GT Viper 0.5t Instruction Manual

Note: Operator must read and fully
understand the operating instructions
before using this product.
Operating Instructions
& Safety Manual
Chain Block
Manual
Rated Capacities
0.5 through to 30 tonnes
HOISTS
www.gtlifting.co.uk
Head Office Units 13/14, Brickyard Road, Aldridge, West Midlands WS9 8SR UK
T+44 (0)1922 457916 F+44 (0)1922 743664 Eoffi[email protected]
A5 Viper Chain Block Manual V2.indd 1 04/03/2014 07:33

2
CONTENTS
Safety Information 2
General Information 3
Safety Precautions 4 - 5
Safety Warnings 6 - 7
Safety Procedures 8
Maintenance 9 - 12
Maintenance Checklist 13
Trouble Shooting 14
Specifications & Dimensions 15
SIGNAL WORDS
Note use of the following signal words DANGER,
WARNING & CAUTION with safety messages. The
appropriate signal word for each has been selected
using the following guidelines:
Indicates an imminently hazardous situation that, if not
avoided, will result in death or serious injury. The signal
word is to be limited to the most extreme situations
typically for machine components which, for functional
purposes cannot be guarded.
Indicates a potentially hazardous situation that, if not
avoided, could result in death or serious injury, and
includes hazards that are exposed when guards are
removed. It may also be used to alert against unsafe
practices.
Indicates a potentially hazardous situation that, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
Every year many accidents occur which could have
been avoided by a few seconds of thought and a more
careful approach to handling equipment. You, the
operator can avoid many accidents by observing the
following precautions in this manual. To avoid personal
injury, study the following precautions and insist those
working with you, or you yourself, follow them.
Replace any Caution, Warning, Danger or Instruction
safety label that is not readable or is missing.
Do not attempt to operate this equipment under
the influence of alcohol or drugs. Review safety
instructions with all users.
Operator should be a competent person. DO NOT
ALLOW PERSONS TO OPERATE OR ASSEMBLE THIS
UNIT UNTIL THEY HAVE DEVELOPED A THOROUGH
UNDERSTANDING OF SAFETY PRECAUTIONS AND
HOW IT WORKS.
Never exceed the limit of a lift. If its ability to do a job, or
to do so safely is in question - DON’T TRY IT.
Safety Information
HOISTS
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General Information
3
This manual contains important Information to help you
properly install, operate and maintain your Chain Block
for maximum performance, economy and safety. Please
study its contents thoroughly before putting your Chain
Block into operation. By practicing correct operating
procedures and by carrying out the recommended
preventative maintenance suggestions, you will be
assured of long, dependable and safe service. After you
have completely familiarised yourself with the contents
of this manual, we recommend that you carefully
file it for future reference. The information herein is
directed to the proper use, care and maintenance of
the Chain Block and does not comprise a handbook on
the broad subject of rigging. Rigging can be defined
as the process of lifting and moving heavy loads using
hoists and other mechanical equipment. Skill acquired
through specialised experience and study is essential
to safe rigging operations.
Unpacking
After opening the carton, the Chain Block should
be carefully inspected for damage which may have
occurred during shipment or handling. Check the Chain
Block frame for dents or cracks and inspect the load
chain for nicks and gouges. If shipping damage has
occurred, contact your local GT branch.
Operating a unit with obvious external damage may
cause load to drop and that may result in personal
injury and/or property damage.
To Avoid Injury
Carefully check unit for external damage prior to
installation.
Stop operating in the lifting direction when the hook
block contacts the hoist frame and/or hanger, as noted
by sudden increase in hand chain pull or tipping of the
hook block.
HOISTS
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Choose the Right
Chain Block for the Job
Choose a Chain Block with the capacity for the
job. Know the capacities of your loads, then match
them. The application, the size and type of load, the
attachments to be used and the period of use must
also be taken into consideration in selecting the right
Chain Block for the job. Remember the Chain Block was
designed to ease our burden, and carelessness not only
endangers the operator, but in many cases, a valuable
load.
