Step-by-Step Guide: Installing a New Chain on a Lever Hoist

Posted by Craig Cappel on May 19, 2023

Step-by-Step Guide: Installing a New Chain on a Lever Hoist

Lever hoists are essential tools used in various industries for lifting and pulling heavy loads. Over time, the chain on a lever hoist may wear out or become damaged, requiring replacement. Installing a new chain on a lever hoist is a relatively straightforward process that can be completed with a few basic tools. In this step-by-step guide, we will walk you through the necessary steps to ensure a successful chain replacement on your lever hoist. By following these instructions, you can restore the hoist's functionality and maintain a safe working environment.

Step 1: Gather the Required Tools

Before starting the chain installation process, ensure you have the necessary tools and materials on hand:

  1. New chain: Use only genuine replacement parts. The factory-supplied load chain from the original equipment manufacturer will guarantee it meets the specifications of your lever hoist. Using an aftermarket load chain is unsafe as it can prematurely wear creating a risk for failure while damaging the lifting components.
  2. Replacement pin or connecting link: This is necessary if your new chain does not come pre-assembled with a connecting link.
  3. Safety gloves and goggles: Protect yourself from potential hazards during the installation process.
  4. Wrenches or spanners: Select the appropriate size for the bolts and nuts on your lever hoist.
  5. Chain lubricant: Lubrication is crucial for smooth operation and longevity of the chain.

Step 2: Disconnect the Lever Hoist

To ensure your safety and avoid accidental operation during the chain replacement, disconnect the lever hoist from any load. If it is attached to an overhead structure, make sure it is securely suspended and won't fall while you work.

Step 3: Remove the Old Chain

Using your wrench or spanner, loosen the nuts and bolts securing the old chain to the hoist body. Carefully remove the old chain from the sprocket and pulley, making sure to note the orientation of the chain welds for proper installation of the new one. Inspect the hoist body for any signs of wear or damage that may require maintenance or repair before installing the new chain.

Step 4: Prepare the New Chain

Inspect the new chain for any defects or damage. If it comes pre-assembled with a connecting link, proceed to Step 5. Otherwise, you will need to install a replacement pin or connecting link. To do this, align the two ends of the chain and insert the pin or connecting link, ensuring it is properly seated and secured. Use a wrench or spanner to tighten the connecting link or lock the pin in place.

Step 5: Attach the New Chain to the Hoist Body

Start by placing the new chain around the sprocket and pulley, ensuring it follows the same path as the old chain. Align the end of the new chain with the chain attachment point on the hoist body. Insert the chain pin or connecting link into the attachment point, making sure it is fully engaged. Use your wrench or spanner to tighten the nuts and bolts, securing the chain to the hoist body. Ensure that the chain is properly tensioned but not overly tight, as this can affect its operation.

Step 6: Lubricate the New Chain

Proper lubrication is crucial for the smooth operation and longevity of the new chain. Apply a generous amount of chain lubricant along the entire length of the chain, ensuring it penetrates the links. This will help reduce friction, prevent rust, and maintain optimal performance.

Step 7: Test the Lever Hoist

Before putting the lever hoist back into service, test its operation. Ensure that the chain moves freely along the sprocket and pulley, and that the hoist engages and disengages correctly. Perform a load test using a light load to verify that the hoist can lift and lower it smoothly and securely. Pay attention to any unusual noises or vibrations during the test.

Installing a new chain on a lever hoist is a task that can be accomplished by following a few simple steps. By gathering the necessary tools and materials, disconnecting the hoist, removing the old chain, preparing and attaching the new chain, lubricating it, and conducting a thorough test, you can ensure a successful chain replacement. 

Remember to prioritize safety by wearing protective gear and double-checking the hoist's functionality before using it with heavy loads. By properly maintaining and replacing the chain as needed, you can extend the life of your lever hoist and ensure its reliable performance in various lifting and pulling applications.

#AceIndustries #LeverHoist #NewChain #HoistInstallation

Author Craig Cappel

Craig Cappel has been an enthusiastic part of the sales team at Ace Industries since 2005. Craig participated in the Ace expansion into Texas in 2012, moving to Houston for the launch of the new Distribution warehouse and in 2015 returned to HQ in Georgia to lead the Business Development Center of Excellence. Craig’s focus has been on applications, managing projects ranging from industrial fab, offshore and oil & gas, to entertainment and production rigging. With a current role on the customer service team and website development and sales, Craig also oversees Ace’s in-house hoist repairs and warranty work.

Craig lives in the Atlanta suburbs with two large dogs, both huskies, and can be found painting on large canvases, listening to a broad playlist of music and dreaming of the Hawaii surf.