Portable Winch PCW5000-HS User Manual

READ

CAREFULLY

BEFORE USE

Portable Winch Co.

PORTABLE CAPSTAN GAS-POWERED PULLING WINCHESTM

PCW5000 and PCW5000-HS (High-Speed)

USER MANUAL

Models: PCW5000 – Maximum pulling capacity (single line): 1000 kg (2200 lb) PCW5000-HS – Maximum pulling capacity (single line): 350 kg (700 lb)

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. 3

1.2.1 Warning label – p. 3

1.2.2 Sound pressure level label – p. 4

1.3 Safety information – p. 4

2.0 Before first use – p. 5

2.1 Upon receiving the winch – p. 5

2.2 Is the engine ready to work? – p. 5

2.2.1 Engine oil – p. 5

2.2.2 Gas (petrol) – p. 5

2.2.3 Engine start-up – p. 5

2.2.4 Capstan drum – p. 6

2.2.5 Spark arrestor – p. 7

3.0 Winch usage – p. 7

3.1 Rope – p. 7

3.1.1 Rope type – p. 7

3.1.2 Rope maintenance – p. 8

3.2 At the end of the rope – p. 8

3.2.1 Recommended knots – p. 8

3.2.2 Recommended hooks – p. 9

3.3 Winch anchor – p. 9

3.3.1 Using the polyester sling (included with the winch) – p. 9

3.3.2 Using the hitch plate winch anchor for tow balls up to 50 mm (2’’) diameter – p. 10

3.3.3 Using the winch support plate with square tubing 50 mm (2’’) – p. 11

3.3.4 Using the winch support plate with Heck-Pack system for 50 mm European balls and winch support plate adaptor – p. 11

3.3.5 Using the tree/pole mount with anchor strap – p. 12

3.3.5.1 With the winch support plate – p. 13

3.3.5.2 With the vertical pull winch support – p. 13

3.4 Oil AlertTM system – p. 14

3.5 Rope installation – p. 15

3.5.1 Rope – p. 15

3.5.2 Pulley – p. 15

3.5.3 Direction – p. 15

3.5.4 On a hill – p. 15

3.6 Pulling a load – p. 15

3.6.1 Wrapping the rope on the capstan drum – p. 16

3.6.2 Winching – p. 16

3.6.2.1 If the rope slips – p. 16

3.6.2.2 To ‘’rock’’ the load – p. 17

3.6.2.3 How to pause while winching – p. 17

3.6.2.4 How to maintain a load without releasing the tension – p. 17

3.6.2.5 How to resume winching – p. 17

3.6.2.6 If you must keep tension on the rope at start-up – p. 18

3.6.2.7 If your rope is too short – p. 18

3.6.3 Stopping the winch – p. 18

4.0 Maintenance – p. 19

4.1 Cleaning – p. 19

4.2 Lubrication – p. 19

4.3 Honda engine – p. 19

4.4 Storage – p. 19

4.5 Spark arrestor – p. 19

5.0 Complementary information – p. 20

5.1 Accessories – p. 20

5.2 Warranty – p. 20

5.3 Serial number localization – p. 20

5.4 CE Declaration of conformity – p. 21

5.5 Exploded view and parts list – p. 22

5.6 Technical data – p. 24

5.6.1 Noise emissions – p. 24

5.7 Manufacturer – p. 24

Introduction

Portable Winch Co. wishes to thank you for purchasing a Portable Capstan 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 Portable Capstan WinchesTM are designed to pull non-rolling objects, usually at a plus or minus 45 degree angle from the horizontal. The use of a pulling device implies serious risks of injuries, property damage or even death. Do not underestimate its potential danger.

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 Warning label

The warning label is positioned on the right side of the winch housing. See the meaning of all four icons in the figure 1.

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

2. Only use low-stretch rope. Minimum diameter: 10 mm

(3/8’’). Maximum diameter: 16

mm (5/8’’).

