Portable Winch Company
Contents
1. WARNING 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 CAUTION al WAYS 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 lf 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 an2. 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 A WARNING iF YOU ARE IN DOUBT OF THE ROPE FITNESS RETIRE THE ROPE 12 PORTABLE WINCH 3 2 At the end of the rope 3 2 1 Recommendations Since the Portable Capstan Pulling Lifting Winch 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. 3 PORTABLE WINCH 4 5 Exploded view and parts list 32 WINCH HOMBMXI IN SSS ONOFF SWITCH WITH SUPPORT PLATE FOR GXH SO ENGINE 9 18390007 METAL SCREW NO 10 X 1 2 PAN HEAD SQ DR THROTTLE GABLE ASSEMBLY SSS 33 isses WINCH 44 0022 LABEL ROPE DANGER 44 0026 LABEL ROPE INSTALLATION PCH1000 PCT1800 44 0033 LABEL SPECS SPEED VS DRUM DIAMETER PCH1000 45 0036 HOUR METER 4 6 Technical data e Engine 4 stroke Honda GXH 50cc e Maximum pulling force single line o 57 mm drum 775 kg 1700 Ib o 85mm drum 540 kg 1190 Ib e Rated lifting capacity single line o 57 drum 250 kg 550 Ib o 85mm drum 175 kg 385 Ib e Speed 57 drum 12 m min 40 ft min o 85 drum 18 m min 60 ft min e Installed Capstan drum 57 mm 2 1 4 diameter o Upto 4 wraps of 12 13 mm 1 2 rope Gear box Aluminum alloy Gear ratio 110 1 Unit weight 19 kg 42 Ib Clutch Centrifugal Hope grabbing system can be disabled Dimensions overall Length 50 5 cm x Width 36 6 cm x Height 36 6 cm 19 7 8 x 14 3 8 x 14 3 8 e Rope Double braided polyester not included Unlimited rope length o Minimum diameter 12 mm 1 2 o Maximum diameter 13 mm 1 2 o Recommended rope with buried eye splice 4 7 Noise emissions Here are the different noise emissions of the Portable Capstan Pulling Lifting Winch e Sound pressure level at operator position
4. 4 5 www portablewinch com DATE HOUR METER READING jJ o _ o YES NO GEARBOX Warning labels present and Anchor hooks no cracks Shaft end play less than 0 5 mm 0 020 Drum keyway is tight clean pulley rotating no flat section D LLL APUL AM ME e c amp Ba rJ a HP amp t B ROPE GRABBING SYSTEM WINCH CONTROLS Main plate pivots freely Pivot bolt is tight No excessive wear on pivoting parts Throttle control operational e l l S S Clutch rotor is tight no cracks or uneven wear Clutch drum is tight turns freely wall is gt 2 mm pU ____ oo o o o do LL O E Fuel tank filter are clean Spark arrestor is clean Oilisnewandlevelisgood DOO O Air filter is clean rium z WINCH ROPES HOOKS Mee o o o o bo bobo whole _ damaged Hooks are in good condition Links shackles carabiners etc are good On Off switch is operational S y O Drumismotrotatingatide JJ S 0 o Drumisrotatingatfullthrotle o y o TE course imet ne o o o o ol is operational Nounusualnoisesareheard GENERAL WINCH CONDITION y COC Goo
5. LpA measured o Engine idling 73 dBA o Full throttle 89 dBA e Sound power level LwA measured o Engine idling 85 dBA o Full throttle 102 dBA e Guaranteed sound power level LwA 105 dBA 4 8 Inspection This section applies to winches used for lifting The term inspect implies that any minor repair tightening part replacement cleaning adjustment etc that can be performed during the inspection procedure is done The procedures below are intended to provide a guide to the end user to help maintain compliance with ASME ANSI Standard B30 7 201 and ISO Standard 14492 1 2006 Local authorities may require other periodic test procedures 34 lORTABLE WINCH 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 Check oil level see Honda Owner s Manual 2 Check air filter see Honda Owner s Manual 3 Check fuel level see Honda Owner s Manual 4 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 1 Test throttle adjustment Without rope on the drum 1 Pull on plate and confirm that the maximum course is reached picture 1 2 Observe drum rotating under full throttle 3 Release plate and confirm the minimum course is reached by spring return action picture 2 4 Obser
6. PCA 1265 and secure it with both the hitch pin and the R Note Its lateral movement can be adjusted by positioning the bolts into the square holes 4 Attach the winch anchor hooks 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 16 FORTABLE 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 3 3 5 1 With the winch support plate PCA 1268 Aft
