Dutton-Lainson Company

A Dependable Company Since 1886

120 Volt AC Winches with Remote Switch Manual

Use this manual for 120 Volt AC Models with Remote (hand-held) Switch: SA5015AC, SA7015AC, SA9015AC, SA12015AC

Note: The model numbers on the winch decal do not include “15”, which indicates that a remote switch has been installed. These winches are identified on the decal as SA5000AC/SA7000AC or SA9000AC/SA12000AC.

SAFETY NOTES: Many of the following trouble shooting procedures require removing the winch cover to observe or test components. Even if not mentioned in the procedure, always disconnect the winch from its 120 volt power source when removing or replacing the cover and reconnect the winch to power only when necessary to make a test or observation. Be extremely careful to avoid contact with electrical shock hazards and to keep hands away from any parts that will move when power is applied.

Symptoms & Solutions

Circuit breaker blows immediately when winch is plugged into outlet

Corrective Action:

To 100% confirm that bridge is the problem, disconnect the two wires leading to the switch and then plug power cord into outlet. If circuit breaker blows again, this confirms bridge is the problem. Replace rectifier bridge number 304426. When installing new bridge, make absolutely certain to connect according to wiring diagram. The bridge is most commonly damaged by voltage spikes. Avoid future failures by unplugging winch from power when not in use.

Corrective Action:

If rectifier bridge is not found to be the problem in the step above, then the problem must be in the remote switch cord or switches. Replace remote switch number 5240890. If you are certain that remote switch wiring is not damaged, switches can be replaced individually. IN-OUT switch is number 204491 and OFF-RUN switch is number 204490.

Circuit breaker blows only when control switch is pushed

Corrective Action:

Look for damaged insulation on the motor wires, especially where they contact the winch frame.

Corrective Action:

Test the motor by the following procedure. Unplug winch from power and then disconnect white and black motor wires from the switch wires and disconnect white and black switch wires from the rectifier bridge. Plug winch back in and then carefully touch motor wires directly to the positive (+) and negative (-) terminals of the bridge. If this causes circuit breaker to blow, then motor needs to be replaced (motor number 304921). If motor runs smoothly without blowing breaker, then the problem is somewhere in the switch assembly. Note: NEVER CONNECT MOTOR DIRECTLY TO 120 VOLT AC POWER. This is a DC motor and must run on rectified current.

Corrective Action:

After confirming that the problem is not the motor or motor wires, replace remote switch assembly number 5240890. If you are certain that remote switch wiring is not damaged, switches can be replaced individually. IN-OUT switch is number 204491 and OFF-RUN switch is number 204490.

Motor will not run in either direction

Corrective Action:

Check to be sure that power is available at the outlet.

Corrective Action:

Using a volt meter confirm that 120 volts AC is present between the AC terminals on the rectifier bridge. These are the terminals that have the varistor soldered between them. If voltage is not present here, then there is a problem in the power cord. Next check voltage between the Positive (+) and Negative (-) terminals on the bridge (the terminals without the varistor attached). Voltage should be approximately 90 volts DC. If voltage is not present here, replace the bridge, part number 304426. Next check voltage between the red and blue switch wires where they connect to the motor wires. The voltage should be approximately 90 volts DC when the RUN switch is activated with the IN-OUT switch in either position. The voltage should be zero when the RUN switch is released. If voltage is not present at these wires as described, then replace the remote switch assembly number 5240890. If you are certain that remote switch wiring is not damaged, switches can be replaced individually. IN-OUT switch is number 204491 and OFF-RUN switch is number 204490.

Corrective Action:

If the motor does not run after confirming that voltage is being supplied to it as discussed above and confirming that the motor wires are not broken, then replace motor number 304921. Reminder: NEVER CONNECT MOTOR DIRECTLY TO 120 VOLT AC POWER. This is a DC motor and must run on rectified current.

Motor runs in only one direction

Corrective Action:

Replace IN-OUT switch number 204491.

Winch runs backwards

Corrective Action:

On SA5000/SA7000 models the cable must wind onto the top side of the winch drum and on SA9000/SA12000 models the cable must wind onto the bottom side of the drum. This is critically important and must not be reversed. If you are not sure which model you have, the model number is shown at the bottom of the back decal.

Corrective Action:

Check to be sure that all of the wires connected to the switch are exactly as shown in the wiring diagram.

