Sealey PW1360 User manual

INSTRUCTIONS FOR:
PORTABLE WINCH 1360KG LINE PULL 12V
MODEL NO: PW1360
Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions
and properly maintained, give you years of trouble free performance.
1. SAFETY INSTRUCTIONS
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS.
USE THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE
DAMAGE AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.
PW1360 Issue: 2 - 17/01/14
Original Language Version
© Jack Sealey Limited
 WARNING! Winching a vehicle, especially with a steel cable, has an inherant danger element to it, and there is always some risk
of injury. Proper training is highly advised and constant risk assessment needs to be undertaken.
 WARNING! Never connect DC powered winches to AC current. Motor damage or fatal shock may occur.
 DO NOT lift or hoist loads over people. DO NOT lift loads vertically. The winch was designed for ground use only.
DO NOT overload. Be sure all equipment used meets the winch's maximum line pull rating. We recommend using the pulley block option
to double line the wire rope (see fig.1). Double line with a pulley block to reduce the load on the winch, wire rope and battery.
When double lining, pulley blocks should be rated to a minimum of two times the winch's line pull rating. The cable may break before the
winch stalls. For heavy loads use a pulley block to reduce the load on the cable.
DO NOT immerse the winch in water. Doing so will immediately effect load holding and brake efficiency and in time will damage the motor
and cause accelerated gearbox wear invalidating the warranty.
DO NOT operate the winch with less than 5 turns of wire rope around the winch drum, since the wire rope end may not withstand the full
load.
DO NOT pull from extreme angles, (see fig.2), because this will cause the rope to build up on one end of the drum, will damage the wire
rope, and invalidate the warranty.
 WARNING! The winch's line pull capacity is the maximum line pull of the first layer. Never operate a winch by pulling a load that is at
or over the rated capacity.
 DO NOT hook the wire cable back to itself because it could damage the wire rope. Use a Self Recovery Kit, (see fig.3) contact your dealer
for full details..
Make sure the winch is securely mounted on the vehicle or bracket before operation.
 Before moving a load inspect the wire rope. Prevent kinks and uneven wire layering before they occur. Loosened wire rope must be
properly tensioned under a load of about 100lbs (45.4kg).
 Postion a Wire Rope Dampener (available as an optional extra) over the wire rope near the hook end when pulling, as this will slow the
snap back of a broken wire rope and prevent serious injury and/or damage.
 DO NOT move your vehicle to assist the winch in pulling the load. It will be easy to overload, and cause wire rope damage.
 DO NOT enter the danger zone. Keep away from the danger zone during operation. The danger zone is the area of the winch drum, the
fairlead (if fitted), the wire rope, the pulley block (if used), and the hook.
 DO NOT approach or span the wire rope when the winch is under load.
 When using the winch to move a load, place the vehicle transmission in neutral, apply the handbrake and chock all wheels. The vehicle
engine should be running during winch operation so that the battery is fully charged. Never use the winch if there is any doubt as to the
efficiency of the battery.
 DO NOT disconnect the free spool clutch when there is load on the winch.
 After operation release the load immediately. DO NOT allow the cable to tighten anymore.
 Inspect winch, wire rope, hooks and other accessories frequently. A mashed, pinched, kinked or frayed wire rope with broken strands
should be replaced at once because a damaged wire rope has a reduced load carrying capability and could break easily.
Keep tension on the cable to re-spool the cable on the drum tightly after operating. It must be respooled with a load of about 45.4kg
(100lbs).
 DO NOT allow the wire rope to slide through your hands, use heavy rigger gloves when handling wire rope.
 Disconnect the clutch first then use the hand saver strap to hitch the hook to pull the wire rope. DO NOT pull the wire rope using your
finger and do not put your finger through the hook.
 DO NOT operate the winch when under the influence of drugs, alcohol or medication.
 If there is something wrong with the winch, cut the power at once, then check it carefully. If required, return it to your dealer for servicing.
 Wear eye protection, insulated work clothes, non-slip shoes, keep hair tied up and wear rigger gloves. Remove all jewellery.
 DO NOT machine or alter the winch in any way.
 Take good care of the winch when not in use.
 WARNING! Unplug the remote control before working in or around the fairlead or the wire rope drum, (the danger zone). Never tuck it
under your arm or allow anyone to hold it when you are in the danger zone, so as to avoid the hand control being accidentally activated.
 WARNING! Do not use the winch to hold loads in place. Use other means of holding loads such as tie down straps.
 WARNING! If you are within four feet of the winch do not hold the wire rope and remote control at the same time.
 WARNING! Mount the winch to a firm base. Be sure that your structural support is strong enough to withstand the weight and rated pulling
strength of the winch.
NOTE: Whilst mounting orientation is at your discretion, the winch is to be operated with the wire rope in an under wound orientation on
the drum.The winch is designed to rope out and rope in, in one direction. DO NOT attempt to reverse the operation of the winch.
 WARNING! DO NOT weld or machine any part of the winch, this will weaken it and void the warranty.
 WARNING! Batterires contain explosive gases.The following precautions should be taken before making battery connections: wear eye
protection; remove all jewellery; follow the wiring diagram included in the installation instructions; keep spectators away. In the event of a
battery explosion, acid should be washed away as soon as possible, seek medical help immediately.
 WARNING! Use of any other accessories or attachments other than those recommended in this instruction manual may result in personal
injury or property damage and could void the warranty.
NOTE: The safety precautions and instructions discussed in this manual can't cover all possible conditions and situations that may occur. It
must be understood by the operator that common sense and caution are factors whch cannot be built into this product but must be applied
by the operator.

