PCW5000 - Portable Winch Company
Contents
1. fuz WINCH 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 e Portable Winch part number PCA 1151 e Honda part number 350 2M7 801 3 0 Winch usage WARNING MOST WINCHING SITUATIONS PRESENT POTENTIAL DANGERS 3 1 Rope WARNING 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 5 8 For most situations we recommend using 12 mm 1 2 double braid polyester rope Please contact us for other rope types suitability A WARNING DO NOT USE 3 STRAND POLYPROPYLENE YELLOW ROPE A Polypropylene and polyethylene ropes are dangerous for winching because of their great elasticity and low melt point A Make sure the rope is not damaged and that it offers an adequate resistance to pull the load WINCH A WARNING STRETCH EQUALS DANGER A A stretched rope can recoil a2. Cer PART NUMBER DESCRIPTION QTY 1 31 0010 HCS 1 2 13 X 6 GR5 ZN 1 2 35 0004 FLAT WASHER 1 2 ZN 4 3 10 0098 BUSHING FOR SAFETY HOOK 2 4 PCA 1281 SAFETY HOOK 3 4 TON 2 5 31 0024 BHCS 1 4 20 X 1 55 6 6 10 0099 ALUMINIUM ROPE EXIT HOOK 1 7 44 0019 VINYL GRIP 1 8 10 0094 WINCH HANDLE 1 9 44 0027 ROPE INSTALLATION LABEL PCW5000 1 10 70 0023 SUCI SWITCH WITH SUPPORT PLATE FOR GXH 50 1 11 35 0006 FLAT WASHER 1 4 ZN 2 12 39 0007 METAL SCREW NO 10 X 1 2 PAN HEAD SQ DR 1 13 31 0019 HCS 3 8 24 X 1 GR5 ZN 1 14 33 0005 NYLON LOCKNUT 1 2 13 ZN 1 15 44 0020 PCW5000 SERIAL NUMBER AND WARNING LABEL 1 16 44 0023 DECIBEL WARNING 93 dB LABEL 1 17 10 0095 GUARD PLATE PCW5000 1 18 32 0002 HEX FLANGE SERRATED BOLT M6 1 X 12 MM ZP 6 19 10 0103 ROPE KEEPER 1 20 10 0101 ROPE ENTRY PULLEY 1 21 10 0119 SHOULDER BOLT 5 8 X 1 1 2 ZN 1 22 10 0100 ROPE GUIDE FOR CAPSTAN DRUM 57 MM 1 23 43 0013 SHAFT KEY FOR CAPSTAN DRUMS 57 MM amp 85 MM 1 24 31 0025 BHCS 1 4 20 X 3 4 SS 6 25 10 0096 CAPSTAN DRUM 57 MM 1 26 10 0102 DRUM RETAINING WASHER 1 27 10 0001 CAPSTAN DRUM 85 MM 1 28 31 0025 BHCS 1 4 20 X 3 4 SS 2 29 10 0106 ROPE GUIDE FOR CAPSTAN DRUM 85 MM 1 30 44 0001 REPLACEMENT UNIVERSAL SERIAL NUMBER amp 0 WARNING LABEL 23 WINCH 5 6 Technical data PCW5000 PCW5000 HS e Engine 4 stroke Honda GXH 50 cc e Gear box Aluminum alloy e Unit weight dry 16 kg 35 Ib e Dimensions overall
3. 5 2 Warranty Portable Winch Co products are warranted against defects in materials and workmanship while owned by the original purchaser as defined below 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 sales receipt The warranty ownership is transferable provided the end user has a copy of the original purchaser s invoice This warranty does not apply to wear parts defined as being in contact with the rope while winching The PCW5000 and PCW5000 HS Portable Capstan Winches are covered as follows e Winch components o Private use Five 5 year warranty service by Portable Winch Co and or its retailers o Commercial use One 1 year warranty service by Portable Winch Co and or its retailers e Engine The Honda engine is warranted by Honda Motor Corporation and the duration varies according to country and usage All Honda service centers can repair the winch engine under warranty Hang on to your proof of purchase invoice with serial number It will be used to establish the beginning of the warranty period Portable Winch Co will replace or repair at its option any defective product All other Portable Winch accessories are covered by a complete one 1 year warranty Please refer to the Portable Winch Co complete warranty on www portablewinch com if you have any questions Extend your warranty
4. a READ HIABLE CAREFULLY WINCH BEFORE USE Portable Winch Co PORTABLE CAPSTAN GAS POWERED PULLING WINCHES PCW5000 and PCW5000 HS High Speed USER MANUAL Models PCW5000 Maximum pulling capacity single line 1000 kg 2200 Ib PCW5000 HS Maximum pulling capacity single line 350 kg 700 Ib 2012 Portable Winch Co All Rights Reserved English version ui 257778 www portablewinch com 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 ls the engine ready to work p 5 2 21 Engine oil p 5 2 2 2 Gas petrol p 5 2 2 8 Engine start up p 5 2 24 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 Atthe 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 8 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 ada