7. 2 with buried eyed splice and a minimal breaking strength of 3150 kg 6945 Ib 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 PORTABLE WINCH CO 1 888 388 PULL 7855 1170 Thomas Tremblay Sherbrooke QC 565 CANADA T l 1 819 563 2193 d www portablewinch com Force de tire Pulling force Capacit en levage Rated lifting capacity Vitesse de treuillage Winching speed No de s rie Serial number Ann e de fabrication Year manufactured WINCH 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 57 mm 12 m min 1 3 Safety information 85 mm 18 m min WARNING po NOT LET CHILDREN USE THE PORTABLE CAPSTAN PULLING LIFTING WINCH KEEP CHILDREN AND ANIMALS AWAY FROM THE WORK AREA WARNING NEVER LET SOMEONE WITHOUT TRAINING USE THE PORTABLE CAPSTAN PULLING LIFTING WINCH 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 A WARNING INF
8. 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 13 FORTABLE WINCH 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 A CAUTION DON T DO THIS WHEN YOU ANCHOR THE WINCH MAKE SURE THAT YOU DO NOT DO A COMPLETE WRAP AROUND THE ANC
9. 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 FORTABLE 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 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 e Portable Winch Co 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 WARNING 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 WARNING po 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
10. Bearing condition turns evenly and smoothly by hand 39 hers WINCH Clean adjust spark plug Check adjust idle speed 3 Check adjust valve clearance C ean fuel tank and filter lean 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 3 General winch condition Make an assessment of the general winch condition in a clear manner such as Excellent Good Needs Repairs Requires Further Evaluation etc 4 8 5 Winches not in reqular service 1 A winch which has not been used for more than one month but less than six months shall be given a Frequent Inspection before being put in service 2 A winch which has not been used for more than six months shall be given a periodic inspection prior to being put in service 4 9 Manufacturer The PCH1000 Portable Capstan Pulling Lifting Winch is 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 www portablewinch com 40 WINCH Schedule I Periodic inspection log sheet every 100 hours of operation WINCH SERIAL NUMBER over 600 hours print more mnm of these pages at 1 2 3
11. WHEELS TO PREVENT ROLL BACK 3 3 3 Using the winch support plate PCA 1268 with square tubing 50 mm 2 PCA 1267 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 15 PORTABLE WINCH 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 4 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 of the winch support plate adaptor
12. 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 Winch 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 e 4 mm 5 32 hex wrench included with your winch e 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 16 wrench Then remove the washer the safety lip and the spacer bushing 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 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 Figure
13. 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 warranty policies on www portablewinch com if you have any questions Extend your warranty 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 Its simple simply register your winch on www portablewinch com or by phone at 1 888 388 PULL 7855 or 1 819 563 2193 30 4 4 CE Declaration of conformity cer WINCH DECLARATION OF CONFORMITY of Declare that the product For intended purpose PORTABLE WINCH CO 1170 Thomas Tremblay St Sherbrooke QC J1G 5G5 CANADA Tel 1 819 563 2193 www portablewinch com Portable Capstan Pulling Lifting Winch Model PCH1000 Serial numbers 1001 and higher Pulling and lifting objects at angles up to vertical Conforms to the dispositions of Machinery Directive 2006 42 EC And also conforms to the disposition of 2004 108 EC Electromagnetic Compatibility Directive Mr Gerold Vonblon Landstrasse 28 A 6714 Nuziders Is authorized to compile the technical file oigned by Name Pierre Roy Position Managing Director Done at Sherbrooke QC Canada On April 18 2012 ORTABLE WINCH
