Congratulations
You have purchased the finest winch available in its service
class. It features a strong worm and gear drive to provide load
reversing protection. An exclusive semi-automatic RAM-LOK
TM
clutch disengaes for free-spooling and is spring loaded for
positive engagement. It was designed and manufactured to
provide you with the utmost in utility. As with any device that
combines power and movement in its use, there are dangers if
improperly used. At the same time, there are easier and faster
was for getting the job done if certain precautions are taken
first.
Please read this manual carefully. It contains useful ideas
in obtaining the most efficient operations from your Ramsey
Winch and safety procedures you need to know before beginning use. When you follow our guidelines for operation, your
Ramsey Winch will give you many years of satisfying service.
Thank you for choosing Ramsey. You will be glad you have
one working for you.
Please Note: Ramsey RE 12000 Series winches are designed
for front mount vehicle use. It is not designed for and should
not be used in industrial applications (car haulers/carriers,
wreckers, hoisting, etc.) and Ramsey does not warrant them
to be suitable for such use. Ramsey makes a separate, complete line of winches for industrial/commercial use. Please
contact the factory for further information.
Ramsey Winch Company
OWNER’S MANUAL
Front Mount Electric Winch
RE 12000
Special for Military H-1 Hummvee
Layer of Cable 1234
(lbs) 12,000 10,000 8,600 7,500
(kg) 5,450 4,540 3,900 3,400
(ft)*204070100
(m)* 6 12 21 30
(lbs) NO 2,000 4,000 6,000 8,000 10,000 12,000
(kg) LOAD 900 1,810 2,720 3,630 4,540 5,450
Line Speed First Layer (FPM) 14 7 5 4 3.5 2.5 2
(MPM) 4.2 2.1 1.5 1. 2 1 0.7 0.6
Amp Draw 24V 30 50 85 110 135 160 190
* Depends on cable being uniformly wound onto drum.
Rated Line Pull Per Layer
Cumulative Cable
Capacit y P er Layer
(3/8" - 9mm - dia. Cable)
Line Pull Firs t Lay er
Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Tips for Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Techniques of Operation . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Electrical Connections and Operations . . . . . . . . . . . . . . .4
Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Winch Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
CAUTION: Read and understand this manual before installation and operation of winch. See precautions.
2
Safety Precautions To Guard
Against Possible Injury…
A minimum of five wraps of cable around the drum
barrel is necessary to hold the rated load. Cable
clamp is not designed to hold the load.
A. Keep yourself and others a safe distance to the side of
the cable when pulling under load.
B. Don't step over a cable, or near a cable under load.
C. Use supplied hook strap when handling hook for spooling
wire rope.
D. Don't move the vehicle to pull a load on the winch cable.
This could result in cable breakage.
E. Use a heavy rag or gloves to protect hands from burrs
when handling winch cable.
F. Apply blocks to wheels when vehicle is on an incline.
G. Winch clutch should be disengaged when winch is not in
use and fully engaged when in use.
H. Modification, alteration, or deviation to the winch should
only be made by Ramsey Winch Company.
I. Keep the duration of your pulls as short as possible. If
the motor becomes uncomfortably hot to the touch, stop
and let it cool for a few minutes. Do not pull more than
two minutes at or near rated load. Do not maintain power
to the winch if the motor stalls. Electric winches are for
intermittent usage and should not be used in constant
duty applications.
J. Disconnect the remote control switch from the winch
when not in use. A Ramsey Part # 282053 safety on-off
switch in your vehicle is recommended.
K. Note: Do not use winch in hoisting applications due to
required hoist safety factors and features.
L. Do not exceed maximum line pull ratings shown in
tables.
M. To respool correctly, it is necessary to keep a slight load
on the cable. This is accomplished by (wearing gloves)
holding the cable with one hand and the remote control
switch with the other, starting as far back and in the cen-
ter as you can, walking up keeping load on the cable as
the winch is powered in. Do not allow the cable to slip
through your hand and do not approach the winch too
closely. Turn off the winch and repeat the procedure until
all the cable except a few feet is in. Disconnect the
remote control switch and finish spooling in cable by
rotating the drum by hand with clutch disengaged. On
hidden winches, spool in cable under power but keep
hands clear.
Tips for Safe Operation
Do not underestimate the potential danger in winching operations. Neither should you fear them. Do learn the basic dangers and avoid them.
