01200406

Instruction Manual
MAXPULL Manual Winch

Model ME-5-B, ME-10-B (Type SI, NSIL and SIC)
Model RME-5-B, RME-10-B (Type SI, NSIL and SIC)
（Mechanical Brake)

・ 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 and RME (Mechanical Brake) .............................................................. 3
３． Names of Each Part.......................................................................................................................................... 4
４． Name Plate and Warning Labels................................................................................................................. 5
５． Installation ........................................................................................................................................................... 6
６． Precautions on Usage Environment .......................................................................................................... 7
７． Installing the Wire Rope.......................................................................................................................... 7-10
８． How to Operate the Winch, and Pre-work Inspection/Precautions........................................... 10
Inspection before Use ............................................................................................................................10-11
How to Fix the Handle into Place ............................................................................................................ 12
Ratchet Handle Operation for Model RME ......................................................................................... 12
Handle Operation with the Load Lifted up (Exclude Model RME) ............................................. 13
Precautions While Working .................................................................................................................13-14
Troubleshooting and Its Measures ......................................................................................................... 15
９． Maintenance Inspection and Repair....................................................................................................... 16
Disassembly and Inspection of the Mechanical Brake Unit ....................................................16-19
１０． Questions or Comments ............................................................................................................................. 19

Appendix◇◇◇

Appendix 1.
Appendix 2.
Appendix 3.

MAXPULL Winch Inspection Sheet
Parts List for Model ME-5-B and ME-10-B
Ratchet Handle Parts List for Model RME
Stopper Parts List for Type SI and NSIL◇

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 load lifting only. Do not use it to lift people, or to move lifted people laterally. This
winch is not appropriate for lifting people, neither legally, structurally, or from a safety 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 andproperty 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 thatcannot 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 and RME (Mechanical Brake) *Includes Type SI, NSIL and SIC

ME-5-B

ME-10-B

RME-5-B

RME-10-B

Wire Rope Tension

500kg (1,100lbs)

1,000kg (2,200lbs)

Wire Rope(Wire Rope Composition)

Φ6mm (6×37)
1/4 inch (6×36)

Φ8mm (6×37)
5/16 inch (6×36)

Gear Ratio

13.3：1

19：1

Effective Handle Length

250mm（9.84 inch）

300mm（11.81 inch）

Handle Force

9.9kg (21.8lbs)

11.6kg (25.6lbs)

Weight (Winch+Handle)

About 30kg(66lbs)

About 30kg(66lbs)

Model〇 Model ME and RME are an endless winch for both direction pulling.
〇 Model ME and RME with B type brake (Mechanical Brake) are suitable for both direction pullingof the truck on inclined place in one direction or the load lifting.

● 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 vertical lifting and horizontal pulling.
● Due to the structure of the manual winch, the mechanical brake mechanism may not be operated
properly when there is no load or a load that is too light for the rated load (about 5% or less of load
rating wire rope tension).
● 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３．Names of Each Part

Model ME
Gear Case
Warning Label (C)Gear Case Cover“Wire Rope Winding Direction” Sticker
Stay Bolt

Pressure Rollers
Side Frame

HandleDrum

Warning Label (B)Name Plate
Handle Holder

ClutchClutch Cover“Handle Rotatio n Direction” Sticker

Iｎｓｔａｌｌａｔｉｏｎ Aｄａｐｔｏｒ

Model RＭＥ (Ratchet Model)
Ratchet Unit

Type SI

Stopper Armless
Stopper unit is covered withthe clutch cover to privent
an accidental operation.

Frame“Stopper Position” Sticker
Safety Leaf Spring
Stopper
Warning Label (A)Type NSIL

Noiseless Mechanism
Silent lifting and lowering
is possible with this unit.

Figure 1

Names of Each Part4

Bed Plate

Type SIC

Packing for Drip-proof
Entire brake unit isdust and drip-proof.

４．Name Plate and Warning Labels
The following labels and name plate are attached to the winch. Read and understand the contents ofeach label fully starting operation. If any label or name plate becomes damaged or illegible, contact
MAXPULL MACHINERY & ENGINEERING Co., Ltd. or your local distributor immediately. A replacement
will be supplied at your own cost.

