02160915

Instruction Manual
MAXPULL Manual Winch

Model ME-5-L
Model ME-10-L（Manual Latch-type Stopper Brake)＊For Horizontal Pulling work

・ For your safety, always read this manual andunderstand the contents fully before starting
operation.
・ Keep this manual at a designated place at all times
to have quick access when required.

Table of Contents◇ How to Use This Equipment Safely ............................................................................................................... 2
１． Inspecting the Winch Upon Delivery ........................................................................................................ 3
２． Specifications
Specifications on Model ME (Manual Latch-type Stopper Brake) ............................................ 3-4
３． Name of Each Part............................................................................................................................................ 4
４． Installation ........................................................................................................................................................... 5
５． Precautions on Usage Environment .......................................................................................................... 6
６． Installing the Wire Rope ........................................................................................................................... 6-9
７． How to Operate the Winch, and Pre-work Inspection/Precautions .......................................... 10
Inspection Before Use .................................................................................................................................. 10
How to Use the Manual Latch-type Stopper Brake.......................................................................... 11
How to Fix the Handle into Place ............................................................................................................ 12
Precautions While Working ....................................................................................................................... 13
Troubleshooting and Its Measures ......................................................................................................... 14
８． Maintenance Inspection and Repair....................................................................................................... 15
Disassembling and Inspecting the Manual Latch-type Stopper Brake .............................. 15-16
９． Questions or Comments ............................................................................................................................. 17

Appendix◇ Appendix 1. MAXPULL Winch Inspection Sheet◇ Appendix 2. Parts List for ME-5-L and ME-10-L◇

Safety Information1

［ How to Use This Equipment Safely ］

Thank you for purchasing MAXPULL manual winch.
Thoroughly read this Instruction Manual before using the equipment to ensure that the operator
understands the equipment and can operate it correctly.
Store this Instruction Manual in a location that is easily accessible for everyone that will be operating theWinch and make sure everyone has read it.
2 categories “DANGER” and “WARNING” on this instruction manual.
Indicates an imminently hazardous situation which, if ignored, will result indeath or serious injury and/or property damage.
Indicates a potentially hazardous situation which, if ignored, could result indeath or serious injury and/or property damage.

(General Handling)● Careless or incorrect handling may result in severe accidents. Do not allow the equipment to be handled bythird parties or people who are not thoroughly familiar with the contents of this manual.
● Read this manual thoroughly before use, and familiarize yourself with the contents. Always store this manual
within easy reach of any operators of this equipment.
● This winch is designed for horizontal load pulling only. Do not use it to lift people, or to move lifted
equipment laterally. This equipment is not appropriate for lifting people, neither legally, structurally, or from asafety perspective.
● This winch has been designed and manufactured for use as a manual winch. Do not modify the winch to use
other power sources (electrical motors, air motors, hydraulic motors, etc.).
● Fine operation adjustments have been made to the brake mechanism and reduction gears. Do not make any
modifications, such as welding or machining, to this winch.
● Only use genuine winch product parts and accessories.
● Never apply loads in excess of the rated maximum load.
● Never operate the winch when you are tired, after drinking alcohol and/or having medicine.
※ Please understand that we shall not be held responsible for any and all damage or loss arising frominjuries or accidents that occur due to the customer’s failure to follow the instructions described in thismanual, or from injuries or accidents that occur due to the customer’s remodeling.

［ Safety Precautions ］◆This winch has been designed and manufactured as a general purpose winch for industrial use.
Therefore, be sure to install safety equipment such as emergency brakes and risk-sensing emergency stops on
the equipment end when using the winch in applications where a major impact on human life and property is
expected.
◆ Make sure to follow all required safety regulations for the location where the unit will be installed and forthe equipment that will be used. (Ordinance on Industrial Safety, etc.)◆ When using the product in places where condensation occurs due to temperature difference in the installing
environment, such as on food machinery or in a clean room, and particularly when using on devices that cannot
tolerate grease, please make sure to attach a damage prevention apparatus, such as an oil sump, in preparation
for unlikely events of grease leakage.
● CALIFORNIA PROPOSITION 65 WARNING: This product contains chemicals known to the State of California tocause cancer and birth defects or other reproductive harm.
2１．Inspecting the Winch Upon Delivery● Installing the wrong product may cause injury and damage to the equipment.
In addition, do not remove nor disfigure any warning label or the name plate on the winch.
● To avoid danger, keep babies and children from the enclosed plastic bag, winch, and other parts andaccessories.
❒ Please check the following items first when the winch is delivered to you.
(1) Do the descriptions on the name plate such as the model and specifications etc., match what you
have ordered?
(2) Are there any damages caused by accidents during transport?
(3) Are there any missing or detached parts?
(4) Are there any loose bolts and nuts?
Please contact us if you have any questions or concerns regarding the above items.