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

4. Never use the winch for lifting people.

1.2.2 Sound pressure level label The sound pressure level label is also

positioned on the right side of the winch housing (figure 1). The meaning of the icon in figure 1 to the side is:

1. The guaranteed measured sound pressure level (LpA) at operator position is 93 dB. We recommend wearing hearing protection when using your Portable Capstan

WinchTM.

1.3 Safety information

DO NOT LET CHILDREN USE THE PORTABLE CAPSTAN

WINCHTM. KEEP CHILDREN AND ANIMALS AWAY FROM THE WORK AREA.

NEVER LET SOMEONE WITHOUT TRAINING USE THE PORTABLE

CAPSTAN WINCHTM. MAKE SURE THE USER KNOWS ABOUT THE SAFETY AND USAGE

PROCEDURES AND HAS READ THIS MANUAL AND THE HONDA ENGINE USER MANUAL.

INFORM ALL USERS OF THE SAFETY GUIDELINES AND USAGE

PROCEDURES.

FAMILIARIZE YOURSELF WITH THE PRODUCT AND THE SAFETY

GUIDELINES BEFORE WORKING WITH THE PORTABLE CAPSTAN WINCHTM.

MAKE SURE THAT YOUR CLOTHES ARE NOT GOING TO GET

CAUGHT INTO THE PORTABLE CAPSTAN WINCHTM MOBILE PARTS.

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, NEAR THE

ROPE GUIDE OR THE ROPE ENTRY PULLEY WHEN THE ENGINE IS RUNNING.

ALWAYS KEEP BYSTANDERS OUTSIDE THE WORKING AREA.

NEVER PULL ROLLING OBJECTS THAT MIGHT ROLL OUT OF YOUR

CONTROL.

THE PORTABLE CAPSTAN WINCHTM IS NOT INTENDED FOR

LIFTING PURPOSES.

NEVER USE THE PORTABLE CAPSTAN WINCHTM TO LIFT PEOPLE.

ALWAYS WEAR GLOVES.

WE RECOMMEND WEARING HEARING PROTECTION.

DO NOT TOUCH THE CAPSTAN DRUM IMMEDIATELY AFTER

OPERATION AS IT WILL GET HOT AND BURN BARE SKIN.

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 liter of SAE 10W-30 API SJ oil. For special usage or conditions such as extreme weather, refer to page 7 of 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 WinchTM is equipped with a 4-stroke engine. Refer to page 7 of the Honda

engine user manual.

2.2.3 Engine start-up

Refer to page 3 of 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).

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/or the cover.

2.2.4 Capstan drum

Your Portable Capstan WinchTM is equipped with either a 57 mm (2-1/4") or 85 mm (3-3/8") diameter capstan drum.

If you wish to change the drum, follow these simple installation steps. All bolts require a 4 mm (5/32") hex wrench, included with your winch manual.

1) Remove the rope guide (figure 1);

2) Remove the bolt located at the end of the drum shaft (figure 2);

3) Remove the original drum from the shaft (figure 3). If necessary, you may push it forward with two screwdrivers. Make sure that the shaft key stays in place. Install bolt and washer;

4) Replace it with the new drum (figure 4);

5) Install the rope guide (included with the new drum) 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) Insert the spark arrestor into the exhaust tube. Make sure the holes are aligned (figure 1);

2) Fasten lightly the metal screw provided with the appropriate screwdriver (figure 2).

Refer to page 10 of the Honda engine user manual for the spark arrestor cleaning instructions.

Portable Winch 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 rope. We recommend using double-braided polyester rope with a minimum diameter of 10 mm (3/8''). Maximum rope diameter is 16 mm (5/8"). For most situations, we recommend using 12 mm (1/2'') double-braid polyester rope. Please contact us for other rope types 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 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 ON PARTS WHICH ARE IN CONTACT WITH THE ROPE.

3.2 At the end of the rope

3.2.1 Recommended knots

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) will keep

about 75% of your rope’s capacity.

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