5. low stretch rope PORTABLE WINCH CO 1 888 388 PULL 7855 www portablewinch com Minimum diameter 10 mm 1170 Thomas Tremblay Mod le Model PCWSO00 Sherbrooke orc 3 8 Maximum diameter 16 4149 CE us mm 5 8 3 Never place your hands near the drum while the engine is running 4 Never use the winch for lifting people WiNCH 1 2 2 Sound pressure level label The sound pressure positioned on the righ housing figure 1 Th icon in figure 1 to the side is 1 The guaranteed measured sound pressure level position is 93 dB We recommend wearing hearin using _ your Winch level label is also t side of the winch e meaning of the 0 LPA Bi CE LpA at operator g protection when Portable Capstan 1 3 Safety information A WARNING DO NOT LET CHILDREN USE THE PORTABLE CAPSTAN WINCH KEEP CHILDREN AND ANIMALS AWAY FROM THE WORK AREA A WARNING CAPSTAN WINCH PROCEDURES AND MANUAL A WARNING PROCEDURES WARNING GUIDELINES BEFOR WARNING NEVER LET SOMEONE WITHOUT TRAINING USE THE PORTABLE MAKE SURE THE USER KNOWS ABOUT THE SAFETY AND USAGE HAS READ THIS MANUAL AND THE HONDA ENGINE USER INFORM ALL USERS OF THE SAFETY GUIDELINES AND USAGE FAMILIARIZE YOURSELF WITH THE PRODUCT AND THE SAFETY E WORKING WITH THE PORTABLE CAPSTAN WINCH MAKE SURE THAT YOUR CLOTHES ARE NOT GOING TO GET CAUGHT INTO THE PORTABLE CAPSTAN WI
6. to the eye bolts as shown in section 3 3 3 5 Wrap the rope around the drum and start winching The winch will align itself automatically with the load 11 WINCH A CAUTION 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 A CAUTION 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 To do this follow these steps 1 Figure 1 Place the tree pole mount at the base of the tree or pole Insert the sling s hook into the anchor point on the left then feed the sling s end through the ratchet system 2 Figure 2 Slide the whole set up upward to the desired height and remove the supplied wrench 3 Figure 3 Tighten the sling with the wrench while making sure the rubber pads are properly positioned The pads should offer maximum contact surface with the tree or pole 12 WINCH 3 3 5 1 With the winch support plate PCA 1268 After the installation of the tree pole mount section 3 3 5 follow these steps 1 Figure 1 Insert the winch support plate onto th
7. use oil gas petrol mixture your Portable Capstan Winch 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 WINCH Make sure to pull on the recoil starter in the axis of the rope outlet figure 1 below If you pul 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 Winch 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
8. 1 Figure 1 no 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 1 no 2 Slide the winch support plate PCA 1268 onto the square tubing and secure it with both the hitch pin and the R pin Note Its lateral movement can be adjusted by positioning the bolts into the square holes 3 Figure 2 Attach the winch anchor hooks to the eye bolts 4 Figure 2 Wrap the rope around the drum and start winching The winch will align itself automatically with the load A CAUTION 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 A CAUTION MAKE SURE THE ANCHORING VEHICLE S HAND BRAKE IS ON AND WORKING PROPERLY POSITION BLOCKS BEHIND THE WHEELS TO PREVENT ROLL BACK 3 3 4 Using the winch support plate PCA 1268 with Heck Pack system for 50 mm European balls PCA 1266 and winch support plate adaptor PCA 1265 1 Figure 1 Bolt the winch support plate adaptor PCA 1265 onto the Heck Pack system PCA 1266 with the 4 bolts provided 2 Figure 2 Insert the Heck Pack on the ball and fasten it down with the lever 3 Figure 2 Slide the winch support plate PCA 1268 onto the square tubing and secure it with both the hitch pin and the R pin Note Its lateral movement can be adjusted by positioning the bolts into the square holes 4 Attach the winch anchor hooks
