Ramsey ATV-2500 User Manual
Ramsey Winch Company
* CABLE MUST BE UNIFORMLY WOUND ONTO DRUM.
1,133
2,500
1
2.12
7
LAYER OF CABLE
(3/16"-4.8 mm- dia. cable)
4.5
63
453
1,000
45
18
5.3
227
500
20.8
6.3
LOAD
NO
1517.6
84
12.3
3.8
680
1,500
11.3
37
716
1,580
4.56
15
947
2,090
7.6
25
815
1,800
2
3
15.2
50
634
1,400
4
5
(lbs)
(kgs)
Rated line pull per layer
Cumulative cable
capacity per layer
(ft)*
(m)*
Line pull
(lbs)
(kgs)
Line speed
(fpm)
(mpm)
Amp draw
(12v)
2,000
906
10.2
3.0
96
first layer
first layer
2,500
1,133
8.5
2.6
121
ATV2500 WINCH
OWNER'S MANUAL
ATV Electric Winch
Note: Fairlead does not attach directly to winch. Winch
shown with mounting plate (P/N 251073), sold separately.
Model ATV2500
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 guidelines for operation, your R
you for choosing Ramsey. You will be glad you have one working for you.
Please Note: R
cations (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.
TV 2500 winches are designed primarily for A
amsey A
amsey winch will give you many years of satisfying service. Thank
TV use. This winch is not designed to be used in industrial appli
-
Contents
Performance Specifications . . . . . . . . . .cover
Safety Precautions . . . . . . . . . . . . . . . . . . . .2
Tips for Safe Operation . . . . . . . . . . . . . . . .2
Techniques of Operation . . . . . . . . . . . . . . .3
General Installation . . . . . . . . . . . . . . . . . . .3
Rotating the Motor on your ATV . . . . . . . .4-6
Winch Operation . . . . . . . . . . . . . . . . . . . . .7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . .7
Cable Installation . . . . . . . . . . . . . . . . . . . . .7
Trouble Shooting Guide . . . . . . . . . . . . . . . .8
Electrical Schematic (Wireless Remote) . . . .9
Winch Parts List (Wireless Remote) . . .10-11
Wireless Remote Control Operation . . . . . .11
Electrical Schematic (Manual Switch) . . . .12
Manual Switch Operation . . . . . . . . . . . . . .13
Manual Switch Installation . . . . . . . . . .13-14
Winch Parts List (Manual Switch) . . . .16-17
Electrical Schematic (Rocker Switch) . . . .18
Rocker Switch Operation . . . . . . . . . . . . . .19
Rocker Switch Installation . . . . . . . . . .19-20
Winch Parts List (Rocker Switch) . . . . .22-23
Warranty . . . . . . . . . . . . . . . . . . .back cover
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 the 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. 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. 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 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 ATV 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.
. Apply blocks to wheels when A
F
incline.
G. Winch clutch should be disengaged when
winch is not in use and fully engaged when in
use.
TV is on an
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 damage to the winch.
Store the wireless remote control transmitter in a
safe place where it will not become damaged.
Inspect it before you use it.
When ready to begin winching, push and hold the
On/Off button on the transmitter until it flashes.
Do not engage clutch with motor running.
2
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 ATV
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 ATV frame.
When double lining during stationary winching,
the winch hook should be attached to the chassis
of the ATV. 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 arrangement.
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 recognize the sound of a
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 ATV up or ease
your ATV down a steep grade, it will also pull
another ATV or a load while your ATV 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
, anchor to a tree or heavy rock.
y
or basic self
F
When anchoring to a tree, always use a tree trunk protector.
-recover
hook. It will slow the snap back in the event of a
broken cable.
Use the ATV 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.
Winches equipped with cable guide fairleads can pull
from several directions. Pull from an angle only to
straighten up the ATV--otherwise you can damage structural members or other parts of your ATV and cause
excess cable buildup on one end of the winch drum.
General Installation
The winch shown in this owners manual is solely
and exclusively designed for ATV mounted, nonindustrial applications. All other applications will
void warranty.