２．Specifications
Specifications on Model ME (Manual Latch-type Stopper Brake)

Model

ＭＥ－５－ＬＭＥ－１０－Ｌ

Wire Rope Tension

500kg (1,100lbs)

1,000kg (2,200lbs)

Gear Ratio

13.3：1

19：1

Wire Rope(Wire Rope Composition)

Φ6mm (6×37)
1/4 inch (6×36)

Φ8mm (6×37)
5/16 inch (6×36)

Effective Handle Length

250mm（9.84 inch）

300mm（11.81 inch）

Weight (Winch+Handle)

About 30kg(66lbs)

About 30kg(66lbs)

Handle Force

9.9kg (21.8lbs)

11.6kg (25.6lbs)〇 Model ME is an endless winch for both direction pulling.
〇 Model ME-5-L and ME-10-L (Manual Latch-type Stopper Brake) are suitable for both direction
pulling of the truck on flat place or the safety nets and the banner.
The brake of this winch is a manual latch-type stopper brake. When performing the handle rotation operation,
the manual latch-type stopper brake needs to be released.
●The ME-5-L and ME-10-L models of the manual latch-type stopper brake are designed and produced specificallyfor horizontal pulling (horizontal towing) work. Therefore, using them for vertical pulling (vertical lifting) work is
extremely dangerous. Please make sure NOT to use them for vertical lifting work under any circumstances. It willlead to accidents and injuries.
●The operation of the manual latch-type stopper brake should be performed by the person who is conducting therotation operation of the winch handle by him/herself. There is no brake applied during handle operation, so theload will start moving on its own if you let go of the handle. In addition, if the retention force of the handle to theload is weak, the handle will rotate and hit the operator in the body resulting in injury. Until the operator applies
the manual latch-type stopper brake on his/her own, the operator should firmly keep hold of the handle.
●Be fully alert of accidents due to reverse-rotation of the handle caused by load when conducting handle
operation. The brake is completely ineffective between the time of releasing the stopper and applying the stopper,
so securely set the handle so it does not fall out during work and keep hold of it. There is risk that the handle will
rotate in reverse or move due to the load resulting in serious consequences.
●Always check that you have securely set the handle into place before conducting work, and pay careful attention
to continue to keep hold of the handle while operating.
3●In all manual winch work, there is a risk depending on pulley resistance or installed position that the wirerope will twist, etc. resulting in an unpredictably large force exerted on the winch.
●Always make sure to use the winch below its capacity (wire rope tension) in order to safely perform work
such as horizontal pulling.
●In using the manual winch, we recommend that you check the necessary safety regulations before
conducting maintenance management, and that you educate workers regarding winch operations.

３．Names of Each Part
Gear Case
Gear Case Cover

Stay Bolt

Pressure Rollers
Side Frame
Drum

HandleName Plate
Handle Holder

ClutchClutch CoverFrame
Bed Plate
Stopper Lever Installation Adaptor
Manually Opelated Latching Stopper Brake
Ｓｔｏｐｐｅｒ ”ＯＦＦ”（Ｓｔｏｐｐｅｒ ｉｓ ｒｅｌｅａｓｅｄ）

Ｓｔｏｐｐｅｒ ”ＯＮ”
（Ｓｔｏｐｐｅｒ ｉｓ ａｐｐｌｉｅｄ）

Figure 1 Names of Each Part
4

４．Installation●Installation and mounting of the manual winch must NOT be performed by anyone other than specialized
contractors or people with expert knowledge.
●Make sure the winch does not fall or tip over while in transport or during installation.
Be thoroughly careful when moving the winch.
●Install the winch in an area with easy access to the winch for inspections and maintenance.
●Please check that the installing area or mounting frame of the manual winch has sufficient strength and that
it is a level surface.
●If there is a clearance due to distortion, etc. between the mounting adapter of the manual winch and thesurface of the mounting frame, insert a shim plate and use the designated bolts and nuts to tighten and fix it
into place.
●Please do not fix it into place by welding, because not only will it lower the precision of the winch andbecome a cause for injuries, it will also make it impossible to conduct maintenance.
❒Please follow the items below when mounting the winch body.
(1)
The installation position of the winch in which it is easiest for the operator to conduct workis the position where the handle rotation center (clutch) is at the height of the worker’s
waist.
Please fix the winch into place at this height before working.
In addition, please do not install the winch in places where it is unstable under the worker’s
feet.
(2)
Please install the winch in a spacious area where work can be done safely that gives theoperator a view of the load and wire rope conditions while operating the winch.
(3)
In terms of the position of the winch and pulley, they should be installed in a straight line
along the wire rope that comes out of the drum, and use a winch that has a diameter (pitch
diameter) over 15 times of the diameter of the wire rope being used and that rotatessmoothly. In addition, please attach a non-slip device for the wire rope to the pulley.

