Portable Winch PORTABLE CAPSTAN WINCH PCW5000 User manual

Portable Winch Co.
PORTABLE CAPSTAN WINCHTM
PCW5000
USER MANUAL
Model: PCW5000
Maximum pulling capacity (single line): 1136 kg (2500 lb)

2
Summary
Introduction – p. 3
1.0 Safety guidelines – p. 3
1.1 Safety messages – p. 3
1.2 Label – p. 3
1.3 Safety information – p. 4
2.0 Before first use – p. 5
2.1 Upon receiving the winch – p. 5
2.2 Is the engine ready to work? – p. 5
2.2.1 Engine oil – p. 5
2.2.2 Gas – p. 5
2.2.3 Engine start-up – p. 6
2.2.4 Capstan drum – p. 6
2.2.5 Spark arrestor – p. 7
3.0 Winch usage – p. 8
3.1 Rope – p. 8
3.1.1 Rope type – p. 8
3.1.2 Rope maintenance – p. 8
3.2 At the end of the rope – p. 9
3.2.1 Recommended knots – p. 9
3.2.2 Recommended hooks – p. 10
3.3 Winch anchor – p. 10
3.3.1 Using a polyester sling – p. 11
3.3.2 Using the Hitch Plate – p. 11
3.3.3 Using the Receiver Hitch – p. 12
3.3.4 Using the Tree/Pole Mount – p. 13
3.4 Oil AlertTM system – p. 13
3.5 Rope installation – p. 14
3.5.1 Rope – p. 14
3.5.2 Pulley – p. 14
3.5.3 Direction – p. 14
3.5.4 On a hill – p. 14
3.6 Pulling a load – p. 14
3.6.1 Wrapping the rope on the capstan drum – p. 15
3.6.2 Winching – p. 15
3.6.2.1 If the rope slips – p. 15
3.6.2.2 To ‘’rock’’ the load – p. 16
3.6.2.3 How to pause while winching – p. 16
3.6.2.4 How to maintain a load without releasing the tension – p. 16
3.6.2.5 How to resume winching – p. 16
3.6.2.6 If you must keep tension on the rope at start-up – p. 17
3.6.2.7 If your rope is too short – p. 17
3.6.3 Stopping the winch – p. 17
4.0 Maintenance – p. 17
4.1 Cleaning – p. 17
4.2 Lubrication – p. 18
4.3 HondaTM engine – p. 18
4.4 Storage – p. 18
4.5 Spark arrestor – p. 18
5.0 Complementary information – p. 18
5.1 Accessories – p. 18
5.2 Warranty – p. 20
5.3 Serial number localization – p. 20
5.4 CE Declaration of conformity – p. 21
5.5 Parts list – p. 22
5.6 Manufacturer – p. 24

3
Introduction
Portable Winch Co. wishes to thank you for purchasing a PCW5000 Portable 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 you may
have, please refer to an authorized Portable Winch Co. dealer or contact us directly.
1.0 Safety guidelines
The PCW5000 Portable WinchTM is designed to pull non-rolling objects, usually at plus or
minus 45 degree angle from the horizontal.
The use of a pulling device implies serious risks of injuries, property damage or even death. Do
not underestimate its potential danger.
1.1 Safety messages
Your safety and the safety of others are very important. You will find important safety messages
in this manual. Read them carefully.
These security messages are warning you of potential injuries to either you or others. Every
safety message is preceded by a warning symbol and one of the following terms:
DANGER, ATTENTION or PRECAUTION.
These indicator words mean:
You WILL be MORTALLY or SEVERELY INJURED if you do not follow
these instructions.
You COULD be MORTALLY or SEVERELY INJURED if you do not
follow these instructions.
You COULD be INJURED if you do not follow these instructions.
1.2 Label
The warning label is positioned on the right side of the winch housing.

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1.3 Safety information
Do not let children use the Portable WinchTM. Keep children and animals away from the work
area.
Never let someone without training use the Portable WinchTM. Make
sure the user knows about the safety and usage procedures and has read this manual and
the HondaTM engine user manual.
Inform all users of the safety guidelines and usage procedures.
Familiarize yourself with the product and the safety guidelines before
working with the winch.

