Note: Fairlead does not attach
directly to winch. Winch shown with
mounting plate, sold separately.
LAYER OF CABLE12345
Rated lin e pul l pe r lay er ( lbs)25002090180015801400
(kgs)1133947815716634
CumulaƟve cable (Ō)*715253750
capa city per l ayer (m)*2.124.567.611.315.2
(3/16" - 4.8mm - dia. cable)
*CA BLE MUST BE UN IFORMLY WO UND ONTO DR UM.
Line pull (lbs)NO5001000150020002500
Įrst lay er
Line sp eed ( fpm)18171512117.5
Įrst lay er (mpm)5. 55.14.63.73.42.3
Amp dr aw (12v )366090116140160
(k gs)LOA D2274536809061133
Ramsey Winch Company
OWNER’S MANUAL
BADGER Electric Winch
Model BADGER 2500
W/Wireless Remote Control
BADGER 2500 WINCH
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
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.
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
General Installation ................ 3
Installation .............................. 3
Electrical Schematic ............... 4
Techniques of Operation ........ 5
General Operating Instructio ns 5
Wireless Remote Control Operation 5
Maintenance ........................... 6
Troubleshooting Guide ........... 7
Winch Parts List ..................... 8-9
Warranty ................................ Back Cover
Safety Precautions To Guard
Against Possible Injury
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 min utes. 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 disen
gaged. Always use hook strap to hold hook
when spooling.
M. Do not use the winch to hold a load on the trail er while towing. Secure the load to the trailer
with straps or tie-downs. The winch is not
designed to be a load holding device.
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.
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.
2
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. 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.
General 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 drawing below.
Tighten mounting bolts to 16 ft-lbs (22 Nm) 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.
Refer to Installation and Operating Instructions for
Ramsey Wireless Remote Control for electrical connections and installation.
Mounting Hole Pattern
Four 11/32” (8,6 mm) diameter holes
on 4.88” (124 mm) x 3.00” (76,2 mm)
n
patter
5/16-18 NC
4 Places
3
Cable must exit
under the drum
4
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.
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.
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.
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 “ENGAGED” position. The winch is now
ready for pulling.
Wireless Remote Control Operation
Caution: When the transmitter reaches a temperature below 0°F (-18°C) it will not operate. In
extremely cold temperatures, keep transmitter in a
pocket of innermost layer of clothing when not in
use.
The transmitter has push buttons labeled according
to their function. Make sure the motor has stopped
fully before reversing to prevent premature solenoid failure. To operate the winch hold “ON/OFF”
button for 2 seconds to activate the “IN and “OUT”
functions. Run winch forward and reverse to check
connection and to verify winch operating directions.
The transmitter is clearly labeled and a red LED
flashes when the winch is in operation. Pushing
both buttons at the same time will not damage your
winch in any way. Press and hold the “ON/OFF”
button on the transmitter to disable the transmitter
when winch is not in use. This will prolong the battery life of the transmitter. The transmitter automatically turns off after 20 minutes.
Refer to page 5 of Wireless Remote Control
Installation Instructions for remote operation
notes.
5
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.
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.
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.
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.
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.
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.
6
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
MOTOR RUNS, BUT DRUM
DOES NOT TURN
POSSIBLE CAUSE
Defective solenoid or stuck solenoid.
Defective remote control or low battery in transmitter.
Long period of operation.
Insufficient battery
Bad connection
Insufficient charging system
.
Clutch not engaged.
CORRECTION
Jar solenoid assy to free contacts. Check
each solenoid by applying +12 volts to
coil terminal (it should make an audible
click when energized).
Check winch operation with auxiliary toggle switch. Check battery in transmitter.
Cooling-off periods are essential to prevent overheating.
Test for faulty vehicle battery.
Check battery cable for corrosion; clean
and grease
Replace with larger capacity charging
system.
If clutch engaged but symptoms still exist,
it will be necessary to disassemble winch
to determine cause and repair.
MOTOR WILL NOT OPERATE
MOTOR WATER DAMAGED
WINCH RUNS IN OPPOSITE
DIRECTION OF TRANSMITTER
BUTTONS
Stuck or defective solenoid.
Defective remote control or low
battery in transmitter.
Defective motor.
Loose connections.
Submerged in water or water
from high pressure car wash.
Motor leads crossed.
Jar solenoid assy to free contacts. Check
solenoid by applying +12 volts to coil
terminal (it should make an audible click
when energized).
Check winch operation with auxiliary toggle switch. Check transmitter battery
If solenoids operate, 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.
Reverse electrical connections to motor.
Solenoid control wires crossed.
7
Reverse position of green and yellow
wires on solenoid assy.
Parts List
ITEM
NO
QTYPART NO. DESCRIPTION
11251214MOTOR KIT
21251247MOTOR END GEAR SET KIT
31251191CLUTCH KIT
41251192CABLE DRUM KIT
51251193CABLE & HOOK KIT
61251213CLUTCH END GEAR KIT
71251236ROLLER FAIRLEAD KIT
81251195BUSHING KIT
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 manufacturers
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 desirablewithout 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.
Quality Management System
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-914113-0713-C
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