●If the positions of the winch and pulley are not appropriate, the wire rope may drop off of the drum grooveor the wire rope may be damaged resulting in shorter life. Furthermore, it may also cause failure or damage
to the winch body.
●Install the pulley so that it is in a straight line along the wire rope coming out of the drum.

5５．Precautions on Usage Environment
Make sure not to install or use the winch in the following special environments, because it will shorten its
life and it will be extremely dangerous.
●The limit of usage and installation in cold climates is -10℃(14℉). Using it at -10℃(14℉) or below will cause
cold shortness of the metal, as well as alteration and deterioration of grease, resulting in accidents.
●Locations with a high ambient temperature of 40℃(104℉) or over and humidity that exceeds 90%.
●Locations with a lot of dust, oil or locations that require waterproof properties.
●Locations with a lot of acid or salt.
●Locations outdoor exposed to wind, rain or snow.
(1)
Please consult us in advance when using the winch in special environments such as theones described above.
(2)
When the winch is installed outdoor and exposed to wind, rain or snow, we recommend
protecting it with a rainproof cover in order to prevent corrosion due to rust.
(3)
Depending on the installation location, we recommend installing a tray, etc. to collect oilyliquid, because condensation may occur inside the gear case and brake mechanism of awinch installed in a location with temperature difference; and, over time, the grease coatedon the gear and sliding part inside may become oily by dissolving in the condensed water;
and the oily grease may drop from the joint of the gear case.

６．Installing the Wire Rope

In the ME model winch, the wire rope can be wound around the drum from any location.
●Use a wire rope that meets the specifications for the winch.
Using a wire rope with the wrong specifications may cause it to break.
❒ Follow this procedure to install the wire rope onto the drum.
(1) Loosen the side frame fixing bolts and side frame fixing nuts, then remove the side frame andpressure rollers.
Ｓｔａｙ Ｂｏｌｔ
Ｄｒｕｍ
Ｐｒｅｓｓｕｒｅ Ｒｏｌｌｅｒ ｆｏｒ Ｗｉｒｅ ＲｏｐｅＳｉｄｅ Ｆｒａｍｅ Ｆｉｘｉｎｇ Ｎｕｔ

Ｄｒｕｍ
Ｂｅｄ ＰｌａｔｅＳｉｄｅ ＦｒａｍｅＳｉｄｅ Ｆｒａｍｅ Ｆｉｘｉｎｇ Ｂｏｌｔ

Figure 2 Remove the Side Frame and the Pressure Rollers for Wire Rope6

(2) Pass the wire rope through the groove in the end on the stay bolt side of the drum on the left, takeit out from the bed plate side after winding it half way around along the groove in the end of thedrum on the right, wind it half way around along the second groove from the end of the drum on
the left, and then wind it to the drum on the right from the stay bolt side.
As described now, please wind the wire rope around the left and right drums in spiral form.
Ⓐ When taking both ends of the wire rope out of one side, the wire rope needs to be woundaround the 3.5 winding drum as shown in Figure 3-1, and then finally taken out from the bed plateside of the drum on the left. (The groove in the front of the drum on the right is free.)Ⓑ When taking one end of the wire rope out of one side, the wire rope needs to be wound aroundthe 4 winding drum as shown in Figure 3-2, and then finally taken out from the stay bolt side on
the right.
Ｗｉ ｎｄ ｔ ｈｅ ｗｉ ｒｅ ｒ ｏｐｅｔｏ ｔ ｈｅ ｆｒｏｎｔ ｆｒ ｏｍ ｔｈｅ ｂａｃｋＷｉ ｎｄ ｔ ｈｅ ｗｉ ｒｅ ｒ ｏｐｅｔｏ ｔ ｈｅ ｆｒｏｎｔ ｆｒ ｏｍ ｔｈｅ ｂａｃｋ
Ｓｔａｙ Ｂｏｌｔ

