UNIT NO. 3.

CHAIN LEVER HOISTS

Chain lever hoists are closely related to hand chain blocks, but have the advantage that they
are able to be used in any plane, unlike the chain block which is limited to vertical use only.
The lifting force is applied by a ratchet handle instead of a chain wheel, which usually has a
'free' position in the unloaded state, enabling the hook to be placed in the required position
quickly. This makes them ideal for applications, such as machinery shifting and steel
erection, which may require a pulling action.

The current Harmonised Standard for lever hoists is BS EN 13157:2004, Cranes – Safety –
Hand powered lifting equipment. Clause 5.2 of this standard gives the specific requirements
which lever hoists must meet. As well as chain lever hoists the standard gives the
requirements for lever hoists which utilise wire rope and webbing as the lifting media. In this
unit we are only concerned with lever hoists utilising chain.

TYPES OF LEVER HOIST

Although the vast majority of lever hoists manufactured and in use today are fitted with link
chain, at least one manufacturer still offers them fitted with roller chain. Further, older
models fitted with roller chain may still be found in service. Figure 1 shows typical examples
of both types.

Roller Chain Link Chain

Typical Lever Hoists

Figure 1

Roller Chain
Although we looked at loads chains earlier in our studies, our considerations were all related
to short link chain. We must therefore briefly take note of special matters that relate to roller
chain, similar to that commonly used as drive chain, eg on a bicycle, when used as a load
chain.

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Unlike link chain, which has flexibility in all directions, roller chain only has flexibility in
one plane – along the line of the plane of the link plates. It is constructed from individual
plates which are riveted together with case hardened pins and rollers are fitted at each joint.
These both space the internal width of the link and give flexibility to the joint.

With roller chain, most of the wear takes place on the rivet pins, about which the plates
swivel. The wear in the chain can therefore be determined by measuring the elongation over a
number of links. A maximum increase in length of 2% is permitted, as this is the point at
which the case hardened skin of the pins will have just worn through. Beyond this point rapid
wear and failure would occur.

To check the length, the chain should be laid on a flat surface and pulled tight. It will be
found that the rivet pins are usually centre punched as a result of the riveting process. These
punch marks give a convenient marker from which to measure. The measurement over a
number of links, usually 12, can then be compared to the original and the elongation
calculated.

If the original length is unknown, as will usually be the case, the wear can be determined
using the 'SHUNT ' method. Because the roller can be assumed to move equal amounts over
the sprocket wheel in both directions it can also be assumed that the wear on the pins will be
even. The chain should be measured as described above. It should then be pushed together,
the chain remaining flat, thus taking out the slack and the new 'shunted' length measured.

It can be seen that the original, or mean, length will be equal to the closed length plus half of
the difference between the two measurements. Therefore, if the difference in the two
measurements is 4% then the actual elongation will be 2% and the chain should be discarded.

In addition to the general wear that will occur with use, lack of lubrication will cause this to
be more rapid. Lack of lubrication and corrosion will cause some of the links to 'lock' and
therefore jump or jam during operation. Overloading will also cause the links to become stiff
and lock due to the pins having become bent. These points require special attention during the
examination.

LINK CHAIN LEVER HOISTS

At one time all lever hoists were manufactured with cast iron/steel bodies and handles and
one or two models made this way are still available for special applications. The majority of
modern lever hoists are manufactured with pressed steel bodies and handles and some are
made with high grade aluminium alloy. Lower capacity models have a single fall of chain but
the higher capacity units have two or more falls.

The only difference between the roller chain models and those fitted with link chain is the
load wheel or sprocket. We can therefore look at one of the common link chain models for
our studies. Figure 2 shows an exploded view of a typical lever hoist. You will note the close
resemblance to hand chain block we considered in unit 3.8.

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 Exploded View of a Typical Lever Hoist
Figure 2

SAFETY REQUIREMENTS OF BS EN 13157

Mechanical strength
BS EN 13157 requires lever hoists to have a factor of safety of at least 4:1. They must be
designed to withstand 1500 continuous cycles with a load of 110% of the WLL without
failure or the need for maintenance or replacement parts, other than lubrication.

Brakes
The braking function must be automatic when the operating force ceases in any motion.

Brake discs must not contain any asbestos.

The fracture of a pawl spring must not lead to a failure of the braking system. Where the
system utilises several springs, if any one fails the design must be such that the remaining
springs will ensure the correct engagement of the pawl.

The brake must only be able to be altered, maintained or interfered with by the use of tools, ie
cannot be meddled with either intentionally or accidentally.

Operation
The lever should have a travel distance of not more than 150mm before a pawl or load
retaining device engages.

The maximum effort to lift the rated capacity must not exceed 55daN at the end of the lever
and if the operating effort is below 20daN the hoist must be fitted with an overload protection
device. If the overload device triggers it must not lead to a release of the operating lever.

