A lever block — also called a lever hoist or chain lever block — is a manually operated mechanical device that uses a ratchet-and-pawl system and a Grade 80 load chain to lift, lower, pull, or tension loads. Unlike a chain block, which is designed for vertical lifting only, a lever block can apply force in any direction: vertically, horizontally, or at any angle. That versatility makes it the preferred tool for rigging, tensioning, positioning structural members, and any application where a chain block cannot reach or cannot apply force from the correct angle. Australian lever blocks must comply with AS 1418.2, which requires a self-sustaining mechanical brake, G80 load chain, and a minimum 4:1 design factor at the Working Load Limit (WLL).
What Is a Lever Block?
A lever block is a manually operated lifting and pulling device that generates mechanical advantage through a ratchet mechanism, a hardened load chain, and a geared load wheel. Working Load Limits in the AIMS range run from 750 kg to 6.3 t, and many brands extend to 9 t. The device is compact, portable, and can apply lifting or pulling force in any direction without fixed rigging infrastructure.
Naming: "Lever block" is the standard Australian term. "Lever hoist" is the US and international engineering equivalent — same device, different name. "Chain lever block" and "lever chain hoist" are also used interchangeably. This article uses "lever block" throughout, matching the standard used by Kito Crosby Australia, Garrick, Pacific, and Austlift.
What it is not: A lever block is not a chain block (chain block = vertical-only, operated by pulling a hand chain in a continuous loop). It is not a come-along (come-along = wire rope, lower load ratings, not rated for overhead lifting). These distinctions are covered in the comparison sections below.
Position in the lifting kit: In a well-equipped workshop or rigging kit, lever blocks and chain blocks serve different functions. Many riggers and maintenance tradespeople carry both: a chain block for heavy, direct vertical lifts from a fixed overhead point; a lever block for positioning, tensioning, angular pulls, and low-headroom environments. The two tools complement each other rather than compete.
How a Lever Block Works
A lever block converts back-and-forth lever movement into rotational movement at the load wheel via a ratchet-and-pawl mechanism. The load wheel drives the load chain up or down, one lever stroke at a time. The self-sustaining mechanical brake holds the chain in position whenever the lever is released — without any action by the operator.
Key components
- Operating lever: The handle moved back and forth. Lever length determines mechanical advantage — a longer lever requires less effort per stroke but more strokes to travel the same chain distance. Never add a pipe or cheater bar extension: this exceeds the designed mechanical advantage and can overload the ratchet mechanism.
- Load wheel (load sheave): A precisely machined grooved wheel sized to accept a specific chain pitch. The chain pockets must match the chain's grade and pitch exactly — a mismatched chain will not seat correctly and will jump under load.
- Ratchet and pawl: The ratchet wheel transmits motion in one direction only. The pawl drops into ratchet teeth to prevent reverse movement. Dual-pawl designs (standard on quality units) are more reliable under vibration and repeated use than single-pawl designs.
- Self-sustaining mechanical brake: A friction-plate brake that automatically holds the rated load without the operator gripping anything. The brake engages the moment the lever is released. It does not rely on the pawls alone — the brake holds the chain mechanically under static load indefinitely. AS 1418.2 requires this brake as a mandatory feature. Any lever block without a self-sustaining brake is non-compliant for workplace use in Australia.
- Load chain: Grade 80 (G80) hardened alloy steel chain. Each unit is factory proof-tested at 125% of WLL on this specific chain. Substituting a lesser-grade chain negates the WLL rating and creates an unquantified failure risk.
- Free chain function: A separate lever or knob that disengages the ratchet from the load wheel, allowing the chain to be fed in or out by hand without ratcheting through lever strokes. Critically: the brake remains engaged when free chain is active — the load does not drop. Free chain is a rapid positioning tool, not a load release mechanism.
- Direction selector: A three-position switch: Up (lift), Down (lower), and Neutral. Setting to Neutral locks the chain for storage and transport.
Overload response: When the load at the hook reaches or exceeds the WLL, the lever will not complete a full stroke — it slips. This is the designed safety response, not a mechanical failure. Never attempt to force the lever, add extension to it, or bypass this response. The lever block is telling you the load exceeds its rating.