2. SPECIFICATIONS & PERFORMANCE
Portable winch that can be safely and securely stowed in the vehicle. To use,simply attach the winch onto the tow ball and snap the quick
connector into the supply cable plug. Remote control means that you can always be in the right position to oversee the winching. Wire rope is
long enough to reach an anchor point or to lower boat trailers down slipways. The winch is free to rotate on the ball so it will always face the
direction of the pull - no risk of the rope bunching up at one end of the drum as with xed winches. The main benet of this type of winch over a
xed vehicle mounted winch is that it can be used on both the front and the back of a vehicle if a tow hitch is tted at both ends. Winch simply
drops on to a ball or can be used with a ring hitch. Winch is supplied ready to t. Supply cables include ring terminals to permanently connect
the cables for regular use.
Fig.1
Fig.2
Fig.3
Original Language Version
© Jack Sealey Limited
Model No:.................PW1360
Voltage:...................12V
Line Pull*: .................1360kg
Motor Power: ..............2kW
Gear Ratio:................586:1
Line Speed*:
No Load:..................3.6mtr/min
At Maximum Load: . . . . . . . . . . 1.7mtr/min
Current Draw:
No Load:..................8A
At Maximum Load: . . . . . . . . . . 65A
Cable Ø: ..................5.4mm
Cable Length:..............15.2mtr
Winch Weight: .............16.4kg
Gross Weight:..............18kg
Replacement Rope Wire: .....PW1360.WR
* Performance quoted at rst layer of cable on drum
PERFORMANCE SPECIFICATIONS
CHART 1.
PW1360 Issue: 2 - 17/01/14

Original Language Version
© Jack Sealey Limited
3. INSTALLATION
3.1 BALL HITCH MOUNTING INSTRUCTIONS
3.1.1 If using the ball hitch mounting plate ensure that the mounting area has sufcient strength to support a load well in excess of the
rated winch capacity.
3.1.2 Slide the mounting plate on to the bottom of the winch and pass it over the ball hitch.
3.2 FIXED MOUNTING INSTRUCTIONS
3.2.1 Ensure that the mounting surface is of sufcient strength to support a load well in excess of the rated winch capacity.
3.2.2 Fasten the winch to the mounting surface with three 13mm bolts, washers and lockwashers. Position the winch so that the cable does
not rub the front opening of the winch.
3.2.3 For double line use, install an eye hook on the winch stand close to the base of the winch for fastening the stationary cable hook, see
g.4. Be sure that the eye hook is of sufcient strength to withstand loads in excess of the single line rating of the winch.
3.2.4 The winch is equipped with keyhole slots in the base for use with quick mounting shoulder studs. They should be mounted securely into
the winch stand. After positioning the winch on the studs, a 10mm bolt should be placed in one of the other holes available to keep the
winch securely in position.
3.2.5 Make sure that the winch is positioned so that the hook will not be drawn into the drum and the cable will not rub the front opening. DO
NOT reverse the direction the cable is wound on to the drum.
3.3 WIRING HARNESS INSTALLATION
3.3.1 The wiring harness is designed to be permanently installed on a vehicle and stored in the boot or truck bed etc. This prevents
tampering, accidental or misuse of the winch, since the harness is required to power it electrically. The wiring harness can be made
removeable from the vehicle with the 'Electrical Quick Connect', see parts list for details.
3.3.2 Feed the positive lead (long) wire through any convenient access hole in the car boot. (It may be necessary to remove a grommet or
plug). It may also be necessary to remove the circuit breaker assembly from the positive wire in order to feed the wire under the car.
3.3.3 Pull the positive lead wire along the underside of the car into the engine compartment and up to the battery.
3.3.4 Fasten the short lead from the circuit breaker to the positive (+) battery terminal, (if it is a nut and bolt type) or to the battery side of the
starter solenoid. Use the lugs on the circuit breaker casing to attach it to a safe position.
3.3.5 Attach the negative wire to an earth on the chassis using a 6mm bolt and locknut. Make sure it is a clean, tight connection.
3.3.6 Fasten the wiring to the underside of the car using wiring clamps and brackets, or cable ties as needed, making sure that it is not
located near the exhaust or hot or moving parts. Wiring should be fastened securely and without slack. Excess wire should remain in
the boot.
NOTE: If the winch is mounted at the front of the vehicle, cut the harness to the length needed. If spliced, make sure the splice is tight
and well insulated. Attach the earth as described in 3.3.5.
CHECK THE WINCH THOROUGHLY BEFORE OPERATING!
4. OPERATING INSTRUCTIONS
WARNING! This electric winch should be respected as power equipment. High forces are created when using a winch, creating
potential safety hazards. DO NOT allow children or anyone not familiar with the operation of the winch to use it.
WARNING! Inspect the cable before each use, replace it immediately if it is damaged or worn.
WARNING! The auxillary handle is for emergency use only. DO NOT use the auxillary handle to assist the motor when it is
running. Always remove the auxillary handle when it is not in use.
WARNING! When releasing a load with the clutch, maintain control of the speed. Excess speed could result in winch damage and
severe personal injury.
4.1 WINCHING
4.1.1 Connect the power supply plug into the connector on the back of the winch, see g.6. The plug pushes and snaps into place and
will only t in one position. Connect the remote switch cable by plugging it in on the back of the winch, see g.6. Leave the vehicle
engine running at fast idle.
4.1.2 With the clutch lever in the 'engaged' position you can pay out or pay in the cable. Allowing the switch to return to the off position will
automatically stop the winch and lock the load in position.
NOTE: It is normal for smoke to be produced during initial paying out use.
WARNING! Even though the winch is equipped with circuit breaker overload protection, special care should be taken not to create an
overload. Pay attention to the sound of the winch and the load being pulled. Make certain that the cable tension does not rise suddenly
because of a bind in the load.
WARNING! The electric motor is designed for intermittant use only. Extended use without cooling off periods will cause overheating
resulting in motor damage. Maximum recommended run time is four minutes.
4.1.3 When winching is complete, secure the load with appropriate tie down straps or chains. When the load is being transported on a trailer
relieve the tension on the winch cable, to avoid damage to the winch and trailer due to high shock when travelling.
Fig.4 Fig.5
PW1360 Issue: 2 - 17/01/14

