Ramsey Winch ATV2500 User manual

Ramsey Winch Company
OWNER’S MANUAL
ATV Electric Winch Model ATV2500
CAUTION: Read and understand this manual before installation and operation of winch. See Safety Precautions.
Note: Fairlead does not attach directly
to winch. Winch shown with mounting
plate, sold separately.
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 precau-
tions 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 ATV 2500 winches are
designed primarily for ATV use. This winch is
not designed to be used in industrial applica-
tions (car haulers/carriers, wreckers, hoisting,
etc.), and Ramsey does not warrant it to be
suitable for such use. Ramsey makes a sepa-
rate, complete line of winches for industrial/
commercial use. Please contact the factory for
further information.
ATV2500 WINCH
LAYER OF CABLE 1 2 3 4 5
Rated line pull per layer (lbs) 2500 2090 1800 1580 1400
(kgs) 1133 947 815 716 634
Cumulave cable ()* 7 15 25 37 50
capacity 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
first layer (kgs) LOAD 227 453 680 906 1133
Line speed (fpm) 18 17 15 12 11 7.5
first layer (mpm) 5.5 5.1 4.6 3.7 3.4 2.3
Amp draw (12v) 36 60 90 116 140 160

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.
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 winch-
es 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 spool-
ing in cable by rotating the drum by hand with
clutch disengaged. Always use hook strap to
hold hook when spooling.
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 flash-
es. Do not engage clutch with motor running.
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
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 vehi-
cle 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 con-
fidence 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.
3
For basic self-recovery, anchor to a tree or rock. When anchoring to
a tree, always use a tree trunk protector..
Winches equipped with cable guide fairleads can pull from sev-
eral 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.
Caution: Supplied 7/8” long mounting boltS with
lockwaSherS are for arecommended winch mount-
ing plate thickneSS of 3/16”. ifadifferent 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.

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.
Your battery must be kept in good condition. A fully
charged battery and proper connections are essen-
tial. Run the vehicle engine during winching opera-
tions to keep battery charged.
Maintenance
Corrosion on electrical connections will reduce per-
formance or may cause a short. Clean all connec-
tions. 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 lubri-
cated with broad temperature range lithium-based
grease.
Lubricate cable periodically using light penetrating
oil. Inspect for broken strands and replace if nec-
essary. If the cable becomes worn or damaged, it
must be replaced.
To minimize corrosion of the internal motor com-
ponents 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 sub-
merged.
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 fray-
ing.
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 ham-
mer 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.
4
The short end of the cable should
extend approximately 1/8” beyond
the top edge of pocket.

CONDITION POSSIBLE CAUSE CORRECTION
MOTOR RUNS IN ONLY
ONE DIRECTION
Defective solenoid or stuck solenoid. Jar solenoid assy to free contacts. Check each solenoid
by applying +12 volts to coil terminal (it should make an
audible click when energized).
Defective remote control or low bat-
tery in transmitter.
Check winch operation with auxiliary toggle switch. Check
battery in transmitter.
MOTOR RUNS
EXTREMELY HOT
Long period of operation. Cooling-off periods are essential to prevent overheating.
MOTOR RUNS, BUT WITH
INSUFFICIENT POWER
OR WITH LOW LINE
SPEED
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.
MOTOR RUNS, BUT
DRUM DOES NOT TURN
Clutch not engaged. If clutch engaged but symptoms still exist, it will be neces-
sary to disassemble winch to determine cause and repair.
MOTOR WILL NOT
OPERATE
Stuck or defective solenoid. Jar solenoid assy to free contacts. Check solenoid by
applying +12 volts to coil terminal (it should make an
audible click when energized).
Defective remote control or low bat-
tery in transmitter.
Check winch operation with auxiliary toggle switch. Check
transmitter battery
Defective motor. If solenoids operate, check for voltage at armature post;
replace motor.
Loose connections. Check all electrical connections from the battery to the
motor.
MOTOR WATER
DAMAGED
Submerged in water or water from
high pressure car wash.
Allow to drain and dry thoroughly, then run motor without
a load in short bursts to dry windings.
WINCH RUNS IN
OPPOSITE DIRECTION
OF TRANSMITTER
BUTTONS
Motor leads crossed. Reverse electrical connections to motor.
Solenoid control wires crossed. Reverse position of green and yellow wires on solenoid
assy.
Troubleshooting Guide
5

Electrical Schematic - Wireless Remote only
6
Electrical Schematic - Rocker Switch only

Electrical Schematic - Wireless Remote and Rocker Switch
7
For certain mounting applications, where the solenoid needs to be mounted at the rear of
the vehicle, switch the battery and motor leads. In this case, connect the black w/yellow stripe
lead to the positive (+) terminal of the battery, and the longer black lead to the negative (-)
terminal. Connect the red lead and the shorter black lead to the motor terminals.