Inspect
All Chain Blocks should be visually inspected before
use, in addition to regular periodic maintenance
inspections. Inspect Chain block for operation warning
notices and legibility. Deficiencies should be noted
and brought to the attention of supervisors. Be sure
defective Chain Blocks are tagged and taken out of
service until repairs are made. Under no circumstances
should you operate a malfunctioning Chain Block.
Check for gouged, twisted, distorted links and foreign
material. Do not operate Chain Blocks with twisted,
kinked or damaged chain links. Load chain should be
properly lubricated. Hooks that are bent, worn or have
openings which are enlarged beyond normal throat
opening should not be used. If latch does not engage
in throat opening of hook, the Chain Block should be
taken out of service. Chains should be checked for
deposits of foreign material, which may be carried into
the Chain Block mechanism. Check brake for evidence
of slippage under load.Each GT Viper Chain Block is
built in accordance with the specifications contained
herein and at time of manufacture was tested to our
interpretation of applicable sections of the European
standard BS EN 13157.
Consult your local GT branch for any usage of GT Viper
Chain Blocks that does not involve working in a direct
line of pull.
As side loading can damage chain or roller guides and
could result in injury and/or property damage. Using
Chain Blocks inverted is outside the design parameters
and should not be done.
Do’s & Do Not’s
Safe Operation of Chain Blocks
The following are Do’s and Do Not’s for safe operation
of overhead Chain Blocks. Taking precedence over any
specific rule listed here, however, is the most important
rule of all, Use Common Sense. A few minutes spent
reading these rules can make an operator aware of
dangerous practices to avoid and precautions to take
for his/her own safety and the safety of others. Frequent
examination and periodic inspections of the equipment
as well as a conscientious observance of safety rules
may save lives as well as time and money.
4
This symbol points out important
safety instructions which if not
followed could endanger the
personal safety and/or property
of yourself and others. Read
and follow all instructions in this
manual and any provided with the
equipment before attempting to
operate your GT Viper Chain Block.
Safety Precautions
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5
To Avoid Injury
1. DO be familiar with Chain Block operating controls,
procedures and warnings.
2. DO make sure the Chain Block suspension hook is
securely attached to a suitable support.
3. DO maintain a firm footing or be otherwise secured
when operating Chain Block.
4. DO make sure that load slings or other approved
sling attachments are properly sized and seated in
the hook saddle.
5. DO make sure that the hook latch, is closed and not
supporting any part of the load.
6. DO make sure that the load is free to move and will
clear all obstructions.
7. DO take up slack chain carefully, check load
balance, lift a few centimetres and check load
holding action before continuing.
8. DO make sure that all persons stay clear of the
suspended load.
9. DO avoid swinging of load or load hook.
10. DO protect load chain from weld spatter or other
damaging contaminants.
11. DO promptly report any malfunction, unusual
performance, or damage of the Chain Block.
12. DO inspect Chain Block regularly, replace damaged
or worn parts and keep appropriate records of
maintenance.
13. DO use GT Viper genuine parts when repairing a
Chain Block.
14. DO apply lubricant to the load chain as
recommended in this manual.
15. DO replace damaged or malfunctioning hook latch.
16. DO NOT use a hook without a latch.
17. DO NOT lift more than rated load.
18. DO NOT use damaged Chain Block or Chain Block
that is not working correctly.
19. DO NOT use the Chain Block with twisted, kinked,
damaged or worn chain.
20. DO NOT lift a load unless chain is properly seated
in chain wheel(s).
21. DO NOT use load chain as a sling or wrap chain
around load.
22. DO NOT lift a load if any binding prevents equal
loading on all supporting chains.
23. DO NOT apply the load to the tip of the hook.
24. DO NOT operate unless load is centred under Chain
Block.
25. DO NOT operate Chain Block with other than
manual power.
26. DO NOT permit more than one operator to pull on a
single hand chain at one time.
27. DO NOT allow your attention to be diverted from
operating the Chain Block.