14. preceded by a warning symbol and one of the following terms DANGER WARNING or CAUTION These indicator words mean DANGER vou WILL be MORTALLY or SEVERELY INJURED if you do not follow these instructions WARNING You COULD be MORTALLY or SEVERELY INJURED if you do not follow these instructions CAUTION vou 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 wngure 1 to the right 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 Winch 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
15. 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 CAUTION wake SURE THE BENT HITCH PIN IS SECURED WITH THE R PIN PRIOR TO PULLING WARNING 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 WARNING IMPORTANT AFTER PULLING FOR A FEW SECONDS RELEASE THE TENSION AND CHECK THE SOLIDITY OF THE INSTALLATION 3 4 Moving a load WARNING USING COMMON SENSE WHILE MOVING A LOAD 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 WARNING CHECK WINCH POSITION ROPE CONDITION SOLIDITY OF THE ANCHOR POINT KNOTS CARABINERS OR SHACKLES IN ORDER TO PREVENT INJURIES OR MATERIAL DAMAGE A WARNING INSTALL THE ROPE IN SUCH A WAY THAT IT DOES NOT RUB AGAINST OTHER OBJECTS OR THROUGH AN OBSTRUCTION GENERALLY IF THE ROPE TOUCHES AN OBJECT YOUR INSTALLATION IS INCORRECT 2 M WINCH WARNING NEVER PUT YOUR HANDS ON THE CAPSTAN DRUM THE ROP
16. vertical support pulley with the rope axe and start to pull 3 4 18 oss WINCH WARNING 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 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 3 6 Using the vertical pull winch support PCA 1264 with square tubing 50 mm 2 PCA 1267 A WARNING ONLY USE VEHICLES EQUIPPED WITH CLASS TOWING HITCHES WARNING NEVER ATTEMPT TO LIFT MORE THAN THE RATED LIFTING CAPACITY OF 250 KG 550 LB 19 ii CAUTION perrorm A TEST PULL WITH A LIGHT LOAD IN ORDER TO ASSES VEHICLE STABILITY AND EQUIPMENT INSTALLATION 4 e 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 Then reinforce it with the R pin 20 I mns WINCH 4 Figure 4 Attach the winch anchor hooks to the eye bolts of the vertical pull winch support 5 Figure 5 Install
17. E GRABBING SYSTEM THE ROPE GUIDE OR THE ROPE ENTRY PULLEY WHEN THE ENGINE IS RUNNING WARNING Look AT YOUR SET UP TO MAKE SURE THAT THE WINCH ANCHORS AND THE ROPE ENTRY PULLEY ARE ALIGNED WITH THE ROPE WARNING 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 DO NOT OPERATE WITH THE WINCH TILTED OR THE OIL ALERT WILL KICK IN SEE SECTION 3 5 DANGER po NOT WRAP THE ROPE AROUND YOUR HANDS OR YOUR BODY ALSO BEWARE OF THE ROPE ACCUMULATING NEXT TO YOU MAKE SURE YOUR FEET DO NOT GET TANGLED IN IT WARNING CAREFULLY WATCH THE CAPSTAN DRUM DURING THE OPERATION AND MAKE SURE 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 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 27 PORTABLE WINCH nM 3 4 1 Installing the rope on the Portable Capstan Pulling Lifting Winc WARNING NEVER PUI 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 2 2 Start the engine
18. HOR 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 v TET SEIS rds 7 gir 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 CAUTION USING A STUMP AS AN ANCHOR POINT MEANS PAYING SPECIAL ATTENTION IN ORDER TO PREVENT THE SLING FROM SLIPPING OVER IT A WARNING MAKE SURE THE ANCHOR POINT IS STRONG ENOUGH TO RESIST THE PULL WITHOUT BREAKING OR BEING DAMAGED Hours WINCH 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 5 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 AND WORKING PROPERLY POSITION BLOCKS BEHIND THE
19. IND 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 2 Load lifting charts for the correct drum size and number of wraps of rope to use 3 4 2 4 Lowering a load CAUTION ALWAYS WEAR GLOVES WARNING YOUR PORTABLE CAPSTAN PULLING LIFTING WINCH S EQUIPPED WITH A ROPE GRABBING SYSTEM THIS SYSTEM IS NOT DESIGNED TO STOP FAST MOVING LOADS DAMAGE CAN OCCUR TO THE ROPE AND OR THE ROPE GRABBING SYSTEM WHEN SHOCK LOADED AND POSSIBLY LEAD TO CATASTROPHIC FAILURE DANGER po NOT WRAP THE ROPE AROUND YOUR HANDS OR YOUR BODY ALSO BEWARE OF THE ROPE ACCUMULATING NEXT TO YOU MAKE SURE YOUR FEET DO NOT GET TANGLED IN IT THE PORTABLE CAPSTAN PULLING LIFTING WINCH S NOT DESIGNED FOR LOWERING HEAVY LOADS OVER LONG DISTANCES FRICTION OF THE ROPE ON THE CAPSTAN DRUM WILL GENERATE HEAT THAT COULD DETERIORATE OR EVEN MELT THE ROPE YOU MAY WANT TO RUN SOME TESTS IN ORDER TO EXPERIMENT YOU CAN ALSO USE PULLEY BLOCKS ON THE LOAD TO REDUCE FRICTION ON THE DRUM CAUTION AFTER EACH LOWERING OPERATION IT IS IMPERATIVE TO CHECK ROPE CONDITION WARNING NEVER GO OVER THE RATED LIFTING CAPACITY 250 KG 550 LB SINGLE LINE A WARNING NEVER BYPASS THE ROPE GRABBING SYSTEM WARNING NEVER