● Check the measurement unit of pound(lbs) or kilogram(kgf) on name plate and make sure thatthe load must not exceed the load rating of the winch before use the winch.
● Never remove nor disfigure any warning label or name plate on the winch.

Location of Name Plate

There are two types of Name Plate which indicated at Metric System and Yard-Pound System.

Figure 2

Name Plate

Types and Location of Waring Labels
Warning Label(A)Warning Label(B)Warning Label(C)Figure 3 Warning Labels

5５．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 andthat it is a level surface.
● If there is a clearance due to distortion, etc. between the installation adaptor of the manual winch andthe surface 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） After installing the winch, if the “Handle Rotation Direction” sticker affixed to the clutch cover
is no longer visible, request it to us for a new one at your cost and re-affix it at the visible
position. This is to prevent an accidental operation.
（４） 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 latching 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
groove or 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.

6６．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 willcause 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 the ones
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 oily liquid,because condensation may occur inside the gear case and brake mechanism of a winch installed
in a location with temperature difference; and, over time, the grease coated on the gear andsliding part inside may become oily by dissolving in the condensed water; and the oily grease
may drop from the joint of the gear case.

７．Installing the Wire Rope
In the ME and RME 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.
Loosen the side frame fixing bolts and side frame fixing nuts, then remove the side frame and pressurerollers.
Ｓｔａｙ Ｂｏｌｔ
Ｄｒｕｍ
Ｐｒｅｓｓｕｒｅ Ｒｏｌｌｅｒ ｆｏｒ Ｗｉｒｅ ＲｏｐｅＳｉｄｅ Ｆｒａｍｅ Ｆｉｘｉｎｇ Ｎｕｔ

Ｄｒｕｍ
Ｂｅｄ ＰｌａｔｅＳｉｄｅ ＦｒａｍｅＳｉｄｅ Ｆｒａｍｅ Ｆｉｘｉｎｇ Ｂｏｌｔ

Figure 4

Remove the Side Frame and the Pressure Rollers for Wire Rope

(1) Pass the wire rope through the groove in the end on the stay bolt side of the drum on the left, take7

it 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 the Figure 5-1, and then finally taken out from the bed
plate side 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 the Figure 5-2, and then finally taken out from the stay bolt sideon the right.
Ｗｉｎｄ ｔｈｅ ｗｉｒｅ ｒｏｐｅｔｏ ｔｈｅ ｆｒｏｎｔ
ｆｒｏｍ ｔｈｅ ｂａｃｋ

Ｓｔａｙ Ｂｏｌｔ
Ｔｈｉｓ ｇｒｏｏｖｅ ｉｓ ｆｒｅｅＷｉｎｄ ｔｈｅ ｗｉｒｅ ｒｏｐｅｔｏ ｔｈｅ ｆｒｏｎｔ
ｆｒｏｍ ｔｈｅ ｂａｃｋ

Ｓｔａｙ Ｂｏｌｔ
Ｄｒｕｍ

Ｄｒｕｍ

Ｂｅｄ Ｐｌａｔｅ
Ｂｅｄ Ｐｌａｔｅ
Ｄｒｕｍ

Ｄｒｕｍ

Ｔｈｅ ｓｈａｐｅ ｏｆ ｔｈｅ ｗｉｒｅ ｒｏｐｅ
ｗｏｕｎｄ ｏｎ ｔｈｅ ｄｒｕｍ

Figure 5-1 ⒶHow to wind the wire rope when
taking both ends of the wire rope out of one side(3)

