Ramsey Winch Company
OWNER'S MANUAL
Front Mount Electric Winches
Model REP 5000 12 and 24 volt available
Layer of Cable |
|
1 |
2 |
3 |
4 |
|
Rated Line Pull Per Layer |
(lbs) |
5,000 |
4,200 |
3,600 |
3,200 |
|
(kg) |
2,260 |
1,900 |
1,630 |
1,450 |
||
|
||||||
Cumulative Cable Capacity Per |
(ft)* |
15 |
30 |
55 |
80 |
|
Layer 1/4" (6mm) dia. Cable |
(m)* |
4 |
9 |
16 |
24 |
First Layer Line Pull |
(lbs) |
NO |
1,000 |
3,000 |
5,000 |
||
(kg) |
LOAD |
450 |
1,350 |
2,260 |
|||
|
|
||||||
|
(FPM) |
12V |
15 |
11 |
8 |
5 |
|
Line Speed |
(MPM) |
12V |
4.6 |
3.4 |
2.4 |
1.5 |
|
First Layer |
(FPM) |
24V |
20 |
17 |
12 |
8 |
|
|
(MPM) |
24V |
6.1 |
5.2 |
3.7 |
2.4 |
|
Amp Draw |
|
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.
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
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.
2
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
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