Portable Winch PCH1000 User Manual

READ CAREFULLY

BEFORE USE

SERIAL NUMBER:

PORTABLE CAPSTAN GAS-POWERED PULLING/LIFTING WINCHTM

Maximum pulling force (single line): 775 kg (1700 lb) Rated lifting capacity (single line): 250 kg (550 lb)

Portable Winch Co.

PCH1000

USER MANUAL

www.portablewinch.com English version

Summary Introduction – p. 3

1.0 Safety guidelines – p. 3

1.1 Safety messages – p. 3

1.2 Labels – p. 4

1.3 Safety information – p. 5

2.0 Before first use – p. 6

2.1 Upon receiving the winch – p. 6

2.2 Is the engine ready to work? – p. 6

2.2.1 Engine oil – p. 6

2.2.2 Gas (petrol) – p. 6

2.2.3 Engine start-up – p. 7

2.2.4 Capstan drum – p. 7

2.2.5 Spark arrestor – p. 9

3.0 Winch usage – p. 9

3.1 Rope – p. 9

3.1.1 Rope type – p. 9

3.1.2 Rope usage – p. 10

3.1.3 Rope inspection and maintenance – p. 10

3.2 At the end of the rope – p. 13

3.2.1 Recommendations – p. 13

3.2.1.1 Pulling – p. 13

3.2.1.2 Lifting – Rope with buried eyed splice – p. 13

3.3 Winch anchors – p. 14

3.3.1 Using the polyester sling – p. 14

3.3.2 Using the hitch plate winch anchor for tow balls – p. 15

3.3.3 Using the winch support plate with square tubing – p. 15

3.3.4 Using the winch support plate with Heck-Pack system and winch support plate adaptor – p. 16

3.3.5 Using the tree/pole mount with anchor strap – p. 17

3.3.5.1 With the winch support plate – p. 17

3.3.5.2 With the vertical pull winch support – p. 18

3.3.6 Using the vertical pull winch support with square tubing – p. 19

3.4 Moving a load – p. 21

3.4.1 Installing the rope on the Portable Capstan Pulling/Lifting WinchTM – p. 23

3.4.2 Lifting – p. 23

3.4.2.1 Communications – p. 24

3.4.2.2 Load lifting charts – p. 25

3.4.2.3 Lifting operation – p. 26

3.4.2.4 Lowering a load – p. 26

3.4.2.5 Sending the rope back down – p. 28

3.4.3 Pulling – p. 28

3.4.3.1 Releasing the tension – p. 28

3.5 Oil AlertTM system – p. 29

4.0 Complementary information – p. 29

4.1 Accessories – p. 29

4.2 Serial number localization – p. 29

4.3 Warranty – p. 30

4.4 CE declaration of conformity – p. 31

4.5 Exploded view and parts list – p. 32

4.6 Technical data – p. 34

4.7 Noise emissions – p. 34

4.8 Inspection – p. 34

4.8.1 Initial inspection and test – p. 35

4.8.1.1 Engine – p. 35

4.8.1.2 Winch operation – p. 35

4.8.2 Daily inspection and test – p. 37

4.8.3 Frequent inspection (every 25 hours of operation) – p. 38

4.8.4 Periodic inspection (every 100 hours of operation) – p. 38

4.8.5 Winches not in regular service – p. 40

4.9 Manufacturer – p. 32 Schedule I: Periodic inspection Log Sheet (every 100 hours of operation) – p. 41 Schedule II: Inspecting the rope log sheet (every day) – p. 43

Introduction

Portable Winch Co. wishes to thank you for purchasing a PCH1000 Portable Capstan Pulling/Lifting WinchTM. This manual was written to help you make the best use of your new

winch and to use it in the most secure way. READ IT CAREFULLY BEFORE USING THE WINCH. For any problems or questions please refer to an authorized Portable Winch Co. dealer

or contact us directly.

1.0 Safety guidelines

The PCH1000 Portable Capstan Pulling/Lifting WinchTM is designed for lifting objects at angles up to vertical. It is fitted with a rope grabbing system that can maintain the load in position, and provide stop and go operation. THE ROPE GRABBING SYSTEM IS NOT DESIGNED TO STOP A FAST MOVING LOAD OR TO LIFT PEOPLE. The use of a lifting device implies serious risks of injuries, property damage or even death. DO NOT UNDERESTIMATE ITS

POTENTIAL DANGER.

WHEN LIFTING, NEVER GO OVER THE RATED LIFTING CAPACITY (250 kg

(550 lb)) SINGLE LINE.