28. DO NOToperate the Chain Block beyond limits of
load chain travel.
29. DO NOT use Chain Block to lift, support or transport
people.
30. DO NOT lift loads over people.
32. DO NOT allow sharp contact between two Chain
Blocks or between Chain Block and obstructions.
33. DO NOT allow the chain or hook to be used as a
earth for welding.
34. DO NOT allow the chain or hook to be touched by a
live welding electrode.
35. DO NOT remove or obscure the warnings on the
Chain Block.
36. DO NOT adjust or repair a Chain Block unless
qualified to perform Chain Block maintenance.
37. DO NOT attempt to lengthen the load chain or
repair damaged load chain.
38. DO NOT use a Chain Block inverted.
Safety Precautions
HOISTS
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6
DO NOT leave a load suspended on the Chain
Block unattended.
DO NOT wrap the load chain around the load
and hook onto itself as a choker chain or bring
the load in contact with the Chain Block.
DO NOT heat treat and DO NOT weld any part of
the Chain Block, especially the load chain.
DO NOT attempt to lift load beyond the rated
capacity.
DO NOT hold the load chain in a loaded state
while operating the Chain Block as serious
injury may occur if the brake did not operate
properly.
Important Safety Warnings
HOISTS
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7
DO NOT use the Chain Block for lifting or moving
people, or lifting loads over people.
DO NOT run the hook assembly into the frame of
the block.
DO NOT shock load Chain Block, chain or hook. DO NOT operate the Chain Block unless it is
rigged to pull in a straight line from hook to
hook, and the frame is allowed to freely swivel
on the upper hook.
Important Safety Warnings
HOISTS
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45
1t
Chain Block
Rated Load
Hand Chain Pull to
lift Rated Load Kg
Safety Procedures
1. The Chain Block must always be rigged to lift in a
straight line from hook to hook. The Chain Block
must always be free to swivel on theupper hook.
Under no conditions should the Chain Block frame
be allowed to bear on any support when in use as
this would cause bending of the hook or frame and
damage the unit.
2. When preparing to lift or move a load, be sure that
the attachments to both hooks are firmly seated in
the saddles of the hooks. Avoid off centre loading
of any kind especially loading on the tip of the
hook.Also observe that the chain hangs straight
(without twists) from Chain Block to lower hook.
3. When lifting, raise the load only enough to clear
the floor or support and check to be sure brake will
hold the load and that attachments to the load are
firmly seated. Continue the lift only after you are
assured the load is free of all obstructions.
4. Do not load beyond the rated capacity of the Chain
Block. Rated capacity can be achieved with the
following hand chain pulls. Since these hand chain
pulls can easily be applied by one person, under
no circumstances should more than one person
operate the hoist hand chain. Overloading can
cause immediate failure of some load carrying
parts or result in damage causing failure at less
than the rated capacity.
Exceeding the rated capacity of the Chain Block may
cause load to fall.
To Avoid Injury
Do not exceed the hand chain pulls specified in safety
procedure 4.
5. Do not wrap load chain around the load or bring
the load in contact with the Chain Block. Doing
this will result in the loss of the swivel effect of the
hook which could mean twisted chain and jammed
liftwheel. The chain could be damaged at the hook.
6. Stand clear of all loads and avoid moving load over
the heads of other personnel. Warn personnel of
your intention to move a load in their area.
7. Do not leave the load in the air unattended.
8. Do not lower the hook to a point where the chain
becomes taut between the liftwheel and loose end
pin.
9. Do not run the lower hook block into the Chain
Block frame. Frame and/or chain guide damage
may result.
10. The Chain Block has been designed for manual
operation only.
Special Note for User:
Twisting of Chain
3 tonne Chain Blocks and above have multiple falls of
load chain. THE LOAD CHAIN MUST BE INSPECTED
FOR TWISTS PRIOR TO EACH LIFT. If the Chain Block
bottom hook has looped through the multi fall of load
chain this can create a twist in the load chain that can
damage the Chain Block and cause injury.
