CHAIN PULLEY BLOCK

Dos & Donts

L&T Power TPPC BU

ITPCL CUDDALORE

Dos
Ensure that the chain block is in sound condition and good working order. Take action for immediate repair or replacement of damaged parts. Use recommended parts only. The use of un-authorised parts may be dangerous and will invalidate the warranty. Ensure the support for the chain block is capable of withstanding a load of at least 1 times the chain block safe working load. Keep the chain block clean for the best and safest performance. Locate the chain block in a suitable, well lit work area. Keep work area clean and tidy and free from unrelated materials. Ensure all non-essential persons keep a safe distance whilst the chain block is in use. Ensure load sling(s) are fully engaged in load hook and that hook safety bar is in the closed position. Raise and lower in a smooth, controlled manner and DO NOT shock load the chain block by allowing the attached load to fall freely, even for very short distances. Check the brake operation by stopping when the load has been raised a short distance (100mm) and ensuring that it is held with no downward creep. DANGER: Use the chain block for lifting only, NOT for supporting the lifted load. Use a qualified person to lubricate and maintain the chain block. Store chain block in a dry and weather proof area when not in use.

Donts
DO NOT operate the chain block if damaged. DO NOT allow untrained persons to operate the chain block. DO NOT exceed the rated capacity (safe working load) of the chain block. DO NOT raise or lower the load with jerky or abrupt movements of the hand chain. DO NOT attempt to lift a load if the load chain is kinked or knotted. DO NOT try to raise a load with two, or more, chain blocks - use a single block of adequate capacity. DO NOT use the chain block to drag the load across the floor. Always position the load directly below the block. DO NOT wrap the load chain around the load - always us separate, suitable, slings/chains/ropes of the correct capacity. DO NOT allow anyone to stand or pass beneath the raised load. DO NOT use the chain block for purposes other than that for which it is intended.

L&T Power TPPC BU

ITPCL CUDDALORE

L&T Power TPPC BU

ITPCL CUDDALORE

CARE & SAFE USE AND INSPECTION CHECKS

HAND OPERATED CHAIN PULLEY BLOCK

Never lift a load in excess of safe working load marked on the block. Twisting of load chain should be avoided in single fall or multiple fall. Load to be applied centrally. No direct binding of load with load chain, i.e. never use load chain as a sling. No extreme slant slinging. No over lifting, No over lowering, No rough handling. Don't forget to oil the load chain after use, do not use grease for lubricating load chain. If Load chain jumps, does not work smoothly or marks in use, it is probably out of pitch & should be replaced.

Do not allow dirt and hard grease to gather in pockets of the load or hand chain. Do not store or leave the pulley blocks lying on the ground where they can collect dirt. Care shall be taken when replacing the chains that same Grade and size of chain is fitted; Grade of chain is marked on pulley blocks by manufacturer.

Gears should be periodically greased. (HPC lithon-2 is recommended) Never weld the load chain. Hook should be used with safety latch. Hook should be periodically examined for opening, i.e. for elongation. Never lift load from hook corner. Examine the hook for swivel movement, that is top hook under no load and bottom hook with load should be possible to rotate.

Brake system is through Ratchet and Pawl mechanism, hence never remove pawl. Friction washers should not be lubricated. They are made of brake lining material. Operator should always wear helmet during operation and no person should stand under lifted load.

Operator should warn persons around to avoid any accidents. Care should taken that lifted load should not swing during operation. Handling to be done carefully while block is operated above furnaces or on any heating equipment.

It is always recommended to use Pulley Block as per class Designed. Pulley Block should be examined, inspected & tested by an impartial & competent authority once in a year for its wear and safe working as certified in Factories Act 1948.

L&T Power TPPC BU

ITPCL CUDDALORE

Routine examination The chain pulley block should be regularly inspected for damage and wear and to ensure that it is operating smoothly. Where the hoist is used infrequently, a visual check should be made of the chain pulley block each time it is used.