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For free spooling, to enable the load chain to be positioned under no load conditions, the
brake may be opened, but must automatically apply when a load greater than 30kg is applied
to the load chain. The descent must not be greater than 300mm before the brake applies.

Lever hoists and their components must be capable of operation within the temperature range
of -10ºC to +50ºC.

Chains and Chain Wheels

Link chain load chains must comply with BS EN 818-7, fine tolerance short link chain grade
T. Roller chain load chains must comply with ISO 606, short pitch transmission precision
roller chains.

The free end of the load chain must be fitted with a stop to prevent the chain from passing
through the machine which must sustain 2.5 times the static chain tensile force at the rated
capacity.

Load wheels/sprockets must be made as a single piece.

A chain guide must be fitted to prevent the load chain jumping off the chain wheel.

MARKING
BS EN 13157 requires lever hoists to be fitted with a permanent identification plate in a
clearly visible position. This must give the following minimum information for chain lever
hoists:
a) Name and address of the manufacturer
b) Series or type designation
c) Identification number/mark
d) Rated capacity (WLL)
e) Year of manufacture
f) Dimensions and grade (or quality in case of roller chain) of chain
g) Directions of movement

MANUFACTURER'S TESTS
Type Verification
BS EN 13157 requires the manufacturer of series produced lever hoists to carry out various
type tests to prove the design on one or more samples. These include:
a) Breakage test to ensure the required factor of safety has been achieved
b) Static overload test at 1.5 times the rated capacity for units of less than 20t WLL and
at 1.25 times the rated capacity for units of 20t or greater WLL to ensure there is no
damage or deformation and that the unit remains in working order and it is possible to
make the dynamic test on the same unit
c) Dynamic test at 1.1 times the rated capacity to ensure the mechanism and structural
elements remain undamaged
d) Functional test to ensure performance is in accordance with the design criteria
e) Light load test of between 2% and 10% of the WLL to ensure the correct working of
the brake
f) Static load test of the chain anchorage/end stop
g) Endurance test of 1500 cycles with a load of 110% of the WLL over a travel path of at
least 300mm. The speed of operation of each cycle must be no less than that achieved
by an operator working continuously for 1 minute. There should be no replacement of

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 parts or maintenance, other than lubrication of the load chain. At the end of the test
the unit must still hold a static test load of 150% of the WLL and show no signs of
failure.

Manufacturing Tests and Examination

On completion of manufacture each lever hoist must be subject to :
a) Dynamic test at 1.1 times the WLL
b) Functional test
c) Thorough examination

THE USE OF LEVER HOISTS

Before we consider the matters to be taken into account during an examination we will take a
look at the use of lever hoists and the defects and damage that can occur due to misuse. Full
details of the safe use of lever hoists is given in Section 3 of the LEEA Code of Practice for
the Safe Use of Lifting Equipment, which you should also study.

The load chain should not be used to form a sling around a load and back hooked. This would
remove the swivel action of the bottom hook, possibly leading to the chain becoming twisted
and additional forces would be imposed on the chain links at the point of choke which can
bend and can also distort the links and, at worst, crack the weld. Similarly in the case of roller
chain it can cause riveted link pins to crack out through the side plates or rollers to become
seized and jam.

No part of the load or slings should be in contact with the point of the hook as this can distort
and open the hook. The hook should not be overcrowded as this will damage the slings and
can distort and open the hook.

Lever hoists are designed so that the handle offers sufficient leverage to operate the unit at
maximum load. Additional leverage should not be exerted, eg by placing a pipe over the
lever. This will bend the handle, loosen the ratchet assembly and cause various problems with
the operational mechanism.

The lever hoist should not be shock loaded. this will lead to all types of damage, eg stretched
chain, opening of hooks, damage to gears or brakes. If suspended from a crane hook for
accurate load positioning, the SWL of lever hoists should be reduced by 15% to allow for the
effects of dynamic loading or shock loading may occur.

Care should be taken not to drop the lever hoist, eg when handling, dismantling or erecting.
This can cause damage to the casing which will press on the gears or other mechanisms,
cause distortion of the lever hoists alignment or bend and distort the handle.

EXAMINATION
Chain lever hoists fall under the heading of 'lifting equipment' in modern legislation and
therefore should be examined by a competent person at periods not exceeding twelve months.

The requirements for load tests to be made as part of the examination will vary dependant on
the circumstances, as will the extent to which it may be necessary to dismantle and clean the
lever hoist and we will consider these matters. Further, some organisations have laid down
procedures for dealing with these matters, which their employees will need to follow. It must,

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however, be understood that these matters are the responsibility of the competent person
making the examination and that he may be held to account to justify his decisions.