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Make sure that your clothes are not going to get caught into the winch
mobile parts.
The exhaust gas contains toxic carbon monoxide. Never run the engine in
a closed area without proper ventilation.
Replace any safety labels that are damaged, illegible or missing.
Never put your hands on the capstan drum 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.
The Portable WinchTM is not intended for lifting purposes.
Never use the Portable WinchTM to lift people.
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 HondaTM 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 HondaTM 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
Fill the gas tank with unleaded fuel. Do not use oil/fuel mixture; your Portable WinchTM is
equipped with a 4-stroke engine. Refer to page 7 of the HondaTM engine user manual.

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2.2.3 Engine start-up
Refer to page 3 of the HondaTM engine user manual
for start-up instructions.
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), the friction of the rope on the plastic cover
might damage the rope and the cover.
2.2.4 Capstan drum
Your Portable WinchTM is equipped with a standard 57 mm (2-1/4") diameter capstan drum.
If you are using the optional 85 mm (3-3/8") drum (PCA-1100 (not included)), follow these simple
installation steps (figures 1, 2, 3 and 4 can be found on the next page). All bolts require a 4 mm
(5/32’’) hex wrench, included with your winch manual.
1) Remove the rope guide (figure 1, no 1);
2) Remove the bolt located at the end of the drum axle (figure 1, no 2);
3) Remove the drum from the axle pushing it forward with two screwdrivers (figure 2);
4) Replace it with the optional drum (figure 3);
5) Make sure that the shaft key stays in place (figure 3, no 1); install bolt and washer (figure
3, no 2);
6) Install the rope guide using the bolts in the bottom holes (figure 4, no 1). The support
block is placed in the upper part of the rope guide (figure 4, no 2).
NOTE: Make sure that the rope guide is not in contact with the capstan drum.

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2.2.5 Spark arrestor
In certain areas, it is forbidden to use a gas engine
without a spark arrestor. Check local regulations. An
optional spark arrestor is available from Portable Winch
Co. and HondaTM Power Products dealers.
Installation:
1) Insert the spark arrestor into the exhaust tube.
Make sure the holes are aligned (figure 1 to the
right).
2) Fasten lightly the metal screw provided with a
Philips #1 screwdriver (figure 2 to the right).
Refer to page 10 of the HondaTM engine user manual for
the spark arrestor cleaning instructions.

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3.0 Winch usage
Most winching situations present POTENTIAL DANGERS!
3.1 Rope
Stay out of the winch line’s path.
3.1.1 Rope type
Use only low stretch rope. We recommend using double-braided polyester rope with a
minimum diameter of 10 mm (3/8''). Maximum rope diameter is 16 mm (5/8"). For most
situations, we recommend using 12 or 13 mm (1/2’’) DBP rope. Please contact us for other rope
types suitability.
DO NOT USE 3-STRAND POLYPROPYLENE YELLOW ROPE!
Polypropylene and polyethylene ropes are dangerous for winching because of their great
elasticity and low melt point.
Make sure the rope is not damaged and that it offers an adequate resistance to pull the
load.
STRETCH EQUALS DANGER!
A stretched rope can recoil and cause serious burns as the rope leaves your hand.
All ropes stretch: a longer one more than a shorter one. The more you pull, the more it
stretches.
A stretched rope can also move the load in an unpredictable or dangerous way.
A stretched rope can recoil and bring your hand towards the winch causing severe
injuries. NEVER WRAP THE ROPE AROUND YOUR HAND.
Always wear GLOVES.
3.1.2 Rope maintenance
Visually inspect your rope before each usage. If it shows any sign of
deterioration (cut strands, excessive abrasion), replace it.
If your rope is dirty, wash it. Dirty ropes deteriorate faster and cause
premature wear of the capstan drum and rope guide.

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3.2 At the end of the rope
3.2.1 Recommended knots
You have to attach the load to the end of the rope. Even if a
simple knot can do the job, we recommend the installation of a
hook with the bowline knot (figure 1 on the right) because it can
be easily undone if you need to change the hook. Moreover, it
retains about 70% of the rope’s capacity while most knots will
reduce it by more than 50%.
Even better, the double bowline knot (figure 2 below) will keep
about 75% of your rope’s capacity.

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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 latch (figure 3).
3.3 Winch anchor
OPTION 1: In most cases, the winch is anchored to a fixed point using the 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.

