7.1 Manual Chain Blocks & Lever Hoists

Manual Chain Blocks and Lever Hoists

Manual chain blocks and lever hoists multiply human effort through gears and hold load with a mechanical brake. Their similar load chain and hooks do not make them interchangeable: suspension, operating direction, duty, travel and free-chain features differ by model.

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Chain Blocks

A hand chain turns a wheel and reduction gearing that drives a pocket wheel carrying calibrated load chain. A load brake, often based on the Weston principle, develops clamping action under load and holds when the operator stops pulling. The brake depends on clean, correctly assembled friction parts and a continuous load path; it is not a separate parking device that excuses shock loading.

Suspend the hoist from a support and connector rated for the reaction. The body should hang freely without bearing against structure. Check that top and bottom hooks articulate and that the load chain enters the pocket wheel untwisted. On multi-fall hoists, a twisted bottom block can turn the chain over and cause jamming.

Pull the hand chain smoothly in its intended plane. Excessive effort is a warning of overload, fouling, brake trouble or damaged chain—not a reason to extend the hand chain or use a powered drive.

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Lever Hoists

A lever hoist uses a ratcheting handle to lift, pull or tension. Many models have a neutral or free-chain setting for positioning without load. The exact mechanism differs, but the safe rule is consistent: never select free chain while the hoist supports load. Confirm engagement before loading and keep hands clear of the handle's possible movement.

Whether a lever hoist may pull horizontally, tension a load or be used at an angle comes from its instructions. It is still lifting equipment when used for lifting and must not be used for people unless specifically designed and authorised for that purpose.

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Load Chain

Hoist load chain is calibrated to fit its pocket wheel. Replace it only with the exact type and grade approved for that hoist. Sling chain of similar diameter is not a substitute. Do not weld, splice, galvanise or plate a load chain in the field.

Inspect the entire working length for wear, elongation, bent or twisted links, gouges, corrosion, weld defects and heat damage. Measure over the number of links and at the locations specified by the manufacturer. Values such as 3% pitch elongation or 10% diameter wear occur in some standards and manuals, but the controlling discard limit is the one for the exact hoist and chain. A chain that rides, jumps or binds on the wheel is withdrawn immediately.

Lubricate only as instructed and keep lubricant away from brake friction surfaces. Do not use grease to conceal corrosion or force a stiff chain through the mechanism.

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Hooks, Brake and Controls

Check hook opening, twist, wear, latch where fitted, swivel and connection to chain or body. A latch retains a slack connection; it does not reinforce an overloaded hook. Confirm that direction selector markings are legible and the brake holds during a trial lift.

Do not side load the hoist body or hook tip. Never wrap load chain around a load and hook it back onto itself unless the hoist is explicitly designed for that use. Avoid two operators applying force unless instructions permit it; human effort is not a calibrated overload limiter.

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Examination, Maintenance and Testing

Under LOLER, a manual hoist used for ordinary load lifting has a 12-month default thorough-examination interval, or six months when used to lift people, unless a competent-person examination scheme specifies another interval. Pre-use checks and maintenance remain separate.

After repair or overhaul, the manufacturer or authorised repair procedure determines inspection, brake testing, functional testing and any load test. LOLER does not set universal static factors of 1.5 below 20 t and 1.25 above 20 t. HSE notes that routine overload testing is not required for most lifting equipment at every examination.

Only competent, authorised personnel should open the brake or gear case. Incorrect friction-disc order, contamination or pawl assembly can allow uncontrolled movement.

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Operating Sequence

1. Verify identity, WLL, examination status and support.
2. Inspect hooks, chain, controls and body.
3. Remove twists and align the load path.
4. Take up slack and make a trial lift just clear.
5. Confirm brake holding and load balance.
6. Operate smoothly, never leaving a suspended load unattended.
7. Land and stabilise the load before removing tension.

The key distinction is between calibrated load chain, which must mesh with the hoist, and ordinary chain sling, which must not be substituted.