Wireless Remote Control
Installation and Operation
If your winch includes a Wireless Remote Control,
refer to pages 2-4 of Wireless Remote Control
Installation Instructions for instructions for installing
the solenoid, receiver, antenna, and toggle switch.
Install the Wireless Remote Control before the
Rocker Switch, if using both.
Refer to page 6 of Wireless Remote Control
Installation Instructions for remote operation notes.
Caution: When the transmitter reaches a tem-
perature 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 sole-
noid 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 trans-
mitter to disable the transmitter when winch is not
in use. This will prolong the battery life of the trans-
mitter. The transmitter automatically turns off after
20 minutes.
Rocker Switch Operation
Press Rocker Switch toward “IN” position to spool
cable “IN” and press Rocker Switch toward “OUT”
position to spool cable “OUT”.
Rocker Switch Installation
Before Beginning Installation
1. Disconnect negative (-) battery cable from
battery.Turn off vehicle ignition. Disengage
winch clutch.
2. Remove hood or cowling as necessary for easi-
er access to installation area.
3. Locate and mark mounting location for Solenoid
Assembly. Choose a mounting location that will
remain protected and dry. Solenoid must be
mounted within 24” of winch motor. Solenoid
should be mounted on a flat surface.
4. 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.
5. Make sure locations are close enough for wiring
connections to be made without making altera-
tions to wire lengths.
Caution: Donot ConneCt negative battery
Cable or engage ClutCh until installation is
Complete. WinCh CoulD begin spooling Cable
unexpeCteDly Causing injury or Damage to
WinCh.
Installing the Solenoid
(If installing Wireless Remote, install solenoid
according to instructions in Wireless Remote
Installation Instructions)
1. Either use Solenoid Assembly as a guide to
mark and drill (2) 7/32” holes in location deter-
mined for solenoid or use Tube clamps (item
#18-15) to mount it.
2. Use (2) 3/4” long #10 screws (item #18-11), (2)
#10 flat washers (item #18-16), and (2) #10 zinc
locknuts (item #18-4) to mount solenoid. Tighten
to 60 in-lbs (7 Nm) torque.
8

Installing the Rocker Switch
For clarification, see wiring schematic on pages
6-7.
1. Install green Wire Connector (item #18-20) to
green wire on Rocker Switch (item #17) and
black Wire Connector (item #18-19) to black wire
on Rocker Switch, as shown at right.
2. The Rocker Switch assembly (item #17) will be
assembled with the two halves of the housing
already attached. Install the Mounting Bracket
(item #18-8) using (2) #6 screws (item #18-12)
and shake-proof washers (item #18-18). See
figure below. Tighten securely.
Do not overtighten.
3. Install (2) Handle Bar Clamps (item #18-2)
around ATV handle bars at a convenient location.
Use a 3/4” long #10 screw (item #18-11) and #10
locknut (item #18-3) to secure them. See figure
below and at right. Secure loosely, do not
tighten.
9

