Ramsey Winch Company
OWNER'S MANUAL
Front Mount Electric Winches
Model REP 5000
12 and 24 volt available
Layer of Cable 1234 (lbs) NO 1,000 3,000 5,000
(lbs) 5,000 4,200 3,600 3,200 (kg) LOAD 450 1,350 2,260
(kg) 2,260 1,900 1,630 1,450
(FPM)
12V
15 11 8 5
(ft)*15305580
(MPM)
12V
4.6 3.4 2.4 1.5
(m)* 4 9 16 24
(FPM)
24V
20 17 12 8
(MPM)
24V
6.1 5.2 3.7 2.4
12V
45 100 155 210
24V
20 50 105 160
* Depends on cable being uniformly wound onto drum. Ramsey performance data is compiled from actual winch testing.
Amp Draw
First Layer Line Pull
Rated Line Pull Per Layer
Cumulative Cable Capacity Per
Layer 1/4" (6mm) dia. Cable
Line Speed
First Layer
Congratulations
You have purchased the finest winch available in its service
class. It features a highly efficient 3 stage planetary gear set
which transmits torque from a permanent magnet D.C. motor.
A safe positive clutch allows free spooling for quick cable
deployment. An automatic load holding brake is designed to
hold the full rated capacity of the winch. 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 ways 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 operation from your Ramsey Winch and safety procedures you
need to know before beginning use. When you follow our
guidlines 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.
Contents
Performance Specifications . . . . . . . . . . . . . . . .Front Cover
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Tips for Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Techniques of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Electrical Connections and Operation . . . . . . . . . . . . . . . . .5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Winch Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
Please Note: Ramsey REP 5000™ winches are designed for front
mount vehicle use. The winches are 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.
CAUTION: Read and understand this manual before installation and operation of winch. See Safety
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 anchor 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. Do not step over a cable, or near a cable under load.
C. Use supplied hook strap when handling hook for spooling
wire rope.
D. Do not use a vehicle to pull a load on the winch cable. This
could result in cable breakage and/or winch damage.
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 one
minute 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. Unplug the remote control switch from the winch when not
in use. A Ramsey Part No. 282053 Safety On/Off Switch is
recommended to disconnect power to the winch when not
in use.
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
on Front Cover. Shock loads must not exceed these ratings.
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 center
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.
Tips for Safe Operation
Don't 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 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 winch. After the
job is done you can unspool and rewind for a neat lay of the
cable.
Store the remote control switch 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 can cause
cable damage. Always use a sling or chain of suitable
strength. When double lining during stationary winching, do
not attach hook to winch mounting plate.
Observe your winch while winching, if possible, while standing at a safe distance. Make sure cable does not jam.
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.
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.
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 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.
Your winch will not only pull your vehicle up or ease it 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.
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.
Use the vehicle wheel power to help the winch, but don’t overtake the winch line. Plan your pull. You can’t always hook up
and pull out in one step. Examine all the areas for anchoring
possibilities as well as leverage situations, direction, and goal.
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.
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.
For a direct pull of 2000 lbs., hitch truck to a tree or
solid anchor, and take out of gear.
To double the pull, use 2-part line and tie off to chassis.
Take out of gear.
3
Installation
The winch shown in this owners manual is solely and
exclusively designed for vehicle mounted, non-industrial
applications. All other applications will void warranty.
It is very important that the winch be mounted on a flat
surface so that the three major sections (the motor end,
the cable drum, and the gear housing end) are properly
aligned. It is recommended that Ramsey kits be used to
mount the winch. They are designed to align the winch
and distribute up to the full rated load evenly, to avoid
possible damage to the winch or vehicle.
NOTE: If a recommended mounting kit is not used, a kit
of equal design should be used.
The following winch mounting channels are available for
mounting the REP 5000 winch:
#408052 - Short (23.63") black
#408120 - Medium (30.00") black
#408101 - Long (36.00") black
It is recommended that a Ramsey mounting channel be
used with all non-Ramsey mounting kits.