The uneven spooling of cable, while pulling a load, is not a
problem, unless there is a cable pileup on one end of drum. If
this happens, reverse the winch to relieve the load and move
your anchor point further to the center of the vehicle. After the
job is done you can unspool and rewind for a neat lay of the
cable.
Store the remote control switch inside your vehicle where it
will not become damaged. Inspect it before you plug it in.
When ready to begin spooling in, plug in remote control switch
with clutch disengaged. Do not engage clutch with motor running.
Never connect the hook back to the cable. This causes cable
damage. Always use a sling or chain of suitable strength as
shown in the illustration.
Observe your winch while winching, if possible, while standing
at a safe distance. If you use vehicle drive to assist, stop and
get out every few feet to assure the cable is not piling up in
one corner. Jamming cable can break your winch.
Do not attach tow hooks to winch mounting apparatus. They
must attach to vehicle frame.
When double lining during stationary winching, the winch hook
should be attached to the chassis of the vehicle.
Since the greatest pulling power is achieved on the innermost
layer of your winch, it is desirable to pull off as much line as
you can for heavy pulls (remember, you must leave 5 wraps
minimum on the drum). If this is not practical, use a snatch
block and double line arrangement (see illustration).
Neat, tight spooling avoids cable binding, which is caused
when a load is applied and the cable is pinched between two
others. If this happens, alternately power the winch in and out
a few inches. Do not attempt to work a bound cable under
load, free by hand.
3
Techniques of Operation
The best way to get acquainted with how your winch
operates is to make a few test runs before you actually
need to use it. Plan your test in advance. Remember you
hear your winch as well as see it operate. Get to recognize the sound of a light steady pull, a heavy pull, and
sounds caused by load jerking or shifting. Soon you will
gain confidence in operating your winch and its use will
become second nature with you.
When pulling a heavy load, place a blanket, jacket or tarpaulin over the cable five or six feet from the hook. It will
slow the snap back in the event of a broken cable. Also
open the vehicle hood for additional protection.
For basic self-recovery, anchor to a tree or heavy rock.
When anchoring to a tree, always use a tree trunk protector.
Stakes driven in solid earth and chained together make a
good anchor point for self-recovery when no solid
anchor point is available.
For a solid anchor, bury a log with earth or sand or place
it in a deep ravine.
Use the vehicle wheel power to help the winch, but do
not overtake the winch line. Plan your pull. You cannot
always hook up and pull out in one step. Examine all the
areas for anchoring possibilities as well as leverage situations, direction, and goal.
Your winch will not only pull you up or ease you down a
steep grade, it will also pull another vehicle or a load
while your vehicle is anchored in a stationary position.
The following sketches show you a few techniques.
For direct pull of 2,000 lbs, hitch truck to a tree or solid
anchor, and take out of gear.
To double the pull, use 2-par t line with snatch block and
tie off to chassis. Take out of gear.
Winches equipped with cable guide fairleads can pull
from several directions. Pull from an angle only to
straighten up the vehicle-otherwise you can damage
structural members or other parts of your vehicle and
cause excess cable buildup on one end of the winch
drum.
Installation
This winch is designed to be used exclusively in the
Ramsey Military H-1 Hummvee mounting kit. Install the
winch in the H-1 Hummvee Mounting Kit P/N 295376
according to the instructions supplied with the mounting
kit.
Substitution of attaching hardware items (bolts, nuts, or
washers) different from those supplied with your winch
mounting kit can lead to failure causing damage or serious injury. Use SAE Grade 5 bolts or better.
Electrical Connections and Operations
For normal self recovery work, your existing electrical
system is adequate. For power requirements for this
winch, refer to the table on page one of this manual. Your
battery must be kept in good condition. A fully charged
battery and proper connections are essential. Run the
vehicle engine during the winching operation to keep the
battery charged.
Connect the battery cables according to the instructions
with the mounting kit. A good electrical ground is
required for proper performance.
The remote control switch is water-proof and has push
button stations on either side. It is designed this way to
prevent quick winch reversals which lead to solenoid failure. Make the winch motor has stopped fully before
reversing.
When first setting up your winch, follow the directions for
inserting the proper “IN” or “OUT” labels in the thumb
button. The switch is also color coded to aid you in not
having to guess at the direction your winch will run.
Cable Installation
1. Unwind cable by rolling it out along the ground to
prevent kinking. Securely wrap the end of the cable,
opposite hook, with plastic or similar tape to prevent
fraying.
2. Insert the end of the cable, opposite hook end,
under drum and into the 7/16” dia. hole in drum
barrel. Secure cable to drum barrel, using setscrew
furnished with winch. Tighten setscrew securely.