4. Install the Mounting Arm (item #18-7) to the
Handle Bar Clamps using a 7/8” long #10
screw (item #18-10), shake-proof washer (item
#18-17), and locknut (item #18-3). Install the
shake-proof washer between the handle bar
clamps and the mounting arm. Do not tighten.
5. Install the Mounting Bracket (with rocker switch
attached) to the Mounting Arm Bracket using
a 3/4” long #10 screw, shake-proof washer,
and locknut. Install the shake-proof washer
between the mounting arm bracket and the
mounting bracket.
6. Tighten all screws for the handle bar clamps
and mounting brackets securely, positioning
the rocker switch as desired.
7. Route the Rocker Switch wire down the handle
bars to where the solenoid is mounted. Turn
the handle bars fully right and left to ensure
enough slack in the wire. Make sure wire is not
drawn taut across any surface that could dam-
age it. Use cable ties to anchor wire. Do not
connect wires to solenoid yet.
8. Push ATV Accessory wire and red wire from
switch into plastic splice (item #18-21). Fold
splice clip over itself and snap closed.
Connect Wiring to Solenoid
Caution: tighten nuts on terminal stuDs to
35-40 in-lbs. (3-4 nm) torque. Donot over-
tighten.
For clarification, see wiring schematics on pages
6-7. If installing the Wireless Remote Control,
install the solenoid according to the instruc-
tions in the Wireless Remote Control Installation
Instructions.
1. Connect Red Battery Lead between “A” termi-
nal on Solenoid and positive (+) vehicle battery
terminal.
2. Connect Black Motor Lead between #2 ter-
minal on motor and C terminal on solenoid.
Connect Black w/Yellow Stripe Motor Lead
between #1 terminal on motor and B terminal
on solenoid.
3. Connect Black Battery Lead to “E” terminal
on Solenoid and route to negative (-) vehicle
battery terminal but do not connect.
4. Plug black wire from switch into right terminal
(terminal above black with yellow stripe motor
lead). Plug Green wire from switch into left ter-
minal (terminal above black motor lead). If the
Wireless Remote is installed, unplug the wires
from the solenoid, connect the switch wires,
then plug the wires from the wiring harness
into the “piggyback” connectors above the
switch wires.
Finish Installation
1. Confirm that winch clutch is disengaged.
2. Connect negative (-) battery cable to vehicle
battery. Connect Black Battery Lead from
winch to negative (-) vehicle battery terminal.
3. With ignition switch OFF, press Rocker switch
to “OUT”—winch should not operate. If the
winch does operate with the ignition off, con-
firm that proper accessory wire from ignition
was spliced.
4. Spool a few feet of cable out by hand. Engage
winch clutch. Turn ignition switch ON and
press Rocker switch to “OUT”—winch should
spool cable out. If winch does not operate with
ignition on, check wiring against the schematic
on pages 6-7.
5. If winch spools cable IN instead of OUT, turn
off ignition and reverse black and green wires
on solenoid.
10

NOTES

ATV2500 Parts List
12
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 GEAR KIT
7 1 251236 ROLLER FAIRLEAD KIT
8 1 251195 BUSHING KIT
9 1 251196 TIE BAR KIT
10 1 251197 ELECTRICAL WIRING KIT
11 1 282058 WIRELESS RECEIVER & TRANSMITTER KIT
12 1 251190 WIRELESS TRANSMITTER KIT
13 1 251234 SOLENOID KIT
14 1 251235 TOGGLE SWITCH KIT
15 1 251198 ANTENNA KIT
16 1 256116 BRAKE KIT
17 1 282065 ROCKER SWITCH
18 1 *HARDWARE KIT

ATV 2500 PARTS
13
16
3
7
5
4
89
10 11
12
13 14
15
16
2
17

14
* 18. Hardware Kit
Item
No. Qty. Description
18-1 1 CABLE TIES, PKG. (NOT PICTURED)
18-2 2 HANDLE BAR CLAMP BRACKET
18-3 3 LOCKNUT - #10-24NC HEX BLACK
18-4 2 LOCKNUT - #10-24NC HEX ZINC
18-5 2 LOCKWASHER - 3/8 MED SECTION ZINC (FAIRLEAD MTG)
18-6 4 LOCKWASHER - 5/16 MED SECTION ZINC (WINCH MTG)
18-7 1 MOUNTING ARM BRACKET
18-8 1 MOUNTING BRACKET
18-9 2 NUT - 3/8-16NC REG HEX ZINC (FAIRLEAD MTG)
18-10 1 SCREW - #10-24NC X 7/8” LG TRUSS, CROSS RECESS BLACK
18-11 4 SCREW - #10-24NC X 3/4” LG TRUSS, CROSS RECESS BLACK
18-12 2 SCREW - #6-32NC X 1/4” LG SOCKET BUTTON HEAD BLACK
18-13 2 SCREW - 3/8-16NC X 1” LG HEX HEAD GR5 ZINC (FAIRLEAD MTG)
18-14 4 SCREW - 5/16-18NC X 1” LG HEX HEAD GR5 ZINC (WINCH MTG)
18-15 2 TUBE CLAMP
18-16 2 WASHER - #10 FLAT ZINC
18-17 2 WASHER - #10 SHAKE PROOF
18-18 2 WASHER - #6 SHAKE PROOF
18-19 1 WIRE ASSEMBLY - BLACK
18-20 1 WIRE ASSEMBLY - GREEN
18-21 2 WIRE SPLICE

NOTES

RAMSEY WINCH COMPANY
P.O. BOX 581510 TULSA, OKLAHOMA 74158-1510 USA
PHONE: [phone] FAX: [phone]
http://www.ramsey.com
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, post-
age 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 work-
manship 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 reg-
istration 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 work-
manship.
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 inspec-
tion 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 dis-
claimed: 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 dis-
claimer/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.
OM-914159-0816-D