Ｓｔａｙ Ｂｏｌｔ
Ｄｒ ｕｍＴｈｉｓ ｇｒｏ ｏｖｅ ｉ ｓ ｆｒｅ ｅＤｒ ｕｍ

Ｂｅ ｄ Ｐｌ ａｔ ｅ

Ｂｅ ｄ Ｐｌ ａｔ ｅ
Ｄｒ ｕｍ

Ｄｒ ｕｍ

Ｔｈｅ ｓｈａｐ ｅ ｏ ｆ ｔｈｅ ｗ ｉｒ ｅ ｒｏ ｐ
ｗｏ ｕｎ ｄ ｏｎ ｔｈｅ ｄｒ ｕｍ
Ｔｈｅ ｓｈａｐ ｅ ｏ ｆ ｔｈｅ ｗ ｉｒ ｅ ｒｏ ｐｅ
ｗｏ ｕｎ ｄ ｏｎ ｔｈｅ ｄｒ ｕｍFigure 3-1 ⒶHow to wind the wire rope
when taking both ends of the wire ropeout of one side

Figure 3-2 ⒷHow to wind the wire rope
when taking one end of the wire rope outof one side

7

(3)

Once you are done winding the wire ropes: [1] Set the pressure rollers to the stay bolt so thatthe wire rope does not drop off of the drum groove. [2] Set the side frame back to normal. [3]Use your hand to screw in the two bottom bolts. [4] Use your hand to screw in the two top
bolts. [5] Use your hand to screw in the two nuts of the stay bolt. After you have screwed in allbolts and nuts with your hand, use a tool such as a wrench to do the final tightening in thesame order, and check that the bolts and nuts in each part are tightened securely. Also,
confirm that the wire rope is inserted in the drum grooves in the proper order. (A flat washer
and spring washer are attached to each bolt and nut)

Ｓｔａｙ Ｂｏｌｔ①Ｐｒｅｓｓｕｒｅ Ｒｏｌｌｅｒ ｆｏｒ Ｗｉｒｅ Ｒｏｐｅ
⑤Ｓｉｄｅ Ｆｒａｍｅ Ｆｉｘｉｎｇ Ｎｕｔ②Ｓｉｄｅ Ｆｒａｍｅ④Ｓｉｄｅ Ｆｒａｍｅ Ｆｉｘｉｎｇ Ｂｏｌｔ
（Ｕｐｐｅｒ Ｓｉｄｅ）③Ｓｉｄｅ Ｆｒａｍｅ Ｆｉｘｉｎｇ Ｂｏｌｔ
（Ｌｏｗｅｒ Ｓｉｄｅ）

Figure 4 Attaching of Side Frame(4) Wire ropes that are wound just by your hands are loose.
a. When using an endless wire rope, remove the looseness of the wire rope by sufficiently
tightening it with a wire stretcher (Shimelar, etc.). (Refer to Figure 5-1)
Next, operate the handle to rotate both winch drums about 15 to 20 times each to theleft/right in order to remove the looseness of the wire rope between them. (Refer to Figure
5-2)
Lastly, use the wire stretcher to do the final tightening one more time, and check that thelooseness of the wire rope has been completely removed before conducting the actual work.
(Refer to Figure 5-3)
b. When using the wire rope in a method other than the endless method, constantly pull theoutgoing wire rope and apply tension. (Refer to Figure 6-1)
The looseness between the winch drums will be gradually removed. Once you stop applying
tension, the wire rope between the two drums will start getting loose, so make sure to apply
tension at all times. (Refer to Figure 6-2)
In both cases, always set the side frame and perform the work to remove looseness from the wirerope, or to apply tension, in a state where the wire rope is fixed into place.
(5)
Looseness in the wire rope will result in slipping, so even in cases where the wire rope stretchesdepending on the usage condition, follow the same steps as described above to remove thelooseness of the wire rope.
8

ｉｎ ｔｈｅ ｗｉｒｅ ｒｏｐｅ
Ｐｕｌ ｌｙＡｐｐｌｙ ｔｈｅ ｔｅｎｓｉｏｎ
Ｌｏｏｓｅ ｉｓ ｅｌｉｍｉｎａｔｅｄ ｏｎ ｔｈｅ ｓ ｉｄｅ ｓｅｎｔ ｏｕｔ
Ｗｉｎｄｉｎｇ Ｄｉｒｅｃｔｉｏｎ