Winch smokes

Corrective Action:

It is not unusual for the winch to smell hot or smoke during the first few uses while powering the winch in the Out direction. The brake device gets extremely hot and sometimes creates smoke for the first few uses. This should not happen when the winch is pulling cable in.

Motor runs hot

Corrective Action:

Limit motor run time to a maximum of four minutes followed by at least 20 to 30 minutes of cooling. Motor run time is critical even when winch is not pulling its full capacity or is letting cable out.

Motor has difficulty pulling load

Corrective Action:

If motor slows down a lot and groans to pull load, winch is probably overloaded. Reduce the amount of load being pulled or use a pulley block and hook to increase the pulling capacity of the winch.

Corrective Action:

On SA5000/SA7000 models the cable must wind onto the top side of the winch drum and on SA9000/SA12000 models the cable must wind onto the bottom side of the drum. If the cable is wound the wrong direction, the motor will be working against the brake and may have difficulty pulling the load. If you are not sure which model you have, the model number is shown at the bottom of the back decal.

Corrective Action:

First confirm that cable is wound on winch spool in the correct direction. Then remove the winch cover and observe the brake disc on the motor shaft. If the brake disc spins while the winch is pulling in a load, it needs to be replaced. Order brake disc number 304407 for SA5000/SA7000 models or number 304422 for SA9000/SA12000 models.

Motor runs but winch fails to pull cable

Corrective Action:

Move clutch lever to engaged gears position.

Corrective Action:

Move clutch lever to freewheel position and then let it gently return to the engaged position using spring pressure only. DO NOT FORCE THE LEVER TO THE STOP. Remove the two small phillips head screws and the clutch lever and examine the position of the spring keeper lug in relation to the stop in the side of the housing. If the lug is touching or very close to the stop (see photo), then clutch is out of adjustment. There are two possible causes which need to be investigated. The thrust bearings could be worn out or the clutch pad could be damaged. To investigate these possibilities, remove the winch cover and disassemble the clutch mechanism as follows. With a flat blade screwdriver pry the end of the clutch spring from the hole in the winch base. The spring tension is quite high and the spring will snap violently when it comes free, so be careful to keep your hands and other body parts away. Rotate the plastic O-ring so the the cut out portions align with the pegs on the spring keeper. The O-ring can then be expanded with a pencil, pocket knife or similar tool and the spring keeper can be lifted free from the clutch nut. Thread the clutch nut off of the stud (it is a left hand thread). You will then see the outer thrust bearing with a hardened bearing race (flat washer) on both sides. Lift both of the gears off of the stud and notice that there is a small spring washer between them. The inner thrust bearing and two races can then be removed. There may be additional spacer washers on the stud and these should remain on the stud. Check the condition of both of the thrust bearings and the races and replace if noticeably worn, dry or burned. Order and install thrust bearing kit 5703194, which includes two bearings and four races. Examine the condition of the clutch pad. This is bonded to the large gear in newer models or bonded to the flange of the small gear in older models. If there are portions of the clutch pad missing or torn away, or any other significant damage to the pad, a replacement is necessary. If the clutch pad in your winch is bonded to the large gear, you can replace just that gear. Order 120 tooth gear assembly 306102 for SA5000/SA7000 models or 84 tooth gear assembly 306101 for SA9000/SA12000 models. If the clutch pad in your winch is bonded to the clutch gear flange it will be necessary to order clutch gear assembly 306100 in addition to one of the above gears. Reassemble and adjust the clutch by the following procedure. Place one of the thrust bearings (with a race on each side) on the clutch stud. Next install the clutch gear and the spring washer oriented as shown in the photo on the stud followed by the large gear turned with the pad facing the clutch gear. Install the outer thrust bearing (with a race on each side) and then install the clutch nut (left hand thread). Use the plastic spring keeper to tighten the nut by hand only. Then insert one leg of the clutch spring into the hole in the spring keeper. Note that on SA5000/SA7000 models the legs of the clutch spring are not equal length. The longer leg attaches to the spring keeper. On SA9000/SA12000 models both legs are the same length and it makes no difference which one attaches to the spring keeper. Position the keeper on the clutch nut so that the lug is positioned at the 2:30 o’clock position (see photo). Reinstall the plastic O-ring and rotate it slightly to lock the spring keeper in place on the clutch nut. Grip the free end of the spring with pliers or vise grips and insert the end into the hole in the winch base. This is challenging because the spring tension is quite high. Make sure the end goes all the way into the hole. Slip the clutch lever onto to the spring keeper and move the lever to the freewheel position and gently allow it to return to the engaged position using the force of the spring only. DO NOT FORCIBLY MOVE THE LEVER PAST WHERE THE SPRING TAKES IT. Remove the lever and check the position of the lug on the spring keeper. It should be at approximately the 2:30 o’clock position (see photo). If not, without moving the position of the clutch nut, disassemble the spring, O-ring and spring keeper and reposition the keeper on the nut so that the lug is at 2:30 o’clock and reassemble. Recheck to confirm that the spring keeper stops in approximately the same position when the lever is moved to freewheel and allowed to return to engaged using spring pressure only. Note that if the lug on the spring keeper is set too high, the clutch may slip under heavy load. If it is set too low the clutch will be too tight and will create excess strain on the motor and excess load and heat on the thrust bearings. Our clutch adjustment video may be helpful.