20. NOT BE IN THE SLACK CONDITION WHEN THE LOAD MOVEMENT BEGINS WARNING sipE PULL OF LOAD IS NOT ALLOWED WITH THE PCH1000 PORTABLE CAPSTAN PULLING LIFTING WINCH WARNING 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 15 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 Winch is equipped with a 4 stroke engine Refer to the Honda engine user manual PORTABLE WINCH 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 k x 1 ENTE a The engine on off switch is located on the winch housing to the left of the
21. ORM ALL USERS OF THE SAFETY GUIDELINES AND USAGE PROCEDURES WARNING FAMILIARIZE YOURSELF WITH THE PRODUCT AND THE SAFETY GUIDELINES BEFORE WORKING WITH THE WINCH WARNING MAKE SURE THAT YOUR CLOTHES ARE NOT GOING TO GET CAUGHT INTO THE WINCH MOBILE PARTS WARNING NEVER USE THE PORTABLE CAPSTAN PULLING LIFTING WINCH TO LIFT PEOPLE WARNING USE ONLY 12 MM TO 13 MM 1 2 DIAMETER DOUBLE BRAID PORTABLE WINCH CO POLYESTER ROPE WITH THIS WINCH A WARNING NEVER LIFT OBJECTS OVERHEAD OF PEOPLE WARNING ALWAYS USE THE PORTABLE CAPSTAN PULLING LIFTING WINCH HORIZONTALLY USING A PULLEY OR THE VERTICAL PULL WINCH SUPPORT TO REDIRECT THE ROPE VERTICALLY DANGER THE EXHAUST GAS CONTAINS TOXIC CARBON MONOXIDE NEVER RUN THE ENGINE IN A CLOSED AREA WITHOUT PROPER VENTILATION CAUTION REPLACE ANY SAFETY LABELS THAT ARE DAMAGED ILLEGIBLE OR MISSING M WINCH WARNING 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 WARNING ALWAYS KEEP BYSTANDERS OUTSIDE THE WORKING AREA DANGER NEVER PULL ROLLING OBJECTS THAT MIGHT ROLL OUT OF YOUR CONTROL WARNING NEVER TRY TO MOVE FIXED OR OBSTRUCTED LOADS WARNING AVOID EXCESSIVE INCHING E G GIVING SHORT PULSES TO THE MOTOR WARNING Ai WAYS INITIATE MOVEMENTS OF THE LOAD WITH THE LOWEST AVAILABLE SPEED THE ROPE SHALL BE TIGHTENED AND SHALL
22. SERIAL NUMBER THE ORIGINAL HIABLE WINCH READ CAREFULLY BEFORE USE Portable Winch Co PORTABLE CAPSTAN GAS POWERED PULLING LIF TING WINCH PCH1000 USER MANUAL Maximum pulling force single line 775 kg 1700 Ib Rated lifting capacity single line 250 kg 550 Ib 2013 Portable Winch Co All Rights Reserved Ub www portablewinch com English version Cm 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 15 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 9 3 1 2 Rope usage p 10 Sal Rope inspection and maintenance p 10 3 2 At the end of the rope p 13 3 2 1 Hecommendations 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 39 4 X Using the winch support plate with Heck Pack system and winch support plate adaptor p 16 3 39 5 Using the tree pole mount with anchor strap p 17 3 3 5 1 With the win
23. SHOCK LOAD THE SYSTEM 26 onere WINCH WARNING BEWARE OF ROPE SNARLS WHILE LOWERING IF ROPE GETS TANGLED PULL ON ROPE WHILE ENGINE IS RUNNING UNTIL CLEARED CAUTION po 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 Winch the rope grabbing system engages therefore holds a load in position and keeps the rope under tension To release it follow these steps 1 2 Figure 1 no 1 Pull horizontally and gently on the pulling rope to engage the throttle this will release the tension applied by the rope grabbing system on the pulling rope Figure 1 no 2 Pull gently on the rubber handle of the rope attached to the rope grabbing system this will disengage the system WARNING po NOT COMPLETELY DISENGAGE THE ROPE GRABBING SYSTEM IN CASE OF EMERGENCY SIMPLY LET THE RUBBER HANDLE GO THE SYSTEM WILL RE ENGAGE WARNING NEVER LET THE PULLING ROPE SLIDE SUDDENLY IF A LOAD IS SUSPENDED Figure 1 no 3 Slowly payout the pulling rope push it towards the winch if necessary this may occur if you have four wraps of rope on the drum and a light load while keeping the rope grabbing system slightly open Figure 1 no 4 Release the tension applied to the rubber handle this will re engage the rope grabbing system You can now let go the pulling rope and grab it further Hepeat steps 1 to 4 until t
