Congratulations
You have purchased the finest winch available in its service
class. The TR5000 features a highly efficient 3 stage planetary gear set. The TR5000 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.
This winch 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 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 TR5000 model winch is designed
for general 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
it 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
Electric Winch Model TR5000
12 Volt
Contents
Performance Chart ................................Front Cover
Safety Precautions ................................................2
Tips for Safe Operation..........................................2
Techniques of Operation ........................................3
Installation ............................................................3
Maintenance..........................................................4
Operating Instructions ..........................................4
Trouble Shooting Guide..........................................5
Winch Parts List ................................................6-7
Warranty................................................Back Cover
CAUTION: Read and understand this manual before installation and operation of winch.
See Safety Precautions.
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)*10203550
(MPM)
12V
4.5 3.3 2.4 1.5
(m)* 3 6.1 10.7 15.2 Amp Draw
12V
45 100 155 230
* Depends on cable being uniformly wound onto drum. Ramsey performance data is compiled from actual winch testing.
First Layer Line Pull
Rated Line Pull Per Layer
Cumulative Cable Capacity Per
Layer 1/4" (6mm) dia. Cable
Line Speed
First Layer
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. Winch clutch should be disengaged when winch is not in
use and fully engaged when in use.
G. Modification, alteration or deviation to the winch should
only be made by Ramsey Winch Company.
H. 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.
I. 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.
J. Note: Do not use winch in hoisting applications due to
required hoist safety factors and features.
K. Do not exceed maximum line pull ratings shown in tables
on Front Cover. Shock loads must not exceed these ratings.
L. 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.
M. Note: Do not use the winch to hold a load on a trailer while
towing. Secure the load to the trailer with straps or tiedowns. The winch is designed to hold the load only while
winching.
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.
3
Installation
The TR5000 winch must be mounted on a level surface, with
the cable underwound as shown in the drawing below. Use
the dimensional drawing below to determine a mounting location. Use (4) 3/8-16NC SAE Grade 5 or better bolts to mount
the mounting plate to the surface where the TR5000 will be
installed. Tighten these bolts to 23 ft-lbs (17 Nm) torque.
Connect the Red battery lead from the solenoid to the Positive
(+) terminal of a 12V battery or other 12V power source.
Connect the Black battery lead to the Negative (-) terminal.
The amp draw for the winch is shown in the table on the first
page. Make sure that the battery or power source is sufficient
to operate the winch.
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.
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.
15.28
388,2
83,3
3.28
6,4
.25
13.40
340,3
69,0
2.72
138,1
5.44
138,1
5.44
.45
11,5
*
*
13,5
.53
5.50
139,7
DRUM FLANGE
Ø
197,8
7.79
3.75
95,2
8.28
210,3
6.88
174,8
3.88
98,4
CABLE SPOOLS
"IN" UNDER DRUM
DRUM
2.50
63,5
Ø
174,6
6.88
3.25
82,6
DIMENSIONS SHOWN ARE INCHES OVER MILLIMETERS
FOUR
Ø.406 HOLES IN A 5.437±.015 x 5.437±.015
(138,1mm x 138,1mm) RECTANGULAR PATTERN.
MOUNTING BOLT PATTERN:
*
Operating Instructions
The winch clutch allows rapid unspooling of the wire rope for
hooking onto the load or anchor point. The clutch shifter tab is
located on the gear-housing end of the winch and operated 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 to the
"IN" position. The winch is now ready for pulling.
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 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 the
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 periodic intervals (such as with each oil
change to your vehicle). Note: Refer to the Troubleshooting
Guide if the motor has been submerged.
Cable Installation
It is not necessary to disassemble the winch or remove it
from where it is mounted to replace the cable.
Disengage the clutch. Remove the old cable and observe the
manner in which it is attached to the cable drum. Loosen but
do not remove the cable anchor.
Unwind the new cable by rolling it out along the ground, to
prevent kinking.
Before installing the new cable assembly, make sure the end
of the cable is squarely cut and wrapped with tape to prevent
fraying.
Feed the taped end of the cable through the fairlead and under
the drum. The cable should go between the drum and the
spring tensioner.
Slide the cable to the end of the slot on the drum under the
cable anchor.
Tighten the cable anchor securely to the drum so that the
cable is held securely.
Wind 5 wraps of cable onto the drum by rotating the drum.
Wind on the rest of the cable by pulling in a light load to keep
the tension constant. Allow the cable to swivel by using a
length of chain or a block between the cable hook and the
load.
4
5
Ramsey Electric Winches Troubleshooting Guide
Defective solenoid or stuck
solenoid
Jar solenoid to free contacts. Check by applying 12 volts to coil terminal
(it should make an audible click when energized)
Defective remote control switch
Disengage winch clutch, remove remote control switch plug 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, replace or
parallel another battery to it
Bad connection Check battery cables 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 to free contacts. Check solenoid by applying 12 volts to coil
terminal (it should make an audible click when energized)
Defective remote control switch
Disengage winch clutch, remove remote control switch plug from the
socket and jump pins at 8 and 4 o’cloc
k. Motor should run. Jump pins at
8 and 10 o’clock. Motor should run.
Defective motor If solenoids operate, check 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 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 (allen) wrench, slightly
loosen all the capscrews and then snugly re-tighten them in criss-cross
pattern, but do not over-tighten. The ring gear must rotate by hand. Reassemble the winch.
