1. An emergency crank handle is provided for use in
the event of a power failure. Remove the electrical
power from the winch.
WARNING: NEVER OPERATE THE WINCH
ELECTRICALLY WITH THE EMERGENCY
HANDLE IN POSITION.
2. Remove the plastic plug from the side of the winch
housing and insert the handle so that it completely
engages with the drive shaft. The handle can be
cranked in either direction with the clutch in the
engaged position. To make cranking easier, the
clutch can be placed in the free wheel position while
holding onto the emergency handle.
WARNING: IF THE CLUTCH IS PLACED IN FREE
WHEEL FOR HAND CRANKING, BE SURE TO
MAINTAIN A FIRM GRIP ON THE HANDLE AT
ALL TIMES.
Because the emergency crank handle for models
SA9000AC, SA9015AC, SA12000AC & SA12015AC
attaches to the clutch side of the winch, it is equipped
with a spring operated clip which will be depressed by the
clutch handle in the free wheel position when cranking in
a clockwise direction to retrieve the cable. This clip is a
safety feature and will re-engage the clutch mechanism in
the event that the operator loses control of the handle with
a load on the winch.
(See FIG. 4)
WARNING: EVEN WITH THIS SAFETY FEATURE
THE HANDLE WILL STILL SPIN VIOLENTLY ONE
OR TWO TURNS BEFORE RE-ENGAGING THE
CLUTCH TO STOP THE WINCH. DO NOT LOSE
CONTROL.
3. Always remove the handle from the winch after use
and replace the plastic plug.
For long life and trouble-free operation your winch
should periodically be inspected for any required main-
tenance. This should be done at least once annually
and more frequently in adverse conditions such as salt
water areas or areas of extreme dust and dirt.
1. Carefully inspect the winch cable for any kinks, frays
or abnormal stiffness and replace at the first sign of
this kind of damage. Go to Dutton-Lainson web-
site: http://www.dutton-lainson.com/ts.php for
trouble shooting manual, select winch model
number and click on symptom “Cable Damage”
for complete diagnoses and corrective action.
Periodic lubrication with a light oil will improve the life
of the cable. In order to replace the winch cable, it is
necessary to remove the clutch handle, by removing the
two clutch handle screws, and the four cover mounting
bolts. Be sure that the power is disconnected from the
housing and lift the housing off of the winch by gently
stretching it open near the lower front corner. Rotate the
winch reel so that you have access to the rope clamp.
Remove the old cable and replace it with a new cable
of the same size. Be sure that the cable passes under
both sides of the rope clamp and that the clamp is
tightened securely. NOTE: CABLE IS WOUND OVER
THE TOP OF THE DRUM ON MODELS SA5000AC,
SA5015AC AND SA7000AC, SA7015AC AND UNDER
THE DRUM ON MODELS SA9000AC, SA9015AC
AND SA12000AC, SA12015AC. SEE ATTACHMENT
METHOD BELOW (FIG. 5).
CABLE ATTACHMENT METHODS
2. With the cover removed as described above, inspect
the entire gear train and all drive shafts for any sig-
nificant wear or loose bearing fits. Grease all of the
gears on the inside of the winch base and apply a
drop of oil on all of the bearings in the base. Also,
very sparingly oil all of the bearings in the clutch
mechanism and place a drop of oil on the roller
clutch. Do not over lubricate these areas and do not
use grease in the roller clutch. The clutch mecha-
nism and the brake pads and brake disc must be
kept clean and oil free.
3. Check the operation of the roller clutch. 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 coun-
terclockwise the motor shaft should not turn. Also,
check all nuts, bolts, retaining rings, etc., to be sure
that they are tight and secure.
4. If the clutch has been slipping and requires adjust-
ment the following procedures should be used. The
clutch is adjustable in ten degree increments. With a
screwdriver and pliers, remove the end of the clutch
spring from the hole in the winch base. The spring
tension is quite high so be careful to maintain a firm
grip on the spring. The O-ring should be rotated so
that the cut out portions align with the lugs on the
spring keeper. (See FIG. 6)
The ring can then be expanded with a pencil or sim-
ilar object and the spring keeper can be lifted free
from the clutch nut. Rotate the keeper clockwise 10
degrees and install on the next serration in the
clutch nut. Reinstall O-ring and rotate slightly so
that the cut outs are not in line with the lugs on the
Model SA5000AC/SA5015AC Model SA9000AC/SA9015AC
Model SA7000AC/SA7015AC Model SA12000AC/12015AC
FIG. 5
FIG. 4
Emergency Handle
Illustration
AUXILIARY HANDLE
WINCH MAINTENANCE
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