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4.
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 EN 14492-1: 2006 +A1:2009
and EN ISO 12100:2010. Local authorities may require other
periodic test procedures.
4.1
Daily inspection and test
This has to be performed every day (written records are not necessary):
a.
Observe that the throttle is 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.
d.
PCT1800: If the winch does not work,
check the power source. Make sure the voltage
and/or the frequency used is correct. Disconnect
the wire from the electrical outlet and remove the lid of the
control box. Make sure there are no unconnected wires,
poorly connected relays or loosened screws. If the unit still
does not work, contact a qualified electrician or your dealer.
PRIOR TO INSPECTING OR REPAIRING THE WINCH, BE
SURE TO DISCONNECT FROM POWER SOURCE.
4)
PCH1000 and PCH2000: Test the operation of the on/off switch.
5)
PCH2000: Test the operation of the emergency STOP switch.
6)
Check that the rope entry pulley (brass pulley) is rotating
freely; if not clean and lubricate. Replace pulley if any flat
spots are present.
7)
Inspect the rope for excessive wear, damage or distortion
(see section 3.1.2 rope inspection and maintenance).
8)
Inspect slings and straps used to anchor the winch for
cuts and abrasion.
9)
If using a new anchor point, test it (see section 2.4.2.3).
4.2
Frequent inspection (every 25 hours of operation)
This has to be performed every 25 hours of operation (written
records are not necessary):
1)
Inspect control mechanism for any sign of wear or loose parts.
2)
PCH1000 and PCH2000: Clean engine air filter. Service more
frequently when operating in dusty areas.
3)
PCH1000 and PCH2000: Change engine oil.
4)
Without load, test the winch controls by pulling the rope end.
a.
Observe that the throttle is 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)
PCH1000 and PCH2000: Test the operation of the on/off switch.
6)
PCH2000: Test the operation of the emergency STOP switch.
1) Inspect rope grabbing system
(see Figure) for any sign of wear or
loose parts.
2) PCH1000 and PCH2000: check
engine oil and air filter.
3) Without load, test the winch
controls by pulling the rope end.
7)
Inspect the rope for excessive wear, damage or
distortion (see rope inspection and maintenance
section 3.1.2).
8)
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.
9)
Inspect all warning and instruction labels for deterioration.
10) Ensure the instruction manual is present and legible.
11) Look for leaks around gearbox. If any found, verify gearbox oil level.
12) 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.
13) 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.
4.3
Periodic inspection (every 100 hours of operation)
4.3.1
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.
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 indicate 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.
a.
Inspect clutch rotor (engine side) for:
i.
Cracks;
ii.
Loose screws;
iii.
Uneven wear or other damage.
b.
Inspect clutch drum (gearbox side) for:
i.
Wear: minimum thickness: 2 mm (0.080");
ii.
Tightness: no noticeable axial movement;
iii.
Bearing condition: turns evenly and smoothly
by hand.
4.3.2
Engine
(PCH1000 and PCH2000 only)
1)
Clean/adjust spark plug;
2)
Check/adjust idle speed;
3)
Check/adjust valve clearance;
4)
Clean fuel tank and filter;
5)
Clean spark arrestor if equipped.
a.
NOTE: These items should be serviced by your Honda
servicing dealer, unless you have the proper tools and are
mechanically proficient. Refer to the Honda shop manual for
service procedures.
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