Ramsey BADGER 2500 User Manual
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
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