Attach fairlead to channel using hardware furnished with
winch.
Attach winch to channel. Place (4) flatwashers and nuts
into pockets of winch mounting feet and thread capscrews with lockwashers through mounting holes in
channel and into hardware in winch feet (see figure at
right).
Substitution of attaching hardware items (bolts, nuts or
washers) different from those supplied with your winch
and mounting kit can lead to failure causing damage or
serious injury (use SAE grade 5 bolts or better and
torque to 34 ft.lbs.).
Place end of wire rope through fairlead and attach cable
hook. Use clevis pin and cotter pin (see figure at right).
Operating Instructions
The winch clutch allows rapid unspooling of the wire
rope for hooking onto the load or anchor point. The
clutch is operated by the shifter tab located on the gear
housing end of the winch as follows:
1. To DISENGAGE the clutch, move the clutch shifter
tab to the “OUT” position. Wire rope may now be
free-spooled off the drum.
2. To ENGAGE the clutch, move the clutch shifter tab
into the “IN” position. The winch is now ready for
pulling.
4
Electrical Connections and Operations
For normal self recovery work, your existing electrical
system is adequate. Your battery must be kept in good
condition. A fully charged battery and proper connections are essential. Run the vehicle engine during winching operations to keep the battery charged.
The solenoid assembly reverses the direction of cable
drum rotation. Route red and black battery cable up to
the battery.
CAUTION: BE SURE BATTERY CABLES ARE NOT
DRAWN TAUT ACROSS ANY SURFACES WHICH COULD POSSIBLY DAMAGE THEM.
Connect red cable to positive (+) battery terminal and black cable to negative (-) battery terminal.
The remote control switch is water proof. It has push
button stations on either side. It is designed this way to
prevent quick winch reversals which lead to solenoid failure. Make sure the motor has stopped fully before
reversing direction of winch. To actuate winch simply
plug remote control switch into receptacle in black solenoid cover of winch. Run winch forward and reverse to
check connection and to determine winch operating
directions. Snap appropriate “IN” and “OUT” disc into
proper thumb cavity. The switch is also color coded to
aid you in not having to guess at the direction your
winch will run. DO NOT LEAVE THE SWITCH PLUGGED
IN WHEN WINCH IS NOT IN USE.
Maintenance
All moving parts in the winch are permanently lubricated
with high temperature lithium grease at the time of
assembly. Under normal conditions factory lubrication
will suffice.
Lubricate the cable periodically using light penetrating oil.
Inspect for broken strands and replace if necessary with
Ramsey part number listed in Parts List. If the cable
becomes worn or damaged, it must be replaced.
Corrosion on electrical connections will reduce performance or may cause a short. Clean all connections especially in remote control switch and receptacle. In salty
environments use a silicone sealer to protect from corrosion.
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 help dissipate any moisture buildup in
the motor. This should be performed at regular intervals
(such as with each oil change on your vehicle). Note:
Refer to Troubleshooting Guide if the motor has been
submerged.
Cable Installation
1. Unwind the new cable by rolling it out along the
ground to prevent kinking. Remove old cable and
observe the manner in which it is attached to the
cable drum flange.
2. Before installing the new cable assembly, make sure
the end of the cable is squarely cut and wrapped
with tape to prevent fraying. Form a short 90° bend
approximately 1/2” long on the end of the cable.
3. Position the cable drum so that the large 13/32”
diameter hole in the motor end side of the drum
flange is approximately on the top.
4. Insert the bent end of the cable into the 13/32” hole
in the drum flange and carefully run the winch in the
“reel in” direction approximately 3/4 revolution until
the 1/4” diameter threaded hole in the drum flange is
at the top.
5. Secure the cable to the drum flange using the cable
anchor and capscrew shown in the parts drawing.