Ｔｈｅ ｓｈａｐｅ ｏｆ ｔｈｅ ｗｉｒｅ ｒｏｐｅ
ｗｏｕｎｄ ｏｎ ｔｈｅ ｄｒｕｍ

Figure 5-2 ⒷHow to wind the wire rope when
taking one end of the wire rope out of one sideOnce 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 all bolts and nuts with your hand, use a tool such as a wrench to do the final tightening inthe same 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 6 Attaching of Side Frame(4) Wire ropes that are wound just by your hands are loose.
8

a. When using an endless wire rope, remove the looseness of the wire rope by sufficiently
tightening it with a wire stretcher. (Refer to Figure 7-1)
Next, operate the handle to rotate both winch drums about 15 to 20 times each to the left andright in order to remove the looseness of the wire rope between them. (Refer to Figure 7-2)
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 7-3)
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 8-1)
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 8-2)
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.
Ｅｌｉｍｉｎａｔｅ ｔｈｅ ｌｏｏｓｅ
ｉｎ ｔｈｅ ｗｉｒｅ ｒｏｐｅ
Ｐｕｌｌｙ
Ａｐｐｌｙ ｔｈｅ ｔｅｎｓｉｏｎ
ｏｎ ｔｈｅ ｓｉｄｅ ｓｅｎｔ ｏｕｔ
Ｌｏｏｓｅ ｉｓｅｌｉｍｉｎａｔｅｄＷｉｒｅ Ｓｔｒｅｔｃｈｅｒ
Ｔｗｏ Ｄｒｕｍｓ
Figure 7-1 Tightening the endless wire rope

Ｗｉｎｄｉｎｇ
Ｄｉｒｅｃｔｉｏｎ

Ｅｌｉｍｉｎａｔｅ ｔｈｅ ｌｏｏｓｅ
ｉｎ ｔｈｅ ｗｉｒｅ ｒｏｐｅ
ｂｅｔｗｅｅｎ ｔｈｅ ｔｗｏ ｄｒｕｍｓ

Figure 8-1 If the endless method is not used

Ｒｏｔａｔｅ ｔｈｅ ｔｗｏ ｄｒｕｍｓ
ｔｏ ｔｈｅ ｌｅｆｔ ａｎｄ ｒｉｇｈｔ
Figure 7-2 Tightening the endless wire rope

Ａｐｐｌｙ ｔｈｅ ｔｅｎｔｉｏｎ ａｌｗａｙｓ
Ｎｏ Ｌｏｏｓｅ

Ｅｌｉｍｉｎａｔｅ ｔｈｅ ｌｏｏｓｅ
ｉｎ ｔｈｅ ｗｉｒｅ ｒｏｐｅ

Figure 8-2 If the endless method is not used

Ｆｉｎａｌ ｔｉｇｈｔｎｉｎｇ ｗｉｔｈ ｔｈｅ ｗｉｒｅ ｓｔｒｅｔｃｈｅｒ
Figure 7-3 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.

9● It is shown without the side frame to make it easier to understand. When using a wire stretcher totighten 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 isapplied to the wire rope.

８．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 vertical liftingand horizontal pulling work safely.
● Wind the wrong direction will result in no functioning of the brake and serious accidents or injuries dueto the load falling. Make sure the winding direction of the wire rope is same as the direction on the sticker
affixed on the winch or describing on this manual.
● Make sure that the stopper arm is set to the “A” position of the “lifting” position as shown in the Figure
9. Set the position of the stopper arm correctly using this manual and the sticker affixed on the winch.
(Exclude the Stopper Armless Type SI, SIC and NSIL)● Check that the wire rope is properly inserted in the left/right drum grooves and the designated numberof winding times is secured.
● Check that the wire rope is coming out in parallel to the drum groove so that the wire rope does notdrop off of the drum groove.
● Immediately replace the wire rope when any of the following conditions occur: breakage of the wirerope’s wire strands; reduction in outer diameter (those with diameter reduction ratio of 7% or more than
the nominal 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.

● Do not remove the name plate or the “Handle Rotation Direction”, “Wire Rope Winding Direction”,“Stopper Position” sticker and any warning labels, and do not use a winch when it is dirty.
When you cannot read the sticker or name plate due to considerable dirt, or when it has fallen off andhas been lost, please submit a request to us for a new one and re-attach it to the designated location.
● The mechanical brake unit on a winch that has been left out without using for a long time may not
operate properly. Please conduct inspection or disassembly & inspection of the brake unit and confirm
that it operates properly before using the winch.

