when using this product.
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DANGER
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CAUTION
Safety Precautions
Designed for Utility Recovery, and General Utility Winching Applications.
THIS PRODUCT IS NOT INTENDED FOR LIFTING/HOISTING
! !
CAUTION
Introduction
Save this Manual
6.6” (166.5mm)
17.15” (435.5mm)
5.34” (135.5mm)
4-M10
6.3” (160mm)
4.5” (114mm)
7.56” (192mm)
3.23”
(82mm)
9.79” (238.7mm)
64
10.36” (263.15mm)
MOUNTING BOLT PATTERN
6.6” (166.5mm) x 4.5” (114mm)

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1. READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING YOUR WINCH. After installing the Winch, practice
using it before the need arises. NEVER ALLOW PERSONS UNFAMILIAR WITH THIS PRODUCT TO OPERATE IT.
ALWAYS WEAR SAFETY GLASSES AND LEATHER GLOVES WHILE WORKING WITH MACHINERY.
2. DO NOT EXCEED RATED CAPACITY OF THE
WINCH. DO NOT OVERLOAD! DO NOT ATTEMPT
PROLONGED PULLS OF HEAVY LOADS!
Overloads can damage the Winch and/or the wire
rope and create unsafe operating conditions.
FOR LOADS OVER 75% OF THE RATED WINCH
CAPACITY, WE RECOMMEND THE USE OF A
PULLEY BLOCK (KWA14550 not included) TO
DOUBLE LINE THE WIRE ROPE (Figure 3). This
reduces the load on the Winch, the strain on the
wire rope and electrical system.
3. Never apply a load to your winch with the wire rope fully extended. Keep at least 5 wraps on the winch drum.
4. THE VEHICLE ENGINE SHOULD BE RUNNING DURING WINCH OPERATION. If winching is performed with the engine
turned off, the battery may be too weak to restart the engine.
5. DO NOT operate your vehicle to assist the Winch in pulling the load. The combination of the Winch and vehicle pulling
together could overload the wire rope and the Winch.
6. WHEN IN USE, ALWAYS STAND CLEAR OF WIRE ROPE,
HOOK AND WINCH.
7. INSPECT WIRE ROPE AND EQUIPMENT FREQUENTLY.
A FRAYED, KINKED OR FLATTENED WIRE ROPE NEEDS
TO BE REPLACED IMMEDIATELY. Periodically check the
Winch installation to ensure that all bolts are tight.
8. USE HEAVY LEATHER GLOVES when handling wire rope.
DO NOT LET WIRE ROPE SLIDE THROUGH YOUR GLOVED
OR UNGLOVED HANDS. ALWAYS USE THE HAND-SAVER
STRAP when guiding the wire rope in or out (Figure 4).
9. NEVER WINCH WITH LESS THAN 5 WRAPS OF WIRE
ROPE AROUND THE WINCH DRUM since the wire rope
end fastener may NOT withstand full load.
10. KEEP CLEAR OF WINCH, TAUT WIRE ROPE AND HOOK WHEN OPERATING WINCH. NEVER STEP OVER TAUT
WIRE ROPE.
11. NEVER HOOK THE WIRE ROPE BACK ONTO ITSELF. This will damage the wire rope. Use a KEEPER 02953 3” X 6’
WINCH STRAP, sling, tree saver or other recommended accessory for this type connection (Figure 5).
12. NEVER USE YOUR WINCH FOR LIFTING OR
MOVING PEOPLE!
13. YOUR WINCH IS NOT INTENDED FOR OVER HEAD
HOISTING OPERATIONS.
14. AVOID CONTINUOUS PULLS FROM EXTREME ANGLES.
This will cause the wire rope to pile and jam in the Winch,
causing damage to the wire rope or Winch (Figure 6).
FIGURE 4
This KEEPER®Winch is equipped with a series wound, 12 Volt DC motor and is designed for INTERMITTENT GENERAL
DUTY USE. This electric winch is similar to most electric motor driven tools and should not be allowed to become overly
hot. Stop winch if motor starts to labor or end of motor becomes hot to the touch. Stop winching and allow motor to cool
down. Minimum electrical requirements are 60 amp alternator and battery with 650 CCA (cold cranking amp) capacity.