8
0.5t
2t
3t
5t
10t
20t
21
33
36
39
42
45
Safety Procedures
HOISTS
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Inspection
To maintain continuous and satisfactory operation, a
regular inspection procedure must be initiated so that
worn or damaged parts can be replaced before they
become unsafe. The intervals of inspection must be
determined by the individual application and are based
upon the type of service to which the Chain Block will
be subjected. The inspection of Chain Blocks is divided
into two general classifications designated as frequent
and periodic.
Frequent Inspections
These inspections are usually visual examinations
by the operator or other designated personnel. The
frequent inspections are to be performed daily or
monthly and shall include the following items:
a. Braking mechanism for evidence of slippage -
Daily.
b. Load chain for lubricant, wear, damaged links or
foreign material - Daily.
c. Hooks for damage, cracks, twists, latch
engagement and latch operation - Monthly.
Any deficiencies noted are to be corrected before the
Chain Block is returned to service.
Periodic Inspections
These are visual inspections by an appointed person
who makes records of apparent external conditions
to provide the basis for a continuing evaluation. For
normal service, the periodic inspections are to be
performed yearly and for heavy service, the periodic
inspections are to be performed semi-annually. Due to
the construction of the Chain Block, it will be necessary
to partially disassemble the unit to perform the periodic
inspections.
The periodic inspections are to include those items
listed under frequent inspections as well as the
following:
a. Chain for excessive wear or stretch.
b. Worn, cracked or distorted parts such as hook
blocks, chain guide, stripper, loose end pin, shafts,
gears, hook collar and bearings.
c. Inspect for wear on the tip of the pawl, teeth
of the ratchet and pockets of the liftwheel and
handwheel.
d. Loose or missing bolts, nuts, pins or rivets.
e. Inspect brake components for worn, glazed or
contaminated friction discs and scoring of the
handwheel hub, ratchet and friction hubs.
f. Corroded, stretched or broken pawl spring.
g. Free movement of the pawl on the pawl stud. Also,
apply a thin coat of lubricant to the pawl stud
before reassembling the unit.
h. Hooks - dye penetrant, magnetic particle or other
suitable crack detecting inspections should
be performed at least once a year, if external
conditions indicate there has been unusual usage.
Any deficiencies noted are to be corrected before the
Chain Block is returned to service. Also, the external
conditions may show the need for a detailed inspection
which, in turn, may require the use of non destructive-
type testing. Any parts that are deemed unserviceable
are to be replaced with new parts before the unit
is returned to service. It is very important that the
unserviceable parts be destroyed to prevent possible
future use as a repair item and properly disposed of.
NOTE: Only qualified personnel to perform Chain Block
maintenance
9
Maintenance
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To determine if load chain should be continued in
service, check wear, pitch and gauge lengths.Chain
worn beyond length indicated, nicked, gouged or
twisted should be replaced before returning Chain
Block to service.
Chain should be clean, free of twists and pulled taut
before measuring. For gauge limits please contact GT
for more information.
Note that worn chain can be an indication of worn
Chain Block components. For this reason, the Chain
Block’s chain guide roller and lift wheel should be
examined for wear and replaced as necessary when
replacing worn chain. Also load chains are specially
heat treated and hardened and should never be
repaired.
Using other than GT Viper supplied load chain may
cause the chain to jam in the Chain Block and/or allow
the chain to break and the load to drop.
To Avoid Injury
Due to the size requirements and physical properties,
use only GT Viper Grade 80 Load Chain in GT Viperk
Chain Blocks.
Important: Do not use replaced chain for other
purposes such as lifting or pulling. Load chain may
break suddenly without visual deformation. For this
reason, cut replaced chain into short lengths to
prevent use after disposal. Before returning chain
to service or after replacing a load chain, lubricate
liberally with chain oil or equal lubricant. Remove
excess lubricant from the chain by wiping with a cloth.
