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)

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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

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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.