9. 2 Pulley Using a pulley at some distance in front of the winch offers many advantages e Pulling angle lifts the load and reduces friction e The winch is maintained at a relatively horizontal position e Winch and operator are away from the load s path 3 5 3 Direction Install the rope in such a way that it does not rub against other objects Try to set up the rope so that the front of the load is slightly lifted Do not pull downwards or through an obstruction A Generally if the rope touches the ground while pulling your installation is incorrect 3 5 4 On a hill 4 WARNING DO NOT PULL A LOAD DIRECTLY TOWARD THE WINCH IN A DOWNWARD SLOPE SINCE IT COULD SLIDE WITHOUT YOU BEING ABLE TO STOP IT IN THAT SITUATION USE A PULLEY AT THE BOTTOM OF THE HILL AND POSITION THE WINCH OUTSIDE OF THE LOAD S PATH 3 6 Pulling a load 4 WARNING CHECK WINCH POSITION ROPE CONDITION SOLIDITY OF THE ANCHOR POINT KNOTS CARABINERS OR SHACKLES IN ORDER TO PREVENT INJURIES OR MATERIAL DAMAGE 15 fuz WINCH 3 6 1 Wrapping the rope on the capstan drum WARNING never PUT YOUR HANDS ON THE CAPSTAN DRUM THE ROPE GUIDE OR THE ROPE ENTRY PULLEY WHEN THE ENGINE IS RUNNING 1 Start the engine and let it idle for 30 seconds to warm up 2 Run the rope OVER THE ROPE KEEPER and the rope entry MAT pulley and under the drum figure 1 no 1 3 Wrap the rope around the drum 3 or 4 turns figure 1 no 2 4 Bring the r
10. 37 1 cm Length x 36 6 cm Width x 36 6 cm Height 14 5 8 x 14 3 8 x 14 3 8 e Rope Low stretch double braided polyester not included Unlimited rope length o Minimum diameter 10 mm 3 8 o Maximum diameter 16 mm 5 8 o Recommended 12 13 mm 1 2 5000 Gear ratio 110 1 e Pulling force according to drum diameter o Installed 57 mm 2 1 4 drum 1000 kg 2200 Ib o Optional 85 mm 3 3 8 drum 635 kg 1400 Ib e Speed according to drum diameter o Installed 57 mm 2 1 4 drum 12 m min 40 min o Optional 85 mm 3 3 8 drum 18 m min 60 min PCW5000 HS Gear ratio 53 1 e Pulling force according to drum diameter o Installed 85 mm 3 3 8 drum 350 kg 700 Ib o Optional 57 mm 2 1 4 drum 500 kg 1100 Ib Speed according to drum diameter o Installed 85 mm 3 3 8 drum 36 m min 120 min o Optional 57 mm 2 1 4 drum 24 m min 80 min 5 6 1 Noise emissions Here are the noise emissions of the Portable Capstan Winches Sound pressure level at operator position LpA measured o Engine idling 73 dBA o Full throttle 89 dBA 5 7 Manufacturer The Portable Capstan Winches are manufactured by Portable Winch Co 1170 Thomas Tremblay Street Sherbrooke Quebec J1G 5G5 CANADA Phone 1 819 563 2193 Toll free Canada amp USA 1 888 388 PULL 7855 Fax 1 514 227 5196 Email info portablewinch com Web site www portablewinch com 24
11. NCH MOBILE PARTS 4 DANGER RUN THE ENGINE IN CAUTION OR MISSING A WARNING ROPE GUIDE OR TH WARNING THE EXHAUST GAS CONTAINS TOXIC CARBON MONOXIDE NEVER A CLOSED AREA WITHOUT PROPER VENTILATION REPLACE ANY SAFETY LABELS THAT ARE DAMAGED ILLEGIBLE NEVER PUT YOUR HANDS ON THE CAPSTAN DRUM NEAR THE E ROPE ENTRY PULLEY WHEN THE ENGINE IS RUNNING ALWAYS KEEP BYSTANDERS OUTSIDE THE WORKING AREA rm WINCH A DANGER NEVER PULL ROLLING OBJECTS THAT MIGHT ROLL OUT OF YOUR CONTROL WARNING THE PORTABLE CAPSTAN WINCH 15 NOT INTENDED FOR LIFTING PURPOSES WARNING never use THE PORTABLE CAPSTAN WINCH TO LIFT PEOPLE A CAUTION aways wear GLOVES A CAUTION we RECOMMEND WEARING HEARING PROTECTION CAUTION po 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
12. OF THE WINCH WITH THE ROPE FIGURE 2 BELOW AS IT WILL CREATE FRICTION AND WILL REDUCE PULLING CAPACITY GO UNDER THE ROPE ENTRY PULLEY FIGURE 1 BELOW IN THIS CASE THE ROPE ENTRY PULLEY OF THE WINCH WILL NOT BE USED WARNING 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 4 Oil Alert system The GXH 50 Honda engine is equipped with an Oil Alert system that automatically turns off the ignition when the oil level goes below a safe level The Oil Alert system also turns off the ignition when the winch is operating at an angle greater than 20 degrees 4 degrees Make sure that your set up keeps the winch at a relatively