Hand Chain
Hand Chain should be cleaned, inspected and gauged
in the same manner as load chain. As received from
the factory, the hand chain may contain an unwelded
link. This link can be placed in a vice and twisted
open to facilitate changing chain length. Please note
that opening and closing of the connecting link more
than twice is not recommended. Also, connecting
links must not be made by cutting the weld side of
a standard hand chain link. Hand chain should be
assembled to hand wheel free from twists with weld
on vertical link facing inwards towards hand wheel
and weld on horizontal link facing towards the hand
wheel side plate. Care must be taken to ensure that
there is no twist in the hand chain loop.
Lubrication
Lubricate load chain with a light coat of chain oil or
equal lubricant.Be sure the lubricant reaches the
bearing surfaces between the links. Remove excess oil
from the chain.
Used motor oil contain unknown carcinogenic
materials.
10
10
10
Chain Block
Rated Load
0.5t
1
1.5t
2t
3t (Single Fall)
3t (Double Fall)
5t
10t
20t
30t
Hand Chain
5
6
7.1
8
10
7.1
10
10
5
Chain Stock
Diameter (mm)
Maintenance
HOISTS
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To Avoid Health Problems
Never use used motor oils as a chain lubricant. Only
use chain oil as a lubricant on the load chain. The Chain
Block normally requires no additional lubricant except
for periodically lubricating the load chain as indicated or
when the unit is disassembled for periodic inspections,
cleaning or repairs. The brake is designed to operate dry.
Do not use any grease or lubricant on the braking surfaces.
When lubricating parts adjacent to the brake, do not use an
excessive amount of lubricant which could seep onto the
brake surface.
Using any grease or lubricant on the braking surfaces will
cause brake slippage and loss of load control which may
result in injury and/or property damage.
To Avoid Injury
Do not use any grease or lubricant on the braking surfaces.
The brake is designed to operate dry.
When the Chain Block is disassembled for periodic
inspections, check the pawl for free movement and apply
a light coat of WD-40 or similar lubricant to the pawl stud.
When the Chain Block is disassembled for cleaning or
repairs, the following locations should be lubricated using
approximately 29.5ml per Chain Block of suitable grease or
equivalent:
• gears
• liftwheel rollers
• gear bearing rollers
• chain guide and dead end pin
Note: To assure extra long life and top performance, be
sure to lubricate the various parts of the Chain Block using
the lubricant specified above.
Exterior Finish
The exterior surfaces of the Chain Blocks have a durable,
scratch resistant finish. Normally, the exterior surfaces can
be cleaned by wiping with a cloth.
Preventative Maintenance
In addition to the periodic inspection procedure, a
preventative maintenance program should be established
to prolong the useful life of the Chain Block and maintain its
dependability and continued safe use. The program should
include the periodic inspections with particular attention
being paid to the lubrication of various components using
the recommended lubricants.
Testing
Before using, all altered, repaired or used Chain Blocks
that have not been operated for the previous 12 months,
should be tested by the user for proper operation. First test
the unit without a load and then with a light load of 20kg to
be sure that the Chain Block operates properly and that the
brake holds the load when the hand chain is released. Next
test with a load of 100% rated capacity. In addition, Chain
Blocks in which load sustaining parts have been replaced
should be tested with 100% of rated capacity by or under
the direction of an appointed person and a written report
prepared for record purposes.
To Avoid Injury
Use only GT Viper supplied replacement parts. Parts may
look alike, however GT Viper parts are made of specific
materials or processed to achieve specific properties. Any
repairs to this chain block must be undertaken by a suitably
qualified and competent person. Following any repairs,
this Chain Block must be tested in line with the guidelines
set out in the current BS EN 13157 standard prior to its
reintroduction to service.
11
Maintenance
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Points of Inspection Type of Outcome
Inspections
Hook Top/Bottom
Deformation of hook visual There should be no deformation of the hook.
Safety catch should close against the tip of the
hook securely.
