Ramsey REP 5000 User Manual

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