Corrective Action:

Remove the winch cover. Run the winch and observe which parts are turning and which are not. This should make the source of the problem obvious. Refer to the owner’s manual or website for the necessary repair parts.

Winch will not hold load

Corrective Action:

On SA5000/SA7000 models the cable must wind onto the top side of the winch drum and on SA9000/SA12000 models the cable must wind onto the bottom side of the drum. If the cable is wound the wrong direction, the brake will not work. If you are not sure which model you have, the model number is shown at the bottom of the back decal.

Corrective Action:

Check condition of the small brake pads that contact the brake disc on the motor shaft. If the pads are severely worn or either pad is missing, order and install a brake spring replacement kit. Kit number 5703210 for SA5000/SA7000 models or kit number 5703160 for SA9000/SA12000 models.

Corrective Action:

Check the operation of the roller clutch in the brake disc. Carefully rotate the brake disc and observe the motor shaft. When the disc is turned clockwise the motor shaft should turn with it. When the disc is turned counterclockwise the motor shaft should not turn. If the operation is not as described, order and install a new brake disc assembly. Order number 304407 for SA5000/SA7000 models or number 304422 for SA9000/SA12000 models.

Corrective Action:

Confirm that load is within capacity of winch.

Winch will not freewheel cable out

Corrective Action:

First confirm that clutch is in freewheel position. Then with no load on winch jog power switch to see if clutch will open and allow freewheeling. If this does not work, remove any load from the winch, put the clutch lever in the freewheel position and remove the winch cover. Then gently pry the clutch gear and mating gear apart by inserting a screwdriver between them.

Cable stuck on winch reel

Corrective Action:

Cable may have become wedged between the wraps of lower layers. There is no easy solution to this except to pull on the cable hard enough to pull it free. Avoid this problem by keeping cable neatly and tightly wound on the drum. See cable damage section below.

Cable damage

Corrective Action:

The cable is considered a perishable item and will periodically need to be replaced. Follow these suggestions to maximize cable life: Shorten the cable to the minimum length necessary for your application remembering to keep at least three turns on the drum before starting to pull a load. Excess cable length makes loose, crisscrossing wraps more likely. Make certain that the first layer of cable on the drum is wound neatly and tightly and additional layers will follow in neat, tight wraps. It is essential to keep some tension on the cable during this process. Never start pulling a load with loose cable on the drum. This will almost certainly cause kinks and crushing and wedging cable into lower layers. Allowing loose cable to wind onto drum may also cause it to get caught in gears or other parts causing serious winch damage. It is also important to keep winch reasonably aligned with the load being pulled so that the cable does not severely rub the edges of the cable opening.

Cable breaks

Corrective Action:

See Cable damage section above.

Corrective Action:

The winch has sufficient power to break the cable if overloaded. Monitor load carefully to prevent a sudden rise in cable tension. Keep cable in good condition and replace when damaged.

Hook spreads open

Corrective Action:

Make certain that load is fully engaged into the throat of the hook allowing the safety latch to close. Engaging only the point of the hook on the load could cause hook to open up or break.

Corrective Action:

Overloading the hook will cause it to spread open and possibly break. Reduce load or use a pulley block and hook to reduce tension on the cable and hook.

Dutton-Lainson Company

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