Ｗｉｒｅ Ｓｔｒｅｔｃｈｅｒ
Ｔｗｏ Ｄｒｕｍ ｓ

Figure 5-1

Tightening the endless wire rope

Ｅｌｉｍｉｎａｔｅ ｔｈｅ ｌｏｏｓｅ ｉｎ ｔｈｅ ｗｉｒｅ ｒｏｐｅ
ｂｅｔｗｅｅｎ ｔｈｅ ｔｗｏ ｄｒｕｍｓ

Figure 6-1
Ｒｏｔａｔｅ ｔｈｅ ｔｗｏ ｄｒｕｍｓ ｔｏ ｔｈｅ ｌｅｆｔ ａｎｄ ｒｉｇ ｈｔ

Figure 5-2

Ｎｏ Ｌｏｏｓｅ Ａｐｐｌｙ ｔｈｅ ｔｅｎｔｉｏｎ ａｌｗａｙｓ

Tightening the endless wire rope

Ｅｌｉｍ ｉｎａｔｅ ｔｈｅ ｌｏｏｓｅ
ｉｎ ｔｈｅ ｗｉｒｅ ｒｏｐｅ

Figure 6-2

Ｆｉ ｎａ ｌ ｔｉｇｈｔｎｉｎｇ ｗｉｔｈ ｔｈｅ ｗｉｒｅ ｓ ｔｒｅｔｃｈｅｒ

Figure 5-3

If the endless method is not used

If the endless method is not used

Tightening the endless wire rope

*These figures are for explaining how to remove the looseness from the wire rope and are different
than setting up the wire rope.

●It is shown without the side frame to make it easier to understand.
When using a wire stretcher to tighten the wire rope, perform the operation with the side frame set into
place.
●Do not apply load when the side frame is removed.
When removing the side frame, confirm that no load is applied to the wire rope.

9７．How to Operate the Winch, and Pre-work Inspection/Precautions●Please check that the winch body is completely attached and fixed into place.
If you start work while the attachment/fixing of the winch is unstable, it will lead to accidents and injuries.
●Check that the load is below the winch’s capacity before starting work.
When working with the winch, there is a risk that the wire rope will become twisted or an unpredictable
overload will be applied to the winch due to the pulley resistance or the installed position of the pulley.
Always make sure to use the winch below its indicated capacity in order to conduct the horizontal pulling
work safely.
●It is dangerous to wind the wire rope in the wrong direction, because the moving direction of the pulled
load will be opposite.
Only conduct work after checking the winding direction of the wire rope and the moving direction of thepulled load.
●Check that the latch-type stopper can be switched smoothly.
Set the stopper in the proper position by following the instructions in this manual and on the warning sticker
attached to the winch.
●Check that the wire rope is properly inserted in the left/right drum grooves and the designated number ofwinding times is secured.
●Check that the wire rope is coming out in parallel to the drum groove so that the wire rope does not drop
off of the drum groove.
●Immediately replace the wire rope when any of the following conditions occur: breakage of the wire rope’s
wire strands; reduction in outer diameter (those with diameter reduction ratio of 7% or more than thenominal diameter); wire rope with a kink; considerable deformation; or, corrosion, etc.
●Make sure there are no damaged parts or other conditions that may affect the operation of the winch.
●Please do not take off the warning sticker and name plate attached to the winch body.
Do not take off the sticker or name plate indicating the “stopper position” etc., or use the winch when dirty.
When you cannot read the sticker or name plate due to considerable dirt, or when it has fallen off and has
been lost, please submit a request to us for a new one and re-attach it to the designated location.
●The latch-type stopper on a winch that has been left out without using for a long time may not operateproperly.
Please conduct inspection and confirm that it operates properly before using the winch.

Inspection Before Use❒Always conduct inspection of the following items before use.
Confirmation of the manual latch-type stopper brake
When the stopper lever (red knob) is pulled up, the stopper will be turned off and the brake will be
released, and when it is laid flat (pulled down to the front) the stopper will be turned on and the brake
will be applied. (Refer to Figure 1 on pg. 4)
Check that the drums or handle does not rotate when the stopper is turned on.
If the winch is already installed and the wire rope is wound up, then firm hold on to the handle, switch
the stopper 3 or 4 times, and check that the brake operates properly before conducting work.
It may be difficult to release the stopper when a load is applied. Rotating the handle by a little toreduce the load on the stopper will make it easier to release the stopper.
When releasing the stopper, the entire load will be applied to the handle. Set the handle securely sothat it does not fall out, and pay careful attention when conducting work.
10How to Use the Manual Latch-type Stopper Brake

The brake method of this winch is manual latch-type stopper method. The brake will not work if the
stopper is released. Follow the items below to safely conduct work.