When free chain is engaged, the ratchet disengages from the load wheel — but the mechanical brake remains fully engaged. The chain moves freely for rapid positioning, but the load cannot drop. This is one of the most misunderstood features in the field: many operators avoid using free chain because they believe it will release the load. It does not. Use it to take up slack quickly at the start of a lift, or to reposition chain before rigging.
Lever Block vs Chain Block: Which Do You Need?
A lever block and a chain block both use a hardened Grade 80 load chain to move a load, but they are designed for fundamentally different tasks. The critical difference is direction of pull: a chain block is designed for vertical lifting only; a lever block can apply controlled force in any direction. Choosing the wrong tool for the job is both a productivity problem and a safety issue.
| Factor | Lever Block | Chain Block |
|---|---|---|
| Pull direction | Any angle — vertical, horizontal, angular | Vertical only |
| Operation | One hand (lever motion) | Two hands (pulling hand chain continuously) |
| Headroom required | Low — compact body, short hook-to-hook dimension | Higher — hand chain must hang and be pulled downward |
| Portability | High — no loose hand chain to manage | Moderate — hand chain requires management to prevent tangling |
| Speed for long vertical travel | Slower — stroke by stroke | Faster — continuous hand chain pull |
| Maximum WLL (manual) | Typically up to 9 t | Up to 50 t (large models) |
| Precision positioning | Excellent — fine control per lever stroke | Good for vertical; limited off-axis |
| Best application | Pulling, tensioning, angular lifts, confined spaces | Direct vertical lifts from a fixed overhead point |
| Relative cost (same WLL) | Generally higher | Generally lower |
Decision rule:
- Pull is vertical, headroom is not a constraint → chain block
- Pull is horizontal, angular, or headroom is restricted → lever block
- One tool needed for a variety of applications across multiple sites → lever block
- Heavy, repetitive vertical lifts over long chain travel → chain block (faster hand chain operation)
Most sites with regular rigging work benefit from having both in the kit. The lever block handles positioning, tensioning, and non-vertical pulls; the chain block handles sustained overhead lifting.
AIMS stocks both: see chain block guide for the companion article, and browse lever blocks at AIMS.
Lever Block vs Come-Along: Key Differences
A come-along (also called a cable puller or hand winch) and a lever block are sometimes confused because both use a lever and both pull loads. The critical differences are the pulling medium, load rating, and — most importantly — whether the device is rated for overhead lifting.
| Factor | Lever Block | Come-Along (Cable Puller) |
|---|---|---|
| Pulling medium | Grade 80 steel load chain | Wire rope (cable) |
| WLL range | 750 kg to 9 t | Typically 500 kg to 4 t |
| Rated for overhead lifting? | Yes — AS 1418.2 certified | No — wire rope come-alongs are not rated for overhead lifting |
| Chain/cable wear visibility | Chain wear is visible and measurable | Internal wire rope strand failure may not be visible externally |
| Wet or corrosive environments | Chain resists corrosion better; G80 chain is identifiable by grade | Wire rope corrodes faster; internal strand failure is harder to detect |
| Long pulls | Limited by chain length (standard 1.5–3 m) | Longer cable drum available — suits long horizontal pulls |
| AS 1418.2 compliance | Yes | No — come-alongs are pulling/tensioning devices only |
See the come-along guide for full specifications on cable pullers.
WLL Ratings and Lever Block Sizes
WLL (Working Load Limit) is the maximum load a lever block is rated to lift or pull under normal service conditions, incorporating the 4:1 design factor required by AS 1418.2. It replaces the older term SWL (Safe Working Load) in current Australian standards — both terms refer to the same value. If you see SWL on an older piece of equipment, treat it identically to WLL.