24. ch 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 Winch 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 Alert 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 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 41 Schedule Il Inspecting the rope log sheet every day p 43 2 hers WINCH Introduction Portable Winch Co wishes to thank you for
25. d Needs repairs o ooo d S S o o y OS Requires further evaluation oS ooo o y oO NOTES 42 v WINCH Schedule Il 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 WINCHING ROPE COMMISSIONING RT s DATE CONSTRUCTION Daily verification NOTES AND DATE INSPECTION OR INCIDENT SIGNATURE
26. d 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 CAUTION VISUALLY INSPECT YOUR ROPE BEFORE EACH USAGE IF IT SHOWS ANY SIGN OF DETERIORATION CUT STRANDS EXCESSIVE ABRASION REPLACE IT CAUTION F 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 10 PORTABLE WINCH 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
27. er the installation of the tree pole mount section 3 3 5 follow these steps 1 Figure 1 Insert the winch support plate onto the square tubing of the tree pole mount 1263 and fasten it down with the hitch pin and R pin Note Its lateral movement can be adjusted by positioning the bolts into the square holes 2 Figure 2 Attach the winch anchor hooks to the eye bolts of the winch support plate 17 lORTABLE WINCH 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 WARNING AFTER PULLING FOR A FEW SECONDS WITH THE TREE POLE MOUNT RELEASE THE TENSION OFF THE PORTABLE CAPSTAN PULLING LIFTING 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 1263 align the holes and insert the pulley 2 Figure 2 Tighten the nut with your fingers until it touches the support Then secure it with the R pin Figure 3 Attach the winch anchor hooks to the eye bolts of the vertical pull winch support Figure 4 Wrap the rope around the drum and align the
28. erson These signals should not be in conflict with the standard signals 3 4 2 2 Load lifting charts WARNING BEFORE ATTEMPTING TO LIFT A LOAD IT IS IMPERATIVE TO EVALUATE ITS APPROXIMATE WEIGHT When lifting a load you may figure the minimal number of wraps required on the capstan drum in order to move the load Below are two charts in accordance with the capstan drum size used These charts are designed to help figure out the number of wraps you need to lift a load and also allow its lowering The friction on the capstan drum is relative to the size of the drum installed the number of wraps and the load weight therefore too many wraps may prevent a load to lower WARNING IMPORTANT NOTE IF THE MOTOR STALLS WHILE LIFTING A LOAD YOU HAVE EXCEEDED THE RATED LIFTING CAPACITY THEREFORE YOU MUST LOWER THE LOAD TO RELEASE THE TENSION ON THE ROPE AND INSTALL A BLOCK AND TACKLE DEVICE TO INCREASE THE LIFTING CAPACITY BEFORE RESTARTING TO PULL Number of m capstan drum Never use only one wrap on the drum 81 kg 170 kg 177 Ib 374 lb 171 kg 250 kg 375 Ib 550 Ib Number of wraps on the MOL WARNING Never use only one wrap on the drum 4 WARNING 80 kg 176 lb 81 kg 175 kg 177 lb 385 Ib 25 hers WINCH 3 4 2 3 Lifting operation CAUTION 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 WARNING KEEP IN M
29. he load is at desired position or completely lowered Once at desired position let the rubber handle go this will re engage the system if needed If needed stop the engine with the on off switch 27 PORTABLE WINCH 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 However when pulling a load on the ground that does not risk falling or rolling back you may want to disengage the rope grabbing system If you do not and the load get stuck you may have trouble getting some slack since the rope will already be stretched to its maximum and the rope grabbing system will be very hard to disengage WARNING IF THERE IS ANY RISK THE LOAD MAY FALL OR ROLL BACK DO NOT COMPLETELY DISENGAGE THE ROPE GRABBING SYSTEM Using the winch without the rope grabbing system allows you to release the tension and benefit from the elasticity of the rope to restart pulling and let the engine reach its maximum revolution RPM To disengage the rope grabbing system open the spring loaded cam upwards and
