Ramsey Winch UTV HONCHO 5000 User manual

OM 914257-0314-A
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 motor. A safe positive clutch allows free spooling for
quick cable deployment. Your Ramsey 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 guide-
lines 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 UTV 5000 winches are designed primarily for ATV/UTV use. This winch is not designed to 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.
CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF
WINCH. SEE SAFETY PRECAUTIONS.
Ramsey Winch Company
OWNER’S MANUAL
UTV HONCHO 5000 Winch
NOTE: Fairlead does not attach directly to winch.
123456
(lbs) 5,000 4,200 3,600 3,200 2,800 2,600
(kg) 2,270 1,900 1,630 1,450 1,270 1,180
(Ō) 5 15 30 40 55 60
(m) 1.5 4.5 9 12.1 16.7 18.2
(lbs) 1,000 3,000 5,000
(kg) 454 1,363 2,272
(FPM) 39 31 8 6
(MPM) 12.1 9.7 2.6 2.1
(12V) 72.8 180 295 420
Layer of Cable
Rated Line Pull
Per Layer
CumulaƟve Cable
Capacity Per Layer*
NO
LOADLayer
Line Speed First
Layer
Amp Draw
Line Pull First
*Depends on cable being
uniformly wound onto drum.

Performance SpeciĮcaƟons ………………………………………………………. cover
Safety PrecauƟons ………………………………………………………. 1
Tips for Safe OperaƟon ………………………………………………………. 2
Techniques of OperaƟon ………………………………………………………. 2
General InstallaƟon ………………………………………………………. 3
Toggle Switch InstallaƟon ………………………………………………………. 3
OperaƟng InstrucƟons ………………………………………………………. 4
Maintenance ………………………………………………………. 4
Cable InstallaƟon ………………………………………………………. 4
Trouble ShooƟng Guide ………………………………………………………. 5
Winch Parts List ………………………………………………………. 7-8
Solenoid Parts List (Pendant) ………………………………………………………. 9
Solenoid Parts List (Remote) ………………………………………………………. 10
Warranty ………………………………………………………. 11
TABLE OF CONTENTS

1
Safety Precautions To Guard
Against Possible Injury.....
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 UTV 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 UTV 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 uncomfort-
ably hot to the touch, stop and let it cool for a
few minutes. Do not pull more than one min-
ute at or near the rated load. Do not main-
tain power to the winch if the motor stalls.
Electric winches are for intermittent usage
and should not be used in constant duty
applications.
J. Do not use winch in hoisting applications
due to required hoist safety factors and fea-
tures.
K. Do not exceed maximum line pull ratings
shown in tables. Shock loads must not
exceed these ratings.
L. To respool correctly, it is necessary to keep
a slight load on the cable. Do not allow the
cable to slip through your hand and do not
approach the winch too closely. When all
the cable except a few feet is in, stop and
finish spooling in cable by rotating the drum
by hand with clutch disengaged. Always
use hook strap to hold hook when spooling.
SAFETY PRECAUTIONS

2
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.
Observe spooling of cable onto drum. Side
pulls can cause cable to pileup at one end of
the drum. To correct uneven stacking, spool
out that section of the cable and move it to the
other end of the drum and continue winching.
Uneven spooling which causes cable pileup can
interfere with the winch tie rods causing dam-
age to the winch.
Never connect the hook back to the cable. This
causes cable damage. Always use a sling or
chain of suitable strength.
Observe your winch while winching. If possible,
while standing at a safe distance. If you use
UTV drive to assist, stop and get off 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 UTV frame.
When double lining during stationary winching,
the winch hook should be attached to the chas-
sis of the UTV. 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. If this is not practical,
use a snatch block and double line arrange-
ment.
Neat, tight spooling avoids cable binding which
is caused when a load is applied and the cable
is pinched between two other wraps of cable.
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 recog-
nize the sound of a light steady pull, a heavy
pull, and sounds caused by load jerking or shift-
ing. Soon you will gain confidence in operat-
ing your winch and its use will become second
nature with you.
Your winch will not only pull your UTV up or
ease your UTV down a steep grade, it will also
pull another UTV or a load while your UTV is
anchored in a stationary position.
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 UTV 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 anchor-
ing possibilities as well as leverage situations,
direction, and goal.
Winches equipped with cable guide fairleads can
pull from several directions. Pull from an angle only
to straighten up the UTV--otherwise you can damage
structural members or other parts of your UTV and
cause excess cable buildup on one end of the winch
drum.
For basic self-recovery, anchor to a tree or heavy rock.
When anchoring to a tree, always use a tree trunk pro-
tector.
OPERATION TIPS AND TECHNIQUES