Damage to the hook visual There should be no crack or serious damage
Bend in the neck of hook visual Hook should hang square to lifting unit or top hook
or to side plates (bottom block)
Suspension pin visual Should not be bent, cracked or worn
Side plates and suspension visual There should be no cracks, damage or wear
plates
Rivets, bolts and nuts visual All fasteners should be tight
Safety catch visual Should close properly
Chain visual Should be properly lubricated and free from
bends, nicks or stretch, rust and dust
Chain guide rollers visual Should rotate freely and keep chain in the pockets
of the chain wheel(s)
Functions
Lifting and Lowering Lift and lower Hoist should operate smoothly and easily
a light load Pawl should click during lifting
of 25kg
Braking Lift and lower Lifting and lowering operations should be smooth
the full safe and without any of the following defects
working load
1. Load falls if chain is released
2. Load falls while lowering
3. Load slips
12
Maintenance Check List
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Problem Cause Solution
13
Line load to be positioned vertically
Reduce angle of pull
a) Unload and de-swivel
b) Replace hook assembly
Refer to maintenance and repair
section of this manual
Unravel and straighten chain
Load block to recommended capacity only
Return to supplier for repair
Replace block
Refer to manual for maintenance and
inspection details
Always store unit in a dry and clean
area
Load block to recommended capacity
only
Return to supplier for repair and testing
Return to supplier for repair and testing
Load is not being pulled in a vertical
direction
Pull is at an angle greater than 60°
Swivel Hook has ceased operating
Block is dirty, or hampered with
foreign matter
Fall of chain is tangled
Block is overloaded
Brake mechanism has jammed
Wear and tear
Poor maintenance and inspection
Poor storage and handling
Block is overloaded
Brake mechanism worn
Brake mechanism worn
1. Chain is jammed
2. Block Seized
3. Slippage of load
4. Block not braking
Trouble Shooting
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14
Rated Capacity 0.5t 1t 1.5t 2t 3t 3t 5t 10t 20t 30t
Running Test Load (kN) 6.3 12.5 20 25 40 40 62.5 125 250 375
Standard Lift (m) 2.5 2.5 2.5 3 3 3 3 3 3 3
Effort Required to 210 260 265 272 320 280 358 370 370 370
Lift Rated Load (N)
No. of Load Chain Falls 1 1 1 1 1 2 2 4 8 12
Load Chain Diameter (mm) 5 6 7.1 8 10 7.1 9 10 10 10
A 126.5 143 148 152 181 156 181 181 192 330
B 136 156 182 198 266 214 266 365 630 670
Dimensions (mm) C 266 324 392 407 621 465 636 798 890 1000
D 36 40 52 52 60 60 68 85 106 106
K 25.5 28 38 38 42 42 50 57 84 84
Net Weight (kg) 7 10.5 17 18 42 21 42 72.6 162 228
Extra Weight per metre of extra lift 1.5 1.8 2.1 2.3 3 3.1 4.6 9.8 19.6 28.3
GT Viper Chain Blocks
Specifications & Dimensions
HOISTS
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15
Spare Parts Diagram
HOISTS
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Fig.
No. Description
22. Brake Pawl
23. Circlip
24. Brake Hub
25. Brake Disc
26. Ratchet Gear
27. Brake Cover
28. Hand Wheel
29. Retainer
30. Hand Chain Cover
31. Bottom Hook Assembly
32. Bottom Hook Assembly (3-5t)
33. Bottom Hook Assembly (10t)
34. Bottom Hook Assembly (20t)
35. Top Hook Assembly (3-5t)
36. Top Hook Assembly (10t)
37. Top Hook Assembly (20t)
Fig.
No. Description
1. Lock Nut
2. Name Plate
3. Retainer
4. Bearing for Splined Gear
5. Gear Cover
6. 2nd Gear
7. 3rd Gear
8. 1st Gear
9. Load Sprocket
10. Pinion Shaft
11. Gear Side Plate
12. Support Pin
13. End Anchor
14. Chain Guide
15. Chain Stripper
16. Chain Stripper Pin
17. Hand Chain Side Plate
18. Hook Pin
19. Top Hook Assembly
20. Pawl Pin
21. Pawl Spring
16
Spare Parts List
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