●When conducting handle operations, be fully alert of accidents caused by rotation of the handle due to load.
The handle will rotate if the stopper is released when tension is being applied to the wire rope.
The brake does not work at all during the time from turning the stopper OFF (release) until turning it ON(apply), so set the handle securely to ensure that it does not fall out while working and keep hold of it.
There is risk that the handle will rotate and cause serious injury.
●Always be very careful to conduct work after checking that the handle has been set securely in place and tocontinue to keep hold of the handle.

Ｒ ａｔ ｃ ｈｅ ｔ

Ｌｅｖｅｒ Ｐｏｓｉｔｉｏｎ
when stopped

Ｌｅｖｅｒ Ｐｏｓｉｔｉｏｎ
when rotating the handle(1) First, grasp the handle firmly in your hand, keep hold of it, and then move the lever to the position shownin Figure 7 to turn the stopper OFF (release). It may be difficult to release the stopper when a load is applied
because it will weigh down the stopper. Rotating the handle by a little will be easier to release the stopper. In
addition, if the stopper is released without holding onto the handle while tension is being applied on the wirerope, no brake will be applied, and the drum and handle will rotate rapidly. This is very dangerous because it
may result in serious injuries to the arm or other areas caused by the rotating handle.
(2) When ending the handle operation and activating the brake, apply the stopper while firmly holding on to
the handle. At this time, perform the handle rotating operation so that the stopper is applied to the ratchet.
Take your hands off of the handle after confirming that the stopper is securely applied to the ratchet. (Refer toFigure 8)

Ｅｎｇａｇｅ ｔｈｅ Ｓｔｏｐｐｅｒ with the RatchetＲｅ ｌｅ ａｓ ｅ ｔｈｅ Ｓｔｏｐｐｅ ｒ ａｎ ｄ Ｒａｔ ｃｈ ｅｔFigure 7 When conducting handle operation

Figure 8 When ending handle operation

11

How to Fix the Handle into Place

For all winch models, loosen the wing screw as shown in Figure 9, and insert the handle into the handle
holder. Make sure that the handle does not fall out while working by firmly screwing in the wing screw,which fixes the handle into place, into the blind holes of the handle. If the wing screws loosen whileworking, screw them into the blind holes one more time before restarting to work.
Please do not fix the handle into place in positions other than the blind holes. It is dangerous because
the handle will fall out.

ＨａｎｄｌｅＢｌｉｎｄ Ｈｏｌｅ

Ｈａｎｄｌｅ Ｈｏｌｄｅｒ

Ｗｉｎｇ Ｓｃｒｅｗ

Figure 9 Handle Set

12Precautions While Working●Never use the winch for purposes such as traversing with a person on top, going on top of the load, etc.
●Before starting work, always conduct an inspection of the winch and wire rope as well as the entire
traversing equipment.
If you find a problem, fix it immediately and start working after that.
●Keep out of the range in which the traversing load moves while working.
Entering the range may result in serious accidents such as being run over by the load or being wedged
between it.
●Workers should not be distracted from the load or traversing equipment while working.
●Never apply a load exceeding the winch’s capacity under any circumstances.
●Absolutely refrain from extending the length of the handle to conduct work beyond the winch’s capacity,from pulling down the handle with your weight by hanging onto it, and from pressing your leg against thehandle to operate it.
It could lead to serious accidents such as by causing damage to the winch body or stopper break, or by
cutting the wire rope.
●Keep all personnel away at safe distances from 1) operating winches, 2) loads, 3) transverse areas, and 4)
areas near the wire rope to avoid potential breaks.
●Always wear anti-slip safety shoes to protect your toes and keep proper footing and balance at all times.
●Always wear safety glasses, helmet, heavy duty working gloves, and protective clothing when handlingwire ropes and winches.

●Make sure to temporarily stop the winch operation when the winding wire rope is stretched, check
whether there are any problems with the load condition or equipment, etc. before conducting work.
●When operating the winch, firmly screw in the wing screws (wing bolts) into the blind holes for fixing thehandle into place before conducting work.

13

Troubleshooting and Its Measures
Problem

The stopper brake
does not work

The handle does not
rotateIt makes an abnormalsound when
operating
The handle load hassuddenly becomeheavier

The handle load hassuddenly become
lighterChecking of the Cause

MeasureIs the stopper not
applied?

Please apply the stopper.

Is there settling of the
stopper brake spring?

Please replace the parts.

Is the stopper brakedamaged?

Please replace the damaged parts.

The load cannot be stopped unless the wire
Is the wire rope loose?
rope is stretched.
Please stretch the wire rope.
If the stopper is dirty, disassemble and clean it
Is there any mud or debris
while referring to “Disassembling andstuck to the stopper
Inspecting the Manual Latch-type Stopper
brake?
Brake”.

