SERIAL NUMBER: READ CAREFULLY BEFORE USE Portable Winch Co. PORTABLE CAPSTAN GAS-POWERED PULLING/LIFTING WINCHTM PCH1000 USER MANUAL Maximum pulling force (single line): 775 kg (1700 lb) Rated lifting capacity (single line): 250 kg (550 lb) © 2013 Portable Winch Co. - All Rights Reserved www.portablewinch.
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 2.2.2 2.2.3 2.2.4 2.2.5 Engine oil – p. 6 Gas (petrol) – p. 6 Engine start-up – p. 7 Capstan drum – p. 7 Spark arrestor – p. 9 3.0 Winch usage – p. 9 3.1 Rope – p. 9 3.1.1 3.1.2 3.1.3 Rope type – p. 9 Rope usage – p. 10 Rope inspection and maintenance – p. 10 3.
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.
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.
1.2.5 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
3.3.2 Using the hitch plate winch anchor (PCA-1261) for tow balls up to 50 mm (2'') diameter 1) Figure 1: Push the safety hooks in the rectangular openings of the hitch plate. The rubber plate must be under the winch; 2) Figure 2: Start the winch engine; 3) Figure 3: Slide the plate on the ball hitch and pull the winch forward; 4) Figure 4: Wrap the rope around the drum and start winching. The winch will align itself automatically with the load.
4) Figure 2: Wrap the rope around the drum and start winching. The winch will align itself automatically with the load. IF YOU NEED TO PULL DOWNWARD, YOU WILL NEED TO INSTALL EITHER A PULLEY OR A ROLLER TO PREVENT DAMAGE TO THE WINCH SUPPORT PLATE. MAKE SURE THE ANCHORING VEHICLE’S HAND BRAKE IS ON AND WORKING PROPERLY. POSITION BLOCKS BEHIND THE WHEELS TO PREVENT ROLL BACK. 3.3.
IF YOU NEED TO PULL DOWNWARD, YOU WILL NEED TO INSTALL EITHER A PULLEY OR A ROLLER TO PREVENT DAMAGE TO THE WINCH SUPPORT PLATE. MAKE SURE THE ANCHORING VEHICLE’S HAND BRAKE IS ON AND WORKING PROPERLY. POSITION BLOCKS BEHIND THE WHEELS TO PREVENT ROLL BACK. 3.3.5 Using the tree/pole mount with anchor strap (PCA-1263) The tree/pole mount is intended to use with either the winch support plate (PCA-1268) or the vertical pull winch support (PCA-1264). Therefore, you must first install the tree/pole mount.
3) Figure 3: Wrap the rope around the drum and start winching. The winch will align itself automatically with the load. IF YOU NEED TO PULL DOWNWARD, YOU WILL NEED TO INSTALL EITHER A PULLEY OR A ROLLER TO PREVENT DAMAGE TO THE WINCH SUPPORT PLATE. AFTER PULLING FOR A FEW SECONDS WITH THE TREE/POLE MOUNT, RELEASE THE TENSION OFF THE PORTABLE CAPSTAN PULLING/LIFTING WINCHTM. CHECK THE SOLIDITY OF THE INSTALLATION AND TIGHTEN THE SLING AGAIN. 3.3.5.
IMPORTANT: DON’T GO OVER THE ROPE ENTRY PULLEY OF THE WINCH WITH THE ROPE (FIGURE 2 BELOW) AS IT WILL CREATE FRICTION AND WILL REDUCE LIFTING CAPACITY. GO UNDER THE ROPE ENTRY PULLEY (FIGURE 1 BELOW). IN THIS CASE, THE ROPE ENTRY PULLEY OF THE WINCH WILL NOT BE USED. IMPORTANT: AFTER PULLING FOR A FEW SECONDS, RELEASE THE TENSION AND CHECK THE SOLIDITY OF THE INSTALLATION AND TIGHTEN THE SLING OF THE TREE/POLE MOUNT AGAIN. 3.3.
PERFORM A TEST PULL WITH A LIGHT LOAD IN ORDER TO ASSES VEHICLE STABILITY AND EQUIPMENT INSTALLATION. 1) Figure 1: Slide the square tubing (PCA-1267) into the vehicle’s receiver and secure it with both the hitch pin and the ‘’R’’ pin; 2) Figure 2: Insert the vertical pull winch support onto the square tubing, align the holes and insert the pulley; 3) Figure 3: Tighten the nut with your fingers until it touches the support.