3
General Installation
The winch shown in this owners manual
is solely and exclusively designed for UTV
mounted, non-industrial applications. All other
applications will void warranty.
Install Winch and Mounting Kit according to
instructions supplied with Mounting Kit. Install
winch and roller fairlead to mounting kit using
hardware supplied with winch. Tighten
mounting bolts to 34 ft-lbs torque.
It is very important that the winch be
mounted on a flat surface, with the
cable feeding from the bottom of the
drum.
Toggle Switch Installation
Do not attach motor and battery leads until
instructed to do so.
Before beginning Installation:
• Disengage winch clutch.
• Locate and mark mounting location for
toggle switch.
1. Route red, yellow, and green wires from
solenoid to toggle switch location. Make
sure that wires are not drawn taut against
any surfaces that might damage them.
2. Drill 1/2” hole in location for toggle switch.
3. Insert switch through hole.
4. Place directional plate over switch and
secure using knurled nut. Using wrench,
tighten backup nut securely against surface
where hole was drilled. Make sure direc-
tional plate is installed in the same direction
as the toggle switch movement.
5. Place rubber boot over switch and tighten
securely.
6. Connect red wire to center spade on toggle
switch. Connect green wire to the toggle
switch terminal in the “OUT” position.
Connect the yellow wire to the toggle switch terminal position
in the “IN” position.
When finished, connect the Red battery lead
from the solenoid to the Positive (+) terminal of
the vehicle battery. Connect the Black battery
lead to the Negative (-) terminal.
Free-spool a length of cable from the winch.
Engage the clutch, and operate the toggle
switch in the IN and OUT direction and confirm
that the winch operates correctly.
If the winch spools cable in the opposite direc-
tion from what is indicated on the directional
plate, reverse the yellow and green wires.
Remote Control Switch
Installation
Connect the Red battery lead from the sole-
noid to the Positive (+) terminal of the vehicle
battery. Connect the Black battery lead to the
Negative (-) terminal.
For some mounting kits, it may be necessary
to alter the remote control switch’s plug by
cutting off one of the pull tabs. Do not alter
the plug until you confirm that it is
necessary. See the diagram below.
INSTALLATION NOTES

4
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 winch.
2. To engage the clutch, move the clutch shifter
tab to the “IN” position. The winch is now
ready for pulling.
Your battery must be kept in good condition. A
fully charged battery and proper connections are
essential. Run the vehicle engine during winch-
ing operations to keep battery charged.
The remote control switch is waterproof. It
has push button stations on either side. It is
designed this way to prevent quick winch rever-
sals, which lead to solenoid failure.
Make sure the motor has stopped fully before
reversing. To actuate winch simply plug remote
control switch into receptacle in black solenoid
cover of winch.
Run winch forward and reverse to check con-
nection and to determine winch operating direc-
tions. 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
SWITCH PLUGGED IN WHEN WINCH IS NOT
IN USE.
Maintenance
Corrosion on electrical connections will reduce
performance or may cause a short. Clean all
connections. In salty environments use a sili-
cone sealer to protect from corrosion.
To minimize corrosion of the internal motor
components that may occur due to condensa-
tion, 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 Troubleshooting Guide if the
motor has been submerged.
All moving parts in the winch are permanently
lubricated with broad temperature range lithium
based grease. Under normal conditions factory
lubrication will suffice.
Lubricate cable periodically using light penetrat-
ing oil. Inspect for broken strands and replace if
necessary. If the cable becomes worn or dam-
aged, it must be replaced.
Cable Installation
Note: Cable should be installed so that
it feeds from the bottom of the drum.
It is not necessary to disassemble the winch or
remove it from where it is mounted to replace
the cable.
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. Loosen
but do not remove the cable anchor.
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.
Slide the cable to the end of the slot on the
drum flange under the cable anchor.
Tighten the cable anchor securely to the drum
so that the cable is held securely.
Wind five wraps of cable onto the drum by rotat-
ing the drum while free-spooled. Wind 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 block between the
cable hook and the load.
OPERATING INSTRUCTIONS / MAINTENANCE /
CABLE INSTALLATION