Standard WLL sizes in Australia
| WLL | Typical application | Lever effort (approx.) | Standard chain lift |
|---|---|---|---|
| 750 kg | Light rigging, tensioning, auto workshops, small equipment positioning | ~200–250 N | 1.5 m |
| 1.5 t | General workshop, pipe pulling, machinery repositioning | ~250–320 N | 1.5 m |
| 3 t | Fabrication, structural steel, plant maintenance, civil construction | ~280–350 N | 1.5 m |
| 6 t | Heavy fabrication, mining, large equipment positioning | ~300–380 N | 1.5 m |
| 9 t | Heavy industry, offshore, large-scale rigging operations | ~350–400 N | 1.5 m |
How to select WLL: The required WLL is determined by the weight of the load and the rigging configuration. A common and dangerous mistake is selecting a lever block rated exactly to the load weight without accounting for sling angle. When two legs of a bridle sling support a load at an angle, each leg carries more than half the load weight. At a 60° included sling angle (30° from vertical per leg), each leg carries 58% of the load. At a 120° included angle (60° from vertical per leg), each leg carries 100% of the load. Excessive sling angles can double the effective load on the block.
Always select from the data plate — never by appearance. The WLL must be read from the permanently attached manufacturer's data plate on the unit. If the plate is missing or unreadable, the block is out of service until properly identified.
Grade 80 (G80) Chain — Why It Matters
The load chain in a lever block is not standard chain. It is Grade 80 (G80) — a high-alloy heat-treated steel chain with a minimum proof force of 2× WLL and a minimum breaking force of 4× WLL, establishing the 4:1 design factor required by AS 1418.2. These are tested minimums, not nominal values.
What G80 means: The grade number (80) refers to the minimum tensile strength in kg/mm² of the chain material. G80 = 800 MPa minimum tensile strength. G80 chain is typically yellow-passivated or painted orange/gold to distinguish it visually from lower grades. The link geometry and tolerances are tightly controlled so the chain seats correctly in the load wheel pockets.
Non-G80 chain will not work safely in a lever block. Standard chain types that must never be substituted include:
- G70 transport chain — used in vehicle load restraint tie-downs; lower tensile strength, different link geometry
- G43 high-test chain — used in agricultural and marine applications; not rated for overhead lifting
- Grade 30 proof coil chain — general-purpose hardware chain; not rated for any lifting application
- Builder's chain / farm chain — unrated; no defined minimum tensile or geometry standard
Substituting any of the above into a lever block removes the WLL rating entirely and creates an unquantifiable failure risk. The fact that the chain fits the load wheel does not mean it is safe — G43 and G70 chain can physically fit some G80 load wheels and still be fundamentally unsafe for overhead lifting.
Chain extension
Extending lever block chain beyond the factory length is possible but must be done correctly. Use matching-grade G80 chain of the same pitch and diameter as the original factory chain, connected with a rated G80 master coupling link (not a repair link — a coupling link designed for this purpose and rated to the same WLL). Chain extension must be confirmed as compatible with the specific hoist model by the manufacturer. Extension that is not manufacturer-approved voids the factory WLL guarantee.
Chain inspection and replacement
Replace the load chain when any of the following conditions are present:
- Link wire diameter reduced by 10% or more from nominal (measure with a vernier caliper or chain gauge)
- Any link shows visible cracking, bending, or deformation
- Corrosion pitting at the weld area of any link (the weld zone is the most stress-sensitive point)
- Chain has been shock-loaded (load dropped onto the chain suddenly)
- Chain jumped in the load wheel during operation — remove the entire chain for inspection, not just visual inspection of the affected link
AS 1418.2 — The Australian Standard for Lever Hoists
In Australian workplaces, lever hoists must comply with AS 1418.2 (Cranes, hoists and winches — Part 2: Serial hoists and winches, including manually operated appliances). This standard is referenced by the Work Health and Safety Regulations 2017 in all Australian states and territories. Compliance is not optional for workplace use.
What AS 1418.2 requires
| Requirement | Detail |
|---|---|
| Load chain grade | G80 minimum — Grade 80 alloy steel chain only |
| Design factor | 4:1 minimum at WLL for all load-bearing components |
| Factory proof test | 125% of WLL — every unit load-tested before dispatch; test certificate or compliance declaration required |
| Self-sustaining brake | Brake must hold rated load without operator holding the lever, indefinitely. Must engage automatically on lever release. |
| Positive latch hooks | Top and bottom hooks must have positive safety latches that prevent sling or chain from riding out under load |
| Data plate | Permanently affixed plate showing manufacturer name, model, WLL, and serial number. Must not be removed. |
| Free chain function | When engaged, chain must feed freely. Brake must remain engaged in free chain mode. |
WHS obligations: Under WHS Regulation 2017 (all jurisdictions), lifting equipment must be used in accordance with the manufacturer's instructions, maintained to the manufacturer's schedule, and inspected at the required intervals by a competent person. Inspection records must be kept and must include the date, inspector's name and qualifications, findings, and any remedial action taken.
