Pacific Hoists PLB302 User manual

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
INSTRUCTION MANUAL
LEVER BLOCK
READ THIS OPERATING MANUAL BEFORE USING THE LEVER BLOCK
Please read this operation manual before using this product. This manual contains important
information regarding safety, operation, installation & maintenance. ALWAYS operate, inspect
and maintain this product in accordance with AS1418.2

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
INTRODUCTION
Thank you for purchasing your new Lever Block. This manual lifting device now uses the latest
technology to ensure you of a higher quality, robust design with a high level of operator safety
which is easier and safer to use, ensuring a longer service life.
It is important that this manual be kept in a safe place where any operator of the Lever Block
can refer to it and understand the operating principles of this device. All users of this Lever
Block should read this manual in full and understand the safe operating principles of the
device.
FEATURES
Features of the Lever Block include:
•Designed in accordance with European Standard EN13157 & AS1418.2
•The Lever Block is the safest free-wheeling lever block on the market
•New patented braking system to ensure the integrity of the load under all conditions
•Design improvements result in 25% less operator effort to lift the rated load
•New style load hooks with cast “notched” safety latches increase service life of the latches
and improve the safety of the lifting operation
•Improved design of load sprockets for safer operation
•Key internal components are now CNC machined for improved overall product reliability
•All Lever Blocks are individually load tested in accordance with AS1418.2
A comprehensive range of spare parts is readily available.

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
SPECIFICATIONS
Model
PLB302
PLB408
PLB416
PLB432
PLB463
Capacity
kg
250
800
1600
3200
6300
Lift
m
1
1.5
1.5
1.5
1.5
Test Load
kg
375
1200
2400
4800
9450
Pull on lever to lift full load
N
227
285
315
360
370
No. of load chain falls
1
1
1
1
2
Type of load chain
mm
Ø4x12
Ø5.6x17
Ø7.1x21
Ø10x28
Ø10x28
Min. distance between hooks
H
mm
250
340
400
520
640
Length of lever handle
D
mm
168
273
378
418
418
Dimensions
A
mm
100
158
185
212
212
B
70
98
111
124
124
C
86
132
145
198
230
Ø
18
25
30
36
43
E
20
26
29
37
43
Net weight
kg
1.9
5.8
9.5
16.8
21.5
Weight (with chain)
kg
2.3
6.9
11.4
20.8
29.7

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
PRE-START CHECKLIST
Regular inspection of your Lever Block will have a twofold result by ensuring the unit is
suitable for safe operation and will assist with extending the operating life of the unit. The
following inspection should be performed both prior to, and after, every use:
•Ensure the Lever Block is correctly suspended from a suitable support which keeps the
load chain off the ground whilst in storage
•Ensure the selected Lever Block is the correct capacity to perform the task required
•Handle your Lever Block with care and do not throw, drop or drag it along the ground
•Familiarise yourself with how the unit operates and understand its safety features
•Inspect the unit for any missing parts before and after every use
•Ensure the safety latches are working correctly and are aligned properly in the hook
•Check for free movement of the load chain by operating the lever handle
•Check the load hooks for ease of rotation
•Inspect the load chain before and after each use
•Check that the hand-wheel assembly rotates freely without jamming