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3.3.1 Using a 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).
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 (figure 1).
Using a stump as an
anchor point means paying special attention in
order to prevent the sling from slipping over it.
Make sure the anchor
point is strong enough to resist the pull
without breaking or being damaged.
Position the winch in line with the load (figure 1).
When the winch is under tension, it will try to align
itself with the load. The friction of the sling against
the anchor point could prevent correct alignment.
If that is the case, release the tension on the rope
and position the sling on the anchor point so that
the tension is equally distributed on both winch
anchor hooks.
DON’T DO THIS! When you anchor the winch, make sure that you DO
NOT do a complete wrap around the anchor point (figure 2). This set-up will prevent proper
alignment of the winch with the load and will put uneven tension on the winch anchor hooks.
3.3.2 Using the Hitch Plate (PCA-1261, sold separately) with tow balls up to 50 mm (2’’)
diameter
1) Push the safety hooks in the rectangular openings of the hitch plate (figure 1 next page);
2) Start the winch engine;
3) Slide the plate on the ball hitch and pull the winch forward (figure 2 next page);

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4) Wrap the rope around the drum and start winching (figure 3).
NOTE: Do not leave the winch on the hitch with the engine running; the resting position
will cause the Oil AlertTM device to turn the HondaTM engine off (see section 3.4).
Use the hitch plate only with Category II ball hitch (1500 kg – 3500
lb) or higher.
Make sure the anchoring vehicle’s hand brake is on and working
properly. Position blocks behind the wheels to prevent roll back.
3.3.3 Using the Receiver Hitch winch anchor for 2’’ receivers (PCA-1262, sold separately)
1) Slide the square tubing into the vehicle’s
receiver and secure it with both the hitch pin
and the ‘’R’’ pin (figure 1, no 1).
2) Adjust the maximum desired lateral
movement by positioning the bolts into the
holes (figure 2, no 1).
3) Attach the winch anchor hooks to the eye
bolts (figure 2, no 2).
4) 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.

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3.3.4 Using the Tree/Pole Mount with rubber pads (PCA-1263, sold separately)
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 (figure 1, no 1); then feed the sling’s end through the ratchet
system (figure 1, no 2);
2) Slide the whole set-up upward to the desired height (figure 2);
3) Tighten the sling with the wrench supplied while making sure the rubber pads are
properly positioned. The pads should offer maximum contact surface with the tree or pole
(figure 3);
4) Install the receiver hitch (without the square tubing) and fasten it with the hitch pin and
‘’R’’ pin (figure 4).
5) Attach the winch anchor hooks to the eye bolts (figure 5);
6) Wrap the rope around the drum and start winching. The winch will align itself
automatically with the load (figure 6).
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 WinchTM. Check the solidity of the installation and tighten the
sling again.
3.4 Oil AlertTM system
The GX-50 HondaTM engine is equipped with an Oil AlertTM system that automatically turns off
the ignition when the oil level goes below a safe level. The Oil AlertTM system also turns off the

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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.
3.5 Rope installation
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.
3.5.2 Pulley
Using a pulley at some distance in front of the winch offers many advantages:
•pulling angle ‘lifts’ the load and reduces friction;
•the winch is maintained at a relatively horizontal position;
•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.
Generally, if the rope touches the ground while pulling, your installation is incorrect.
3.5.4 On a hill
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
Check winch position, rope condition, solidity of the anchor point
and knots in order to prevent injuries or material damage.

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3.6.1 Wrapping the rope on the capstan drum
NEVER put your HANDS on the CAPSTAN DRUM or the ROPE
GUIDE 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 small pulley and under the drum (figure 1);
3) Wrap the rope around the drum (3 turns) (figure 2);
4) Bring the rope behind the rope hook (figure 3);
5) Stand about 1 m (3’) of the winch and pull gently 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 anchors and the front 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 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.
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.
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.

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3.6.2.2 To ‘’rock’’ the load:
Pull the rope until the engine comes close to stalling and release the tension. Pull again on the
rope to put tension and repeat as needed.
Be careful with this method since it generates heat and can wear the
rope quickly.
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.
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 to a fixed
object:
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).
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 some of the rope to release some tension. While holding the rope with one hand,
start the engine by pulling on the crank and pull the throttle up. You can now resume winching.

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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:
You will have to link two ropes together.
1) If you have to link two rope lengths, do it
with two bowline knots (figure 1) (see
section 3.2.1).
2) Leave about 1 m of rope tailing out of the
knot on the rope holding the load (figure 1,
no 1). You will need it to resume winching
after undoing the knots.
Stop the winch BEFORE
the knot reaches the small pulley since it
cannot go through the winch (figure 2).
3) If necessary, attach the load to a fixed object
and release tension off the rope.
4) Undo the knots and use the remaining
length to wrap around the capstan.
3.6.3 Stopping the winch
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.
Inspect the winch, hooks,
rope and polyester sling to detect any damage
or signs of wear.
Periodically, remove the capstan drum and clean
around the shaft (figure 1 to the right).
Accumulated debris can damage the shaft seal. Apply grease or oil to prevent corrosion.