Inspection before Use❒Always conduct inspection of the following items before use.
(1)

Checking the Stopper Arm Position
Make sure that the stopper arm is set to the “A” position of green arrow as shown in the Figure 9.
If the stopper arm is at position “B” of red arrow, the brake is not applied. Do not move the stopperarm from the position “A” while the winch is under load. Do not touch the stopper arm carelessly
when working or under loaded. If the stopper come off when touched the stopper arm, the brake
will not work. When checking the operation of the brake, keep the brake position to the "A". The
safety spring is to prevent accident to lifting up the stopper arm and no braking.

10

If it is necessary to release the brake (pulling out the wire rope from winch drum by hand) in an
emergency, first remove the handle from the handle holder. And make sure that no load is applied
to the wire rope and winch. Next, lift the stopper arm while pressing the safety spring against the
winch, and set the stopper arm to position "B" of red arrow. The drum is now ready to spin and thewire rope can be pulled out by hand.
When finished to pulling out the wire rope by hand, be sure to return the stopper arm to theposition "A" of green arrow. The stopper arm can get over the safety spring and lower it to set it.
(Note: Type SI , SIC and NSIL do not correspond to the item of “(1) Checking the Stopper Arm
Position” because the stopper is built into the clutch cover.)Warning Label (A)Ｂ Red Arrow
Ｂ ＲＡＫＥＦＲＥ Ｅ

Stopper Position Sticker
Safety Leaf Spring

Ｐ ＯＳ ＩＴ ＩＯＮ
ＢＲ Ａ ＫＡ
ＢＬ Ｅ
Ｗ ＩＮ ＤＩ ＮＧ
ＲＥ ＷＩ ＮＤＩＮ

ＧＡGreen Arrow
Stopper Arm
Figure 9 Stopper Arm Position

(2)

(3)

Checking the Brake Operation
Turning the handle to the lifting direction (right rotation in view of the winch front: clockwise)
makes a clicking sound. Turning the handle to the lowering (counterclockwise) does not makesound. When the winch always makes clicking sound by turning the handle to the lifting direction
for 3 or 4 times, the brake unit operates correctly.
For the models with ratchet handle, operate the handle by setting the switch lever to“Lifting/Lowering”. Refer to “Ratchet Handle Operation for Model RME” on page 12.
The brake unit is designed not to function without load. When inspecting without load, turn the
drum with both hands. When the drum turns to the direction indicated on the stickers as an arrow
which the wire rope winding direction (counterclockwise) and the drum does not turn to the
opposite direction (clockwise), the brake operates correctly. Repeated turning the drum for 3 or 4
times to make sure the drum does not turn to the reverse direction. Remove the handle before
turning the drum by hands.
(Note: The noiseless mechanism type NSIL, does not make a clicking sound.)In this case, be careful not to get your hand caught in the rotating part and do not get injured.
If you have already lifted an object, hold the handle firmly with both hands and turn the handle
three or four times in the lifting direction and the lowering direction, and turn the handle to checkthat the brakes are working properly before operation.
Checking the Wire Rope Winding Direction
When the handle is turned in the lifting direction, the winding direction is correct if the wire rope
is wound onto the drum. Conversely, if the wire rope is wound up when the handle is turned in thelowering direction, the brake will not work due to the mechanical brake structure.
Do not wind the wrong direction of the wire rope. Wind the wrong direction will result in nofunctioning of the brake and serious accidents or injuries due to the load falling.
According to the sticker attached to the winch, wind the wire rope in the correct direction. Lifting11

direction in view of the winch front is right rotation for the handle and left rotation for the drum.

How to Fix the Handle into Place

For all winch models, loosen the wing screw as shown in the Figure 10, and insert the handle into thehandle holder. Make sure that the handle does not fall out while working by firmly screwing in the wingscrew, which fixes the handle into place, into the blind holes of the handle. If the wing screws loosen
while working, 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.