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
ON SITE CHECKS
There are a number of checks recommended when using the Lever Block on site:
•Lever Blocks can be used for both vertical and horizontal use
•Only competent persons should operate Lever Blocks and should have read and
understood the operation of the device before use
•Follow all site safety rules where applicable in relation to the movement of suspended
loads
•It is recommended that the Lever Block should not be exposed to elements such as: water,
salt spray, steam or chemicals that may compromise the integrity of the device, without
consulting your supplier
•Adopt safe slinging practices and follow all instructions carefully
•Ensure the load requirement of the job is within the rated capacity of the Lever Block
•Check that labelling and/or identification is correct and legible
•Ensure the Pre-Start Check List, as shown previously, has been conducted
•Oil and/or grease must NOT make contact with the braking system of your Lever Block
•Check the environment and locality of the job to ensure personnel safety issues are
acceptable for the intended use
•Check that the load connection point, where the Lever Block is to be attached, is capable
of safely handling the intended load
•Where trolley suspension is required, ensure the trolley is correctly set for the beam width
and that it moves freely along the beam
•Once the Lever Block is suspended, both hooks must be seated correctly ensuring the
safety latches are engaged in the closed position
•Ensure the free end of the load chain is clear of any obstructions before and during
operation.
•Check that the bottom hook will reach its lowest point without fully extending the load
chain
•The load should be free to move, and the landing area cleared before starting any lifting
operation
•When using a Lever Block with 2 falls (or more) of load chain, ensure that the lower hook
block has not been inverted or twisted
•Start the lifting process carefully, and once the load is just clear, stop and check the
integrity of the Lever Block and load assembly, including any rigging, before continuing the
operation
•The operator should always have a clear view of the complete travel path of the load
•Ensure that the load will not be suspended from the Lever Block for any extended period of
time without secondary restraint, it is advisable that suspended loads should not be left
unattended
•Take care when placing heavy loads down into position that fingers and toes are kept
clear

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
GENERAL PRECAUTIONS
•Always understand the operation of the Lever Block before putting it to use
•Always ensure you are working within the required guidelines of Occupational Health and
Safety regulations relevant to the task being undertaken
•Never use a Lever Block to lift a load greater than its rated capacity
•Always check for personnel within the work area and DO NOT use Lever Blocks to
suspend loads over people
•Never use Lever Blocks for lifting or transporting people under any circumstances
•Never use the load chain of a Lever Block to wrap around the load
•Never operate a Lever Block with kinked or twisted load chain
•Always keep control of the load and do not allow it to swing excessively
•Avoid shock loading the Lever Block as it may seriously damage the operating system. If
this occurs, remove the device from use
•Always ensure any slings or rigging gear being used are connected into the hooks,
ensuring safety latches are engaged in the closed position
•Check for fixed obstructions which may catch the load during the lifting operation
•Lever Blocks are designed for manual use only and must not be converted for power
operation in any way
•Never modify your Lever Block from its designed configuration in any way
•Ensure only the original manufacturer’s spare parts are used in the repair of any Lever
Block
•Replace any load chain with original manufacturer’s specified chain only
•Galvanising or plating of load chain or load bearing parts is strictly forbidden without the
express approval of the supplier
•Never replace a worn load chain without having the Lever Block fully inspected by a
competent person

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
OPERATING INSTRUCTIONS
The Lever Block has been designed for manual operation only. It utilises a reciprocal operating
lever handle to drive a series of gears via a unique braking system to raise (or tension) and
lower (or release) a load both vertically and horizontally.
•Place Lever Block into the required position to perform the lifting (or tensioning) operation,
ensuring the top hook is positioned correctly with the safety latch engaged as required
•To raise the bottom hook without any load applied, use the Lever Block in the Free Wheel
mode, as shown in the instructions on the next page
•While the unit is in Free Wheel mode, the load chain can be pulled through the device by
hand in either direction to position the hook in the desired location
•Once the load has been connected to the lower hook, ensure the safety latch is engaged
correctly
•Move the Select Lever to the Raise position
•Operating the lever handle using a circular motion or a reciprocating (back and forth)
motion will begin lifting or tensioning the load
•Start the lifting or tensioning process carefully, and once the load is taken up, stop and
check the integrity of the Lever Block, the load assembly, including any rigging gear, and
that the load path is clear before continuing the lifting or tensioning
•Continually using a reciprocating movement will raise or tension the load while the Select
Lever is in the Raise position
•If the handle movement is stopped at any time during the raising (tensioning) of the load,
the Lever Block will continue to hold the load automatically
•To lower the bottom hook, first move the Select Lever into the Lower position
•Take care before commencing lowering (or retracting) of the load, to ensure that the load
path is clear and unobstructed by obstacles or by persons near the work area
•Operating the lever handle using a circular motion or a reciprocating (back and forth)
motion will lower the load
•When raising or lowering a load, the desired operation is a smooth backward and forward
arm movement. Excessive speed is not recommended
•Once load is in desired position, continuing the reciprocating movement will release the
tension of the load chain
•After ensuring the load has been placed safely and securely, release the safety latch of the
bottom hook and remove it from the load
•The unit can then be used in the Free Wheel mode to quickly move the lower hook to a
position where the Lever Block and chain can be safely removed from the job site
•After removing the Lever Block from use, a visual inspection should be performed to cover
the points listed in the Pre-Start Check List previously described
•Ensure the unit is stored correctly in a suitable secure location where unauthorised
persons do not have access