horizontal level while winching and idling 14 WINCH 3 5 Rope installation WARNING USING COMMON SENSE WHILE INSTALLING THE ROPE IS THE KEY TO A SECURE WINCH USAGE The great variety of situations encountered when winching prevents us from providing specific instructions however you need to consider the following points 3 5 1 Rope Use a low stretch rope in good condition with a minimum diameter of 10 mm 3 8 and a maximum diameter of 16 mm 5 8 with good knots We strongly suggest the bowline knot see section 3 2 1 Use pulleys to redirect the rope and to multiply the pulling capacity when the load is near or over the pulling capacity of the winch 3 5
13. OKS m WINCH A CAUTION 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 A CAUTION USING A STUMP AS AN ANCHOR POINT MEANS PAYING SPECIAL ATTENTION IN ORDER TO PREVENT THE SLING FROM SLIPPING OVER IT WARNING MAKE SURE THE ANCHOR POINT IS STRONG ENOUGH TO RESIST THE PULL WITHOUT BREAKING OR BEING DAMAGED 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 NOTE Do not leave the winch on the hitch with the engine running the resting position will cause the Oil Alert device to turn the Honda engine off see section 3 4 CAUTION USE THE HITCH PLATE ONLY WITH CATEGORY II BALL HITCH 1500 KG 3300 LB OR HIGHER MAKE SURE THE ANCHORING VEHICLE S HAND BRAKE IS ON 10 m WINCH AND WORKING PROPERLY POSITION BLOCKS BEHIND THE WHEELS TO PREVENT ROLL BACK 3 3 3 Using the winch support plate PCA 1268 with square tubing 50 mm 2 PCA 1267
14. e square tubing of the tree pole mount PCA 1263 and fasten it down with the hitch pin and R pin 2 Figure 2 Attach the winch anchor hooks to the eye bolts of the winch support plate 3 Figure 3 Wrap the rope around the drum and start winching The winch will align itself automatically with the load A CAUTION 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 4 WARNING AFTER PULLING FOR A FEW SECONDS WITH THE TREE POLE MOUNT RELEASE THE TENSION OFF THE PORTABLE CAPSTAN WINCH CHECK THE SOLIDITY OF THE INSTALLATION AND TIGHTEN THE SLING AGAIN 3 3 5 2 With the vertical pull winch support PCA 1264 After the installation of the tree pole mount section 3 3 5 follow these steps 1 Figure 1 Insert the vertical pull winch support onto the square tubing of the tree pole mount PCA 1263 align the holes and insert the pulley 2 Figure 2 Tighten the nut with your fingers until it touches the support Then reinforce it with the R pin 3 Figure 3 Attach the winch anchor hooks to the eye bolts of the vertical pull winch support 4 Figure 4 Wrap the rope around the drum and align the vertical support pulley with the rope axe and start to pull 13 fuz WINCH WARNING THE PORTABLE CAPSTAN WINCH IS NOT INTENDED FOR LIFTING PURPOSES WARNING important DON T GO OVER THE ROPE ENTRY PULLEY
15. ed debris can E 1 damage the shaft seal Apply oil to prevent corrosion 4 2 Lubrication The rope entry pulley figure 1 no 1 must turn freely Lubricate it regularly with light oil Dirt and grime lodged between the pulley and the shaft may prevent it from turning freely If required disassemble it to clean the shaft Use an 8 mm hex key The gearbox is lubricated at the factory and should not require additional lubrication or maintenance If there is appearance of a leak check oil level by placing the winch on a level surface and remove the oil plug figure 1 no 2 Use an 8 mm hex key Lean it toward you some oil should leak out of the hole If needed you can add type SAE80W90EP gear box oil 4 3 Honda engine Maintain the engine according to the instructions found in the Honda engine user manual provided 4 4 Storage Always store your Portable Capstan Winch seated on its protection plate Refer to the Honda engine user manual for engine storage instructions 4 5 Spark arrestor If your Portable Capstan Winch is equipped with the optional spark arrestor PCA 1151 sold separately you must clean it every hundred 100 hours to keep it running properly Refer to the Honda engine user manual for cleaning instructions 19 peep WINCH 5 0 Complementary information 5 1 Accessories A complete line of accessories is available You will find the list on our website at www portablewinch com
