Recommended Procedure for Electrical Troubleshooting of SX Winch

1. Inspect Battery Cables
   1. Check Battery Cables for oxidation or corrosion. If cables are dirty the corresponding voltage drop may cause the contactor to act erratically or not work at all. Furthermore, corroded battery cables impair winch performance. Remove and thoroughly clean dirty connections.

           b. Once verifying that the cables are clean (or cleaning them). Check them for tightness. Verify that all fasteners are tight and that the clamps cannot wiggle or move in any fashion. Make certain that the winch cable lugs are not attached to the battery clamps directly beneath the clamping nuts. Instead use a secondary nut or attach the lug to a separate suitable point on the clamp. Placing the winch cable lug between the clamp nut and the clamp may result in a loose clamp thus affecting winch performance.

1.     c. Check that all cables attached to the motor are clean and tight. If cable lugs appear oxidized remove the cable and lightly sand both sides of the lug with 120 to 220 grit sandpaper. Also make sure the small diameter black ground wire that runs from the control box to the ground stud on the motor is securely installed. The contactor inside the control box will not function properly if there is an issue with this ground wire.
2. 

3. ---

   2. Check Battery Voltage – With the vehicle’s engine off use a voltmeter to check that the battery is producing a minimum of 12.0 VDC. If the battery shows less the 12V it should be re-charged or replaced.

4. 

5. ---

   3. Inspect Control Box Wiring

   1. Using a 3mm Allen Key remove the (4) screws attaching the control box to the winch’s tie bar.
   2. Using the same 3mm Allen Key remove the (4) screws holding the Control Box lid to the Control Box base.

1. C. Closely inspect the wiring within the Control Box. Verify that all wires are clean and securely connected. Check for kinked, frayed, or broken wires. If any of the wiring or connectors look suspicious then clean or repair the wiring as appropriate.
2. 

3. ---

    

     4. Test Contactor for Proper Function
   1. a. With the Control Box lid still removed and the winch connected to a 12V battery
   2.  b. Take a 6” to 10” piece of 12 AWG to 18 AWG insulated wire and strip the ends to create a test jumper wire.

4. temporarily touch one end of the jumper wire to the power stud on the Contactor (this stud will have a small red wire attached to it in addition to the large cable going back to the battery). Touch the other end of the jumper wire to the spade terminal on the contactor where the blue wire(s) terminate. The winch should power inward.

   Important: Keep hands, hair, and articles of clothing away from the winch body when performing this step!

   1. c. Temporarily touch one end of the jumper wire to the power stud on the Contactor. Touch the other end of the jumper wire to the spade terminal on the contactor where the white wire(s) terminate.
      1.               The winch should power outward. Important: Keep hands, hair, and articles of clothing away from the winch body when performing this step!
   2. d. If jumping the contactor causes the winch to function properly and all wires and cables appear in good condition, then it is very likely that the remote control or remote socket is causing the issue. Inspect the remote socket. If all pins look good, then replace the

5. remote control. If the remote socket appears damaged, then replace the remote socket.

6. 

7.  

8.  
   1. e. If jumping the Contactor does not cause the winch to function and all steps prior have been carefully carried out, then it is likely that either the Contactor or the Motor is faulty.

9. When jumping the contactor an audible click should be heard. If no click, then the

   contactor likely needs to be replaced. If the Contactor clicks, then follow motor testing in step 5 to determine if the motor or contactor is faulty.

10. ---

    5. Testing the Winch Motor

    1. Disconnect the red power cable from the battery before starting. Leave the black ground cable in place. Be sure the engine of the vehicle is not running.
    2. Disconnect the Drum Light wiring connector.
    3. Loosen the two Phillips screws retaining the Contactor to the Control Box Base.
11. 4. Make note of the position and color of the motor cable attachments to the contactor. Several of them will be removed and used to test the motor. They will need to be reattached once motor testing has been completed.

12. (loosening these screws makes it easier to disconnect the cables from the Contactor).

13. 

     

     

14. e. Remove the motor cable with the blue ends. It will not be used for this test.
15. f. Disconnect the long power cable with the red ends from the contactor. Reinstall it on the motor stud with the black grommet.
16. g. Disconnect the short motor cable with the red ends from the contactor. Leave it installed on the motor.
17. h. Attach the end of the short red cable removed from the contactor in step (g) to the motor stud with the yellow grommet. You are now jumping from the stud with the red grommet to the stud with the yellow grommet.
18. i. Briefly touch the bare lug end of the long cable with the red ends to the positive post of the 12V battery that is already connected to the ground cable. If the motor is in good condition, it will run and operate the winch. Caution – A small spark will jump from the battery post to the cable lug when you do this. Be certain the battery is not charging or has been recently charged when conducting this step. Charging batteries may give off hydrogen gas. Important: Keep hands, hair, and articles of clothing away from the winch body when performing this step!
19. j. If the motor operated properly in Step (i) then the Contactor likely needs to be replaced. If the motor did not operate properly in Step (i) then the motor is faulty and needs to be replaced.
20. k. reinstall all cables and wires in their original location after completing this test.
21. 

22.