Ramsey H-400 User Manual
Ramsey Winch Company
OWNER’S MANUAL
ATV Electric Winch Model ATV 2500
BADGER 2500 WINCH
LAYER OF CABLE 1 2345
Rated line pull per layer (lbs) 2500 2090 1800 1580 1400
(kgs) 1133 947 815 716 634
CumulaƟve cable (Ō )* 7 15 25 37 50
capaci ty per layer ( m)* 2.12 4.56 7.6 11.3 15.2
(3/ 16" - 4.8mm - dia. cable)
*CABLE MUST BE UNIFORMLY WOUND ONTO DRUM.
Line pull ( lbs) NO 500 1000 1500 2000 2500
Įrst layer (kgs) 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
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
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 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.
the most efficient operation from your Ramsey
CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH. SEE SAFETY
PRECAUTIONS.
Contents
Performance Specifications…………. cover
Safety Precautions……………………. 2
Tips for Safe Operation……………….. 2
Techniques of Operation……………... 3
General Installation……………………. 3
Rocker Switch Installation……………. 4-5
Rocker Switch Operation……………… 5
Electrical Schematic (Rocker Switch)…6
Winch Operation………………………… 7
Maintenance ……………………………… 7
Cable Installation………………………… 7
Winch Parts List (Rocker Switch)…… 8-9
Trouble Shooting Guide…………………10
Warranty………………………………….. back cover
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 while mov
ing. Secure the load with tie-downs. The winch
is not designed to be a load-holding device.
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 in cline.
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 min utes. Do not pull more than one minute at or
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. If possible,
while standing at a safe distance.
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
If you use ATV
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.
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.
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.
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 (21.6 Nm) 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.
CAUTION: 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.
For basic self-recovery, anchor to a tree or heavy rock. When anchoring to a tree, always use a tree
trunk protector.
3. Do not attach motor and battery leads until
instructed to do so.
4. Refer to installation instructions for the Rocker
Switch on page 4 to install the Rocker Switch.
3
Rocker Switch Installation
The Rocker Switch will mount to the handle bars
of the ATV.
Before Beginning Installation
1. Install mounting kit and winch according to the
mounting kit instructions.
2. Disconnect negative (-) battery cable from
battery. Turn off vehicle ignition.
3. Disengage winch clutch.
4. Remove hood or cowling as necessary for easier access to installation area.
5. Locate and mark mounting location for Solenoid
Assembly.
6. Locate accessory wire from vehicle ignition
switch that is powered only when ignition is
ON. Use this wire when splicing to Red wire on
Rocker switch.
7. Make sure locations are close enough for wiring
connections to be made without making alterations to wire lengths.
Installing the Solenoid
1. Use Solenoid Assembly as a guide to mark and
drill (2) 7/32”
holes in location determined for solenoid.
2. Use (2) 3/4” long #10 capscrews (item #14-
3), (2) #10 flat washers (item #14-8), and (2)
#10 locknuts (item #14-5) to mount solenoid.
Tighten to 60 in-lbs (7 Nm) torque.
Installing the Rocker Switch
For clarification, see wiring schematic on page 6.
1. Position Tube Clamp (item #14-12) on handle
bars in convenient location.
AUTION: DO NOT CONNECT NEGATIVE BATTERY
C
CABLE OR ENGAGE CLUTCH UNTIL INSTALLATION IS
COMPLETE. WINCH COULD BEGIN SPOOLING CABLE
UNEXPECTEDLY CAUSING INJURY OR DAMAGE TO
WINCH.
Solenoid Mounting: Choose a mounting location
that will remain protected and dry. Solenoid should
be mounted on a flat surface.
2. Mount Rocker Switch housing to Tube Clamp
using #10 capscrew, locknut, flat washer, and
shake-proof washer (items #14-3, #14-5, #14-8,
and #14-9). Tighten securely.
3. Push the Green, Red, and Yellow wires through
the back of the switch housing.
4. Install the Gasket onto the Rocker Switch.
5. Connect Yellow wire (item #12-3) to top
terminal on Rocker Switch (terminal behind “IN”
position). Connect Red wire (item #12-1) to
middle terminal on Rocker switch. Connect
Green wire (item #12-2) into bottom terminal of
Rocker switch.
6. Slide Green, Yellow, and Red wires into loom
(item #12-4). Slide loom up to back of the
switch housing.
7. Snap switch and switch housing together.
4
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