Ratchet Handle Operation for Model RME(1) When unwinding (lowering) the wire rope from the drum, set the switch lever (red ball) to the left
as viewed from the front of the winch as shown in the Figure 11.
When the handle is reciprocated left and right, the wire rope is unwound from the drum when thehandle is moved to the left.
(2) When winding (Lifting) the wire rope around the drum, set the switch lever (red ball) to the right asviewed from the front of the winch as shown in the Figure 12.
When the handle is reciprocated left and right, the wire rope is wound around the drum when thehandle is moved to the right.
(3) Originally, Model RME has been designed for use in an installation location where the handlecannot be rotated 360 degree, however this model can be used as a rotation type like Model ME.
(4) Model RME cannot operate normally without load.
5% or more of the rated load is necessary for normal handle operation.

HandleRatchet Handle
Switch Lever
Blind Hole

Wing Screw
Handle Holder

Figure 10 Fastening of Handle
Reciprocating Operation of the Handle
Id l ing
t io n
Dir
irec
D
e ct
g
n
i
i on
r
e
w
o
L

Reciprocating Operation of the Handle

Idlin

Switch Lever Position(Red Ball)
Left

i re cgDti o n

Lift

ing
D

irec
tion
Switch Lever Position(Red Ball)
Right

Wind off
the wire ropeWindthe wire ropeWindthe wire rope

Wind off
the wire rope

Figure 11 Switch Lever Position
at Lowering Operation

12

Figure 12 Switch Lever Positionat Lifting Operation

Handle Operation with the Load Lifted up (Exclude Model RME)

If the lifted load is held for a long period of time, reverse the handle (the grip faces to the drum side) andinsert to the handle holder as shown in the Figure 13 to 15.
By setting this way, even if the stopper arm is accidentally touch or release the brake, the handle does not
rotate to preventing the load falling. (Exclude Model RME)
In this case also, securely tighten the handle-holder wing screw to the handle.

● When the load is kept lifted for a long period of time, apply another effective brake unit or lock unit
other than the main brake unit on the winch.

Figure 13
Regular Instollation

Figure 14
Winch installation to a pole
(Example 1)

Figure 15
Winch installation to a pole
(Example 2)

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 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● Never stand 1) under loads, 2) transverse areas, or 3) areas near the wire rope to avoid potential breaks.
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 loads or winch in transverse motion or lifting while working.
● Do not jerk or swing the load. Never exceed the maximum load capacity specified for each model andoperate the winch slowly during the starting and stopping point.
● 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
the handle to operate it. Never operate the winch with a motor or any kind. Only use your hands.
It could lead to serious accidents such as by causing damage to the winch body or brake unit, or bybreakage of the wire rope that cause the fall of the loads.
● Grip the handle tightly while working and make sure that the winch is locked before releasing handle.
If the handle started to spinning by itself, do not try to stop a spinning handle until the spinning stops.
13

● Never attempt to invert the load or to hook the load to the structures and/or other objects.
● Do not use the winch for lateral work in the places where the slope changes to descent on theway, as the brakes will not work.
● 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.

● When the winding wire rope is stretched, temporarily stop the operation of the winch and make sure tocheck that the load is in good condition and brake does not slip before starting lifting.
● The brake slippage may occur under conditions that the load does not free fall vertically or theload is too small for rated load.
● When operating the winch, firmly screw in the wing screws (wing bolts) into the blind holes for fixing thehandle into place before conducting work.

14

Troubleshooting and Its Measures
Problem

The stopper brake
does not work

Checking of the Cause

MeasureIs the wire rope being
wound in reverse?

Check the wire rope winding direction.
Make the wire rope wind when handle is turned
clockwise.

Is the wire rope
loosened?

The brake unit does not work without load.
Apply a load to the winch.

Check if there are any
dust, obstacles or wateron the mechanical brake
unit by removing theclutch cover.

If any, clean the brake unit referring to thedisassembly and inspection of the mechanicalbrake unit.
Adjustment of the mechanical brake unit,
referring to the disassembly and inspection of themechanical brake unit.
The brake unit may not operate properly when
the load is insufficient.
Use a winch which is appropriate for the load.
Replace to the new brake lining, referring to thedisassembly and inspection of the mechanicalbrake unit.
Replace to the new brake lining, referring to thedisassembly and inspection of the mechanicalbrake unit.