What to verify when purchasing: Lever blocks sold in Australia at very low price points — particularly through general merchandise importers — may lack the self-sustaining brake specification, carry an unverified WLL, or have no test certificate. Before purchasing, confirm: (1) the unit carries a compliance declaration or test certificate to AS 1418.2; (2) the data plate is permanently attached; (3) the supplier can provide evidence of the factory proof test at 125% WLL.
AIMS stocks Challenger, Pacific, and Austlift lever blocks that meet AS 1418.2 requirements for Australian workplaces.
Lever Block Applications by Industry
Lever blocks are used wherever loads need to be moved, positioned, or tensioned without a fixed overhead crane, or where the pull direction is not vertical. The following are the most common Australian industrial applications.
Steel fabrication and structural work: Pulling beams into alignment before welding, tensioning turnbuckle bracing systems, positioning structural members in low-headroom bays. Single-handed lever operation leaves the other hand free for alignment and clamping work. Lever blocks are standard on fabrication shop floors across Australian manufacturing.
Mining and resources: Preferred over chain blocks in underground environments, on drilling rigs, and in equipment service bays with restricted access. Horizontal and angular pulling capability is essential in underground headings where overhead rigging is impossible. Mining-grade lever blocks must comply with relevant state mining regulations in addition to AS 1418.2. In Queensland and Western Australia, mining regulations specify additional documentation and inspection requirements for lifting equipment.
Marine and offshore: On ship decks, oil and gas platforms, and in engine rooms, the lever block's compact body and multi-directional pull make it the standard tool for moving heavy equipment in confined spaces. Stainless steel or hot-dip galvanised chain options are available for corrosive marine environments where standard zinc-passivated G80 chain would corrode rapidly.
Utilities and electrical infrastructure: Pulling cable through conduit, tensioning overhead lines, positioning transformer assemblies and switchgear. Precise positioning control — one lever stroke at a time — is particularly valuable in overhead line work where small incremental movements are required for alignment.
Plant maintenance: Repositioning heavy motors, gearboxes, pumps, and heat exchangers during overhaul without overhead crane access. A lever block rigged from a chain sling over a structural beam allows horizontal and angular pulls to slide or reposition plant items that a chain block cannot reach from a vertical angle.
Vehicle and equipment recovery: Recovering bogged vehicles or machinery in agricultural, construction, and off-road environments where horizontal pulling capability is required. Lever blocks are rated for controlled horizontal pulls. For dynamic shock-loaded recovery, a rated snatch block and synthetic rope system is preferred — lever blocks are designed for controlled static and quasi-static loading, not impact loading.
Lever blocks are lifting appliances, not load restraint devices. They are not designed or tested for the dynamic loading, vibration, and fatigue cycles of vehicle transport. Load restraint requires equipment rated under AS/NZS 4380 (ratchet straps) or AS 3775 (chain lashing systems). Using a lever block as a load restraint on a vehicle is a non-compliance with the NHVR Load Restraint Guide and creates a serious risk of load shift.
How to Use a Lever Block Safely
The sequence below applies to every lift. Most lever block incidents in Australian workplaces result from skipping steps in this procedure, not from equipment failure.
Before rigging
- Complete the pre-use inspection (see checklist below). If any item fails, do not use the block. Tag it out of service and arrange inspection or replacement.
- Confirm load weight. Never estimate. If the weight is unknown, consult the equipment data plate, engineering drawings, or use a load cell. Estimating routinely leads to WLL exceedances.
- Calculate load on the block. Account for sling angle if using a multi-leg bridle. For direct vertical lifts, load on the block = load weight. For angular configurations, apply the relevant angle factor.
- Select a lever block with WLL equal to or greater than the calculated load on the block. Do not select a block rated exactly to the load weight without the above calculation.