4) Figure 4: Attach the winch anchor hooks to the eye bolts of the vertical pull winch support; 5) Figure 5: Install rope from above in the redirection pulley by threading the rope end or by removing the bent hitch pin. Wrap the rope around the drum according to the load requirement as detailed in section 3.4.2.2 and align the vertical support pulley with the rope axe. MAKE SURE THE BENT HITCH PIN IS SECURED WITH THE R-PIN PRIOR TO PULLING.
NEVER PUT YOUR HANDS ON THE CAPSTAN DRUM, THE ROPE GRABBING SYSTEM, THE ROPE GUIDE OR THE ROPE ENTRY PULLEY WHEN THE ENGINE IS RUNNING. LOOK AT YOUR SET-UP TO MAKE SURE THAT THE WINCH ANCHORS AND THE ROPE ENTRY PULLEY ARE ALIGNED WITH THE ROPE. WHILE WINCHING, POSITION YOURSELF AWAY FROM THE WINCH IN ORDER TO SEE BOTH THE WINCH AND THE LOAD. PULL HORIZONTALLY ON THE ROPE. THE TENSION YOU EXERT ON THE ROPE WILL KEEP THE WINCH LEVELED.
3.4.1 Installing the rope on the Portable Capstan Pulling/Lifting WinchTM NEVER PUT YOUR HANDS ON THE CAPSTAN DRUM OR THE ROPE ENTRY PULLEY WHEN THE WINCH IS RUNNING. 1) Figure 1: Open the rope grabbing system (no. 1) and lock in place with spring pin (no.2); 2) Start the engine and let it idle for 30 seconds to warm-up; 3) Figure 2: Run the rope OVER the rope keeper and the rope entry pulley (no. 1) and UNDER the drum (except when using vertical pull winch support (see section 3.3.5.2).
3.4.2 Lifting 3.4.2.1 Communications When using a signalperson, communication between the operator and the signalperson shall be maintained during all winch movements. If at any time communication is disrupted or not understood, the operator shall stop all winch movements until communication is re-established. Prior to signaling winch operations, all signalpersons shall be competent in the following areas: 1) Basic understanding of winch operations.
Standard voice signals shall be discussed and agreed upon by the operator and the signalperson prior to beginning lifting operations using voice signals. If special signals are required, they shall be agreed upon in advance by the winch operator and the signalperson. These signals should not be in conflict with the standard signals. 3.4.2.2 Load lifting charts BEFORE ATTEMPTING TO LIFT A LOAD, IT IS IMPERATIVE TO EVALUATE ITS APPROXIMATE WEIGHT.
3.4.2.3 Lifting operation ALWAYS WEAR GLOVES. To lift a load, you will need to decide which anchoring accessories you will use. Refer to section 3.3 Winch anchors to decide. 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. Refer to the charts in section 3.4.2.
BEWARE OF ROPE SNARLS WHILE LOWERING. IF ROPE GETS TANGLED, PULL ON ROPE WHILE ENGINE IS RUNNING UNTIL CLEARED. DO NOT TOUCH THE CAPSTAN DRUM IMMEDIATELY AFTER OPERATION AS IT WILL GET HOT AND BURN BARE SKIN. When you stop lifting with the Portable Capstan Pulling/Lifting WinchTM, the rope grabbing system engages, therefore, holds a load in position and keeps the rope under tension. To release it, follow these steps: 1. Figure 1, no.
3.4.2.5 Sending the rope back down After lifting objects, you may want to send the rope back down. Since there is no reverse on the winch and friction is in cause, simply disengage the rope grabbing system, remove the rope from the capstan drum to eliminate friction and let the rope back down. If the rope does not come down, you may have to attach a small rope to it (prior to lifting) in order to pull it back down. 3.4.3 Pulling To pull a load, follow the steps found in section 3.4.1.
3.4.3.1.1 When pulling with the rope grabbing system engaged If the rope grabbing system is used, when you stop pulling with the Portable Capstan Pulling/Lifting WinchTM, the rope grabbing system engages, therefore, applies pressure on the rope and keeps it under tension. To release it, follow steps 1 to 7 of section 3.4.2.4). 3.4.3.1.
4.3 Warranty Portable Winch Co. products are warranted against defects in materials and workmanship while owned by the ''original purchaser''. The ''original purchaser'' is defined as the party or entity which purchases the winch and/or accessories from an authorized Portable Winch Co. retailer as shown by the original invoice. The warranty ownership is transferable, provided the end-user has a copy of the original purchaser’s invoice.
4.4 CE Declaration of conformity DECLARATION OF CONFORMITY We of PORTABLE WINCH CO. 1170 Thomas-Tremblay St. Sherbrooke, QC J1G 5G5 CANADA Tel: +1 819 563-2193 www.portablewinch.