Maladjustment of
mechanical brake unit.
Check if load on thewinch is too small.
Brake lining abrasion
Damage on themechanical brake unit.

Lowering cannot be
performed.
The handle does not
turn.
Abnormal soundduring operation

Suddenly, the handle
force becomes heavy.

Suddenly, the handle
force becomes light.

Has the minimum
temperature of theinstallation and usage
location dropped -10℃(14℉）or below?

Contact to MAXPULLEngagement of themechanical brake unit.

The mechanical brake unit is tighten too much.
Strongly turn the handle in lowering direction.

Are parts such as the gear
damaged due toexcessive load?
Abrasion of the gear or
the bearing
Has the wire rope
dropped off of the drum
groove?

Replace the damaged parts.
Replace the abraded parts.
Make sure that the wire rope does not drop offof the drum groove, because there is a risk thatthe winch will break.

Is it getting caught insomething on the way?

Stop the operation and remove the obstacle
before restarting.

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

Replace the wire rope.

Is it getting caught insomething on the way?

Stop the operation and remove the obstacle
before restarting.

Are the drum and wirerope slipping?

If they are slipping due to abrasion, replace theabraded parts.
If the wire rope is loosening, stretch the wire
rope.
15

● The performance of the mechanical brake unit drops after the mechanical brake unit is too tightenedand stuck. Disassemble and inspect the mechanical brake unit.

９．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 mechanicalbrake unit, 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 and winch. All loads must be lowered before any maintenance inspection
and repair.
Please conduct the maintenance inspection and repair while recording the results in the Appendix 1.
“MAXPULL Winch Inspection Sheet”.

● Please conduct the maintenance inspection and repair after making sure that no tension is applied to
the wire rope and winch. All loads must be lowered before any the maintenance inspection and repair.
● Someone with expert knowledge should perform the maintenance inspection and repair.
● During maintenance inspection and repair, clearly indicate that the winch is “under maintenanceinspection 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.

Disassembly and Inspection of the Mechanical Brake Unit
● Always perform the maintenance inspection after confirming that there is no tension (load) applied to
the wire rope and winch.
● Someone with expert knowledge should perform the maintenance inspection.
Please wear work clothes for the inspection, and conduct inspection after making sure that you aresuitably attired.
● When mud, dirt or water enters, becoming a cause for the mechanical brake unit not to function or thebrakes slip, so please periodically disassemble and inspect the mechanical brake unit.
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 mechanical brake unit may not work properly.
Please operate the winch at least once every two weeks. When using the winch after it has been unused
for a long period, always disassemble and inspect the mechanical brake unit.