- Inspect the anchor point. The anchor must be rated to carry the full load. Use a rated G80 chain sling, rated shackle, or beam clamp as the connection — not rope, webbing sling (unless rated), or non-rated hardware.
Rigging and lifting
- Hook the top hook onto the rated anchor. Ensure the safety latch clicks fully closed and the hook is seated — not just the tip of the hook in contact with the sling.
- Attach the bottom hook to the load via a rated sling, shackle, or lifting lug. Confirm latch closure.
- Set the direction selector to Up.
- Use free chain if needed to take up slack quickly. Then take one lever stroke to tension the chain before lifting. Verify the load is connected correctly and the sling is not twisted or riding up the hook.
- Operate the lever with smooth, complete strokes. Jerky or partial strokes can cause ratchet skip on worn units.
- Do not add a cheater bar or pipe extension to the lever. If the lever won't move through a complete stroke, the load is at or beyond WLL. Stop, reassess.
- Keep the load chain in line with the intended pull direction relative to the load wheel. Side-loading the housing causes chain binding and, in severe cases, housing cracks.
Lowering and completing the job
- Set the direction selector to Down. Lower using lever strokes. Do not attempt to gravity-lower by disengaging the brake — the self-sustaining brake is a primary safety device. Always lower under control using the lever.
- Lower the load fully. Never leave a load suspended from a lever block unattended.
- Set the direction selector to Neutral. This protects the ratchet mechanism during storage.
- Coil and secure the load chain. Store away from acids, solvents, and high-humidity environments.
Pre-Use Inspection Checklist
A pre-use inspection must be completed before every lift. It takes under two minutes. If any item cannot be confirmed as satisfactory, the lever block must be tagged out of service.
| Item | What to check | Reject if |
|---|---|---|
| Data plate | Present, readable, WLL clearly marked | Missing, illegible, or removed |
| Load chain — condition | All links intact, no bending, twisting, or visible cracks. No corrosion pitting at weld zones. Chain runs freely through load wheel. | Any deformation, cracking, or pitting visible |
| Load chain — wear | Measure link wire diameter across several links. Compare to manufacturer's nominal. Use a chain gauge or vernier caliper for accurate measurement. | Wire diameter reduced by 10% or more from nominal |
| Top hook | No deformation, crack, or twist. Safety latch springs fully closed and returns positively. Hook throat not visibly widened. | Latch broken, bent, or missing. Hook throat widened. |
| Bottom hook | Same as top hook | Same as top hook |
| Housing | No cracks, visible damage, or missing cover plates. Pay particular attention to the load wheel aperture area — this is where housing cracks first appear from side-loading or overloading. | Any housing crack or structural damage |
| Brake function | With a small test load on the hook, take one lift stroke. Release the lever. Load must not drift or lower. Hold for 30 seconds. | Any downward movement with lever released = brake failure. Remove from service immediately. |
| Free chain function | Engage free chain. Chain should feed freely by hand. Release free chain — ratchet re-engages and brake holds. | Chain does not move freely, or ratchet fails to re-engage cleanly |
| Direction selector | Moves cleanly between Up / Down / Neutral positions. No sticking or ambiguous positions. | Stiff, missing, or damaged selector |
| Operating lever | Straight, not bent or cracked. Full range of motion. | Any bend, crack, or damage to the lever — do not use a lever block with a bent operating lever under any circumstances |
Periodic inspection by a competent person: In addition to pre-use checks, lever blocks used in Australian workplaces must be inspected at intervals not exceeding 12 months, or more frequently based on frequency and severity of use. High-use equipment in mining and construction typically warrants 6-monthly formal inspection. Inspection records must be maintained and include: date, inspector's name and competency credentials, findings, and any remedial action taken. Keep records for the life of the equipment.