This Winch (FIGURE 2) is not intended for use in lifting/hoisting applications and the manufacturer does not warrant it
to be suitable for such use. The Freespool Clutch disengages the gearbox to allow the wire rope to be pulled out without
using electric power. A Remote Switch with 15’ lead and wireless switch allows a wide variety of mounting options.
General Description
SLOPE* 10% (5.7º) 20% (9º) 40% (18º) 60% (27º) 100% (45º)
Lbs. 48,450 32,400 20,900 16,150 13,600
Kgs. 22,980 14,700 9,480 7,320 6,170
Rolling Load Capacities (1st Layer)
*SLOPE: a one (1') rise over ten (10') feet in length equals a GRADE of 10%. A 10% grade is equal to a 5.71º incline angle. A 100%
grade equals a 45º angle of incline.
Double Line Single Line
FIGURE 3
Sling
FIGURE 5
General Safety Warnings & Cautions
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Wireless Switches (2)
and Plug-in Receiver
15’ Handheld Switch
72” Battery Leads with
Quick Connects
2” Class III
Receiver Mount
Easy Plug in and
Play Wireing
Winch
Mounting
Plate
Wire Rope
Tension Plate
Easy Carry Handle
4-Way
Roller Fairlead
Line Pull Lbs. (kg) Line Speed FPM (MPM) Motor Amp Dr Pull By Layer Lbs. (kg)
0 35 (10.7) 25 1 @ 7500 (3402)
500 ( 227) 32 ( 9.8) 37 2 @ 6525 (2960)
1500 ( 680) 25 ( 7.6) 155 3 @ 5547 (2516)
3500 (1588) 15 ( 4.6) 230 4 @ 4715 (2139)
5500 (2495) 11 ( 3.4) 298
7500 (3402) 9 ( 2.7) 356
12V DC PERFORMANCE

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THIS PRODUCT IS NOT INTENDED FOR LIFTING / HOISTING
FIGURE 6
THIS PRODUCT IS NOT INTENDED FOR LIFTING / HOISTING
FIGURE 8
Winch Installation
Correct installation of your Winch is required for proper operation. Installation should be on a at surface
following the bolt pattern shown in FIGURE 1.
Read and follow directions carefully to ensure proper Winch alignment and trouble free operation.
This Winch MUST be mounted with the wire rope in the under-wind direction ( FIGURE 8).
MUST use only genuine Keeper Winch replacement Wire Rope part number 72’ x 5/16” KWA14613.
! !
WARNING
Improper mounting could damage your Winch and void your warranty.
General Safety Warnings & Cautions (Continued)
15. NEVER OBSCURE THE WARNING INSTRUCTION
LABELS ON THE WINCH.
16. It is highly recommended to lay a heavy cloth (such as
a blanket or tarp) over the wire rope when pulling heavy
loads (Figure 7). If a wire rope failure should occur, the
cloth will act as a damper and help prevent the wire
rope from whipping. If mounted on the front of a vehicle
then raise the hood for further protection.
17. Always operate Winch with an unobstructed view of
the Winching operation.
18. Equipment such as hooks, pulley blocks, straps, etc.
should be sized for winch capacity and periodically
inspected for damage that could reduce their strength.
19. NEVER RELEASE FREESPOOL CLUTCH WHEN
THERE IS A LOAD ON THE WINCH.
20. NEVER WORK ON OR AROUND THE WINCH DRUM
WHEN WINCH OR WIRE ROPE IS UNDER LOAD.
21. DO NOT OPERATE WINCH WHEN UNDER THE
INFLUENCE OF ANY DRUGS OR ALCOHOL.
22. ALWAYS DISCONNECT WINCH POWER LEADS TO BATTERY BEFORE WORKING ON OR AROUND THE WINCH DRUM
so that Winch cannot be turned on accidentally.
23. When moving a load, slowly take up wire rope slack until it is taut. Stop, recheck all Winching connections. Be sure
the hook is properly seated. If a nylon sling is used, check the attachment to the load.
24. When using a vehicle mounted Winch to move a load, place the vehicle transmission in neutral (never in Park), set
vehicle hand-brake, and chock all wheels.
25. DO NOT USE THE WINCH TO HOLD LOADS IN PLACE. Use other means of securing loads such as KEEPER
brand tie-down straps.
26. USE ONLY FACTORY APPROVED SWITCHES, ADAPTERS, REMOTE CONTROLS AND ACCESSORIES. Use of non-
factory approved components may cause injury or property damage and could void your warranty.
