Ramsey Winch REP 5000 User manual

Ramsey Winch Company
OWNER’S MANUAL
Front Mount Electric Winches
Model REP 5000
12 and 24 volt available
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
series wound 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 effi cient
operation from your Ramsey Winch and safety proce-
dures you need to know before beginning use. When
you fol low 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
Layer of Cable 1 2 3 4 (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 39 31 8 6
(ft)*15305580 (MPM) 12V 11.8 9.4 2.4 1.8
(m)* 4 9 16 24 (FPM) 24V 47 26 21 12
(MPM) 24V 14.3 7.9 6.4 3.6
12V 72 180 295 420
24V 38 87 124 184
* 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

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
opera tions. Neither should you fear them. Do learn the
basic dan gers 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 dam aged. Inspect it before you plug it in.
When ready to begin spooling in, plug in remote
control switch with clutch disen gaged. 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
stand ing 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 over take 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 cap screws 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 connec tions are essential. Run the
vehicle engine during winch ing 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 (+) bat tery
terminal and black cable to negative (-) battery
ter minal.
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 fail ure. Make sure the motor has
stopped fully before reversing direction of winch.
To actuate winch simply plug remote control
switch into receptacle in black sole noid 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
perform ance or may cause a short. Clean all
connections espe cially in remote control switch and
receptacle. In salty environments use a silicone
sealer to protect from corro sion.
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-tight en.
6. Wind 5 wraps of cable onto the drum. Winch
on the rest of the cable by pulling in a light load
to keep ten sion constant. Allow the cable to
swivel by using a length of chain or a swivel
block between the cable hook and the load.
5

MOTOR RUNS
EXTREMELY HOT
MOTOR RUNS,
BUT DRUM DOES
NOT TURN
MOTOR WATER
DAMAGED
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
Long period of operation Cooling-off periods are essential to prevent
overheating.
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.
Insufficient battery
Bad Connection
Insuff cient charging system
Check battery cable for corrosion; clean and grease.
Replace with larger capacity charging system.
Clutch not engaged
Defective remote control
switch
Defective Motor
Loose connections
If solenoids operate, confirm defective motor by
checking for voltage at armature post; replace motor.
Tighten connections on bottom side of hood and on
motor.
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 coil terminal (it should make an audible
click when energized).
To confirm, disengage winch clutch, remove
remote control switch from the socket and jump
pins at 8 and 4 o’clock. Motor should run.
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
Winch not mounted square-
ly causing end bearing to
bind drum
Some or all of the (6)
414861 f at capscrews
attaching the 479007 ring
gear retainer are too tight
Check clutch operation according to nameplate.
Make sure clutch shifter knob is fully at “OUT” posi-
tion.
Check mounting to see that the installation instruc-
tions on page 4 have been followed.
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.
Jar solenoid assembly to free contacts. Confirm
defective solenoid by applying 12 or 24 volts as
appropriate to coil terminal (it should make an audible
click when energized).
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 solenoid or stuck
solenoid
POSSIBLE CAUSE
CONDITION CORRECTION

7
13
1
14
23
11
36
210
12
19
3
24
37
11
34
33
18
30
32
16
20
32
12
21
22
15
8
31
37
37
35
25
7
4
5
29 26
17
9
27
6
28
Hawse Fairlead
#251150
Roller Fairlead
#251151
Included with REP 5000H
Mounting hardware included with winch.
Included with REP 5000R
Mounting hardware included with winch.
REP 5000
Item
No. Qty. Part No. Description Item No. Qty. Part No. Description
1 1 247006 Gear Carrier Assembly - Output 20 4 418035 Nut - 3/8-16NC Hx reg Z/P
2 1 247007 Gear Carrier Assembly - Intermediate 24v 21 4 418177 Lockwasher - 3/8 Med Sect Z/P
31
247024
Gear Carrier Assembly - Input 22 4 418181 Washer - 3/8 ID SAE Flat Z/P
4 1 251110 Switch Assembly - 12 ft 23 1 442207 Gasket - Gear Housing Cover
5 1 251169 Cable Assembly - 80' x 1/4" (6mm) Dia. 24 1 444048 Gear - Output Sun
6 1 278158 Solenoid Assembly - 12v 25 2 448061 Tie Bar
1 278192 Solenoid Assembly - 24v 26 1 448071 Cable Anchor
7 1 296285 Brake Assembly 27 1 296589 Motor/End Bearing Assembly - 12v
8 1 332143 Drum - Cable 1 296591 Motor/End Bearing Assembly - 24v
9 1 334143 Gear - Ring 28 1 424023 Clamp
10 1 334147 Gear - Intermediate Sun 29 1 470053 Roll Pin - 1/8 Dia x 3/8 Lg
11 1 338337 End Bearing 30 1 477002 Locking Ring
12 2 412056 Bushing - Drum 31 1 477013 Cam Ring
13 1 412061 Bushing - Shaft 32 2 477004 Ring - Half
14 1 413018 Cover - Gear Housing 33 1 479007 Retainer - Ring Gear
15 4 414316 Capscrew - 3/8-16NC x 1-1/4 Hx Hd GR5 Z/P 34 6 494077 Spring
16 4 414823 Capscrew - 1/4-20NC x 3/4 Soc Button Hd F/B 35 3 518020 Thrust Washer
17 1 414830 Capscrew - 1/4-20NC x 3/8 Button Hd 36 1 518027 Thrust Disc
18 6 414861 Capscrew - 1/4-20NC x 3/4 Flat Soc Hd Nylok 37 1 452005 Shifter Lever
19 6 416273 Screw - #6-32NC x 3/8
REP 5000 Parts List (12v AND 24v)

8
Item
No.
Qty.
Req'd Part No. Description
1 1 289015 Wire Assembly—Battery Red 72"
2 1 289091 Wire Assembly—Red 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—Black 4 Ga. x 17” Lg. (12v)
3 289115 Wire Assembly—Black 6 Ga. x 17” Lg. (24v)
5 1 289208 Wire Assembly—Black 18 Ga. x 12.5” Lg (12v)
1 289209 Wire Assembly—Black 18 Ga. x 14.5” Lg (24v)
6 2 364002 Strap—Copper
7 1 408102 Bracket
81413024 Cover—Solenoid
9 3 414053 Capscrew 1/4—20NCx1-1/4Lg.Hx.Hd. Z/P
10 7 416216 Screw #10—24NCX 1/2” Lg. Rd. Hd. Z/P
11 2 416227 Screw #10—24NCX 3/4” Lg. Truss Hd. Black
12 6 418004 Nut—Hx. Reg. #10—24NC Z/P
13 6 418014 Nut—Hx. Reg 1/4—20NC Z/P
14 4 418140 Washer #10 SAE Flat Z/P
15 2 418141 Lockwasher #10 Med. Sect. Z/P
16 3 418149 Lockwasher 1/4 Med. Sect. Z/P
17 1 418165 Washer 5/16 Shakeproof External Teeth
18 3 418411 Nutsert #10—24NC
19 3 418514 Spacer
20 1 430013 Connector Female—Molded
21 2 440071 Terminal Tab
22 2 440110 Solenoid—12V
2 440114 Solenoid—24V
23 1 440111 Strap—Copper
24 1 482029 Cover—Female Connector
Note: All unidentified hardware comes
supplied with the solenoid.
Solenoid Assembly Parts List
278158 - REP 5000 12V
278192 - REP 5000 24V

NOTES

Ramsey Winch Company
PO Box 581510 - Tulsa OK 74158-1510
Phone: [phone]
Fax: [phone]
Visit us on the web at http://www.ramsey.com
OM-914255-0913-B