Common Problems and Troubleshooting
Most lever block failures in the field are caused by operator error, deferred maintenance, or incorrect equipment selection — not by inherent mechanical defect. The table below covers the most frequently encountered problems.
| Problem | Most likely cause | Action |
|---|---|---|
| Lever won't complete a stroke / slips under load | Load at or beyond WLL — the designed overload response | Stop immediately. Do not apply more force or add a cheater bar. Reassess load weight and sling configuration. Use a higher WLL block if the load genuinely requires it. |
| Brake slips — load lowers when lever released | Brake friction surfaces contaminated with oil, grease, or water; worn or glazed brake discs | Remove from service. Disassemble, clean brake components with degreaser, inspect discs for scoring and glazing. Replace worn discs. Never apply lubricant to brake friction surfaces — brake must run dry. |
| Chain jumps or skips in load wheel | Chain installed backwards (weld facing sprocket); wrong chain grade or pitch installed; worn load wheel pockets; debris in load wheel pocket | Stop immediately — chain jumping is a discard-from-service trigger. Inspect chain orientation (welds must face away from the sprocket), check chain grade and pitch, clean load wheel, measure chain for wear. |
| Handle is stiff or hard to pull | Dirt or corrosion in lever pivot mechanism; brake dragging from contaminated friction surfaces; internal gearing damaged from overloading | Clean and lubricate lever pivot points. Inspect brake for contamination. If internal gearing is suspected, return to service centre. |
| Free chain won't engage, or chain won't feed freely | Dirt or corrosion in free chain mechanism; debris lodged in load wheel pocket; mechanism damaged | Clean mechanism. Do not force. If mechanism is damaged, return to manufacturer's service centre. |
| Chain stiff or corroded | Stored without cleaning in wet or corrosive environment | Clean chain with degreaser, inspect every link for pitting. Apply light chain oil (not heavy grease on load-bearing sections, which attracts grit). If pitting is present, measure and assess against 10% wear discard criterion. |
| Ratchet skipping (click but no chain advance) | Worn ratchet teeth or pawl tip; single-pawl unit with worn pawl | Remove from service. Ratchet and pawl replacement required — this is not a field repair. |
| Hook latch not closing | Bent latch spring; damaged latch seat from side-loading | Remove from service. Hook assembly replacement required — latches cannot be field-repaired. |
When to permanently retire a lever block
Retire from service when any of the following conditions are present: chain wear exceeding 10% of nominal link diameter; any hook crack, deformation, or latch failure that cannot be repaired; housing cracks (particularly near the load wheel aperture); a brake that cannot be restored to full rated hold after cleaning and disc replacement; ratchet/pawl wear with no manufacturer spare parts available; or a missing/illegible data plate where the WLL cannot be verified from manufacturer documentation.
Lever Block Maintenance and Storage
Lever blocks require modest maintenance — but units that are not maintained fail unpredictably in service. A consistent maintenance schedule extends service life by years and prevents the majority of field failures.
After every use
- Clean the load chain with a rag or stiff brush to remove grit, concrete dust, mud, and surface contaminants.
- Set the direction selector to Neutral.
- Coil the load chain carefully and hang the unit from its top hook, or store in a dedicated bag. Never leave chain piled on the floor where it can be run over, corroded, or contaminated.
Every 6–12 months (or per manufacturer schedule)
- Disassemble and clean brake components. Inspect friction discs for wear, scoring, and glazing. Replace discs showing glazing or measurable wear reduction. Reassemble brake dry — no lubricant on brake surfaces.
- Lubricate lever pivot point, ratchet wheel shaft, and load wheel bearings with a light machine oil per manufacturer's specification. Do not apply lubricant to brake friction surfaces.
- Apply a light coat of chain oil to the load chain — a light penetrating lubricant is preferred. Heavy grease attracts grit and clogs load wheel pockets.
- Inspect all hooks, housing, chain, and mechanism. Record inspection findings.
Storage environment: Store away from acids, solvents, chlorine compounds, and high-humidity environments. For extended storage, apply a protective light oil to the chain and wrap in a clean cloth. Do not store with the chain under tension.
AIMS Lever Block Range and Buying Guide
AIMS stocks lever blocks from Challenger, Pacific, and Austlift — all suitable for Australian industrial applications. The following checklist covers what to specify when ordering.
1. WLL: Determine the required WLL based on load weight and rigging configuration (see WLL section above). If in doubt, go up one WLL size — a 3 t block will not perform worse than a 1.5 t block on a 1 t load; it will simply weigh slightly more.
