Note: Fairlead does not attach directly
to winch. Winch shown with mounting
plate, sold separately.
BADGER 2500 WINCH
LAYER OF CABLE 1 2345
Rated line p ull per l ayer (lbs) 2500 2090 1800 1580 1400
(kgs) 1133 947 815 716 634
CumulaƟve cable (Ō )* 7 15 25 37 50
capacity pe r l ayer (m)* 2.12 4.56 7.6 11.3 15. 2
(3/ 16" - 4.8mm - dia. cable)
*CABLE MUST BE UN IFORMLY WOUND ONTO DRUM.
Line pull (lbs) NO 500 1000 1500 2000 2500
Įrst layer (k gs) LOAD 227 453 680 906 1133
Line speed ( fpm) 18 17 15 12 11 7.5
Įrst layer ( mpm) 5.5 5.1 4.6 3.7 3.4 2.3
Amp draw (12v ) 36 60 90 116 140 160
Ramsey Winch Company
OWNER’S MANUAL
ATV Electric Winch 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
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 ATV 2500 winches are
designed primarily for ATV 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.
carefully. It contains useful ideas in obtaining
the most efficient operation from your Ramsey
Winch and safety procedures you need to know
CAUTION: Read and understand this manual before installation and operation of winch. See Safety Precautions.
Contents
Performance Specifications………….. 1
Safety Precautions……………………. 2
Tips for Safe Operation……………….. 2
Techniques of Operation……………... 3
General Installation…………………… 3
Winch Operation………………………. 4
Maintenance…………………………… 4
Cable Installation………………………. 4
Troubleshooting Guide………………… 5
Electrical Schematics………………….. 6-7
Wireless Remote Control Installation
and Operation………………………. 8
Rocker Switch Operation……………... 8
Rocker Switch Installation……………. 8-10
Winch Parts List………………………... 12-14
Warranty…………………………….. Back Cover
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.
F. Apply blocks to wheels when ATV 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.
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 vehicle drive to assist, stop and get out every few feet
to assure the cable is not piling up in one corner.
Jamming cable can break your winch.
When double lining during stationary winching, do
not attach tow hooks to winch mounting plate.
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 to 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
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
the ATV and cause excess cable buildup on one end of the winch
drum.
General Installation
The winch shown in this owners manual is
designed solely and exclusively for ATV-mounted,
non-industrial 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 (22 Nm) torque.
2. It is very important that the winch be mount-
ed on a flat surface, with the cable feeding
from the bottom of the drum.
For basic self-recovery, anchor to a tree or rock. When anchoring to
a tree, always use a tree trunk protector..
C
AUTION: SUPPLIED 7/8” LONG MOUNTING BOLTS WITH
LOCKWASHERS ARE FOR A RECOMMENDED WINCH MOUNT-
ING PLATE THICKNESS OF 3/16”. IF A DIFFERENT MOUNT-
ING PLATE THICKNESS IS USED, THE BOLT LENGTH MUST
BE ADJUSTED ACCORDINGLY OR DAMAGE TO WINCH MAY
OCCUR. REPLACEMENT BOLTS MUST BE SAE GRADE 5
OR 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) for electrical connections
and installation.
3
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.
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 dissipate
any moisture buildup in the motor. This should be
performed at periodic intervals (such as with each
oil change of your vehicle). Note: Refer to the
Troubleshooting Guide if the motor has been submerged.
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.
See supplied instructions for programming a
replacement transmitter.
All moving parts in the winch are permanently lubricated with broad temperature range lithium-based
grease.
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.
The short end of the cable should
extend approximately 1/8” beyond
the top edge of pocket.
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.
4
Troubleshooting Guide
CONDITION POSSIBLE CAUSE CORRECTION
Defective solenoid or stuck solenoid. Jar solenoid assy to free contacts. Check each solenoid
MOTOR RUNS IN ONLY
ONE DIRECTION
by applying +12 volts to coil terminal (it should make an
audible click when energized).
MOTOR RUNS
EXTREMELY HOT
MOTOR RUNS, BUT WITH
INSUFFICIENT POWER
OR WITH LOW LINE
SPEED
MOTOR RUNS, BUT
DRUM DOES NOT TURN
MOTOR WILL NOT
OPERATE
Defective remote control or low bat-
tery in transmitter.
Long period of operation. Cooling-off periods are essential to prevent overheating.
Insufficient battery Test for faulty vehicle battery.
Bad connection Check battery cable for corrosion; clean and grease
Insufficient charging system. Replace with larger capacity charging system.
Clutch not engaged. If clutch engaged but symptoms still exist, it will be neces-
Stuck or defective solenoid. Jar solenoid assy to free contacts. Check solenoid by
Check winch operation with auxiliary toggle switch. Check
battery in transmitter.
sary to disassemble winch to determine cause and repair.
applying +12 volts to coil terminal (it should make an
audible click when energized).
MOTOR WATER
DAMAGED
WINCH RUNS IN
OPPOSITE DIRECTION
OF TRANSMITTER
BUTTONS
Defective remote control or low bat-
tery in transmitter.
Defective motor. If solenoids operate, check for voltage at armature post;
Loose connections. Check all electrical connections from the battery to the
Submerged in water or water from
high pressure car wash.
Motor leads crossed. Reverse electrical connections to motor.
Solenoid control wires crossed. Reverse position of green and yellow wires on solenoid
Check winch operation with auxiliary toggle switch. Check
transmitter battery
replace motor.
motor.
Allow to drain and dry thoroughly, then run motor without
a load in short bursts to dry windings.
assy.
5
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