1. Install Winch and Mounting Kit according to
instructions supplied with Mounting Kit.
Tighten mounting bolts to 16 ft-lbs torque.
2. It is very important that the winch be
mounted on a flat surface, with the cable
feeding from the bottom of the drum.
AUTION: SUPPLIED 7/8” LONG MOUNTING BOLTS WITH
C
LOCKWASHERS ARE FOR A RECOMMENDED WINCH MOUNT
ING PLATE THICKNESS OF
PLATE THICKNESS IS USED, THE BOLT LENGTH MUST BE
ADJUSTED ACCORDINGLY OR DAMAGE TO WINCH MAY
. REPLACEMENT BOLTS MUST BE SAE GRADE 5 OR
OCCUR
EQUIVALENT
.
3. Do not attach motor and battery leads until
instructed to do so.
4. Refer to installation instructions for the
Wireless Remote Switch (in the ATV Wireless
Installation and Operation Manual), the
Remote Mounted Manual Switch (on page 13
of this manual), or the Rocker Switch (page
19) for installation of the appropriate switch
and electrical assemblies for the winch.
3
3/16”. IF A DIFFERENT MOUNTING
-
Rotating the Motor on your ATV
Winch
The ATV winch has the motor studs and leads
positioned on the end of the motor aligned vertically. If you need to rotate the motor on your ATV
winch to gain clearance, you can rotate the motor
90°. The motor studs will then be aligned horizontally.
Before you begin:
Note: If you have installed the optional Brake kit
(P/N 256116) for the ATV winch, make sure you
have the Brake kit installation instructions before
proceeding. You will need to re-install the Brake
kit after you rotate the motor (step 6 on the following pages). Contact Ramsey if you do not
have your installation instructions.
1. Remove the cable from the drum. Turn the
clutch handle to Freespool and pull cable. Slide
the end of the cable out of the pocket again the
drum flange until the cable anchor can be
removed. Be sure to keep the cable anchor for
re-installing the cable. Leave the clutch set to
Freespool.
2. Disconnect the motor leads.
3. Remove the winch from its mounting channel.
Place it on a sturdy, level workbench.
Set the winch down on the clutch end.
1. Remove the tie bar bolts and nuts. Pull tie bars
from between end bearings.
2. Lift the motor end off the drum and set down
with the motor end down. Make sure the shaft,
drum bushing and spring stay with the drum.
4
3. Remove the bolts that hold the end plate to the
motor end housing. Lift off the end plate and
take the nuts and washers out of the mounting
feet. Set aside the gear assemblies and bushing. The input sun and planetary gear carrier
may come out together.
4. Lean the motor end and loosen the motor tie
bolts off the tie bolt nuts. Lean the motor end
back up so that it is sitting upright. Do not let
the motor end cap come apart from the
rest of the motor. Lift the motor end housing
and rotate 90°. Put the tie bolt nuts in the other
set of pockets and carefully lean the motor end
back. Tighten the tie bolts to 45-50 in-lbs.
torque. Do not overtighten.
5. After rotating the motor, the motor end will
appear as shown at right. The motor studs will
be aligned horizontally, and the motor tie bolt
nuts will be in the other set of pockets.
5
6. Replace the gears into the motor end housing,
fitting the input sun gear over the motor shaft.
The planetary gear carrier should be seated so
that the bushing, as shown at lower right, is
flush with the ring gear.
7. Re-install the end plate on the housing with
the bolts you removed earlier. Tighten these
bolts to 45-50 in-lbs. torque. Do not overtighten.
8. Lift the motor end assembly onto the drum.
Turn the drum and motor end assembly so
that the shaft fits into the input sun gear.
Lean the motor end assembly slightly to one
side to insert the tie bars into their holes.
9. Slide the tie bar bolts through the tie bars and
into their nuts. Tighten the tie bar bolts to 4550 in-lbs. torque. Do not over tighten. The finished winch should look as shown below,
with the motor studs aligned horizontally.