4.
ITEM NO. PART NUMBER DESCRIPTION QTY 1 31-0024 BHCS 1/4-20 X 1 - SS 6 2 31-0010 HCS 1/2-13 X 6 GR5 - ZN 1 3 35-0004 FLAT WASHER 1/2 - ZN 4 4 10-0098 BUSHING FOR SAFETY HOOK 2 5 PCA-1281 SAFETY HOOK 3/4 TON 2 6 31-0019 HCS 3/8-24 X 1 - ZN 1 7 35-0006 FLAT WASHER 1/4 - ZN 3 8 70-0023 ON/OFF SWITCH WITH SUPPORT PLATE FOR GXH-50 ENGINE 1 9 39-0007 METAL SCREW NO. 10 X 1/2 (PAN HEAD. SQ. DR.
41 44-0022 LABEL - ROPE DANGER 1 42 44-0026 LABEL - ROPE INSTALLATION PCH1000 - PCT1800 1 43 44-0033 LABEL - SPECS SPEED VS DRUM DIAMETER PCH1000 1 44 45-0036 HOUR METER 1 4.
4.8.1 Initial inspection and test When the new or factory refurbished winch is first put in service, perform the following: 4.8.1.1 Engine 1) 2) 3) 4) Check oil level (see Honda Owner’s Manual); Check air filter (see Honda Owner’s Manual); Check fuel level (see Honda Owner’s Manual); Test On/Off switch by starting the engine with switch on, and turning it off. If the engine fails to turn off, it can be shut down by closing the choke. 4.8.1.2 Winch operation 4.8.1.2.
4.8.1.2.2 Test rope grabbing system 1) With the rope grabbing system (brake) engaged: Attach winch to suitable anchor and attach rope to fixed point at some distance directly in front of the winch (picture below); 2) Pull rope until rope is under tension and let go of the rope; 3) Observe that the tension is maintained by the rope grabbing system. 4.8.1.2.3 Test winch anchoring 1) With the rope grabbing system (brake) disengaged (see section 3.4.
2) If the anchor is moving or show any sign of potentially moving, find a new anchor point and perform the test again. 3) IMPORTANT: Document this initial inspection as the first Periodic Inspection in the log at the end of this document. 4.8.2 Daily inspection and test This has to be performed every day (written records are not necessary): 1) Inspect rope grabbing system (see picture) for any sign of wear or loose parts. 2) Check engine oil and air filter.
b. If the anchor is moving or show any sign of potentially moving, find a new anchor point and perform the test again. DO NOT ANCHOR THE ROPE BACK TO THE WINCH 4.8.3 Frequent inspection (every 25 hours of operation) This has to be performed every 25 hours of operation (written records are not necessary): 1) Inspect control mechanism for any sign of wear or loose parts. 2) Clean engine air filter. Service more frequently when operating in dusty areas. 3) Change engine oil.
3) Inspect anchor hooks for cracks and deformation. Check that the safety clasps are functional. 4) Check end play by pulling and pushing the capstan drum. A small movement is normal, more than 0.5 mm indicates the drum retaining screw could be loose or the washer damaged. 5) Check drum keyway by turning the drum back and forth. A small movement is acceptable and indicates proper gear backlash. Large movement may indicated wear of the keyway; if so remove end screw and inspect.
4.8.4.2 Engine 1) 2) 3) 4) 5) Clean/adjust spark plug; Check/adjust idle speed; Check/adjust valve clearance; Clean fuel tank and filter; Clean spark arrestor if equipped. a. NOTE: These items should be serviced by your Honda servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures. 4.8.4.
Schedule I. Periodic inspection log sheet (every 100 hours of operation) WINCH SERIAL NUMBER: (over 600 hours, print more of these pages at www.portablewinch.com) DATE HOUR METER READING INITIAL INSPECTION #1 #2 #3 #4 #5 #6 YES / NO GEARBOX Warning labels present and legible? Any leaks found? Gearbox oil level is OK All screws and bolts are tight Anchor hooks - no cracks, clasp is working Shaft end-play less than 0.5 mm (0.
ROPES, HOOKS, LINKS Rope is in good condition whole length Rope termination is not damaged Hooks are in good condition Links (shackles, carabiners, etc.
Schedule II. Inspecting the rope log sheet (every day) As specified in section 3.1.3 Rope inspection and maintenance, the rope and its termination should be inspected daily to its full length to detect wear. This page allows you to collect information. It is indicative and may be reproduced and used for daily verification of your rope.
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