The following is a guide to routine checks, which should be carried out, on a chain pulley block, which is used in normal operating conditions. Where a chain pulley block is used or stored outdoors or in corrosive or abrasive conditions, inspection and lubrication must be attended to more frequently. External Inspection (Monthly checks) Component / Function Hook Type of check Inspect visually Inspection / Upkeep 1. There should be no deformation of the hook. 2. There should be no cracks, or serious damage. 3. Hook should hang square to lifting unit or top yoke (top hook) or to bottom block side plates. All fasteners should be tight. Should be properly lubricated (Use "Cylesso TK-140" oil) and free from rust and dust. Should not be bent. Chain pockets should not be deformed / worn out. Should rotate freely. Should rotate freely and keep chain in the pockets of the chain wheel. There should not be any damage and wear.

Inspect visually Rivets, Bolts & Nuts Chain Inspect visually

Slack end pin &Chain Inspect visually anchor pin Chain wheels Load Chain Guide Roller Stripper / Hand chain Guard Lifting and Lowering Braking Lift & lower a light load Lift & lower Safe Working Load Inspect visually Inspect visually Inspect visually

Hoist should operate smoothly and easily. Pawl should click during lifting. Lifting and lowering operations should be smooth without any of the following defects. 1. Load falls, if hand chain is released. 2. Load falls while lowering. 3. Load slips.

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ITPCL CUDDALORE

Internal Construction (Yearly checks) A competent person, as per statutory regulations and to ensure the efficient and safe use of the chain pulley block should carry the routine inspection and tests given above, together with the following inspections every year. Internal Construction (Yearly checks) Component / Function Ratchet Wheel & Pawl Type of check Inspect visually before dismantling brake (see below) Inspection / Upkeep Wear on the ratchet wheel profile and pawl should not be excessive - pawl must engage fully in the ratchet teeth. The pawl should not be rusted. Check that the pawl stud is secure and that the circlip / split pin is retaining the pawl. Clean out chain wheels pockets and check that these are not deformed. Clean of all lubricant and check that gear teeth are not chipped, damaged or worn. Relubricate. Should not be damaged, worn or deformed and must rotate freely. Tip of stripper should not be seriously flattened or damaged. (If in doubt, consult a competent person or fit new items).

Load Chain Wheels & Inspect visually Hand Chain Wheel Spur Wheels and Chain Wheels Chain Guide Rollers Stripper Inspect visually

Inspect visually Inspect visually

Brake

Examine the screw sleeve, split bush, friction washers, ratchet ring and hand chain wheel, pawl, pawl spring and pawl stud. All items must be in good condition. The faces of the screw sleeve, ratchet wheel and hand chain wheel must not be worn or scored. The bores of the screw sleeve and ratchet wheel should not be worn or scored. The friction washers should be measured with a vernier caliper. Minimum permissible thickness is 1.5 mm. Friction washers must not be split or cracked.

L&T Power TPPC BU

ITPCL CUDDALORE

TROUBLE SHOOTING CHART Sr. No. 1. Trouble Load Slippage Cause a. Friction washer(s) may be worn out. b. Friction washer(s) oily. c. Screw sleeve & hand chain wheel is jammed. d. Check washer is not working. e. Ratchet wheel & pawl arrangement is not working. 2. Block not hoisting or lowering loads. a. Check for load chain twist. Cure a. Replace friction washers. b. Clean friction washer with sandpaper. c. Clean screw sleeve & hand chain wheel square threads for burr / rust formation and re-assemble. d. Check serration, if required, replace check washer. Adjust Nyloc nut. e. Check spring, if found defective, replace it. Check ratchet wheel & pawl, if worn out, replace them.Ratchet pawl stuck. Check & clean pawl stud. a. Remove load chain twist.

b. Hand chain or load b. Clean chain wheels & replace chain. chain may be stuck due to foreign particles. 3. Block making noise. a. Split bush may be worn out. a. Replace it.

b. Load chain stripper b. Replace it. damaged. c. Load chain wheel c. Replace it. pockets may be worn out. d. Guide roller damaged. e. Load chain is jumping from wheel pockets. d. Replace it. e. Check load chain dimensions, refer table & replace load chain.

f. Hand chain is f. Check hand chain dimensions, refer table slipping /jumping from & replace load chain. wheel pockets 4. Load chain failure a. Hoist is overloaded. a. Check load to be lifted & capacity.

b. Load chain may be b. Replace load chain. worn out. c. Load chain may be c. Remove load chain twist. twist.

L&T Power TPPC BU

ITPCL CUDDALORE