Charging system

[Dylan Robinson]

I found a killer deal on a barely used Ram PW winch. I put it on my regular non PW 2500. When I went to use it for the first time, it seemed like the charging system would trip a breaker or something and shut down, then reset itself several seconds later. After that I upgraded the alt to the 160a, and changed all the battery cables to a 2/0 welding cable with soldered heat shrunk all copper lugs. With the upgrades the winch seems like it might run a little longer before the charge system shuts off, and then resets. Almost like the computer is shutting it off to keep the alt from burning up. Kinda curious if that is normal or??? I've asked around at a couple mechanic places, and the local dealership, nobody can tell me if the computer has a built in safety, or there is actually something wrong with my charging system.


Dylan Robinson

[Pit Slave]

Mine does that. It's normal as it thinks it has a short in the electrical system. It will automatically reset in a few seconds and continue to charge. Wait a few moments to allow the battery to recover before continuing to winch. It's best to have the engine running at a higher idle while winching.

Sent from my XT1254 using Tapatalk

[Ducky's Dad]

Low Voltage Interrupt (LVI) on the winch was reputed to cause some issues on the 3Gs. There is also a thermal protector on those winches, but it sounds like yours may not be running long enough to trip that switch. How's your battery?

[Dylan Robinson]

Ok makes me feel better knowing their isn't anything wrong with the truck.

Battery is newer (little over a year) grp65 Interstate (850CCA I think). Yeah, so far I haven't opened up the control box on the winch, so not sure if it has any modifications done to it yet, I do know it was off an 06' PW. When I acquired it, ($500 on Craigslist, cradle, winch, cable, bolts, and all) the wired controller was missing, and my meager slush fund was tapped with the winch purchase, so I bought a Warn wireless setup ($45) off ebay. It seems to work ok, but I'm looking for a regular controller. Will the Warn P/N 38626 work??

(https://www.amazon.com/WARN-38626-Winch ... controller)

So far the couple of times I've used it the winch itself hasn't ever refused to function. Once, I ran the entire cable out (except for the last 6-8 wraps) and with the truck off spooled all but the last 6' or so onto the drum under a slight load. Started the truck and drove away. Everything seemed to function ok.

On to the OBA setup....

Dylan

[TwinStick]

My reg 2500 had a 160 amp alt, maybe because of the plow option ? Anyways, mine had issues like that as well. Dual batteries & a 270 amp alt cured that problem. I really don't think the stock 160 amp alt was ever up to the task of a winch w/one battery. They draw up to 440 amps at full load.

[Dylan Robinson]

Yeah, for awhile I suspected something was wrong with the winch itself, so I put an amp clamp on the positive lead to the battery. Just spooling the cable on or off it would draw approximately 60a. With one layer unwrapped off the drum, all four tires locked up on dry pavement it would pull 380a. The charge system would cut out at approximately 360a. It was about 85deg ambient that day. My truck had a 136a (printed on the back of the alt) alt stock. I put in p/n xxxxx-280 (cant member the exact p/n) 160a alt. same Denso p/n as my 04' Limited Durango.

Overall if it functions without hurting anything, I think I'm happy for now. The second time I had to use it, I had it loaded pretty good. I had my 8,700lb toyhauler almost over the bank on my pretty steepish driveway. Right side of the trailer was sunk up to the hubs in mud, while the truck itself was still on the gravel, but I had let it dig some fairly deep holes, because I was afraid of the trailer dragging the truck over the hill. Kind of a hair raising situation for about 20min. LOL



Dylan

[TwinStick]

Yup, been there , done that with our toyhauler in mud & it started moving down a hill after i unhooked it. I was by myself, praying out loud while i was trying rehook before it went over. Luckily the mud was soft enough that it did not bend my stabilizers over. I ended up cranking the jack as far up as it would go, backed up till the bumper hit the tongue, then jumped out & started lowering it fast, as it was sliding & got it back on the ball. I was sweating, shaking & praying---all at the same time. Ground didn't seem that soft at first. It rolled right over my wheel plastic chocks. Thats why i made my own HD ones, with teeth.









A second battery would make your winch work 100% better, even with the 160 amp alt.

[Dylan Robinson]

Yea, I'm sure your right about the second battery. I had bought a K&N cold air intake just so that I could free up some space on that side just for that purpose, but after one trip with it, I took it off. Couldn't hear myself think, when pulling the trailer. lol My buddy does the diesel/stack thing, and I'd wager that my truck was just as annoying to ride in as his. Chock idea is copied and saved in the back of my brain for the next time I'm at the hardware store.

Dylan

[coder]

Hello Dylan Robinson,

Did you also get the wiring harness that come with it? I have a copy of the Mopar Winch Installation Instructions it should show you everything required to add a power wagon winch to any compatible vehicle. If you want it send me a message with your email address and I will send you the PDF. A 160 amp alternator and a 750 cca battery is all you need to power your electrical system.

[Dylan Robinson]

Hmmm, well I got the cables that were hooked directly to the winch motor, and I believe their was some extra wiring that was connected in with that. But just in case, email sent.
Thanks!

Dylan

[Dylan Robinson]

Bump, Just curious if anybody knows. It looks to be the same configuration. Will the Warn P/N 38626 work??

(https://www.amazon.com/WARN-38626-Winch ... controller)


Dylan

[Vee]

It does not have to be the Dodge controller. I bought a new style Warn controller for a Zeon for 50 bucks. Works great. As long as the plug fits, it should work.

Sent from my SM-G900V using Tapatalk

[Dylan Robinson]

OK, Thanks!

Dylan