WHEN LIFTING, NEVER BYPASS THE ROPE GRABBING SYSTEM.

NEVER SHOCK LOAD THE SYSTEM.

NEVER OPERATE WITHOUT PROPER TRAINING AND SUPERVISION.

REMEMBER THE FIRST CAUSE OF ACCIDENT IS HUMAN ERROR. MAKE SURE EVERY PERSON HAS RECEIVED THE APPROPRIATE TRAINING FOR THE JOB.

1.1 Safety messages

Your safety and the safety of others are very important. You will find important safety messages in this manual. READ THEM CAREFULLY.

These security messages are warning you of potential injuries to either you or others. Every safety message is preceded by a warning symbol and one of the following terms:

DANGER, WARNING or CAUTION.

These indicator words mean:

You WILL be MORTALLY or SEVERELY INJURED if you do not follow these

instructions.

You COULD be MORTALLY or SEVERELY INJURED if you do not follow

these instructions.

You COULD be INJURED if you do not follow these instructions.

1.2 Labels

1.2.1 Serial number and warning label

The serial number and warning label is positioned on the right side of the winch housing. Read the meaning of all four icons (figure 1 to the right):

1. Read this instruction manual and Honda engine user’s manual prior to using the winch.

2. Only use low-stretch rope. Minimum diameter: 12 mm (1/2’’). Maximum diameter: 13 mm (1/2’’).

3. Never place your hands near the moving parts while the engine is running.

4. Never use the winch for lifting people.

1.2.1 Sound power level label The sound power level label is also positioned on the right side

of the winch housing. The meaning of the icon in figure 1 to the right is:

1. The guaranteed sound power level is 105 dB. We recommend wearing hearing protection when using your Portable Capstan Pulling/Lifting WinchTM.

1.2.3 Rope ‘DANGER’ label The rope ‘DANGER’ label is positioned on the top of the winch

housing. The meaning of the icon in figure 1 to the right is:

1. It is IMPERATIVE to use ONLY Portable Winch Co. double braided polyester rope 12-13 mm (1/2’’) with buried eyed splice and a minimal breaking strength of 3150 kg (6945 lb).

1.2.4 Rope installation label This label is positioned on the winch housing. It is a reminder

of how to install the rope on the PCH1000.

1.2.5 Winch speed versus drum diameter label This label is positioned on the winch housing. The meaning is

that if the 57 mm drum is installed, the maximum speed of the winch is 12 meters per minute and if the 85 mm drum is installed, the maximum speed is 18 meters per minute.

1.3 Safety information

DO NOT LET CHILDREN USE THE PORTABLE CAPSTAN

PULLING/LIFTING WINCHTM. KEEP CHILDREN AND ANIMALS AWAY FROM THE WORK AREA.

NEVER LET SOMEONE WITHOUT TRAINING USE THE PORTABLE

CAPSTAN PULLING/LIFTING WINCHTM. MAKE SURE THE USER KNOWS ABOUT THE

SAFETY AND USAGE PROCEDURES AND HAS READ THIS MANUAL AND THE HONDA ENGINE USER MANUAL. THE OPERATOR SHOULD BE ABLE TO OPERATE A LIFTING DEVICE AND BE AWARE OF ALL ASPECTS OF SUCH OPERATIONS. HE SHOULD ALSO BE AWARE OF LOCAL REGULATION.

INFORM ALL USERS OF THE SAFETY GUIDELINES AND USAGE

PROCEDURES.

FAMILIARIZE YOURSELF WITH THE PRODUCT AND THE SAFETY

GUIDELINES BEFORE WORKING WITH THE WINCH.

MAKE SURE THAT YOUR CLOTHES ARE NOT GOING TO GET CAUGHT

INTO THE WINCH MOBILE PARTS.

NEVER USE THE PORTABLE CAPSTAN PULLING/LIFTING WINCHTM TO

LIFT PEOPLE.

USE ONLY 12 MM TO 13 MM (1/2’’) DIAMETER DOUBLE BRAID PORTABLE

WINCH CO. POLYESTER ROPE WITH THIS WINCH.

NEVER LIFT OBJECTS OVERHEAD OF PEOPLE.

ALWAYS USE THE PORTABLE CAPSTAN PULLING/LIFTING WINCHTM HORIZONTALLY, USING A PULLEY OR THE VERTICAL PULL WINCH SUPPORT TO REDIRECT THE ROPE VERTICALLY.

