relay DODGE RAM SRT-10 2006 Service Repair Manual

CONDITION POSSIBLE CAUSES CORRECTION
When remote control switch is
activated, there is only a
clickingsound, and the winch
does not operate in either
power inorpower out
modes.Low battery charge, corroded terminals,
defective battery.Use a fully charged conventional
automotive battery with a minimum
of650coldcrankingampsratingto
obtain peak performance from the
winch. Make sure all terminals are
clean and the battery is fully
charged. Replace battery if
necessary.
Check for proper power supply. See
Power Test below.
Faulty ground cable attachment to the
motor housing.Check for proper ground. See
Motor Ground Test below.
Faulty motor armature, brushes, or water
in the motor.Replace the motor.
(Refer to 23 - BODY/WINCH/
MOTOR - REMOVAL)
Faulty control relay. Check and replace relays as
necessary. See Relay Pack Test
below
(Refer to 23 - BODY/WINCH/
RELAY - REMOVAL)
Winchrunsslowlyandlacks
power when pulling a load,
won’t pull load, or stalls easily.Thewireropeisspoolontothedrumin
the wrong direction and working against
the brake in the
power inmode.The wire rope must always spool
onto the drum as indicated by the
drum rotation label on the winch.
Winches are equipped with an
automatic brake and WILL NOT
FUNCTION if the wire rope spools
intheoppositedirection.Thewire
rope spooling can accidentally be
reversed by running the wire rope
all the way out and re-spooling in
with the control switch in the
power
out
mode.
When the remote control is
activated, the winch will
operate only in one direction.One or more of the control pack relays is
damagedCheck and replace relays as
necessary. See Relay Pack Test
below
(Refer to 23 - BODY/WINCH/
RELAY - REMOVAL)
The remote control switch is damaged. Check and replace switch as
necessary. See Remote Switch Test
below.
Power-out mode only. Tripped or damaged thermal switch Let motor cool for atleast30
minutes, then try to power-in again.
Check thermal switch. See Thermal
Switch Test below.
Replace the motor if the thermal
switch is faulty.
(Refer to 23 - BODY/WINCH/
MOTOR - REMOVAL)

CONDITION POSSIBLE CAUSES CORRECTION
When the remote control is
activated, the winch will not
operate and no “clicking” sound
is heard.Tripped or damaged Low Voltage
Interrupt (LVI)Use a fully charged conventional
automotive battery with a minimum
of650coldcrankingampsratingto
obtain peak performance from the
winch. Make sure all terminals are
clean and the battery is fully
charged. Replace battery if
necessary.
Check LVI. See Low Voltage
Interrupt (LVI) Test below.
Replace the relay pack if the LVI is
faulty.
(Refer to 23 - BODY/WINCH/
RELAY PACK - REMOVAL)
Relay Test
1. Disconnect the red (+) battery cable (1).

2. Remove the winch assembly (2) as necessary to gain access to the relay pack and cover (Refer to 23 - BODY/
WINCH - REMOVAL).
3. Disconnect the three cables connected to the
motor on the studs marked F1 (2) , F2 (1) and A
(3).
4. Apply 12 volts to the small terminal (1) of relay #1
(2) and measure the resistance across the two
large studs.

5. Apply 12 volts to the small terminal (1) of relay #2 (2) and measure the resistance across the two large studs.
6. Apply 12 volts to the small terminal (2) of relay #3
(1) and measure the resistance across the two
large studs.
7. Apply 12 volts to the small terminal (1) of relay #4
(2) and measure the resistance across the two
large studs.
8. 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 (Refer to
23 - BODY/WINCH/RELAY - REMOVAL).
Remote Switch Test
1. To check switch, follow the steps below to check for switch continuity.

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 (Refer to 23 - BODY/WINCH/RELAYPACK-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 than1
.
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 (Refer to 23 - BODY/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

Measurement
between pinsResistance Voltage
Results Correction
(V)
“4” to “5” 2 - Yes Relay pack OK.
No 1. Check for any faulty relay or
motor electrical connections and
repair if necessary.
2. Check for a faulty relay and
replace as necessary. Refer to
Relay Test .
“4” to “2” 2 - Yes Relay pack OK.
No 1. Check for any faulty relay or
motor electrical connections and
repair if necessary.
2. Check for a faulty relay and
replace as necessary. Refer to
Relay Test .
“1” to “2”
100K - Yes Relay pack OK.
No Check for shorted Thermal Switch.
Refer to Thermal Switch Test .
“1” to “3” - 12 Yes Relay pack OK.
No 1. Check for any faulty relay or
motor electrical connections and
repair if necessary.
2. Check for faulty LVI, Refer to
Low Voltage Interrupt (LVI) Test .
REMOVAL
1. Disconnect and isolate battery negative (3) and
positive (1) cables.

3. Position the relay pack onto the motor and tighten
thebandclamps(2).
4. Connect the thermal switch electrical connector.

MOTOR
DESCRIPTION
The winch is driven on one end by a two direction
electric motor powered by the vehicle electrical sys-
tem. The motor is internally protected by a thermal
switch that is activated when the motor gets too hot to
operate efficiently.
Winch motor controls consist of a relay pack mounted
to the motor, and a remote control connected to the
relay pack with a cord. The winch power source
cables are connected to the relay pack which in turn
feeds power to the winch motor through electrical
cable connections. The main function of the relay pack
is to allow the operator to switch the winch on and off
in both directions. The winch relay pack also includes
a Low Voltage Interrupt (LVI) used to prevent winch
operation in the event of battery power dropping below
10 volts.
REMOVAL
1. Remove the winch assembly (2). (Refer to 23 -
BODY/WINCH - REMOVAL)
MOTOR
1 - ARMATURE STUD/NUT 7 Nꞏm (60 in. lbs.)
2-MOTORBOLTS(2)9Nꞏm(82in.lbs.)
3 - MOUNTING BAND CLAMPS
4 - GROUND CABLE
5 - GROUND BOLT 14 Nꞏm (10 ft. lbs.)
6 - MOTOR COUPLER
7 - MOTOR DRIVE SHAFT
8 - FIELD STUDS/NUTS 7 Nꞏm (60 in. lbs.)

2. Separate one of the roller shaft clips (1), remove
the shaft (3) and the roller (4).
3. Remove the bolts (3) and separate the support
bracket (1) from the winch assembly (2).
4. Remove the relay pack (1). (Refer to 23 - BODY/
WINCH/RELAY PACK - REMOVAL)

2. Position the motor drive shaft into the motor cou-
pler splines and install the motor (2).
3. Install the bolts (1) and tighten to 9 Nꞏm (82 in.
lbs.).
4. Install the relay pack (1). (Refer to 23 - BODY/
WINCH/RELAY PACK - INSTALLATION)