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4.2 Lubrication
The front 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.
The gearbox is lubricated at the factory
ean it toward you; some oil should
.3 Honda
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).
L
leak out of the hole. If needed, you can
add type SAE80W90EP gear box oil.
TM
4engine
aintain the engine according to the instructions found in the HondaTM engine user manual.
.4 Storage
M
4
lways store your Portable WinchTM in a vertical position. Refer to the HondaTM engine user
.5 Spark arrestor
A
manual for engine storage instructions.
4
your Portable WinchTM is equipped with the optional spark arrestor (PCA-1151), you must
.0 Complementary information
If
clean it every hundred (100) hours to keep it running properly. Refer to the HondaTM engine user
manual for cleaning instructions.
5
.1 Accessories 5
complete line of accessories is available. You will find the list on the next page. We invite you A
to visit our web site regularly at www.portablewinch.com for updates and new products.

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PRODUCT
NUMBER DESCRIPTION
PCA-1100 Optional capstan drum (85 mm (3-3/8'') diameter)
PCA-1215 Double-braided polyester rope - 3300 kg MBS (7200 lb) - 13 mm x 45,75 m (1/2'' x 150')
PCA-1213 Double-braided polyester rope - 3300 kg MBS (7200 lb) - 13 mm x 91,5 m (1/2'' x 300')
PCA-1216 Double-braided polyester rope - 3300 kg MBS (7200 lb) - 13 mm x 183 m (1/2'' x 600')
PCA-1200 Double-braided polyester rope - 1900 kg MBS (4200 lb) - 9,5 mm (3/8'') – sold by the meter
PCA-1255 Rope bag - Medium - Holds 91,5 m (300') of 13 mm (1/2") rope
PCA-1256 Rope bag - Large - Holds 150 m (450') of 13 mm (1/2") rope
PCA-1259 Polyester sling - 50 mm (2'') x 2,44 m (8')
PCA-1260 Polyester sling - 50 mm (2'') x 1,83 m (6')
PCA-1261 Hitch plate winch anchor - Fits towing balls up to 50 mm (2") diameter
PCA-1262 Receiver hitch winch anchor - Fits 50 mm (2") square tubing
PCA-1263 Tree/pole mount w/ rubber pads, anchor strap 75 mm wide x 3 m long (3'' x 9,8') (works with PCA-
1262)
PCA-1273 Double swing side snatch block - 2 x 100 mm (4'') diameter aluminum sheave w/ stainless steel
sides (use with carabiner PCA-1276)
PCA-1274 Swing side snatch block - 100 mm (4'') diameter aluminum sheave w/ stainless steel sides (use with
carabiner PCA-1276)
PCA-1276 Steel oval locking carabiner
PCA-1280 Grab Hook 7 mm (5/16")
PCA-1282 Grab Hook 7 mm (5/16") with latch and 3 chain links
PCA-1281 Safety Hook - Capacity: 750 kg (1500 lb)
PCA-1290 Skidding Cone for logs up to 50 cm (20'') diameter
PCA-0340 Padded waterproof case with removable wheels for winch & accessories
PCA-1372 HPPE rope choker 9,5 mm x 2,1 m (3/8'' x 7') with steel rod -- (Weight: 350 g (12 oz))
PCA-1295 Choker-chain 6 mm x 2,1 m (1/4'' x 7') with C-Hook and steel rod -- (Weight: 2,8 kg (6 lb))
PCA-1299 C-Hook for choker-chain
PCA-1151 Spark arrestor for Honda engine GHX-50

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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. This warranty does not apply to ''as is'' or previously owned winches or accessories.
This warranty does not apply to ‘wear parts’ defined as being in contact with the rope while
winching.
The Portable WinchTM is covered as follow:
•Winch parts: Five (5) year warranty (service by Portable Winch Co. and/or its retailers);
•Engine: The HondaTM engine is warranted by Honda Motor Corporation and the duration
varies according to country and usage. All HondaTM 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
WinchTM accessories are covered by a complete one (1) year warranty.
If you have a defective product, please contact us or your retailer and we will take care of it
immediately.
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 (figure 1, no 1). The serial number is also engraved on the cover of the winch, to
the left of the capstan drum (figure 2, no 1).