THE EXHAUST GAS CONTAINS TOXIC CARBON MONOXIDE. NEVER RUN THE ENGINE IN A CLOSED AREA WITHOUT PROPER VENTILATION.

REPLACE ANY SAFETY LABELS THAT ARE DAMAGED, ILLEGIBLE OR MISSING.

NEVER PUT YOUR HANDS ON THE CAPSTAN DRUM, THE ROPE GRABBING SYSTEM, THE ROPE ENTRY PULLEY OR NEAR THE ROPE GUIDE WHEN THE ENGINE IS RUNNING.

ALWAYS KEEP BYSTANDERS OUTSIDE THE WORKING AREA.

NEVER PULL ROLLING OBJECTS THAT MIGHT ROLL OUT OF YOUR

CONTROL.

NEVER TRY TO MOVE FIXED OR OBSTRUCTED LOADS.

AVOID EXCESSIVE INCHING (E.G. GIVING SHORT PULSES TO THE

MOTOR).

ALWAYS INITIATE MOVEMENTS OF THE LOAD WITH THE LOWEST AVAILABLE SPEED. THE ROPE SHALL BE TIGHTENED AND SHALL NOT BE IN THE SLACK-CONDITION WHEN THE LOAD MOVEMENT BEGINS.

SIDE-PULL OF LOAD IS NOT ALLOWED WITH THE PCH1000 PORTABLE CAPSTAN PULLING/LIFTING WINCHTM.

KEEP IN MIND THAT YOUR SET-UP IS ONLY AS RESISTANT AS THE WEAKEST LINK. THIS IS WHY IT IS VERY IMPORTANT TO USE THE ADEQUATE ACCESSORIES IN ACCORDANCE WITH THE JOB TO BE DONE. IN THIS CASE (LIFTING), IT IS RECOMMENDED TO HAVE A 10 TO 1 SAFETY FACTOR FOR ALL ACCESSORIES.

2.0 Before first use

2.1 Upon receiving the winch

Inspect the box to detect any apparent damage. If there is damage or missing parts, inform the carrier immediately.

2.2 Is the engine ready to work?

2.2.1 Engine oil

Fill the Honda engine with a maximum of 0.25 litre of SAE 10W-30 API SJ oil. For special usage or conditions such as extreme weather, refer to the Honda engine user manual. Check the oil level on a horizontal surface. The oil level should be up to the edge of the opening.

2.2.2 Gas (petrol) Fill the gas (petrol) tank with UNLEADED PETROL. Do not use oil/gas (petrol) mixture; your

Portable Capstan Pulling/Lifting WinchTM is equipped with a 4-stroke engine. Refer to the Honda

engine user manual.

2.2.3 Engine start-up

Refer to the Honda engine user manual for start-up instructions.

FIRST USE: LET THE ENGINE RUN FIVE (5) MINUTES AT IDLE BEFORE FIRST PULL.

The engine on-off switch is located on the winch housing, to the left of the handle (figure 1 to the right).

Make sure to pull on the recoil starter in the axis of the rope outlet (figure 1 below). If you pull vertically (figure 2 below) the friction of the rope on the plastic cover might damage the rope and the cover.

2.2.4 Capstan drum Your Portable Capstan Pulling/Lifting WinchTM is equipped with the 57 mm (2-1/4") diameter

capstan drum and the 117 mm (4-5/8’’) diameter safety lip. If you wish to change the drum for the 85 mm (3-3/8") drum (sold separately), you will also need

to purchase and install the 127 mm (5’’) diameter safety lip. To do so, follow these simple steps: The tools required to change the drum are:

A 4 mm (5/32") hex wrench (included with your winch). An 11 mm (7/16") wrench or adjustable wrench (not included).

1) Figure 1: Remove the two bolts holding the rope guide and then, remove the rope guide;

2) Figure 2: Remove the hex bolt holding the safety lip and drum using the 11 mm (7/16’’) wrench. Then, remove the washer, the safety lip and the spacer bushing;

3) Figure 3: Remove the drum from the shaft. If necessary, you may push it forward with two screwdrivers. Make sure that the shaft key stays in place.

4) Figure 4: Insert the 85 mm (3-3/8’’) drum on the winch shaft. Insert the washer, the safety lip and the spacer bushing on the hex bolt and insert this assembly in the hole of the shaft. Then, tighten the hex bolt with the 11 mm (7/16’’) wrench;

5) Figure 5: Insert the new rope guide in position and tighten it using the two (2) bolts.