MOTOR RUNS IN ONLY ONE
DIRECTION
MOTOR RUNS, BUT WITH
INSUFFICIENT POWER, OR
WITH LOW LINE SPEED
MOTOR WILL NOT OPERATE
CABLE DRUM WILL NOT
FREESPOOL OR IS DIFFICULT
TO FREESPOOL
6
TR5000
TR5000 PARTS LIST
Item
No.
Qty. Part No. Description
Item
No.
Qty. Part No. Description
1 1 247004 Gear Carrier Assembly - Input 22 2 418001 Nut - #10-32 GR2 Z/P
2 1 247005 Gear Carrier Assembly - Intermediate 23 4 418018 Nut - 1/4-20NC Hx Elastic Stop
3 1 247006 Gear Carrier Assembly - Output 24 4 418035 Nut - 3/8-16NC Hx reg Z/P
4 1 251110 Switch Assembly - 12 ft 25 4 418181 Washer - 3/8 ID SAE Flat Z/P
5 1 278039 Solenoid Assembly 26 1 442207 Gasket - Gear Housing Cover
6 1 296612 Brake Assembly 27 1 444048 Gear - Output Sun
7 1 332201 Drum - Cable 28 1 448092 Cable Anchor
8 1 334143 Gear - Ring 29 2 448103 Tie Bar
9 1 334145 Gear - Intermediate Sun 30 1 256125 Motor/End Bearing Assembly
10 1 334153 Gear - Input Sun 31 1 470050 Roll Pin
11 1 338249 End Bearing 32 1 477002 Locking Ring
12 1 408331 Mounting Plate 33 1 477013 Cam Ring
13 2 412056 Bushing - Drum 34 2 477004 Ring - Half
14 1 412061 Bushing - Shaft 35 1 479007 Retainer - Ring Gear
15 1 413018 Cover - Gear Housing 36 6 494077 Spring
16 4 414829 Capscrew - 1/4-20NC x 1 Soc Button Hd F/B 37 1 494121 Spring Plate
17 1 414830 Capscrew - 1/4-20NC x 3/8 Button Hd 38 1 494122 Spring Plate
18 6 414861 Capscrew - 1/4-20NC x 3/4 Flat Soc Hd Nylok 39 3 518020 Thrust Washer
19 4 414923 Capscrew - 3/8-16NC x 1-1/4 Flat Hd Z/P 40 1 518027 Thrust Disc
20 2 416012 Screw - #10-32UNF x 1/2 Flat Hd Z/P 41 1 251274 Cable Assembly - 50' x 1/4" Dia.
21 6 416273 Screw - #6-32NC x 3/8 42 1 452005 Shifter Knob
42
19
41
13
6
34
24
34
32
4
23
9
2
40
21
10
39
15
14
39
3
33
11
8
27
1
39
26
7
13
20
12
17
28
18
35
36
37
38
22
30
29
25
16
31
5
7
Solenoid Assembly 278039 Parts List
Note: All unidentified hardware comes
supplied with the solenoid.
5
1
15
17
6
8
13
19
5
1
15
10
11
3
16
18
16
2
4
10
11
Item
No.
Qty.
Req'd
Part No. Description
1 2 264002 Copper Strap
2 1 289090 Wire Assembly - #10 Ga. Black Ground
3 1 289091 Wire Assembly - Female Conn to Solenoid
4 1 289092 Wire Assembly - #6 Ga. Black 3-1/2"
5 2 289095 Wire Assembly - #6 Ga. Black 6"
6 1 408087 Solenoid Bracket
7 1 413019 Solenoid Cover
8 4 416216 Screw - #10-24NC x 1/2 Slot Z/P
9 2 416227 Screw - #10-24NC x 3/4 F/B
10 6 418004 Nut - #10-24NC Reg Z/P
11 4 418140 Washer - #10 Flat Z/P
12 2 418141 Lockwasher - #10 Med
13 1 418165 Washer - 5/16 Shake Proof
14 1 430013 Connector - Female Receptacle
15 2 440071 Terminal Tab
16 2 440110 Solenoid 12V
17 1 440111 Strap
18 1 440112 Wire Assembly - Battery #4 Ga. 60" Red
19 1 440113 Wire Assembly - Battery #4 Ga. 60" Black
20 1 482029 Cover - Female Receptacle
Limited Lifetime Warranty
Ramsey Winch offers a limited lifetime warranty for each new
Ramsey winch against manufacturing defects in workmanship and
materials on all manufactured 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 purchaser 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 materials and workmanship.
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 limited 1-year warranty.
Battery isolators carry a 90-day limited warranty.
The obligation under this warranty, statutory or otherwise, is limited
to the replacement or repair at the manufacturers factory, or at a
point designated by the manufacturer, of such part as shall appear
to 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 labor or 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.
Impor
tant 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 only for 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 to improve any product through
changes in design or 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 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.
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 any problems with your winch, please follow instructions for prompt service on
all warranty claims.
RAMSEY WINCH COMPANY
P.O. BOX 581510 • TULSA, OKLAHOMA 74158-1510 • USA
PHONE (918)438-2760 • FAX (918)438-6888 •
http://www.ramsey.com
OM-914136-0107-EPrinted in U.S.A.
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