5
UTV 5000 Trouble Shooting Guide
CONDITIONS POSSIBLE CAUSE CORRECTION
MOTOR RUNS IN ONLY ONE DefecƟve solenoid or stuck solenoid. Jar solenoid assembly to free contacts.
DIRECTION Check each solenoid by applying +12 volts
to coil terminal (it should make an audible click
when energized).
MOTOR RUNS EXTREMELY HOT Long period of operaƟon Cooling-oīperiods are essenƟal to prevent
overheaƟng.
MOTOR RUNS, BUT WITH Bad connecƟon Check baƩery cable for corrosion;
INSUFFICIENT POWER clean and grease
OR WITH LOW LINE SPEED Insuĸcient baƩery Test for faulty vehicle baƩery.
Insuĸcient charging system Replace with larger capacity charging system.
MOTOR RUNS, BUT DRUM Clutch not engaged If clutch engaged but symptoms sƟll exist, it will
DOES NOT TURN be necessary to disassemble winch to determine
cause and repair.
MOTOR WILL NOT OPERATE Loose connecƟons. Check all electrical connecƟons from the baƩery
to the motor.
DefecƟve solenoid or stuck solenoid. Jar solenoid assembly to free contacts. Check
solenoid by applying 12 volts to coil terminal
(it should make an audible click when
energized).
DefecƟve 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.
DefecƟve motor If solenoids operate, check for voltage at
armature post; replace motor.
MOTOR WATER DAMAGED Submerged in water or water Allow to drain and dry thoroughly, then
from high pressure car wash Run motor
without a load in short bursts to dry windings.
CABLE DRUM WILL NOT Clutch not disengaged Check clutch operaƟon according to
FREE-SPOOL OR IS nameplate. Make sure clutch shiŌer tab is
DIFFICULT TO FREE-SPOOL fully at “OUT” posiƟon.
Winch not mounted
squarely causing Check that MounƟng Kit instrucƟons have
end bearing to bind drum been followed.
Some or all of the (6) 1/4-20NC Remove gear housing cover and all gears
capscrews aƩaching the ring gear from inside the gear housing. Disengage the
retainer are too tight (see Parts clutch and check to see that the ring gear
Diagram, following page). will rotate by hand. If not, using a hex (Allen)
wrench, slightly loosen all the capscrews and
then snugly re-Ɵghten them in a criss-cross
paƩern, but do not over Ɵghten. The ring gear
must rotate by hand. Re-assemble the winch.
TROUTBLE SHOOTING GUIDE

6
NOTES

7
615
9
36
36
35
4*
21
38
39
37
13
11
30 1
41 29
10
15
12
2
42
23
31 41
17
16
41
3
28
33
8
7
34
14
22
32 20
22
40
25
33
28
19
26
24 27
18
26
24 5
UTV 5000 PARTS DIAGRAM

8
Item No. Qty. Part No. DescripƟon
1 1 247024 Gear Carrier Assembly - Input
2 1 247007 Gear Carrier Assembly - Intermediate
3 1 247006 Gear Carrier Assembly - Output
4* 1 251110 Switch Assembly - 12 Ft.
1 504024 Toggle Switch Assembly
5 1 251236 Roller Fairlead Assembly
6 1 251274 Assembly - Cable, 7/32 Dia. X 60 Ft.
7 1 278158 Solenoid Assembly (Pendant Switch)
278201 Solenoid Assembly (Toggle Switch)
8 1 296589 Motor/ End Bearing Assembly
9 1 296637 Brake Assembly
10 1 332213 Drum - Cable
11 1 334143 Gear - Ring
12 1 334147 Gear - Intermediate Sun
13 1 338337 End Bearing - Gear Housing
14 1 408315 Solenoid MounƟng Bracket
15 2 412056 Bushing - Drum
16 2 412061 Bushing - ShaŌ
17 1 413018 Cover - Gear Housing
18 2 414314 Capscrew-3/8-16NCX1Lg,HXHD,Z/P,GR.5
19 4 414316 Capscrew-3/8-16NCX1 1/4,HXHD,Z/P,G5
20 1 414830 Capscrew-1/4-20NCX3/8,Soc BuƩon Hd
21 6 414861 Bolt-1/4X20NCX3/4,Flat SocHd,NY-LOK
22 2 415007 Capscrew-M6 X 1 X 107MM LG, HX HD Z/P
23 6 416273 Screw ASM-#6-32NCX3/8&L/W,FILHD/PLT
24 6 418035 Nut-3/8-16NC Hex Reg Zinc Plated
25 1 418165 Washer-5/16 Shake Prf,Ext Teeth,Z/P
26 6 418177 Lockwasher-3/8 Med Sect,Zinc Plated
27 4 418181 Washer-3/8 ID SAE Flat, Zinc Plated
28 2 419004 Locknut-M6 X 1MM, Hex With Nylon Insert,
Z
29 1 442207 Gasket - Gear Housing Cover
30 1 444048 Gear - Output Sun
31 1 444097 Gear-Input Sun
32 1 448071 Cable Anchor
33 2 448105 Tie Bar
34 1 452005 ShiŌer Lever
35 1 477002 Locking Ring
36 1 477004 Ring - Half
37 1 477013 Cam Ring
38 1 479007 Retainer - Ring Gear
39 6 494077 Spring
40 2 518019 Thrust Washer
41 3 518020 Thrust Washer
42 1 518027 Thrust Disc
PARTS LIST