Has the minimum
temperature of theinstallation and usage
location dropped-10℃(14℉） or below?
Are parts such as the gear
damaged due toexcessive load?

Please consult us.

Please replace the damaged parts.

Is there wear in thegear or shaft bearing?

Please replace the worn parts.

Is it getting caught insomething on the way?

Please stop the work and remove the obstacle
before restarting.

Has the wire rope
dropped off of the drum
groove?

Please make sure that the wire rope does notdrop off of the drum groove, because there is arisk that the winch will break.

Does the wire rope have
any twists, kinks, etc.?

Please replace the wire rope.
If they are slipping due to wear, please replace
the worn parts.
If the wire rope is loosening, please stretch thewire rope.

Are the drum and wirerope slipping?

14

８．Maintenance Inspection and Repair

Maintenance inspection and repair are necessary in order to maintain the performance of the
MAXPULL Winch and to conduct work safely and securely. This maintenance inspection and repair
consist of the following two types: daily inspection, which is conducted before work; and regularinspection, which is a combination of daily inspection + disassembly and inspection of stopper brake,
conducted periodically.
For both types of maintenance inspection and repair, please make sure that someone with expert
knowledge is conducting it, and clearly indicate that it is “under maintenance inspection and repair”
so that the winch is not operated by mistake.
In addition, maintenance inspection and repair should be done after confirming that no tension isapplied to the wire rope.
Please conduct the maintenance inspection and repair while recording the results in the Appendix,“MAXPULL Winch Inspection Sheet”.

●Please conduct the maintenance inspection and repair after making sure that no tension is applied to thewire rope.
●Someone with expert knowledge should perform the maintenance inspection and repair.
●During maintenance inspection and repair, clearly indicate that the winch is “under maintenance inspection
and repair” so that the winch is not operated by someone else.
●Please do not conduct work without completing the daily inspection.
●If there is a problem, do not start work without fixing the problem. Repair and replace the parts before
starting work.
●Wire ropes are consumables. If there is a problem with even one part of it, please replace it.
●Please do not use any parts other than genuine parts.
●If repair is necessary, please clearly indicate that it is “out of order” so that it is not used.

Disassembling and Inspecting the Manual Latch-type Stopper Brake●Always perform the maintenance inspection after confirming that there is no tension (load) applied to thewire rope.
●Someone with expert knowledge should perform the maintenance inspection.
Please wear work clothes for the inspection, and conduct inspection after making sure that you are suitably
attired.
●Movement of the stopper brake deteriorates when mud, dirt or water enters, becoming a cause for the
stopper not to function, so please periodically disassemble and inspect the stopper brake.
Indoor: Every year
Outdoor: Every 6 months
Very dusty places: Every 3 months
Slight differences exist depending on the installing location and usage frequency.
●If the winch is left out or unused for a long period, the latch-type stopper brake may not work properly.
Please operate the winch at least once every two weeks. When using the winch after it has been unused for along period, always disassemble and inspect the latch-type stopper brake.
●If dirt, dust or the like gathers on the gear teeth of the ratchet wheel of the manual latch-type stopper brake,
the stopper will not turn on and the brake will not be applied. Always conduct maintenance inspection andrepair periodically, and remove dust, dirt or the like gathered on the ratchet wheel, if any. In addition,
grease up the moving parts.
15

（１）Follow the steps below to disassemble and inspect the latch-type stopper brake. (See theparts list in the Appendix)(a) Completely eliminate load from the wire rope and make sure that no force is applied to thewinch, either by removing the load that is being pulled or by killing the tension in the wirerope that is wound around the drum by using a tensioning device (Shimelar, etc.).
Disassembling the latch-type stopper brake while there is tension working on the wire rope
will cause accidents. Always confirm that the wire rope is completely free of load before
starting work.
(b) Remove the handle, remove the two pan head screws (No. 56), and then remove thehandle holder (No. 25) and clutch shield plate (No. 26).
(c) Remove the three tapping screws (No. 43), and then remove the clutch cover (No. 10).
(d) Remove the hardlock nut (No. 47) and then remove the plain washer (No. 46).
(e) The clutch (No. 20) is a screw, so if you turn it to the left it can be removed, and the clutch
collar (No. 98) will come off as well.
(f) On the clutch (No. 20), the ratchet wheel (No. 71) is fixed into place with the hexagon
socket head cap screw (No. 72) (with a helical spring lock washer), so disassemble theratchet wheel by removing the hexagon socket bolt.
(g) Remove the four hexagon socket head cap screws (No. 97) and then remove the stopper
holder (No. 96).
(h) This completes the disassembly of the latch-type stopper brake part.
There are small parts, too, so be careful not to lose any of the removed parts.
(i) Wipe off any dirt on each of the parts and check that there are no scratches or deformation.
If, by any chance, there are parts in which you find a problem, please replace them with newparts.
(j) For assembly, please conduct the steps described above for disassembly in reverse order.
When assembling, coat the greasing on the triple thread screw and moving parts of the
clutch pinion (No. 14).
The recommended grease for the brake part is Multinoc Wide 2 by JX Nippon Oil &Energy Co.
Please use this grease or a grease with equivalent performance as this.
(k) Make sure to tighten nuts, screws and the like so that they do not loosen. Once you aredone with assembling and adjusting, please check that the brake operates properly byfollowing the procedures described in “Confirmation of the manual latch-type stopper
brake”.
This completes the disassembly and inspection work for the latch-type stopper brake.