27. DO NOT MACHINE OR WELD ANY PART OF THE WINCH. Such alteration may weaken the structural integrity of the
Winch and could void your warranty.
28. This is a 12 Volt DC Winch. CONNECT ONLY TO 12 VOLT DC BATTERY. DO NOT CONNECT WINCH TO EITHER 110V
OR 220V AC CURRENT AS WINCH WILL BURN OUT OR FATAL SHOCK WILL OCCUR. This will void warranty.
29. Never allow shock loads to be applied to Winch or wire rope.
30. USE EXTREME CAUTION WHEN WINCHING A LOAD UP AND DOWN A RAMP OR INCLINE.
31. Keep people, pets, and property clear of Winching path, front, rear and sides for 80’.
32. NEVER EXCEED RATING OF YOUR RECIEVER HITCH.
FIGURE 7
Sling
! !
Step 1 Mount the Winch to the mounting kit base
plate, proper mounting bolts are supplied. If
using the Roller Fair Lead included, install now to
mounting plate. You may need to remove one or
more of the rollers on the roller fairlead to pass
through the wire rope. After doing this you may
now attach the clevis hook. See
(Figure 8) for order and bolt direction.
! !
WARNING
DO NOT EXCEED THE RATING OF YOUR RECIEVER HITCH
Cable
Tension Plate
Mounting Plate
2” Class III
Receiver
4-Way
Roller Fairlead
Wire Rope
Under-wind
Direction

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WARNING
USE ONLY 3/8” -16 UNC BOLT AND NUTS WITH MINIMUM ISO GRADE 8.8.
WARNING
Batteries contain gases, which are ammable and explosive. WEAR EYE PROTECTION DURING INSTALLATION AND
REMOVE ALL METAL JEWELRY. Do not lean over battery while making connections.
WARNING
Ensure that the wiring harness does not interfere or come in contact with any hot or moving engine, suspension, steering, braking or
exhaust parts.
MINIMUM ELECTRICAL REQUIREMENTS ARE 60 AMP ALTENATOR AND BATTERY WITH 650 CCA (COLD
CRANKING AMP) CAPACITY.
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Circuit
Breaker
Red 2GA Positive
Battery Terminal
Lead
Step 3 Connect Black 2 GA battery lead to the negative motor terminal located on the bottom of the motor and also
connect the Black 2 GA ground lead from the solenoid pack to the same negative motor terminal.
Step 4 Connect the other terminal end of the Black 2 GA battery lead to the negative battery terminal. If longer
wiring harness is required then purchase KWA14607.
Step 5 Remove the dust cover on the plug receptacle and insert the plug end of the handheld pendant switch. The plug
end is keyed and will t easily onto the socket only one way. DO NOT FORCE.
Step 6 Lift and turn the freespool clutch handle to the Disengage position (See
FIGURE 12). Pull 5 feet of wire rope off
the drum. Return the freespool clutch handle back to Engaged position. Activate the Winch cable in and out by
momentarily pressing the handheld pendant switch to check drum rotation direction. The switch is labeled “IN”
for winching in and “OUT” for winching out. When released the switch will automatically go to the off position.
IF THIS DOES NOT OCCUR THEN REMOVE THE HAND HELD PLUG FROM THE RECEPTACLE.
Step 7 You are now ready to winch. Practice winching operations by freespooling cable out and winching in under low
loads. Make sure all wraps are wound on tight and close against the previous wrap. Plan some tests in advance
and learn to watch and listen. Recognize the sound of a light steady pull, a heavy pull and sounds caused by load
jerking or shifting. You will gain condence. ALWAYS WEAR SAFETY GLASSES, LEATHER GLOVES AND USE THE
HAND SAVER STRAP (
FIGURE 4).
Step 2 Follow electrical connection diagram
(
FIGURE 9). Bolt the circuit breaker to the
terminal end of the Red 2 GA battery lead that is
factory connected to the sealed solenoid
switching pack. Now connect the circuit
breaker to the positive battery terminal.
Black 2 GA
Ground Lead
Black 2GA
Negative
Battery Lead
Winch Installation (Continued)
The handheld pendant switch activates a solenoid that
activates power to the winch motor.
To connect the handheld pendant switch, remove the cover
on the plug receptacle and insert the plug end of remote
switch (See Figure 10). The plug on the pendant control
cord is keyed and will t into the socket only one way.
