CHAIN PULLEY BLOCK INSPECTION

 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.

 

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	Type of check		Inspection / Upkeep
Hook	Inspect visually		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.
Rivets, Bolts & Nuts	Inspect visually		All fasteners should be tight.
Chain	Inspect visually		Should be properly lubricated (Use "Cylesso TK-140" oil) and free from rust and dust.
Slack end pin &Chain anchor pin	Inspect visually		Should not be bent.
Chain wheels	Inspect visually		Chain pockets should not be deformed / worn out. Should rotate freely.
Load Chain Guide Roller	Inspect visually		Should rotate freely and keep chain in the pockets of the chain wheel.
Stripper / Hand chain Guard	Inspect visually		There should not be any damage and wear.
Lifting and Lowering	Lift & lower a light load		Hoist should operate smoothly and easily. Pawl should click during lifting.
Braking	Lift & lower Safe Working Load		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.
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	Type of check		Inspection / Upkeep
Ratchet Wheel & Pawl	Inspect visually before dismantling brake (see below)		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.
Load Chain Wheels & Hand Chain Wheel	Inspect visually		Clean out chain wheels pockets and check that these are not deformed.
Spur Wheels and Chain Wheels	Inspect visually		Clean of all lubricant and check that gear teeth are not chipped, damaged or worn. Re-lubricate.
Chain Guide Rollers	Inspect visually		Should not be damaged, worn or deformed and must rotate freely.
Stripper	Inspect visually		Tip of stripper should not be seriously flattened or damaged. (If in doubt, consult a competent person or fit new items).
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.