Relay Test

Relay Test 

Fig 1: Battery CABle Exploded View

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1. Disconnect the red (+) battery CABle (1).
   Fig 2: Removing/Installing Winch Assembly

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2. Remove the winch assembly (2) as necessary to gain access to the relay pack and cover. Refer to WINCH, REMOVAL .
   Fig 3: Identifying Power CABle Connections

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3. Disconnect the three CABles connected to the motor on the studs marked F1 (2), F2 (1) and A (3).
   Fig 4: Identifying Relay 1

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4. Remove the nut and disconnect the terminal wire (1).
   1. Measure the resistance between the two large studs on relay #1.
      • The resistance should be greater than 1 megaohm.
   2. 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.
   Fig 5: Identifying Relay 2

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5. Remove the nut and disconnect the terminal wire (1).
   1. Measure the resistance between the two large studs on relay #2.
      • The resistance should be greater than 1 megaohm.
   2. 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.
   Fig 6: Identifying Relay 3

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6. Remove the nut and disconnect the terminal wire (1).
   1. Measure the resistance between the two large studs on relay #3.
      • The resistance should be greater than 1 megaohm.
   2. 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.
   Fig 7: Identifying Relay 4

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7. Remove the nut and disconnect the terminal wire (1).
   1. Measure the resistance between the two large studs on relay #4.
      • The resistance should be greater than 1 megaohm.
   2. 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.
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 RELAY, WINCH, REMOVAL .