The switch trigger returns to the “Off” position when
released. To change direction, move the toggle in the other
direction. (See Figure 10).
The red push button activates the LED work light.
! !
CAUTION
The switch assembly must be kept free of dirt and
moisture to ensure safe operation.
Pendant Operation
Wireless Operation (Remote KTA14126)
Plug the receiver into the ve pin plug located on the winch control box (Where the hand held control usually plugs into).
Please take care to line up the keyed notch on the inside of the receiver with the keyway on the outside of the plug (See
FIGURE 11). Your are now ready to remotely operate the winch.
Make sure notch ts into key way as misalignment will damage the unit and void warranty.
Please note that the unit is programmed for a 1 second delay in both starting and stopping. This may represent a 6” to 8”
travel in the wire rope.
Your wireless remote is now installed. Enjoy your wireless remote switch winching experience.
FIGURE 10
IN
OUT
FIGURE 11
Wire
Rope
OUT
Wire
Rope
IN
Wireless
Receiver
Key
Slot
Key
Slot

10 11
Operation Instructions for KTA14126 Wireless Remote
Your wireless remote will operate the winch from up to 100+ feet depending on
weather conditions as rain, snow or fog can shorten the distance.
1. To activate the sender PRESS BOTH the “Winch In” (A) (Arrow towards the winch
drum) and “Winch Out” (B) (Arrow facing away from the drum) buttons at the same
time for 5 seconds or until the indicator light (C) turns red. Refer to Fig.1
2. Plug the receiver (Fig. 2) into the female plug receptacle on the top of the solenoid
box on the winch (Same place you would normally plug your handheld switch
control) Fig. 3
3. You are now ready to winch. When you press either the “Winch In” or “Winch Out”
PLEASE NOTE – If the switch is not used for 5 minutes it will go into sleep mode for
safety and also extend battery life. To revive the sender you will need to repeat step 1.
Wireless remote operation
FIG. 1
FIG. 2
FIG. 3
C
A
B
If you ever have to replace your senders or receiver you can program the new units to
function with the old units by following the procedure below.
1. Unscrew and remove the two metal screws at the plug side of the receiver. Fig. 4
2. Gently pull out the receiving assembly. Fig. 5
3. MAKE SURE THE WINCH IS IN THE FREEWHEEL POSITION
4. Plug the assembly into the female plug receptacle on top of the winch solenoid control
box. The same position as shown in Fig 3.
5. Push down on the Smart Button. Fig 6
6. Fig.1) button in for at
least 2 seconds before releasing and then push the “Winch In” (A in Fig. 1) button in for
two seconds before releasing. The movement of the motor will indicate that you have
successfully reprogrammed the senders.
7. Once you have determined that the units are working, unplug the receiving assembly
from the control box and carefully slide it back into the housing and secure it with the
two screws.
8. You are ready to use the reprogrammed Wireless. **Remember that your winch is in the
freewheel position.
Reprogramming senders to a receiver
FIG. 4
FIG. 5
FIG. 6
Smart Button
Operation Instructions for KTA14126 Wireless Remote

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Your winch incorporates an automatic load holding brake.
After winching in a load, this mechanism holds the load,
up to the rated capacity of the winch. While powering out
the load, the winch controls the rate of speed by applying
the brake in proportion to the amount of the load in the
winch cable. This results in heavier loads powering-out
more slowly than lighter loads.
Similar to the friction-type brakes in your automobile
which can generate heat if used for a long period of time,
the winch brake can generate heat if used to power-out a
load for a long period of time.
Brake Operation
To ensure optimimum winch performance, always
limit powering-out a load to 2 minutes and allow the
brake to cool for 15 minutes before continuing
to winch.
Under normal use, the brake mechanism should not
require any adjustment. Should the brake fail to hold a
load or maintain a constant rate of speed during power-
out operation, the brake spring may be worn and
require replacement.
Freespool Operation
1. Lift and rotate the clutch lever to the “Disengaged”
position as shown in Figure 12. If there is a load on the
wire rope, the clutch lever may not turn easily. DO NOT
FORCE THE CLUTCH LEVER. Release tension on the
wire rope by jogging out some of the wire rope, then
try releasing the clutch.
2. Pull out the wire rope and secure to anchor or load.
3. Check that there are at least ve (5) wraps of wire rope
left on the drum.