9
2
4
6
24
7
9
18
4
6
13
223
1
23
5
3
13
15
2
22
22
SOLENOID (REF)
"A"
4
8
10
11
16
13
14
17
19
20
25
21
YELLOW
GREEN
RED
COVER (REF)
10
12
12
Item No. Qty. Part No. DescripƟon
1 1 289015 BaƩery Cable
2 1 289091 Wire Assembly-Black 16 Ga. X 1-1/2" Lg.
3 1 289092 Wire Assembly-Black 6 Ga. X 3-1/2" Lg.
4 3 289171 Wire Assembly-Motor Lead
5 1 289208 Wire Assembly-Ground
6 2 364002 Strap-Copper
7 1 408102 Solenoid Bracket
8 1 413024 Cover-Solenoid
9 3 414053 Capscrew-1/4-20NCX1-1/4 Lg,HxHd,Z/P,Gr5
10 7 416216 Screw-#10-24NCX1/2Lg,RdHd,Slot,Z/Pl
11 2 416227 Screw-#10-24NCX3/4,Truss,Black
12 2 418001 Nut-#10-32Thd Hex Nut,Zinc Plated
13 6 418004 Nut-Hex #10-24NC Reg.,Zinc Plated
14 6 418014 Nut-1/4-20NC Reg Hex,Zinc Plated
15 3 418140 Washer-#10 Flat Steel,SAE,Zinc Plated
16 2 418141 Lockwasher-#10 Med SecƟon,Plated
17 3 418149 Lockwasher-1/4 Med SecƟon,Zinc Plated
18 1 418165 Washer-5/16 Shake Prf,Ext Teeth,Z/P
19 3 418411 Nutsert #10-24NC
20 3 418514 Spacer
21 1 430013 Connector Female-Molded
22 2 440071 Terminal Tab
23 2 440110 Solenoid 12V
24 1 440111 Strap-Copper
25 1 482029 Cover-Female Connector
Solenoid Assembly 278158 Parts List
(Pendant Switch)

10
2
1
5
21
23
6
8
17
1
5
21
12
3
22
24
22
2
4
12
14
2
3
26 21
28
27 21
SOLENOID (REF)
"A"
1
7
9
10
15
12
13
16
18
19
25
20
COVER (REF)
11
11
9
Item No. Qty. Part No. DescripƟon
1 3 289170 Wire Assembly-Black 2 Ga. x 29 Lg.
2 1 289208 Wire Assembly-Black 18 Ga. x 12-1/2" Lg.
3 2 289091 Wire Assembly-Black 16 Ga. x 1-1/2" Lg.
4 1 289092 Wire Assembly-Black 4 Ga. x 3-1/2" Lg.
5 2 364002 Strap-Copper
6 1 408102 Bracket
7 1 413024 Cover-Solenoid
8 3 414053 Capscrew-1/4-20NCX1-1/4Lg.,HxHd,Z/P,GR5
9 7 416216 Screw-#10-24NC x 1/2 Lg,RdHd,Slot,Z/Pl
10 2 416227 Screw-#10-24NC x 3/4,Truss,Cros-Reces,F/B
11 2 418001 Nut-#10-32Thd Hex Nut,Zinc Plated
12 6 418004 Nut-Hex #10-24NC Reg.,Zinc Plated
13 6 418014 Nut-1/4-20NC Reg Hex,Zinc Plated
14 4 418140 Washer-#10 Flat Steel,SAE,Zinc Plt
15 2 418141 Lockwasher-#10 Med SecƟon,Plated
16 3 418149 Lockwasher-1/4 Med SecƟon,Zinc Plt
17 1 418165 Washer-5/16 Shake Prf,Ext Teeth,Z/P
18 3 418411 Nutsert-#10-24NC
19 3 418514 Spacer
20 1 430013 Connector Female-Molded
21 4 440071 Terminal Tab
22 2 440110 Solenoid
23 1 440111 Strap-Copper
24 1 289015 Wire Assembly-BaƩery Red 72" (REP 6000)
25 1 482029 Cover-Female Connector
1 299741 Wire Assembly-Consists of:
26 1 #18 Ga. Green Wire 123" long
27 1 #18 Ga. Yellow Wire 123" long
28 1 #18 Ga. Red Wire 123" long
Solenoid Assembly 278201 Parts List
(Toggle Switch)

OM 914257-0314-A
RAMSEY WINCH COMPANY
P.O. BOX 581510 TULSA, OKLAHOMA 74158-1510
USA PHONE: [phone] FAX: [phone]
http://www.ramsey.com
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.
Limited Lifetime Warranty
Ramsey Winch offers a limited lifetime warranty for each new Ramsey UTV 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 90 days. Online
registration of your winch is available at www.ramsey.com.
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 lim-
ited 1-year 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 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 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 incorpo-
rate 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