16

（１）Follow the steps below to disassemble and inspect the mechanical brake unit. (See the parts list in
the Appendix 2 and 3.)(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 lifted or by killing the tension in the wirerope that is wound around the drum by using the wire stretcher. Disassembling themechanical brake unit 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 phillips pan head screws (No. 56), and then remove thehandle holder (No. 25).
(c) Disassembly of the ratchet unit is necessary for Model RME (Ratchet Model).
Skip this step (c) for Model ME (Rotation Model).
Remove the two hexagon socket head cap screws M6x15 (No.77) and ratchet handle (No.73).
Set the switch lever to the neutral position (on the winch side)
Remove the two hexagon socket head cap screws M8x15 (No.72) and ratchet wheel (No.71)
and axis (No. 70). The ratchet wheel and the axis have front and back side. Be careful not toassemble wrongly.
(d) Dismount the clutch shield plate (No.26). Skip this step (d) for Model RME (Ratchet Model).
(e) Remove the five tapping screws (No.43) and dismount the clutch cover (No.10).
(f) Remove the hexagon nut (No.47-A), plain washer (No.46), and dodecagon hole tongued
washer (No.22) in this order.
(g) Turn the clutch (No.20) counterclockwise to disassemble. (See Figure 17 on page 18)(h) Disassemble the stopper.
・For type SI and SIC (Stopper Armless Type)
Remove the retaining ring C type (No.51) and the hinge pin washer (No.50) to dismountthe stopper (No.23).
Rotate the stopper until it no longer interferes with the torsion spring (No.80) and pull
the stopper forward.
・For type NSIL (Noiseless Mechanism)
Remove the retaining ring C type (No.51) and the hinge pin washer (No.50), and themagnetic plate (No.91) to dismount the stopper (No.23).
Be careful not to deform the magnet plate. If deformed, the magnet plate may cause themalfunction of the brake.
Lastly, rotate the stopper until it no longer interfere with the torsion spring (No.80) andpull the stopper forward.
・For other cases (Stopper Released Type)
Remove the retaining ring C type (No.51) and the hinge pin washer (No.50), and pull the
stopper (No.23) forward.
Carefully pull the stopper. The steel ball in the stopper pops out.
(i) This completes the disassembly work for the Mechanical brake unit. Be sure not to lose
any small parts removed from the mechanical brake unit.
(j) Due to the dry brake lining, wipe off the dirt or oil on the ratchet gear (No.18), ratchet
metal (No.17), clutch (No.20), and the contact surface of the back plate (No.19) to thebrake lining (No.21) using thinner before assembling.
And make sure that there are no scratches or deformation on the thread.
If any, replace the part(s) with the new one(s).
(k) For assembly, please follow the procedure of disassemble in reverse. When assembling,coat the greasing on the triple thread screw of the clutch pinion (No.14) and the contact
part of the stopper (No. 23) and the hinge pin. Depending on the type of the stopper,
coat the greasing to the movement area of steel ball or to the torsion spring (No.80).
For Type NSIL (Noiseless Mechanism), coat the greasing thinly to the movement part ofthe magnetic plate (No.91) and the outer circumference of the clutch (No.20) where themagnet contact. (See Figure 19 on page 19)17

Also, apply grease thinly to the inner groove of the ratchet metal (No.17).
Be sure not to coat excessive amount of grease due to the malfunction of the brake unit.
The recommended grease for the brake unit is “Multinoc Wide 2 by ENEOS Corporation”.
Use this grease or an equivalent grease.
(l) Assembling of the clutch partThe brake lining is one set for two pieces in the black colour. Assemble the following
order; the clutch (No.20), the brake lining (No.21), the ratchet metal (No.17), the ratchetgear (No.18), and the brake lining (No.21). (See Figure 16 on page 18)
First, install the back plate (No.19) to the winch side, then tighten the assembled clutch
set onto the triple thread screw while rotating clockwise.
(m) As shown in the figure 16, set the boss and the dodecagon hole tongued washer with its
angle of 10 to 15 degrees while the clutch (No.20) is fully closed. When the angle isgreater than above mentioned, the stop time of the brake unit may get longer or thebrake unit has slippage. Cover the clutch cover (No.10) after check that the stopper
operates smoothly by rotating the clutch in the lifting direction (clockwise)(n) Make sure to tighten nuts, screws sufficiently and the like so that they do not loosen.
Once you are done with assembling and adjusting, please check that the brake operates
properly by following the procedures described in “Checking the Brake Operation”.
This completes the disassembly and inspection work for the mechanical brake unit.

● Make sure that the direction of the ratchet gear (No.18) teeth mesh with the stopper. If wrongly
installed, ratchet gear does not mesh with the stopper result in malfunction of the brake unit.
The minimum thickness of the brake lining is 2.45mm (0.0965 inch). Replace the brake lining witha new one when the thickness of it becomes less than this.

● If the lowering work is performed continuously while the load is applied, the brake may become hot.
There is no problem in the function, but please take cooling time depending on the situation.

Back plate (№19)

１０°～１５°Brake lining (№21)(black)

Lo

２０

Boss

Ratchet metal (№17)

２２
Tig

１４ １１－Ａhte

nBrake lining (№21)(black)enosRatchet gear (№18)

Clutch (№20)

Figure 16

Clutch Set

Figure 1718

The angle of the dodecagon hole tongued washer

(Ａ)
(Ｂ)
(Ｃ)
(Ｄ)
(Ｅ)

Hinge Pin
Clutch Pinion (No.14)
Triple Threads screw
Figure 18

Hinge Pin
Make sure that the direction of the ratchetgear (No.18) teeth mesh with the stopper.