⑭Ｃｌｕｔｃｈ Ｐｉｎｉｏｎ
Ｔｒｉｐｌｅ Ｔｈｒｅａｄ Ｓｃｒｅｗ

Figure 10 Triple Thread Screw

16

９．Questions or Comments

If you have any questions about unclear problems, repairs or parts on the parts list, please look up
the following information and contact the distributor, agent or our offices for more information
Check items① Model②Serial Number③Installation Location(Use Environment)④Years in Service

17Appendix 1. MAXPULL Winch Inspection Sheet
Inspector

Inspection Date

Model

Serial Number

Inspection Period
Daily

Periodical

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

〇

year

month

day

Contents of Inspection

Judgment

The name plate and warning labels are affixed in the correct locations, and are clearly
legible.

Pass / Fail

There is no defect on the installation base of the winch.

Pass / FailThe mounting bolts of the winch are not loosened.

Pass / Fail

There is no damage, missing parts, or defect on the winch.

Pass / FailAll bolts, nuts and screws are tightened securely.

There is no deformation or abnormality in the handle and it functions properly.

Check that the latch-type stopper can be switched smoothly and it functions properly.
There is no kink on the wire rope.

There is no frayed the element wire of the wire rope.
The wire rope is lubricated properly.

The wire rope diameter has not fallen by 7% or more of its nominal diameter.

There is no abnormality in the joints of the endless wire rope. (If endless type is used)
The wire rope is not deformed.
The wire rope is not corroded.

The wire rope wound around the drum is properly inserted in the drum grooves.
The wire rope coming out of the winch is in parallel to the drum groove.
The wire rope is not loose.

The wire rope is wound around the drum 3.5 or 4 times.

The designated amount of tension is applied to the wire rope on the side it is sent out of
the winch.

Pass / Fail
Pass / Fail
Pass / Fail
Pass / Fail

Pass / Fail
Pass / Fail
Pass / Fail
Pass / Fail
Pass / Fail
Pass / Fail
Pass / Fail
Pass / Fail
Pass / Fail
Pass / Fail
Pass / Fail

There is no wear or damage on the wire presser and it is functioning properly.

Pass / Fail

There is no damage, abrasion or deform on the stopper.

Pass / Fail

There is no damage, abrasion or deform on the clutch.

Pass / Fail

Refer to “Disassembling and Inspecting the Manual Latch-type Stopper Brake” for the following inspection
×
×
×
×

〇
〇
〇
〇

There is no damage, abrasion or deform on the ratchet wheel.
There is no settling of the spring and the spring functions properly.

＊ If any defects are found during inspection, correct them before the operation.

Pass / Fail
Pass / Fail＊ When repairs are required, clearly state that the winch is “OUT OF ORDER” to prevent the winch being used accidentally.
Remarks

Appendix 2. Parts List for ME-5-L and ME-10-L

＊1
＊2
＊3
＊4
＊5

Same Left and Right
With Helical Spring Lock Washer, Plain Washer and Nut
With Helical Spring Lock Washer
With Helical Spring Lock Washer and Plain Washer
With Bearing

(memo)Safety Information
Read this manual thoroughly before installing and using this product, operate the winch correctly.
Comply with relevant laws and regulations.

1296-22, Nakaya, Nishifukai, Nagareyama-shi,
Chiba 270-0107 JAPAN
TEL:+81-4-7186-6797 FAX:+81-4-7186-6798
Web Site : www.maxpull.co.jp
E-mail : maxpull@maxpull.co.jp
Est.1 2018/03 MELUSWEB