3. Carefully run winch in the “reel-in” direction.
Keeping tension on end of cable, spool all the cable
onto the drum, taking care to form neatly wrapped
layers.
Inspect the cable frequently. If the cable becomes frayed
with broken strands, replace immediately. Cable and
hook assemblies may be purchased from a Ramsey distributor.
Operating Instructions
The RAM-LOK
TM
semi-automatic clutch provides free
spooling and clutch engagement with the cable drum.
With the clutch disengaged, the cable can be pulled off
the drum by hand. For winching in the load, the clutch
must be fully engaged with the drum.
To disengage the clutch, run the winch in the reverse
“reel out” direction until the load is off the cable and the
cable drum stops turning. Rotate the clutch handle 90°
clockwise. The clutch is now locked out and the cable
may be pulled by hand. (NOTE: If the handle will not
rotate, run the winch momentarily in reverse to relieve
pressure on the clutch jaws.) WARNING: DO NOT
ATTEMPT TO DISENGAGE THE CABLE DRUM WHEN
THERE IS A LOAD ON THE CABLE.
To engage the clutch, rotate the handle 90° counterclockwise. Run the winch in reverse until the cable drum
starts turning. To confirm that the clutch is fully engaged,
remove the plastic plug in the top of the clutch housing
to inspect the clutch. After the winch is fully engaged, the
winch is ready for winching in the cable.
Maintenance
Check monthly the action of the clutch, making sure it is
fully engaging and disengaging with the cable drum. With
the clutch in the engaged position, remove the plastic
plug in the top of the clutch housing and observe if the
clutch is engaging. If the clutch is not fully engaging,
inspect the clutch shifter assembly parts. Check for
damage or excessive wear and replace as necessary.
Observe the jaws on both the clutch and cable drum,
checking for rounding of the driving faces. If rounding
has occurred they should be replaced immediately.
4
Spool the cable properly on the drum when storing between
each usage.
Check the oil level in the gear boxes every six months.
At the same time, check electrical connections and mounting
bolts--tighten if necessary.
Corrosion on electrical connections will reduce performance
or may cause a short. Clean all connections, especially in
remote switch receptacle. In salty environments use a silicon
sealer to protect from corrosion.
Be sure the winch has plenty of battery power available.
Replace oil annually or more often if winch is used frequently.
Fill the worm gear box with 3/4 pint of SAE 140 EP oil.
Use 1/2 pint of SAE 20 for spur gear box. Apply cup grease to
lube fitting at top of clutch housing. Should winch be submerged for a brief period, drain oil, flush and replace oil in
gear boxes, and grease all fittings (See Troubleshooting Guide
below).
To minimize corrosion of the internal motor components that
may occur due to condensation, power the winch in or out
periodically. Energizing the motor will generate heat, which will
dissipate any moisture buildup in the motor. This should be
performed at periodic intervals (such as with each oil change
of your vehicle).
Lubricate cable periodically using light penetrating oil. Inspect
for broken strands and replace if necessary. Install new cable
per “Cable Installation” on page 4.
Troubleshooting Guide
CONDITION POSSIBLE CAUSE CORRECTION
MOTOR RUNS IN ONE
DIRECTION ONLY.
(1) Inoperative solenoid or stuck solenoid. (1) Jar solenoid to free contacts. Check by applying 24 volts to coil terminal (it
should make an audible click when energized).
(2) Inoperative remote control switch. (2) Disengage winch clutch, remove remote control switch plug from the socket
and jump pin at 8 and 4 o’clock. Motor should run. Jump pins at 8 and 10 o’clock.
Motor should run.
MOTOR RUNS EXTREMELY
HOT
MOTOR RUNS, BUT WITH
INSUFFICIENT POWER, OR
WITH LOW LINE SPEED.
(1) Long period of operation. (1) Cooling off periods are essential to prevent overheating.
(2) Insufficient battery. (2) Check battery terminal voltage under load. If 20 volts or less, replace or parallel
another battery to it.
(3) Electrical cable from battery to winch
or ground strap from engine block to vehicle chassis too small.
(3) Must be #2 gauge or larger if longer than 15 ft.
(4) Bad electrical connections. (4) Check all connections for looseness or corrosion; tighten, clean and grease.
(5) Insufficient charging system. (5) Replace with larger capacity charging system.
MOTOR RUNS, BUT DRUM
DOES NOT TURN.