30. its maximum and the drum is turning normally b Listen for abnormal noises c Release the rope and observe that the throttle is going to idle by spring return and the drum stops turning when idling 4 Test the operation of the on off switch 5 Check that the rope entry pulley brass pulley is rotating freely if not clean and lubricate Replace pulley if any flat spots are present 6 Inspect the rope for excessive wear damage or distortion See rope inspection and maintenance section 3 1 3 7 Inspect slings and straps used to anchor the winch for cuts and abrasion 8 If using a new anchor point a With the rope grabbing system brake disengaged see section 3 4 3 Test anchor by exerting twice the maximum pulling force of the winch using a block attached to a fixed point and attaching the rope end to the anchor point 37 hrs WINCH b If the anchor is moving or show any sign of potentially moving find a new ancho point and perform the test again WARNING po 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 Clean engine air filter Service more frequently when operating in dusty areas Change engine oil Without load test the winch controls by pulling the rope end a Observe that the throttle i
31. 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 7 Then wrap the rope around the drum 3 or 4 turns no 2 4 Figure 3 Insert the rope into rope grabbing system device by pulling the spring loaded cam lever upwards no 1 This will give enough room to insert the rope 5 Figure 4 Make sure the rope goes over the stainless steel knob no 1 Then push the spring loaded cam back against the rope which will automatically hold a load if the rope end is let go no 2 6 Figure 5 As you pull the rope no 1 the throttle will engage and load will move IMPORTANT It is necessary to pull the rope HORIZONTALLY to get the load started To stop load movement stop pulling on rope no 2 7 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 8 Look at your set up to make sure that the winch anchor and the rope entry pulley are aligned with the rope Check that the rope does not rub against objects along the path 10 Pull on the rope the throttle will go up and the winching will start desti cem iiti 9 7 LIT di ossis WINCH 3 4 2 Lifting 3 4 2 1 Communications When using a signalperson commu
32. let it rest on the frame of the rope grabbing system figure 1 no 1 To re engage it lift it upward again and bring it back towards the pulling rope figure 1 no 2 3 4 3 1 Releasing the tension CAUTION ALWAYS WEAR GLOVES WARNING STRETCH EQUALS DANGER DANGER po NOT WRAP THE ROPE AROUND YOUR HANDS OR YOUR BODY ALSO BEWARE OF THE ROPE ACCUMULATING NEXT TO YOU MAKE SURE YOUR FEET DO NOT GET TANGLED IN IT 28 WINCH 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 Winch 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 2 When pulling with the rope grabbing system disengaged If the rope grabbing system is not used when you stop pulling with the Portable Capstan Pulling Lifting Winch you simply have to release tension gradually to lower the winch gently to the ground 3 5 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 4 0 Co
33. log table at the end of the manual 4 8 4 1 Gearbox 1 Look for leaks If any found check gearbox oil level 2 Look for any loose screws or bolts and particularly look at bolt and locknut holding the safety hooks There should be at least one visible thread on the bolt beyond the locknut 38 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 6 Check that rope entry pulley brass pulley is rotating freely if not clean and lubricate Replace pulley if any flat spots are present 7 Rope Grabbing System Check that plate is pivoting freely and that there is no excessive wear on the pivot surfaces Check if pivot bolt is tight 8 Look at casting for cracks particularly in the anchoring region 9 Remove engine from the gearbox by removing the 6 bolts see picture below a Inspect clutch rotor engine side for i Cracks li Loose screws iii Uneven wear or other damage b Inspect clutch drum gearbox side for i Wear minimum thickness 2 mm 0 080 li Tightness no noticeable axial movement ii