IMPORTANT: Make sure that the rope guide is not in contact with the capstan drum.

2.2.5 Spark arrestor

In certain areas, it is forbidden to use a gas (petrol) engine without a spark arrestor. Check local regulations. An optional spark arrestor is available from Portable Winch Co. and/or Honda Power Products dealers.

Installation:

1) Figure 1: Insert the spark arrestor into the exhaust tube. Make sure the holes are aligned;

2) Figure 2: Fasten lightly the metal screw provided with the appropriate screwdriver.

Refer to the Honda engine user manual for the spark arrestor cleaning instructions.

Portable Winch Co. part number: PCA-1151 Honda part number: 350-2M7-801

3.0 Winch usage

MOST WINCHING SITUATIONS PRESENT POTENTIAL DANGERS!

3.1 Rope

STAY OUT OF THE WINCH LINE’S PATH.

3.1.1 Rope type

USE ONLY LOW STRETCH 12 OR 13 MM (1/2’’) DIAMETER PORTABLE WINCH CO. DOUBLE BRAIDED POLYESTER ROPE WITH A MINIMAL BREAKING POINT OF 3150 KG (6945 LB) WITH THIS WINCH. PLEASE CONTACT US FOR OTHER ROPE TYPE’S SUITABILITY.

DO NOT USE 3-STRAND POLYPROPYLENE YELLOW ROPE!

Polypropylene and polyethylene ropes are dangerous for winching because of their great

elasticity and low melt point.

Make sure the rope is not damaged and that it offers an adequate resistance to pull the

load.

STRETCH EQUALS DANGER!

A stretched rope can recoil and cause serious burns as the rope leaves your hand. All ropes stretch: a longer one more than a shorter one. The more you pull, the more it

stretches. A stretched rope can also move the load in an unpredictable or dangerous way. A stretched rope can recoil and bring your hand towards the winch causing severe

injuries. NEVER WRAP THE ROPE AROUND YOUR HAND.

ALWAYS WEAR GLOVES.

3.1.2 Rope usage

Use rope properly; do not abuse or shock load it. Observe recommended usage factors for bending and work loads. Keep ropes clean and eliminate abrasion whenever possible.

1) Working loads are the loads that a rope is subjected to in everyday activity. For lifting purposes we recommend a minimum safety factor of 7 (app. 15% of the rope minimum break strength) when the rope has a spliced termination. If the rope is knotted with a bowline, we recommend a safety factor of 10.

2) Any sharp bend in a rope under load decreases rope strength substantially and may cause permanent damage and failure. Sheave diameters should be 8 times the rope diameter.

3) Knots are known to reduce rope strength but they are a convenient way to accomplish rope attachment. The strength loss is a result of the sharp bends that occur in the knots. If you must use a knot, use the bowline or double bowline described in section 3.2.1.1.

4) Keep rope clean and as dry as possible. Grit and dirt will work its way inside the rope and degrade it rapidly. You can wash it in the washing machine and hang to dry.

5) Store the rope in a rope bag or in a pail. Coiling the rope will induce twists and knots.

6) Shock loads are a sudden change in tension from a relaxed state or low load to one of high load. Any sudden load that exceeds the work load by more than 10% is considered a shock load. The further an object falls, the greater the impact. Synthetic fibers have a memory and retain the effects of being overloaded and can fail at a later time even though loaded within the work load range.

3.1.3 Rope inspection and maintenance

VISUALLY INSPECT YOUR ROPE BEFORE EACH USAGE. IF IT SHOWS

ANY SIGN OF DETERIORATION (CUT STRANDS, EXCESSIVE ABRASION), REPLACE IT.

IF YOUR ROPE IS DIRTY, WASH IT. DIRTY ROPES DETERIORATE

FASTER AND CAUSE PREMATURE WEAR OF THE PARTS IN CONTACT WITH THE ROPE SUCH AS THE CAPSTAN DRUM AND ROPE GUIDE.

Any rope that has been used for any period will show normal wear and tear. Some characteristics of a used rope will not reduce strength while others will. Below are the conditions that should be inspected on a regular basis.

Double braid ropes consist of a cover or jacket braided over a separately braided core. The strength of the double braid rope is shared between the cover and the core. Damage to the cover also usually affects the core and ultimately the strength of the rope.

Rope inspection is done by running both hands over the entire length of the rope while turning it in order to see all around. It is a visual as well as a touch feeling process.