During the examination the following should be checked:

1) The general appearance and operation of the lever hoist. A functional test should be
made to ensure the smooth operation of the gears and good engagement of the load
chain with the chain wheel/sprocket.
a) Any damage to the casing should be assessed, this may cause the casing to rub
on the gears or other parts of the mechanism, hindering the smooth operation.
b) If the operation is noisy, there is erratic movement or jumping of the gears, it
may be necessary to remove the covers to enable a full examination to be
made.
c) If the chain jumps this may be a sign of elongation of the links due to stretch
or lengthening of the pitch due to wear and therefore incorrect engagement
with the load chain wheel/sprocket. In the case of roller chain it may be caused
by a build up of debris in the chain, which should be cleaned away.
d) The chain stripper should be in good condition, without distortion or burring
of the lead faces.
e) The marking must be clear and legible.
2) A light load test should be made to ensure the correct and safe operation of the brake.
this is the most important test that can be mad and is necessary if the tester and
examiner is to certify that the lever hoist is 'safe to operate' on the report of thorough
examination. A load between 2% and 5% of the WLL should be raised a height of at
least 500mm and then lowered. To be acceptable, when the handle is released at any
point during the test, the brake must hold the load. In the case of lever hoists with
extended heights of lift, or in the case of the larger multi-fall chain models, particular
care is needed and the height of the load during the test should be increased. This is
due to a condition which can arise where the weight of the slack chain is sufficient to
hold the brake open allowing the load to descend.

During this test it should be possible to change the direction of operation by turning
the operating pawl through the free motion position without the mechanism releasing.
The load should be sustained at all times.
3) The chain and slack end chain stop should be examined, paying particular attention to
the following:
a) Twisting of the chain, particularly at the anchorage or in the case of multi-falls
where the bottom block has been turned over.
b) Stretched and distorted links, due to over loading or other misuse. In the case
of roller chain, bent or cracked link plates, distorted rivets or seized rollers.
c) Worn links or worn/cracked spacer rollers and side plates.
For link chain, inner wear of the links results in an elongation of the pitch
which will affect the correct mating of the chain with the load wheel.
Maximum reduction in material diameter 8%, maximum elongation 3%. For
roller chain, wear on the pins will erode the case hardening and rapid wear and
failure will result, maximum elongation of the pitch by 2%. (Careful attention
must be paid to the mating of the chain with the load wheel/sprocket. it may be
necessary to remove the chain from service before it reaches these maximum
percentages)

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 d) Cracked welds (link chain), worn rivet heads (roller chain), nicks and gouges,
which will act as stress raisers.
4) The condition and security of the operating lever should be checked. A bent or
distorted lever will become loose and can cause the mechanism to jam. If the handle is
cracked it might fail in use, presenting a hazard to the operator.
5) Top and bottom hooks and cross heads/retaining collars should be examined paying
particular attention to the following:
a) Distortion of hooks, eg twisting, opening up etc
b) Wear, maximum 8% loss of material section
c) Nicks, cracks and gouges, which act as stress raisers
d) Free rotation and movement of hooks. if there is excessive movement or float
of the hook in the crosshead it will be necessary to remove the hook from its
housing in order to examine the seating and bearing surfaces. Well designed
housings are bolted together to allow this but in many cases they are riveted,
in which case the rivets must be drilled out and subsequently replaced with
bolts and nuts.
e) In the case of roller chain, the retaining collar and swivel band should be
undamaged and secure.
6) Where necessary the lever hoist should be stripped down, degreased and cleaned to
enable a full examination of all of the following:
a) Gears for wear, fracture and alignment, paying particular attention to the load
wheel gear and axis
b) Body side plates are in proper alignment and free from wear
c) Load wheel/sprocket for wear on splines
d) Brake discs for contamination, wear and damage (it is preferable to replace
discs rather than attempt to clean them)
e) Operational/direction pawl and mechanism for damage, wear etc.

In most cases a proof load test will not reveal anything new as the strength of the lever hoist
is already known and , therefore, the test serves no purpose, but will shorten the working life
of the unit. However, if a repair has been made using uncertified load bearing components it
will be necessary to proof load the lever hoist. care is needed to establish the correct proof
load to be applied by reference to the manufacturers' literature. usually the proof load will be
150% of the WLL, although for lever hoists made strictly to the Harmonised Standard it will
only be 110%. This should be raised sufficient distance so as to ensure that every gear wheel,
or rotating component, passes through at least one revolution. Following a proof load test the
block must be thoroughly examined.

It must be realised that a proof load test will not reveal the condition, or prove the correct
operation, of the brake, which can only be ensured by conducting a light load test.

Lever hoists used in extreme conditions may require additional attention. An example of this
being in the offshore environment. In these cases the tester and examiner should work to the
requirements of the Code of Practice for the Selection, Management, Use, Maintenance and
Examination of Hand Chain Blocks and Lever Hoists in the Offshore Environment including
Sub-sea, published by LEEA.

It should also be noted that it has been found that a great number of new lever hoists are
received where the brakes are incorrectly set. It is therefore recommended that all new lever
hoists are subject to an examination and a light load test before issue for use.

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