Securely tighten the capscrew, but do not over-tighten.
6. Wind 5 wraps of cable onto the drum. Winch on the
rest of the cable by pulling in a light load to keep tension constant. Allow the cable to swivel by using a
length of chain or a swivel block between the cable
hook and the load.
5
CONDITION POSSIBLE CAUSE CORRECTION
Defective solenoid or stuck solenoid
Jar solenoid assembly to free contacts. Confirm defective
solenoid by applying 12 or 24 volts as appropriate to coilterminal (it should make an audible click when energized).
Defective remote control switch
To confirm, disengage winch clutch, remove remote control
switch from the socket and jump pins at 8 and 4 o'clock. Motor
should run. Jump pins at 8 and 10 o'clock. Motor should run.
MOTOR RUNS EXTREMELY
HOT
Long period of operation Cooling-off periods are essential to prevent overheating.
Insufficient battery.
Check battery terminal voltage under load. If 10 volts or less for a
12 volt battery or 20 volts or less for a 24 volt battery, replace or
parallel another battery to it.
Bad connection Check battery cable for corrosion; clean and grease.
Insufficient charging system Replace with larger capacity charging system.
MOTOR RUNS, BUT DRUM
DOES NOT TURN
Clutch not engaged
If clutch engaged but symptom still exists, it will be necessary to
disassemble winch to determine cause and repair.
Defective solenoid or stuck solenoid
Jar solenoid assembly to free contacts. Confirm defective
solenoid by applying 12 or 24 volts as appropriate to coilterminal (it should make an audible click when energized).
Defective remote control switch
To confirm, disengage winch clutch, remove remote control
switch from the socket and jump pins at 8 and 4 o'clock. Motor
should run. Jump pins at 8 and 10 o'clock. Motor should run.
Defective motor.
If solenoids operate, confirm defective motor by checking for
voltage at armature post; replace motor.
Loose connections
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 not disengaged
Check clutch operation according to nameplate. Make sure clutch
shifter knob is fully at "OUT" position.
Winch not mounted squarely
causing end bearing to bind drum
Check mounting to see that the installation instructions on page 4
have been followed.
Some or all of the (6) 414861 flat
head capscrews attaching the
479007 ring gear retainer are too
tight.
Remove the gear housing cover, 413018, and all gears from
inside the gear housing. Disengage the clutch and check to see
that the ring gear will rotate by hand. If it will not, using a hex
wrench, slightly loosen all six capscrews and then snugly retighten them in criss-cross pattern, but do not over-tighten. The
ring gear must rotate by hand. Re-assembly the winch.
CABLE DRUM WILL NOT
FREESPOOL OR IS
DIFFICULT TO FREESPOOL
Troubleshooting Guide
MOTOR RUNS IN ONLY ONE
DIRECTION
MOTOR RUNS, BUT WITH
INSUFFICIENT POWER OR
WITH LOW LINE SPEED
MOTOR WILL NOT
OPERATE
6
4
13
23
24
16
8
33
37
37
37
27
7
34
17
22
34
21
5
20
1
26
39
12
36
35
19
32
14
3
15
25
11
2
10
13
38
29
30
6
31
28
18
REP 5000
Item
No.
Qty. Part No. Description
Item
No.