34. mplementary information 4 1 Accessories A complete line of accessories is available Simply visit www portablewinch com 554 4 2 Serial number localization i E The winch serial number is indicated on the ee ie serial number and 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 29 hers WINCH 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 This warranty does not apply to wear parts defined as being in contact with the rope while winching The PCH1000 Portable Capstan Pulling Lifting Winch is covered as follow e Winch components o Private use Two 2 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
35. nication 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 2 Standard hand signals described below whenever hand signals are used 3 Standard voice signals described below whenever voice signals are used otandard hand signals are C 9 ion ur _ oS f A Ai 1 1 HOIST or PAY IN With forearm vertical forefinger pointing up move hand in small horizontal circle 2 MOVE SLOWLY Use one hand to give any motion signal and place other hand motionless together with the hand giving the motion signal Pay in slowly is example shown 3 LOWER or PAY OUT With arm extended downward forefinger pointing down move hand in small horizontal circle 4 STOP Arm extended palm down move arm back and forth horizontally 5 EMERGENCY STOP Both arms extended palms down move arms back and forth horizontally 24 hers WINCH otandard 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 signalp
36. purchasing a PCH1000 Portable Capstan Pulling Lifting Winch 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 quidelines The PCH1000 Portable Capstan Pulling Lifting Winch 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 WARNING WHEN LIFTING NEVER GO OVER THE RATED LIFTING CAPACITY 250 kg 550 Ib SINGLE LINE WARNING WHEN LIFTING NEVER BYPASS THE ROPE GRABBING SYSTEM A WARNING NEVER SHOCK LOAD THE SYSTEM WARNING 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
37. s rising to its maximum and the drum is turning normally b Listen for abnormal noises c Release the rope and observe that the throttle is going to idle by spring return and the drum stops turning when idling 5 Test the operation of the on off switch 6 Inspect the rope for excessive wear damage or distortion see rope inspection and maintenance section 3 1 3 7 Inspect all rope end securement fittings hooks shackles carabiners etc Look for cracks shock marks deformation corrosion pitting gates functionality etc Do not hesitate to retire part when in doubt 8 Inspect all warning and instruction labels for deterioration 9 Ensure the instruction manual is present and legible 10 Look for leaks around gearbox If any found verify gearbox oil level 11 Remove capstan drum and clean any debris that may have accumulated around the shaft and near the oil seal Apply some oil on the shaft before re assembly 12 When in doubt a qualified person should determine if the condition requires further repairs or the equipment to be taken out of service alternately the equipment should be sent to an authorized Portable Winch service center for evaluation gt W 4 8 4 Periodic inspection every 100 hours of operation This has to be performed every 100 hours of operation In addition to the items below perform all items from the Frequent Inspection section 4 8 3 above Write the results of this Periodic Inspection in the
38. 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 11 PORTABLE WINCH 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
39. ve drum not rotating when engine is idling 5 If there are any adjustments to be made perform the adjustments and re test 6 Listen for any unusual noise 35 PORTABLE WINCH 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 3 Test anchor by exerting twice the maximum pulling force of the winch using a block attached to a fixed point and attaching the rope end to the anchor point picture below WARNING po NOT ANCHOR THE ROPE BACK TO THE WINCH 36 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 1 Inspect grabbing system see picture for any sign of wear or loose parts 2 Check engine oil and air filter 3 Without load test the winch controls by pulling the rope end a Observe that the throttle is rising to
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