16. for free We would like to thank you for your purchase By doing so we would like to offer you ONE 1 EXTRA YEAR WARRANTY for FREE It s simple simply register your winch www portablewinch com or by phone at 1 888 388 PULL 7855 or 1 819 563 2193 5 3 Serial number localization The winch serial number is indicated on the safety warning label located on the right side of the winch housing and is also engraved on the cover of the winch to the left of the capstan drum 20 WINCH 5 4 CE Declaration of conformity DECLARATION OF CONFORMITY We PORTABLE WINCH CO of 1170 Thomas Tremblay St Sherbrooke QC J1G 5G5 CANADA Tel 1 819 563 2193 www portablewinch com Declare that these products Portable Capstan Winches Models PCW5000 and PCW5000 HS For intended purpose Pulling non rolling objects at angles 45 from horizontal plane Fulfills all relevant provisions of Machinery Directive 2006 42 EC And also fulfills all relevant provisions of 2004 108 EC Electromagnetic Compatibility Directive Mr Gerold Vonblon Landstrasse 28 A 6714 Nuziders Is authorized to compile the technical file Signed by Name Pierre Roy PORTABLE Position Managing Director WI NCH Done at Sherbrooke QC Canada On April 18 2012 21 22 5 5 Exploded view and parts list WINCH fnac
17. he 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 Winches 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 A and one of the following terms DANGER WARNING or CAUTION These indicator words mean DANGER You WILL be MORTALLY or SEVERELY INJURED if you do not follow these instructions A WARNING You COULD be MORTALLY or SEVERELY INJURED if you do not follow these instructions A CAUTION 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 Line wanve prior to using the winch READ MANUAL ELLA 2 Only use
18. latch figure 3 or shackle figure 4 3 4 3 3 Winch anchor OPTION 1 In most cases 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 OPTION 2 Alternately the winch can be anchored to the load that needs to be moved and the rope end is tied to a fixed point The winch and the load are therefore pulled toward the fixed point where the rope end is tied This method is useful when you need to guide the load while you operate the winch 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 A CAUTION 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 HO
19. nd cause serious burns as the rope leaves your hand A All ropes stretch a longer one more than a shorter one The more you pull the more it stretches A A stretched rope can also move the load in an unpredictable or dangerous way A A stretched rope can recoil and bring your hand towards the winch causing severe injuries NEVER WRAP THE ROPE AROUND YOUR HAND CAUTION ALWAYS WEAR GLOVES 3 1 2 Rope maintenance CAUTION VISUALLY INSPECT YOUR ROPE BEFORE EACH USAGE IF IT SHOWS ANY SIGN OF DETERIORATION CUT STRANDS EXCESSIVE ABRASION REPLACE IT CAUTION 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 mi 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 7096 of the rope s capacity while most knots will reduce it by more than 5096 Even better the double bowline knot figure 2 will keep about 75 of your rope s capacity fuz WINCH 3 2 2 Recommended hooks If you usually pull with a choker chain use a grab hook figure 1 or grab hook with latch figure 2 If you usually pull a sling or a ring use a safety hook with