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
FREE WHEEL INSTRUCTION
To use the Lever Block in free wheel mode:
Move the Select Lever to the central position
.
Hold the Hand Wheel then rotate Position Wheel
clockwise 45 degrees in the tree direction until
engaged
.
To operate the Lever Block in raise or lower mode:
From the free wheel position
.
Hold the Hand Wheel, then rotate the position
wheel anti clockwise 45 degrees until it
disengages into the load position. Move the
Select Lever to Raise (left) or Lower (right) – then
operate the Lever Handle
.

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
SPARE PARTS FOR 250KG MODEL

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
SPARE PARTS FOR 250KG MODEL
CODE
NO
DESCRIPTION
CODE
NO
DESCRIPTION
710500
1
Gear cover
710523
25
Handle assy
710501
3
Drive shaft
710524
26
Changeover pawl
710502
4
Splined gear
710525
27
Spring shaft
710503
5
Right side plate assy
710526
28
Changeover spring
710504
6
Load chain sprocket
710527
29
Selector plate shaft
710505
7
Bush A
710528
30
Handle rubber grip
710506
8
Stay bolt C
710529
31
Selector plate
710507
9
Top hook shaft
710530
32
Nameplate
710508
10
Bush B
710531
33
Hand wheel
710509
11
Chain stripper
710532
34
Hand wheel nameplate
710510
12
Stay bolt A
710532
34
Steel wire retainer
710511
13
Guide roller
710533
35
Step washer
710512
14
Left side plate assy
710534
36
Hand wheel nameplate
710513
15
Pawl spring
710535
37
Stay bolt B
710514
16
Pawl
710536
38
Bushing
710515
17
Brake seat
CHN250
41
Load Chain mm 4 x 12
710516
18
Free spring
710537
42
Chain ring
710517
19
Friction plate
710538
45
Warning plate assy
710518
20
Ratchet wheel
710539
46
Top hook assy
710519
21
Ratchet wheel cover assy
710540
47
Safety latch assy
710520
22
Changeover ratchet wheel
710541
61
Bottom hook assy
710521
23
Spring seat
710542
62
Bottom hook pin
710522
24
Right lever handle assy
710543
73
Circlip 20
710544
74
Pawl washer
710547
77
Spring pin 2x12
710549
79
Split pin 2x16

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
SPARE PARTS FOR 800KG - 6.3 TONNE MODELS

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
SPARE PARTS FOR 800KG MODEL
CODE
NO
DESCRIPTION
CODE
NO
DESCRIPTION
710610
1
Gear cover 0.8T
710633
25
Handle assy
710611
2
Disc gear assy
710634
26
Changeover pawl
710612
3
Drive shaft
710635
27
Spring pin
710613
4
Splined gear
710636
28
Changeover spring
710614
5
Right side plate assy
710637
29
Selector shaft
710615
6
Load chain sprocket
710638
30
Handle rubber grip
710616
8
Chain guide
710699
31
Selector plate
710617
9
Top hook shaft
710639
32
Nameplate
710618
10
Chain leader A
710640
33
Hand wheel
710619
11
Chain stripper
710641
34
Positioned hand wheel
710620
12
Stay bolt B
710642
35
Step washer
710621
13
Chain leader B
710643
36
Hand wheel nameplate
710622
14
Left side plate assy
CHN400
41
Load Chain mm 5.6 x 17
710623
15
Pawl spring
710644
42
Chain ring
710624
16
Pawl
710645
45
Warning plate assy
710625
17
Brake seat
710646
46
Top hook assy
710626
18
Free spring
710647
47
Safety latch assy
710627
19
Friction plate
710648
61
Bottom hook assy
710628
20
Ratchet wheel
710649
62
Bottom hook pin
710629
21
Ratchet wheel cover assy
710651
73
Circlip 26
710630
22
Changeover ratchet wheel
710652
74
Circlip 8
710631
23
Brake torsion spring
710654
77
Spring pin 3x18
710632
24
Adjusting block
710656
79
Split pin 2.5x25