2. Chain lift distance: Standard lever blocks come with 1.5 m of load chain, which suits the majority of workshop and rigging applications. Longer lift models (to 3 m) are available where greater reach is required. Confirm the required reach before ordering — adding chain extension post-purchase is possible but requires matched-grade components.
3. Environment: Standard units suit dry and lightly damp environments. For marine, offshore, or chemical environments, specify stainless chain or hot-dip galvanised chain options where available. Confirm operating temperature range if the unit will be used in cold-store, FGAS, or high-temperature environments.
4. Top hook configuration: Standard top hooks suit most applications where a chain sling or rated beam connection is available. Beam clamp or hook clamp top connections are available where a standard hook anchor is not practical.
5. Certification: Confirm that a test certificate or compliance declaration to AS 1418.2 is included with the unit. This document is required for your equipment inspection records and for WHS compliance.
Not sure which model suits your application? Contact the AIMS team — we can confirm the right WLL and configuration for your job.
Browse the AIMS lever block range — in stock, ready to dispatch.
Frequently Asked Questions
What is the difference between a lever block and a lever hoist?
Nothing — they are the same device with different regional names. "Lever block" is the standard Australian term, used by Kito Crosby Australia, Garrick, Pacific, Austlift, and most local suppliers. "Lever hoist" is the US and international engineering term. Both describe a manually operated ratchet-and-load-chain device that can lift, lower, pull, or tension a load in any direction.
What is the difference between a lever block and a chain block?
The critical difference is the direction of pull. A chain block is designed for vertical lifting only — it is operated by pulling a continuous hand chain in a loop and is intended for use directly beneath a fixed overhead anchor. A lever block operates via a lever ratchet mechanism and can apply force vertically, horizontally, or at any angle. Chain blocks are generally faster for long vertical lifts and available in higher WLL ratings (to 50 t). Lever blocks are more portable, require less headroom, and are the correct tool for any non-vertical application.
What is the difference between a lever block and a come-along?
A come-along (cable puller or hand winch) uses a wire rope drum rather than a load chain. The most critical difference is that come-alongs are not rated for overhead lifting — they are pulling and tensioning devices only. A lever block uses Grade 80 load chain, is factory proof-tested at 125% WLL, and complies with AS 1418.2 for overhead lifting. For any overhead or vertical lifting application in an Australian workplace, use a lever block or chain block — not a come-along.
How does a lever block work?
A lever block converts back-and-forth lever movement into rotational movement at a load wheel via a ratchet-and-pawl mechanism. The load wheel drives a Grade 80 load chain up or down, one stroke at a time. A self-sustaining mechanical brake automatically holds the chain in position whenever the lever is released — the load does not move until the operator actively operates the lever. The free chain function (separate lever or knob) disengages the ratchet so the chain can be repositioned by hand quickly, but leaves the brake fully engaged so the load remains held.
What WLL lever block do I need?
The required WLL depends on both the weight of the load and the rigging configuration. For a direct, single-point vertical lift, the WLL must equal or exceed the load weight. For angular configurations (multi-leg slings, horizontal pulls, or angled pulls), calculate the actual load on the block using the relevant sling angle factor — angular loads can significantly exceed the nominal load weight. Select the next WLL size up if you are between sizes or uncertain about the weight.
Can I use a lever block horizontally or at any angle?
Yes — this is the defining advantage of a lever block over a chain block. A lever block can apply force vertically, horizontally, or at any angle. The self-sustaining brake holds the load statically regardless of pull direction. When using a lever block horizontally or at an angle, ensure the anchor point is rated for the direction and magnitude of force applied, and that the load wheel is in line with the direction of pull — side-loading the housing can cause chain binding and housing damage.
What is the free chain function and when should I use it?
The free chain function disengages the ratchet from the load wheel, allowing the load chain to be fed in or out by hand without operating the lever. The mechanical brake remains engaged when free chain is active — the load does not drop. Use it to take up slack quickly before starting a lift, or to reposition the chain length before rigging. Do not confuse free chain with a load release mechanism — it is a positioning aid only. After using free chain, re-engage the ratchet before taking the first lift stroke.
What is Grade 80 (G80) chain and why do lever blocks need it?