4. Re-engage the drum by lift and rotating the clutch
lever to the “Engaged” position, apply power to engage
clutch (see Figure 12).
FIGURE 12
ENGAGE
DISENGAGE
! !
CAUTION
Lever must be in the engaged position and locked
before winching.
1. KEEP A TIGHTLY WOUND WIRE ROPE DRUM. Keep the wire rope tightly and evenly wound on the drum all the time. Do
not allow the wire rope to become loosely wound. A loosely wound drum allows a wire rope under load to work its way
down into the layers of wire rope on the drum. When this happens, the wire rope may become wedged within the body
of the windings damaging the wire rope. A good practice is to rewind the wire rope under tension after each use. Apply
tension using hand saver strap ( FIGURE 3) and ALWAYS wear safety glasses and leather gloves.
2. DO NOT ALLOW WINCH MOTOR TO OVERHEAT. Keep the duration of pulls as short as possible. If the motor becomes
uncomfortably hot by touching, stop winching and allow the motor to cool down.
KEEP THE VEHICLE ENGINE RUNNING TO RECHARGE THE BATTERY during the cooling break.
3.
USE A PULLEY BLOCK FOR HEAVY LOADS. To maximize Winch and wire rope life, use a pulley block (not included)
to double line heavier loads. (See FIGURE 3) (See part number KWA14550)For maximum performance use pulley
block is load is greater than 75% of the rated capacity of the winch. For the KW7.5RM use a pully block once you
exceed 5,600 lbs. Always use a pulley block (part number KWA14550) that is rated twice the capacity of the winch.
CAUTION If the winch motor stalls, do not continue to apply power.
4. The pull required to start a load moving is often much greater than the pull required to keep it moving.
AVOID FREQUENT STOPS AND STARTS DURING THE PULL.
5. PREVENT KINKS IN WIRE ROPE BEFORE THEY OCCUR (
FIGURE 13).
a. This is the start of a kink. Wire rope should be straightened.
b. Wire rope was pulled and loop has tightened into a kink. Wire rope is
now permanently damaged and MUST be replaced.
c. Result of kinking is that each strand pulls a different amount causing
strands under greatest tension to break and reduce load capacity of
wire rope. The wire rope MUST be replaced. Use only genuine
Keeper Winch replacement part number KWA14613 72’ X 5/16”
! !
WARNING
! !
FIGURE 14
Winch Drum
Before each use, check mounting bolts for tightness, inspect cable for damage. Inspect remote control assembly for any
damage. Periodically use a clean, dry towel to remove dirt and debris from winch housing.
Lubrication: The gear box is permanently lubricated. Do not attempt to disassemble the gear box. This will void
your warranty.
Maintenance & Repair
Never Substitute a heavier or lighter wire rope. Never use
rope made of any other materials other than wire.
Use only recommended Keeper replacement wire rope,
72’ x 5/16” KWA14613.
Attach wire rope to the drum using screw provided
( FIGURE 14).
! !
WARNING
Extending the Life of Your Winch
Replacing The Wire Rope
FIGURE 13

14 THIS PRODUCT IS NOT INTENDED FOR LIFTING / HOISTING
Symptom Possible Causes Corrective Action
Motor will not
operate or runs in
one direction only
Motor runs
extremely hot
Motor runs but with
insufficient power or
line speed
Motor runs but drum
does not turn
Winch runs backwards
1. Broken wires or bad battery
connection
2. Switch inoperative
3. Damaged winch
4. Damaged solenoid
5. Circuit breaker malfunction
1. Long period of operation
2. Damaged during operation
1. Weak/Low battery
2. Battery to Winch wire too long
3. Poor battery connection
4. Poor ground
5. Damaged motor
Clutch not engaged
1. Battery wires reversed
2. Switch wires reversed
3. Switch installed incorrectly
1. Check for poor connection(s) and that all wiring is tight
and clean
2. Check that switch wires are connected properly to
the solenoid
3. Replace or repair
4. Replace solenoid
5. Replace circuit breaker
1. Allow to cool
2. Replace or repair
1. Recharge or replace battery. Check charging system.
2. Use only supplied wires. If increase in length is needed,
drop down wire size to 2 or 3 AWG.
3. Check battery terminals for corrosion. Clean as required.
4. Check and clean connections
5. Replace or repair
Engage clutch
1. Recheck wiring
2. Recheck wiring
3. Check switch installation
Troubleshooting