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
SPARE PARTS FOR 1.6 TONNE MODEL
CODE
NO
DESCRIPTION
CODE
NO
DESCRIPTION
710670
1
Gear cover
710693
25
Handle assy
710671
2
Disc gear assy
710694
26
Changeover pawl
710672
3
Drive shaft
710695
27
Spring pin
710673
4
Splined gear
710696
28
Changeover spring
710674
5
Right side plate assy
710697
29
Selector shaft
710675
6
Load chain sprocket
710698
30
Handle rubber grip
710676
8
Chain guide
710699
31
Selector plate
710677
9
Top hook shaft
710700
32
Nameplate
710678
10
Chain leader A
710701
33
Hand wheel
710679
11
Chain stripper
710702
34
Positioned hand wheel
710680
12
Stay bolt B
710703
35
Step washer
710681
13
Chain leader B
710704
36
Hand wheel nameplate
710682
14
Left side plate assy
CHN410
41
Load Chain mm 7.1 x 21
710683
15
Pawl spring
710705
42
Chain ring
710684
16
Pawl
710706
45
Warning plate assy
710685
17
Brake seat
710707
46
Top hook assy
710686
18
Free spring
710708
47
Safety latch assy
710687
19
Friction plate
710709
61
Bottom hook assy
710688
20
Ratchet wheel
710710
62
Bottom hook pin
710689
21
Ratchet wheel cover assy
710712
73
Circlip 30
710690
22
Changeover ratchet wheel
710713
74
Circlip 9
710691
23
Brake torsion spring
710715
77
Spring pin 3x18
710692
24
Adjusting block
710717
79
Split pin 2.5x25

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
SPARE PARTS FOR 3.2 TONNE MODEL
CODE
NO
DESCRIPTION
CODE
NO
DESCRIPTION
710730
1
Gear cover
710754
26
Changeover pawl
710731
2
Disc gear assy
710755
27
Spring pin
710732
3
Drive shaft
710756
28
Changeover spring
710733
4
Splined gear
710757
29
Selector shaft
710734
5
Right side plate assy
710758
30
Handle rubber grip
710735
6
Load chain sprocket
710759
31
Selector
710736
8
Chain guide
710760
32
Nameplate
710737
9
Top hook shaft
710761
33
Hand wheel
710738
10
Chain leader A
710762
34
Positioned hand wheel
710739
11
Chain stripper
710763
35
Step washer
710740
12
Stay bolt B
710764
36
Hand wheel nameplate
710741
13
Chain leader B
CHN440
41
Load Chain mm 10 x 28
710742
14
Left side plate assy
710765
42
Chain ring
710743
15
Pawl spring
710766
45
Warning plate assy
710744
16
Pawl
710767
46
Top hook assy
710745
17
Brake seat
710768
47
Safety latch assy
710746
18
Free spring
710769
61
Bottom hook assy
710747
19
Friction plate
710770
62
Bottom hook pin
710748
20
Ratchet wheel
710771
71
Metal lock nut M12
710749
21
Ratchet wheel cover assy
710772
73
Circlip 42
710750
22
Changeover ratchet wheel
710773
74
Circlip 9
710751
23
Brake torsion spring
710774
76
Light spring washer 8
710752
24
Adjusting block
710775
77
Spring pin 3x18
710753
25
Handle assy
710776
78
Nameplate rivet 2.5x6
710777
79
Split pin 2.5x25