Grade 80 (G80) is a high-alloy heat-treated steel chain with a minimum tensile strength of 800 MPa. AS 1418.2 mandates G80 chain in lever hoists because its minimum breaking force of 4× WLL provides the required 4:1 design factor for overhead lifting equipment. G80 chain also has precisely controlled link geometry so it seats correctly in the load wheel pockets — non-rated chains (G43, G70, proof coil) cannot reliably seat in a G80 load wheel and will jump under load. The factory proof test at 125% WLL is conducted on the specific G80 chain supplied with the unit. Substituting any other chain grade negates the WLL and AS 1418.2 compliance.
My lever block won't lift the load — what's wrong?
The most common cause is that the load exceeds the WLL — the lever slip-out is the designed overload protection response, not a mechanical failure. Verify the actual load weight (do not estimate), check that sling angles are not multiplying the effective load on the block, and confirm you are using the correct WLL rating. If the load is genuinely within the WLL and the lever still slips, the brake friction surfaces may be contaminated with oil or grease, causing the brake to slip instead of hold — remove the unit from service for brake inspection and cleaning.
Why is the lever block handle stiff or hard to pull?
Two common causes: first, dirt or corrosion has accumulated in the lever pivot and internal mechanism — clean the mechanism and apply a light machine oil to the pivot points (not the brake). Second, the brake friction surfaces are contaminated or dragging — contaminated brakes make the lever work hard in the lifting direction as the brake partially engages against the load. Clean brake components with degreaser, reassemble dry. If internal gearing has been damaged from overloading, return the unit to a service centre.
What does AS 1418.2 require for lever hoists in Australia?
AS 1418.2 requires that lever hoists used in Australian workplaces: use Grade 80 (G80) load chain; are designed to a minimum 4:1 factor at WLL for all load-bearing components; are factory proof-tested at 125% of WLL before dispatch; incorporate a self-sustaining mechanical brake that holds the rated load automatically without operator intervention; are fitted with positive-latch hooks on both top and bottom connections; and carry a permanently affixed data plate showing the manufacturer, model, WLL, and serial number. These requirements are not met by many low-cost imported lever blocks — verify compliance documentation before purchasing for workplace use.
How often should a lever block be inspected in Australia?
A pre-use visual and functional inspection must be completed before every lift. In addition, a formal periodic inspection by a competent person is required at intervals not exceeding 12 months under WHS Regulation 2017. For high-frequency or high-intensity use — including mining, construction, and offshore environments — 6-monthly formal inspection is strongly recommended. Inspection records must be maintained for the life of the equipment, including date, inspector's name and competency credentials, findings, and any remedial action.
What is the difference between WLL and SWL on lever blocks?
WLL (Working Load Limit) and SWL (Safe Working Load) refer to the same value — the maximum load the device is rated to handle under normal service conditions. WLL is the current Australian and international standard term, used in AS 1418.2 and all current equipment standards. SWL is the older terminology that still appears on legacy equipment and older technical drawings. If you see SWL on an older lever block, treat it identically to WLL. The 4:1 design factor is incorporated into both terms — you do not need to apply an additional safety factor on top of the rated WLL/SWL.
Can I use a lever block for load restraint on a vehicle?
No. Lever blocks are lifting appliances, not load restraint devices. They are not designed or tested for the dynamic loading, vibration, and fatigue cycles of vehicle transport. The NHVR Load Restraint Guide and AS/NZS 4380 (ratchet straps) and AS 3775 (chain lashing systems) govern load restraint — these are entirely separate product standards. Using a lever block as a vehicle load restraint is non-compliant with transport regulations and creates a serious risk of load shift in transit.
How do I know when to retire a lever block from service?
Retire a lever block from service when any of the following conditions are present: load chain link diameter worn more than 10% below nominal; any visible crack, deformation, or twisting in any chain link; hook throat visibly widened, cracked, or latch inoperable; housing cracks, particularly near the load wheel aperture; brake that cannot be restored to full rated hold after cleaning and disc replacement; ratchet or pawl wear with no manufacturer spare parts available; or a missing or illegible data plate where the WLL cannot be verified. There is no defined service life in years — retirement is condition-based, not calendar-based.
Cross-reference our Socket Size Chart when sizing a socket — metric, SAE, drive size and all.
