Note: Fairlead does not
attach directly to winch.
Winch shown with mounting
plate, sold separately.
BADGER 2500 WINCH
LAYER OF CABLE 1 2 3 4 5
Rated lin e pul l pe r lay er ( lbs) 2500 2090 1800 1580 1400
(kgs) 1133 947 815 716 634
CumulaƟve cable (Ō)* 7 15 25 37 50
capaci ty per l ayer ( m)* 2.12 4.56 7.6 11.3 15.2
(3/ 16" - 4.8m m - di a. cab le)
*CABLE MUST BE UNIF ORMLY WOUND ONTO DRUM.
Line pu ll (lbs) NO 500 1000 1500 2000 2500
Įrst lay er (kg s) LOAD 227 453 680 906 1133
Line sp eed ( fpm) 18 17 15 12 11 7.5
Įrst lay er (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
BADGER Electric Winch
Model BADGER 2500
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.
to know 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 Badger 2500
winches are designed primarily for general 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.
It contains useful ideas in obtaining the
most efficient operation from your Ramsey
Winch and safety procedures you need
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
Installation .....................................................3
General Operating Instructions ........................4
Maintenance ..................................................4
Cable Installation ............................................4
Trouble Shooting Guide ..................................5
Manual Control Switch Operation ...................6
Winch Parts List......................................... 6-7
Electrical Schematic .......................................7
Warranty ........................................back cover
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 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 Com pany.
I. Keep the duration of your pulls as short as pos
sible. 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 intermit
tent 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 rat
ings.
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 disen
gaged. Always use hook strap to hold hook when
spooling.
M. Do not use the winch to hold a load on the trailer
while towing. Secure the load to the trailer with
straps or tie-downs. The winch is not designed to
be a load holding device.
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.
Do not engage clutch with motor running.
Never connect the hook back to the cable. This
causes cable damage. Always use a sling or chain
of suitable strength.
2
Observe your winch while winching, 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 with
you.
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.
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.
Installation
The winch shown in this owners manual is
designed solely and exclusively for non-industrial
applications. All other applications will void warranty.
It is very important that the winch be
mounted on a flat surface, with the cable
underwound as shown in the dimensional
drawings. See dimensional drawing of
winch below.
The dimensional drawing of the winch is shown for
use in determining a mounting location. Tighten
mounting bolts to 16 ft-lbs. torque.
CAUTION: SUPPLIED 7/8” LONG MOUNTING BOLTS
WITH LOCKWASHERS ARE FOR A RECOMMENDED
WINCH MOUNTING PLATE THICKNESS OF 3/16”. IF A
DIFFERENT MOUNTING 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.
Mounting Hole Pattern
Four 11/32” (8,6 mm) diameter
holes on 4.88” (124 mm) x 3.00”
(76,2 mm) pattern
5/16-18NC
4 Places
Cable must exit
under the drum
3
General 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 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
“ENGAGE” 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 to
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.
All moving parts in the winch are permanently lubricated with broad temperature range lithium-based
grease.
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.
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.
The short end of the cable
should extend approximately
1/8” beyond the top edge of
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.
4
BADGER 2500 Trouble Shooting Guide
CONDITION
MOTOR RUNS IN ONLY ONE
DIRECTION
MOTOR RUNS EXTREMELY HOT
MOTOR RUNS, BUT WITH
INSUFFICIENT POWER OR WITH
LOW LINE SPEED
POSSIBLE CAUSE
Defective Manual Switch.
Long period of operation.
Insufficient battery
Bad connection
Insufficient charging system.
CORRECTION
Replace Manual Switch.
Cooling-off periods are essential to prevent
overheating.
Test for faulty battery.
Check battery cable for corrosion; clean
and grease
Replace with larger capacity charging sys-
tem.
MOTOR RUNS, BUT DRUM DOES
NOT TURN
MOTOR WILL NOT OPERATE
MOTOR WATER DAMAGED
Clutch not engaged.
Defective Manual
Switch.
Defective motor.
Loose connections.
Submerged in water or
water from high pressure
car wash.
If clutch engaged but symptoms still exist,
it will be necessary to disassemble winch
to determine cause and repair.
Replace Manual Switch
Check for voltage at armature post; replace
motor.
Check all electrical connections from the
battery to the motor.
Allow to drain and dry thoroughly, then run
motor without a load in short bursts to dry
windings.
WINCH RUNS IN OPPOSITE
DIRECTION OF SWITCH
OPERATION
Battery leads crossed.
5
Reverse red and black battery leads.
Parts List BADGER 2500(Manual Switch)
ITEM
NO. QTY. PART NO. DESCRIPTION
1 1 251214 MOTOR KIT
2 1 251247 MOTOR END GEAR SET KIT
3 1 251191 CLUTCH KIT
4 1 251192 CABLE DRUM KIT
5 1 251193 CABLE & HOOK KIT
6 1 251213 CLUTCH END GEA R KIT
7 1 251075 HAWSE FAI RLEAD KIT
8 1 251195 BUSHING KIT
9 1 251196 TIE BA R KIT
10 1 289197 BATTERY WIRE (BLACK)
11 1 289199 BATTERY WIRE (RED)
12 1 256116 BRAKE KIT
13 1 251238 MANUAL CONTROL SWITCH KIT
14 1 335044 BOOT
Manual Control Switch Operation
The manual control switch assembly is attached to the
motor power terminals. Rotation of the switch clockwise
spools cable “in” and counterclockwise spools cable
“out”.
6
RAMSEY BADGER 2500 PARTS (Manual Switch)
10
1
6
4
3
8
11
9
12
2
5
7
14
13
Electrical Schematic (Manual Switch)
7
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 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 industrial applications.
Electrical components consisting of motors, solenoids, wiring, wire connectors, and associated parts carry a limited
1-year warranty.
The obligation under this warranty, statutory or otherwise, is limited to the replacement or repair at the manufac-
turers 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 incorporate 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.
CERTIFIED
Accredited by the Council
for Accreditation ( )
Quality Management System
National Accreditation
Program
RAMSEY WINCH COMPANY
P.O. BOX 581510 TULSA, OKLAHOMA 74158-1510 USA
PHONE: (918) 438-2760 FAX: (918) 438-6688
http://www.ramsey.com
OM-914075-0813-N
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