Original Language Version
© Jack Sealey Limited
Fig.8
5. MAINTENANCE
5.1 It is strongly recommended that the winch is used regularly (once a month). Simply power out 10mtr of cable, free spool 5mtr then
power back in. This will keep all the components in good working condition so that the winch can be relied on when needed.
4.1.4 Always disconnect the switch when winching is complete. Never leave the switch connected when it is not in use.
4.2 CLUTCH OPERATION
4.2.1 The clutch lever provides the means of releasing a load without power while maintaining control of the speed and provides free
wheeling, so that the cable can be removed from the winch by hand. The clutch lever is spring loaded, so that it returns to the engaged
position when released. The lever will remain in the free wheel position if moved completely over to the right, see g 8.
4.2.2 In order to release a load without power, rotate the clutch slowly and carefully toward 'Free Wheel'. When the load begins to move, it can
be controlled by moving the clutch lever. It will provide smooth control of the load.
WARNING! Always maintain control of the load. Allowing excess speed could result in winch damage and severe personal injury.
4.2.3 Remember that the gear train and brake mechanism are completely disengaged in the 'Free Wheel' position and in order to power the
winch or hold a load in position, the lever must be allowed to return to the 'Engaged gears' position.
NOTE: It is not necessary to turn the clutch lever completely to the 'Engaged gears' position manually. The spring tension built into the
winch provides adequate force on the clutch lever.
WARNING! never force the clutch lever in either direction.
4.3 EMERGENCY HANDLE
4.3.1. An emergency crank handle is provided for use in the event of a power failure.
4.3.2 Remove the electrical power from the winch. Remove the plastic blanking plug from the side of the winch 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 on to the emergency handle.
WARNING! If the clutch is placed in the free wheel for hand cranking, make sure you maintain a rm grip on the handle at all times. If
the handle is released, it will spin violently.
4.3.3 Because the emergency crank handle 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.
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.
4.3.4 Always remove the handle from the winch after use and replace the plastic plug.
!
Fig.6
Fig.9
PW1360 Issue: 2 - 17/01/14
Fig.7

NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.
IMPORTANT: No liability is accepted for incorrect use of this product.
WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.
INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.
01284 757500
01284 703534
[e-mail]
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk,
IP32 7AR
www.sealey.co.uk
Web
email
Environmental Protection.
Recycle unwanted materials instead of disposing of them as
waste. All tools, accessories and packaging should be sorted,
taken to a recycle centre and disposed of in a manner which
is compatible with the environment.
WEEE Regulations.
Dispose of this product at the end of its working life in compliance
with the EUDirective on Waste Electrical and Electronic Equipment.
When the product is no longer required, it must be disposed of in an
environmentally protective way. Contact your local solid waste
authority for recycling information.
Original Language Version
© Jack Sealey Limited
PW1360 Issue: 2 - 17/01/14
Parts support is available for this product. To obtain a parts listing and/or diagram, please log on to
www.sealey.co.uk, email [e-mail] or phone [phone].