Qty. Part No. Description
1 1 247004 Gear Carrier Assembly - Input 19 6 414861 Capscrew - 1/4-20NC x 3/4 Flat Soc Hd Nylok
2 1 247005 Gear Carrier Assembly - Intermediate 12v 20 6 416273 Screw - #6-32NC x 3/8
1 247007 Gear Carrier Assembly - Intermediate 24v 21 4 418018 Nut - 1/4-20NC Hx Elastic Stop
3 1 247006 Gear Carrier Assembly - Output 22 4 418035 Nut - 3/8-16NC Hx reg Z/P
4 1 251110 Switch Assembly - 12 ft 23 4 418177 Lockwasher - 3/8 Med Sect Z/P
5 1 251169 Cable Assembly - 80' x 1/4" (6mm) Dia. 24 4 418181 Washer - 3/8 ID SAE Flat Z/P
6 1 278039 Solenoid Assembly - 12v 25 1 442207 Gasket - Gear Housing Cover
1 278040 Solenoid Assembly - 24v 26 1 444048 Gear - Output Sun
7 1 296285 Brake Assembly 27 2 448061 Tie Bar
8 1 332143 Drum - Cable 28 1 448071 Cable Anchor
9 1 334143 Gear - Ring 29 1 458131 Motor/End Bearing Assembly - 12v
10 1 334145 Gear - Intermediate Sun - 12v 1 458132 Motor/End Bearing Assembly - 24v
1 334147 Gear - Intermediate Sun - 24v 30 1 470050 Roll Pin - 1/8 Dia x 5/8 Lg
11 1 334153 Gear - Input Sun 31 1 470053 Roll Pin - 1/8 Dia x 3/8 Lg
12 1 338249 End Bearing 32 1 477002 Locking Ring
13 2 412056 Bushing - Drum 33 1 477013 Cam Ring
14 1 412061 Bushing - Shaft 34 2 477004 Ring - Half
15 1 413018 Cover - Gear Housing 35 1 479007 Retainer - Ring Gear
16 4 414316 Capscrew - 3/8-16NC x 1-1/4 Hx Hd GR5 Z/P 36 6 494077 Spring
17 4 414829 Capscrew - 1/4-20NC x 1 Soc Button Hd F/B 37 3 518020 Thrust Washer
18 1 414830 Capscrew - 1/4-20NC x 3/8 Button Hd 38 1 518027 Thrust Disc
39 1 452005 Shifter Lever
REP 5000 Parts List (12v and 24v)
Included with REP 5000R
Mounting hardware included with winch.
Roller Fairlead
#251151
Included with REP 5000H
Mounting hardware included with winch.
Hawse Fairlead
#251150
7
5
1
15
17
6
8
13
19
5
1
15
10
11
3
16
18
16
2
4
10
11
Item
No.
Qty. Part No. Description
1 1 289090 WIRE ASSY - #10 GA BLACK 3"
2 1 289091 WIRE ASSY - FEM CONN TO SOL
3 1 289092 WIRE ASSY - #6 GA BLACK 3-1/2"
4 2 289095 WIRE ASSY - #6 GA BLACK 6"
5 2 364002 STRAP - COPPER
6 1 408087 BRACKET - SOLENOID MTG
7 1 413019 COVER - SOLENOID
8 4 416216 SCREW - #10-24NC X 1/2 RDHD Z/P
9 2 416227 SCREW - #10-24NC X 3/4 TRUSS F/B
10 6 418004 NUT - HEX #10-24NC X Z/P
11 4 418140 WASHER - #10 FLAT
12 2 418141 LOCKWASHER - #10 MED SECT Z/P
13 1 418165 WASHER - 5/16 SHAKE PROOF Z/P
14 1 430013 CONNECTOR - FEMALE RECEPTACLE
15 2 440071 TERMINAL TAB
16 2 440110 SOLENOID - 12V
2 440114 SOLENOID - 24V
17 1 440111 STRAP - CONNECTING
18 1 440112 WIRE ASSY - #4 GA RED BATTERY 60"
19 1 440113 WIRE ASSY - #4 GA BLACK BATTERY 60"
20 1 482029 COVER - FEMALE RECEPTACLE
Solenoid Assembly Parts List
278039 - 12V
278040 - 24V
8
NOTES
NOTES
NOTES
Ramsey Winch Company
PO Box 581510 - Tulsa OK 74158-1510
Phone: (918) 438-2760
Fax: (918) 438-6688
Visit us on the web at http://www.ramsey.com
OM-914145-0107-B
Loading...