(1) Clutch not engaged. (1-4) If clutch is engaged but symptom persists, it will be necessary to disassem-
ble winch to determine cause and repair.
(2) Sheared drum shaft key.
(3) Stripped bronze gear.
(4) Parted shaft.
MOTOR WILL NOT OPERATE.
(1) Inoperative solenoid or stuck solenoid. (1) Jar solenoid to free contacts. Check by applying 24 volts to coil terminal (it
should make an audible click when energized).
(2) Inoperative remote control switch. (2) Disengage winch clutch, remove remote control switch plug from the socket
and jump pin at 8 and 4 o’clock. Motor should run. Jump pins at 8 and 10 o’clock.
Motor should run.
(3) Inoperateve motor. (3) If solenoids operate, check for voltage at armature post; replace motor.
(4) Loose connections. (4) Tighten connections on bottom side of hood and on motor.
MOTOR WATER DAMAGED. Submerged in water or water from high
pressure car wash.
Allow to drain and dry thoroughly, then run motor without load in short bursts to
dry windings.
CLUTCH INOPERATIVE OR
BINDS UP.
(1) Dry or rusted shaft. (1) Clean and lubricate.
(2) Bent yoke. (2) Replace yoke or shifter assembly.
(3) Keys pulled out of shape by overload. (3) If drum shaft keyways are rounded or damaged replace shaft and keys. If not,
file off burrs and replace keys.
CLUTCH SPRING DOES NOT
OPERATE.
Broken spring. Replace spring.
OIL LEADS FROM HOUSING (1) New seal. (1) New seals sometimes leak until seated to shaft.
(2) Seal damaged or worn. (2) Replace.
(3) Too much oil. (3) Drain excess oil per lubrication instructions above.
(4) Damaged gasket. (4) Replace.
5
No.
Quantity Part No. Description
No.
Quantity Part No. Description
1 1 251123 CABLE AND HOOK ASSY-100' X 3/8" 37 3 418040 NUT-3/8-24NF HEX REG Z/P
2 1 276056 SHIFTER ASSEMBLY 38 3 418154 WASHER-1/4 FLAT ALUM.
3 1 278028 SOLENOID ASSEMBLY 39 3 418177 LOCKWASHER-3/8 MED SECT, Z/P
4 1 251110 SWITCH ASSY-12FT LG 40 1 422017 HAWSE FAIRLEAD
5 1 289222 ASSEMBLY-WIRE, GROUND, BLACK, 132" LG 41 2 438014 DRAG BRAKE
6 1 289223 ASSEMBLY-WIRE, BATTERY CABLE, RED, 132" LG. 42 2 442184 GASKET
7 1 312443 CLUTCH BLOCK SUPPORT BRACKET 43 1 442185 GASKET
8 1 316083 BEARING CAP 44 1 442205 GASKET
9 1 324137 JAW CLUTCH 45 1 450001 KEY
10 1 328106 COVER - SPUR GEAR HOUSING 46 2 450006 BARTH KEY
11 1 328134 COVER - GEAR HOUSING 47 4 450016 BARTH KEY
12 1 332136 CABLE DRUM ASSEMBLY 48 1 456001 LUBE FITTING
13 1 334001 IDLER GEAR 49 2 456008 RELIEF FITTING
14 2 334003 SPUR GEAR 50 1 458005 MOTOR
15 1 334129 PINION GEAR 51 1 462015 O-RING
16 1 334161 GEAR R.H. 60:1 52 2 468002 REDUCER
17 1 338203 HOUSING-SPUR GEAR 53 2 468011 PIPE PLUG
18 1 338208 HOUSING-CLUTCH 54 2 468017 PIPE PLUG
19 1 338273 HOUSING-GEAR 55 1 468018 PIPE PLUG
20 1 342023 KEY 56 2 470001 DOWEL PIN
21 1 342033 KEY 57 1 470003 SPIROL PIN
22 1 356901 SHAFT-SPUR 58 1 470033 SPIROL PIN
23 1 357480 SHAFT-DRUM 59 1 472012 PLUG
24 1 358055 CLUTCH BLOCK 60 1 472013 PLUG
25 1 368001 WORM-R.H. 61 1 482013 BOOT
26 3 402001 BEARING 62 1 486009 OIL SEAL
27 2 402002 BALL BEARING 63 1 486017 OIL SEAL
28 4 412003 BUSHING 64 1 486023 OIL SEAL
29 1 412045 BUSHING 65 1 489017 SHIFTER SHAFT
30 12 414038 CAPSCREW-1/4-20NC X 3/4, HXHD,GR-5,Z/P 66 1 490003 SNAP RING
31 3 414059 CAPSCREW-1/4-20NC X 1 GR-5 HXHD Z/P 67 2 494002 SPRING
32 4 414845 CAPSCREW-1/4-20NC X 1 HXSOCHD, NYLOK 68 1 494053 SPRING
33 2 414856 CAPSCREW-1/4-20NC X 3/4 HXSOCHD Z/P 69 3 518002 THRUST WASHER
34 1 416029 SETSCREW-1/4-20 X 5/16 HXSOC, ND STRIP 70 1 518014 THRUST WASHER
35 1 416059 SETSCREW-3/8-16NC X 1/2 HXSOC HD CUP 71 2 518015 THRUST WASH
36 2 416271 SCREW-SELF TAP 1/4-20 X 3/4 HXHD,TYP F,ZP 72 1 518018 FIBER WASHER
73 9 414045 CAPSCREW-1/4-20NC X 7/8 HXHD GR-5, Z/P
RE 12000 Winch Parts List
6
789
NOTES
NOTES
Ramsey Winch Company
Post Office Box 581510
Tulsa OK 74158-1510
Phone: (918) 438-2760 Fax: (918) 438-6688
visit us at www.ramsey.com
914177-1006-B
Warranty Information