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
SPARE PARTS FOR 6.3 TONNE MODEL
CODE
NO
DESCRIPTION
CODE
NO
DESCRIPTION
710790
1
Gear cover
710815
27
Spring pin
710791
2
Disc gear assy
710816
28
Changeover spring
710792
3
Drive shaft
710817
29
Selector shaft
710793
4
Splined gear
710818
30
Handle rubber grip
710794
5
Right side plate assy
710819
31
Selector
710795
6
Load chain sprocket
710820
32
Nameplate
710796
8
Chain guide
710721
33
Hand wheel
710797
9
Top hook shaft
710822
34
Positioned hand wheel
710798
10
Chain leader A
710823
35
Step washer
710799
11
Chain stripper
710824
36
Hand wheel nameplate
710800
12
Stay bolt B
CHN440
41
Load Chain mm 10 x 28
710801
13
Chain leader B
710825
42
Chain ring
710802
14
Left side plate assy
710826
45
Warning plate assy
710803
15
Pawl spring
710827
46
Top hook assy
710804
16
Pawl
710828
47
Safety latch assy
710805
17
Brake seat
710829
48
Bottom hook pin
710806
18
Free spring
710830
61
Bottom hook assy
710807
19
Friction plate
710831
63
Bottom hook connector assy
710808
20
Ratchet wheel
710832
64
Idler sheave
710809
21
Ratchet wheel cover assy
710834
73
Circlip 42
710810
22
Changeover ratchet wheel
710835
74
Circlip 9
710811
23
Brake torsion spring
710836
76
Light spring washer 8
710812
24
Adjusting block
710837
77
Spring pin 3x18
710813
25
Handle assy
710838
78
Nameplate rivet 2.5x6
710814
26
Changeover pawl

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
MAINTENANCE
It is the responsibility of the owner/operator to ensure Lever Blocks are maintained and tested
in accordance with AS1418.2.
•Only authorised personnel should undertake repairs and testing on lifting equipment
•Keep load chains lubricated
•Always check the operation of the brake before starting to move a load
•Brakes must be kept free of oil and grease
•Safety latches should be free of defect and move freely with proper fitment to the hook
•If any of the following defects are evident, the Lever Block should be referred to an
authorised or competent person for a more thorough examination, servicing and testing:
Evidence of possible wear to hooks and fittings; damaged or distorted chain end anchor;
chain wear including bends, notches, elongations, corrosion, not hanging freely or twisted;
load slipping, jamming or will not lift; damaged covers; illegible markings: bent operating
handles or other obvious damage
RECOMMENDED LUBRICANTS
Gears
Molybond TSG-01005880
Shafts and bearings
Shell Retinax EP-04391003
Load chain
CRC 5037 Lithium -00549423

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
SPARE PARTS
General inspections are visual and should be carried out by the operator
or any designated persons responsible for the equipment
Service Inspections should only be performed by authorised personnel
capable of undertaking Service, Repairs and Testing
ITEM CHECK GENERAL
INSPECTIONS
SERVICE
INSPECTIONS
Brake Assembly Slipping under load or difficulty
of release X X
Brake Disc Glazing or score marks. Oil or
contamination X
Pawl: Ratchet Worn or damaged X
Pawl: Spring Engagement, corrosion,
stretching X
Top and Bottom Hooks Corrosion, deformation X X
Hook Retaining Components
Nuts, Bolts, Pins Not tight or secure X X
Hook Latches Damaged, do not engage X X
Suspension Members,
Sheaves, Hand Wheels, Chain
Guides, Attachments,
Suspension Pins and Bolts
Wear, cracks, elongation X X
Gears Distortion, worn or broken
teeth, lack of lubrication X
Load Chain
Grade, wear, elongation,
twisted or damaged, lack of
lubrication
X X
Handle Assembly Bent, damaged, select lever
functional X X
Covers, Labelling Removed, damaged or illegible X X

Pacific Hoists Pty Ltd Australia: [phone]
www.pacifichoists.com.au New Zealand: [phone]
INSPECTION LOG
INITIAL SERVICE DATE: SERIAL NO:
DATE COMMENT SIGNATURE
Pacific Hoists Pty Ltd recommend the following procedures:
•Ensure that you have read the operating instructions fully and understand them prior
to use.
•Perform an initial examination of the Lever Block before use.
•In the event of damage to the Lever Block, immediately suspend the unit from service
and inform your Pacific Hoists Representative.