Triple Thread Screw

Figure 19

Greasing Point for Type NSIL

Greasing Points on the magnetic unit for Type NSIL
(A) – Contact part between torsion spring and hinge pin(B)– Contact part between hinge pin and stopper(C)– Contact part among the magnetic unit, hinge pin washer and retaining ring C
type(D)– Connecting part between linkage screw and linkage plate(E)– Contact part between magnet and clutch (coat the greasing thinly on the outercircumference)

１０．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

19Appendix 1.

MAXPULL Winch Inspection Sheet

Inspector

Inspection Date

Model

Serial Number

Inspection
Period

year

month

day

Contents of Inspection

Judgment〇

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

Pass / Fail〇〇The mounting bolts of the winch are not loosened.

Pass / Fail〇〇

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

Pass / Fail〇〇

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

Pass / Fail〇〇All bolts, nuts and screws are tightened securely.

Pass / Fail〇〇

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

Pass / Fail〇〇

Check that the stopper can be moved smoothly and it functions properly.

Pass / Fail〇〇

The wire rope winding direction is correct.

Pass / Fail〇〇

There is no kink on the wire rope.

Pass / Fail〇〇

There is no frayed the element wire of the wire rope.

Pass / Fail〇〇

The wire rope is lubricated properly.

Pass / Fail〇〇

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

Pass / Fail〇〇

There is no abnormality in the joints of the endless wire rope. (If endless type is used)

Pass / Fail〇〇

The wire rope is not deformed.

Pass / Fail〇〇

The wire rope is not corroded.

Pass / Fail〇〇

The wire rope wound around the drum is properly inserted in the drum grooves.

Pass / Fail〇〇

The wire rope coming out of the winch is in parallel to the drum groove.

Pass / Fail〇〇

The wire rope is not loose.

Pass / Fail〇〇

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

Pass / Fail〇〇

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

Pass / Fail〇〇

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

Pass / Fail

Daily

Periodical〇

Refer to “Disassembly and Inspection of the Mechanical Brake Unit” for the following inspection
×〇

There is no damage on the brake lining and the thickness is 2.45mm (0.0965inch) or more.

Pass / Fail×〇

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

Pass / Fail×〇

There is no damage, abrasion or deform on the ratchet gear.

Pass / Fail×〇

There is no damage, abrasion or deform on the ratchet metal.

Pass / Fail×〇

There is no damage, abrasion or deform on the hinge pin

Pass / Fail×〇

There is no damage, abrasion or deform on the triple thread screw.

Pass / Fail×〇

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

Pass / Fail×〇

The angle of dodecagon hole tongued washer is 10 to 15 degrees.

Pass / Fail×〇

There is no damage, abrasion or deform on the ratchet handle and switch pin. (Model RME)

Pass / Fail×〇

There is no damage, abrasion or deform on the ratchet wheel and the axis. (Model RME)

Pass / Fail×〇

There is no damage, abrasion or deform on the torsion spring and it functions properly.
(Type SI, SIC and NSIL)

Pass / Fail×〇

There is no damage, abrasion or deform on the magnetic plate and it functions properly.(Type NSIL)

Pass / Fail＊ If any defects are found during inspection, correct them before the operation.
＊ When repairs are required, clearly state that the winch is “OUT OF ORDER” to prevent the winch being used accidentally.

Appendix 2.

Parts List of Model ME-5-B and ME-10-B*1 Same Left and Right*2 With Nut, Helical Spring Lock Washer and Plain Washer*3 With Helical Spring Lock Washer*4 With Helical Spring Lock Washer and Plain Washer*5 With Bearing

Appendix 3.

Ratchet Handle Parts List for Model RME
Stopper Parts List for Type SI and NSIL

Ratchet Handle for Model RME(Ratchet Model)

Stopper for Type SI(Stopper Armless)

Stopper for Type NSIL
(Noiseless Mechanism)

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 2022/04 MEBUSWEB