20. nk and pull the throttle up You can now resume winching 17 fuz WINCH 3 6 2 6 If you must keep tension on the rope at start up You can install a rope grab device or a Prussik knot attached to your anchor point in order to keep tension on the rope 3 6 2 7 If your rope is too short If your rope is too short you will have to link two ropes together 1 Figure 1 no 1 Using the bowline knot section 3 2 1 link your two ropes together 2 Figure 1 no 2 IMPORTANT Leave about 1 m 3 of rope tailing out of the knot on the rope 2 the load You will need it to resume winching after undoing the knots 3 Figure 2 A WARNING Stop the winch BEFORE the knot reaches the rope entry pulley of the winch since it CANNOT GO THROUGH it 4 Release tension off the rope If necessary attach the load to a fixed object 5 Undo the knots and use the remaining length 1 m or 3 to wrap around the capstan drum and start winching again 3 6 3 Stopping the winch 18 1 Release tension gradually to lower the winch gently to the ground 2 Bring throttle down to idle 3 Turn ignition switch off 4 0 Maintenance 4 1 Cleaning Once your job is done you should clean and dry your winch CAUTION INSPECT THE WINCH HOOKS ROPE KNOTS AND POLYESTER SLING TO DETECT ANY DAMAGE OR SIGNS OF WEAR Periodically remove the capstan drum section 2 2 4 and clean around the shaft figure 1 Accumulat
21. o stalling and release the tension Pull again on the rope to put tension and repeat as needed A CAUTION BE CAREFUL WITH THIS METHOD SINCE IT GENERATES HEAT AND CAN WEAR THE ROPE QUICKLY WARNING IF THE WINCH IS PULLING THE ROPE BUT THE LOAD DOES NOT MOVE OFTEN THE CASE WHEN USING A VERY LONG ROPE IT S BECAUSE YOUR ROPE IS STRETCHING AND COULD REACH THE BREAKING POINT AND RECOIL TOWARDS YOU SLOWLY RELEASE THE TENSION ON THE ROPE BUT BEWARE OF THE ACCUMULATED TENSION YOU COULD GET BURNED FROM THE ROPE EXITING YOUR HANDS QUICKLY OR BE PULLED TOWARDS THE WINCH 3 6 2 3 How to pause while winching SLOWLY release the tension on the rope and let it slip on the capstan drum CAUTION DO NOT LET THE ROPE SLIP FOR MORE THAN A FEW SECONDS ON THE DRUM WHILE IN TENSION THE HEAT CREATED BY THE FRICTION COULD MELT OR DAMAGE THE ROPE 3 6 2 4 How to maintain a load without releasing the tension You may maintain tension on the end of the rope either by holding it or attaching it 1 Shut the engine off 2 Wrap the rope twice around the rope hook to relieve tension from your hands figure 1 3 Tie two half knots around the rope hook figure 2 Figure 2 3 6 2 5 How to resume winching You must release some tension before restarting the winch engine First untie the two half knots Let go of some of the rope to release some tension While holding the rope with one hand start the engine by pulling on the cra
22. ope behind the rope hook figure 1 no 3 5 Stand about 1 m 3 from the winch and pull gently and horizontally on the rope to get the slack until you feel the tension rising on the rope 6 Look at your set up to make sure that the winch anchor and the rope entry pulley are aligned with the rope 7 Check that the rope does not rub against objects along the path 8 Pull the throttle up and start winching 3 6 2 Winching 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 level Do not operate with the winch tilted or the Oil Alert will kick in A DANGER DO NOT WRAP THE ROPE AROUND YOUR HANDS OR YOUR BODY ALSO BEWARE OF THE ROPE ACCUMULATING IN FRONT OF YOU MAKE SURE YOUR FEET DO NOT GET TANGLED IN IT WARNING CAREFULLY WATCH THE CAPSTAN DRUM DURING THE OPERATION AND MAKE SURE THAT THE ROPE DOES NOT CROSS OVER ON IT IF IT HAPPENS RELEASE THE TENSION ON THE ROPE AND STOP THE ENGINE WHILE UNDOING THE CROSS OVER 3 6 2 1 If the rope slips If the rope slips on the drum while winching add a fourth wrap of rope on the drum When the winch reaches its maximum capacity the engine stalls You then have to redo your set up add pulleys or rock the load see section 3 6 2 2 16 WINCH 3 6 2 2 To rock the load Pull the rope until the engine comes close t
23. ptor 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 Alert 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 Ona 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 Ifthe 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 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 m WINCH Introduction Portable Winch Co wishes to thank you for purchasing a Portable Capstan Winch This manual was written to help you make the best use of your new winch and to use it in t
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