Confirm that the drum freespools properly without
binding.
Refer to the winch mounting kit installation
instructions for re-installing the winch. Re-install
the winch cable according to the instructions in
this manual.
Insert the mounting nuts and washers into the
pockets of the housing as shown. Make sure they
do not fall out while re-installing the end plate.
6
Winch Operation
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 located
on the end of the winch as follows:
1. To disengage the clutch, turn the clutch
shifter to the "FREESPOOL" position. Wire
rope may now be freespooled off the drum.
2. To engage the clutch, turn the clutch shifter to
the "ENGAGED" position. The winch is now
ready for pulling.
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 penetrating
oil. Inspect for broken strands and replace if necessary. If the cable becomes worn or damaged, it
must be replaced.
Cable Installation
Note: Cable should be installed so that it
feeds from the bottom of the drum.
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, watching carefully for the
cable anchor puck.
Before installing the new cable assembly, securely
wrap the end of the cable with tape to prevent
fraying.
Your battery must be kept in good condition. A
fully charged battery and proper connections are
essential. Run the vehicle engine during winching
operations to keep battery charged.
Maintenance
Corrosion on electrical connections will reduce
performance or may cause a short. Clean all connections. 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 Troubleshooting Guide if the motor has
been submerged.
See supplied instr
replacement transmitter.
uctions for programming a
The short end of the cable should
extend approximately 1/8” beyond
the top edge of pocket.
Slide the cable through narrow end of the pocket
against drum flange and wrap the cable around
the anchor puck. Pull the cable and anchor back
into the wide end of the pocket leaving approximately 1/8” beyond edge of pocket as shown.
Use a hammer and drift punch to drive the back
side of the wire rope, firmly seating the wire rope
and anchor into the pocket.
Wind on 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 swivel
block between the cable hook and the load.
7
ATV2500 Trouble Shooting Guide
CONDITIONS POSSIBLE CAUSE CORRECTION
MOTOR RUNS IN ONLY ONE Defective solenoid or stuck solenoid. Jar solenoid assembly to free contacts.
DIRECTION (Wireless remote only) Check each solenoid by applying
Defective remote control Check winch operation with auxilliary
or low battery in transmitter. toggle switch.
(Wireless remote only)
Defective Manual or R
(Manual or Rocker switch only)
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MOTOR RUNS EXTREMELY Long period of operation Cooling-off periods are essential to
HOT prevent overheating.
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MOTOR RUNS, BUT WITH Insufficient battery Test for faulty vehicle battery.
INSUFFICIENT POWER
OR WITH LOW LINE SPEED Bad connection Check battery cable for corrosion;
Insufficient charging system Replace with larger capacity charging
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MOTOR RUNS, BUT DRUM Clutch not engaged If clutch engaged but symptoms still
DOES NOT TURN exist, it will be necessary to disassem-
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MOTOR WILL NOT OPERATE Defective solenoid or stuck solenoid. Jar solenoid assembly to free contacts.
Defective remote control Check winch operation with auxilliary
or low battery in transmitter. toggle switch.
(Wireless remote only) Check transmitter battery.
Defective Manual or Rocker switch. Replace Manual or Rocker switch.
(Manual or Rocker switch only)
ocker Switch Replace Manual or Rocker switch.
+12 volts to coil terminal (it should
make an audible click when energized).
Check battery in transmitter.
clean and grease
system.
ble winch to determine cause and
repair.
Check solenoid by applying 12 volts to
coil terminal (it should make an audible
click when energized).
Defective motor If solenoids operate, check for voltage
Loose connections. Check all electrical connections from
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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
--------------------------------------------------------------------------------------------------------------------------------------------
WINCH RUNS IN OPPOSITE Motor leads crossed. Reverse electrical connections to
DIRECTION OF TRANSMITTER motor.
BUTTONS
Solenoid control wires
crossed. wires on solenoid assembly.
at armature post; replace motor.
the battery to the motor.
bursts to dry windings.
Reverse position of green and yellow
8
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