TWIST:

Every time you set the rope over the capstan drum you are twisting the rope. Depending on the length of the rope, and what percentage of the rope you use, you will sooner or later have a twisted rope with reduced capacity because the strands are not loaded evenly. You can un-twist the rope by spinning the rope to a free end.

It is a good practice to reverse the rope – use both ends. In addition to help with the twist problem, the rope will also wear more evenly.

GREY COLOR:

This comes from aluminium residues from the friction on the capstan drum. Your hands will get dirty but this does not damage the rope.

CUT STRANDS:

A strand is made of one, two or more groups of twisted yarn. Braided ropes are typically 16-, 24- or 32-strand. They can get cut by abrasion against sharp edges or surfaces, or by cyclic tension wear.

If three or more adjacent strands are cut, the rope shall be retired.

REDUCED VOLUME:

The rope can get smaller because of abrasion and cyclic tension wear. If the rope volume is reduced by 50%, the rope shall be retired. For a 12 mm diameter rope, that means that a rope with a circumference of 19 mm shall be retired. Circumference measurement is easier than trying to measure the diameter.

MELTED OR GLAZED FIBERS:

The friction of the rope on the capstan drum generates heat. If the rope is subject to high friction heat for a long period – for example when the load is greater than the winch capacity – it can get damaged very quickly.

If the rope shows fused fibers, visibly charred and melted fibers, yarns and/or strands, is extremely stiff and is unchanged by flexing, it shall be retired.

DISCOLORATION/DEGRADATION:

Chemical contamination can cause fused fibers, brittle fibers and stiffness. Retire the rope.

INCONSISTENT DIAMETER:

Shock loading or broken internal strands can cause flat areas or lumps and bumps on the rope. Retire the rope.

IF YOU ARE IN DOUBT OF THE ROPE

FITNESS – RETIRE THE ROPE!

3.2 At the end of the rope

3.2.1 Recommendations

Since the Portable Capstan Pulling/Lifting WinchTM can be used for pulling and lifting, there are some guidelines to follow:

3.2.1.1 Pulling

For pulling loads, you have to attach the load to the end of the rope. Even if a simple knot can do the job, we recommend the installation of a hook with the bowline knot (figure 1 on the right) because it can be easily undone if you need to change the hook. Moreover, it retains about 70% of the rope’s capacity while most knots will reduce it by more than 50%.

Even better, the double bowline knot (figure 2 below) will keep about 75% of your rope’s capacity.

3.2.1.2 Lifting - Rope with buried eyed splice

For lifting, you have to attach the load to the end of the rope. Even if you believe that a bowline knot could do the job, it is STRONGLY RECOMMENDED to use the Portable Winch Co. rope with buried eyed splice. The installation of a hook with a strong enough safety factor carabiner or shackle to the rope will help prevent any problems that might occur in case of knot failure.

NOTE: Please, check with local authorities for safety regulations in your area.

3.3 Winch anchors

The winch is anchored to a fixed point using the included polyester sling or with optional anchoring devices and the rope end is tied to the object you want to move. The load is moving towards the winch when you pull the rope.

3.3.1 Using the polyester sling (included with the winch)

Go around the anchor point with the sling. Insert each end of the sling in one of the safety hooks located on the winch (figure 1 below).

Position the winch in line with the load. When the winch is under tension, it will try to align itself with the load. The friction of the sling against the anchor point could prevent correct alignment. If that is the case, release the tension on the rope and position the sling on the anchor point so that the tension is equally distributed on both winch anchor hooks.

DON’T DO THIS! WHEN YOU ANCHOR THE WINCH, MAKE SURE

THAT YOU DO NOT DO A COMPLETE WRAP AROUND THE ANCHOR POINT (FIGURE 2 BELOW). THIS SET-UP WILL PREVENT PROPER ALIGNMENT OF THE WINCH WITH THE LOAD AND WILL PUT UNEVEN TENSION ON THE WINCH ANCHOR HOOKS.

AVOID INSTALLING THE SLING ON SHARP EDGES THAT MIGHT

DAMAGE IT. WHETHER YOU ARE USING A POST, A TREE OR A STUMP, ALWAYS INSTALL THE SLING NEAR THE ANCHOR’S BASE.

USING A STUMP AS AN ANCHOR POINT MEANS PAYING SPECIAL

ATTENTION IN ORDER TO PREVENT THE SLING FROM SLIPPING OVER IT.

MAKE SURE THE ANCHOR POINT IS STRONG ENOUGH TO RESIST

THE PULL WITHOUT BREAKING OR BEING DAMAGED.

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