Winch: Testing and Inspection

WINCH










Relay Test




- Disconnect the red (+) battery cable (1).





- Remove the winch assembly (2) as necessary to gain access to the relay pack and cover Winch - Removal.





- Disconnect the three cables connected to the motor on the studs marked F1 (2) , F2 (1) and A (3).





- Remove the nut and disconnect the terminal wire (1).

- Measure the resistance between the two large studs on relay #1.

- The resistance should be greater than 1 megaohm.
- Apply 12 volts to the small terminal (1) and apply ground to the small terminal (2).

- Measure the resistance between the two large studs on relay #1.
- The resistance should be less than 1 ohm.





- Remove the nut and disconnect the terminal wire (1).

- Measure the resistance between the two large studs on relay #2.

- The resistance should be greater than 1 megaohm.
- Apply 12 volts to the small terminal (1) and apply ground to the small terminal (2).

- Measure the resistance between the two large studs on relay #2.
- The resistance should be less than 1 ohm.





- Remove the nut and disconnect the terminal wire (1).

- Measure the resistance between the two large studs on relay #3.

- The resistance should be greater than 1 megaohm.
- Apply 12 volts to the small terminal (1) and apply ground to the small terminal (2).

- Measure the resistance between the two large studs on relay #3.
- The resistance should be less than 1 ohm.





- Remove the nut and disconnect the terminal wire (1).

- Measure the resistance between the two large studs on relay #4.

- The resistance should be greater than 1 megaohm.
- Apply 12 volts to the small terminal (1) and apply ground to the small terminal (2).

- Measure the resistance between the two large studs on relay #4.
- The resistance should be less than 1 ohm.

- If the resistance across any of the relays doesn't go from open to closed (megaohms to tenths) then the relay is bad and needs to be replaced Winch Relay - Removal

Remote Switch Test

1. To check switch, follow the steps below to check for switch continuity.

Power-Out




- Move switch to the power-out position.
- Check for continuity between pins (1) and (4).
- Check for continuity between pins (2) and (5).

Power-In




- Move switch to the power-in position.
- Check for continuity between pins (1) and (4).
- Check for continuity between pins (2) and (3).

2. If there is no continuity, then the remote switch is bad and needs to be replaced.

Thermal Switch Test

The motor will not power-in if the thermal switch is open or if its terminals are in contact with the motor case. The switch should normally open when the temperature at the motor brushes reaches 205+°C (400+°F).

If the Thermal Switch is suspected to be failing check the following:

1. Disconnect the switch.
2. Measure the resistance of the switch at the electrical connector.
3. If the switch is open at room temperature then replace the motor.
4. If the switch is closed then the switch is good.
5. Check for resistance between both terminals and the motor case.
6. If the resistance is less than 1 megaohm then the winch is grounded. Replace the motor Winch Motor - Removal.

Low Voltage Interrupt (LVI) Test

If the LVI is suspected to be failing check the following:

1. Check to make sure the battery has 10.5 to 12 volts.
2. If low, charge battery.
3. Wait for 30 seconds or more.
4. Check for a ground on pin 4.
5. If no ground then check control ground Relay Pack Test.
6. If ground good then replace the relay pack Winch Relay Pack - Removal.

Motor Test

If the motor is suspected to be failing check the following:

1. Disconnect the motor power connectors F1, F2 and A.
2. Measure the resistance between F1 and F2. Resistance should be less than 1?.
3. Measure the resistance between A and ground. Resistance should be less than 1?.
4. If the resistance is greater than 1? the motor brushes could be worn or the internal wiring could be burned. Replace the motor Winch Motor - Removal.

Power Test

1. Check for a tight fit of all connections.
2. Using a volt meter, verify 12 ± 2 volts a the bus bar connecting relays #1 and #3.

Motor Ground Test

1. Check for continuity between the ground stud and the battery.
2. If no continuity then repair the ground cable from the batter to the motor.

Relay Pack Test