Ramsey Winches are designed and built to exacting specifications. Care and skill go into every winch we make. If
the need should arise, warranty procedure is outlined on the back of your self-addressed postage paid warranty
card. Please read and fill out the enclosed warranty card and send it to Ramsey Winch Company. If you have problems with your winch, please follow instructions for proper service on all warranty claims.
Limited Lifetime Warranty
Ramsey Winch offers a limited lifetime warranty for each new Ramsey con-
sumer/RV winch against manufacturing defects in workmanship and materials on all mechanical components.
Warranty registration cards for each winch must be submitted at the time of
purchase or within 30 days. Warranty will only be valid for the original purchase of the winch and installed on the vehicles with which they were originally registered.
New cable assemblies are warranted against defects in workmanship and
materials. No warranty applies after initial use.
All Ramsey mounting kits and other accessories carry a 1-year limited warranty against defects in material and workmanship.
Chrome finish warranted for one year against manufacturing defects.
Cracking, scratching, or corrosion caused by winching not covered by warranty.
This warranty is void if winch is used in commercial/industrial applications
other than front mount self-recovery.
Electrical components consisting of motors, solenoids, wiring, wire connectors and associated parts carry a 1-year limited warranty. Battery isolators
carry a 90-day limited warranty.
An optional extended 2-year limited warranty for all electrical components
may be purchased.
The obligation under this Warranty, statutory or otherwise, is limited to the
replacement or repair at the manufacturer’s factory, or at a point designated
by the manufacturer, upon inspection of such part, to have been defective in
material or workmanship. This Warranty does not obligate Ramsey Winch
Company to bear the cost of transportation charges in connection with the
replacement or repair of defective parts, nor shall it apply to a product upon
which repairs or alterations have been made, unless authorized by the manufacturer, or for equipment misused, neglected, or improperly installed.
IMPORTANT NOTICE: To the fullest extent permitted by applicable law,
the following are hereby excluded and disclaimed: 1. All warranties of
fitness for a particular purpose; 2. All warranties of merchantability;
3. All claims for consequential or incidental damages. There are no
warranties that extend beyond the description that appears on the
face hereof.
Some states do not allow the above exclusions or disclaimers in consumer transactions and as such this disclaimer/exclusion may not
apply to your particular case.
To the extent such warranties of fitness for a particular purpose or merchantability are deemed to apply to this product, they exist for only so long as
the express limited warranty elsewhere set forth is in existence.
Ramsey Winch Company makes no warranty in respect to accessories, same
being subject to the warranties of their respective manufacturers.
Ramsey Winch Company, whose policy is one of continuous product
improvement, reserves the right improve any product through changes in
design and materials as it may deem desirable without being obligated to
incorporate such changes in products of previous manufacture.
If field service at the request of the buyer is rendered and the fault is found
not to be with Ramsey Winch Company’s product, the buyer shall pay the
time and expense cost of the field representative. Bills for service, labor, or
other expenses which have been incurred by the buyer without express
approval or authorization by Ramsey Winch Company will not be accepted.
This warranty gives you specific legal rights and you may also have other
legal rights which vary from state to state.
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