CHAIN BLOCK

INSTRUCTION
MANUAL
Imported exclusively by Pacific Hoists Pty. Ltd. & Pacific Hoists Ltd.
In support of cancer charities in Australia & New Zealand
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 IMPORTANT
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

INTRODUCTION
Thank you for purchasing your new Challenger Chain 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. Choosing the Challenger
brand also directly supports cancer charities in Australia.

It is important that this manual be kept in a safe place where any operator of the Challenger
Chain Block can refer to it and understand the operating principles of this device. All users of
this Challenger Chain Block should read this manual in full and understand the safe operating
principles of the device.

FEATURES
FEATURES OF THE CHALLENGER CHAIN BLOCK INCLUDE THE FOLLOWING:
■ Designed in accordance with European Standard EN13157 & AS1418.2
■ Improved braking performance to ensure the integrity of the load under all conditions
■ Design improvements result in 25% less operator effort to lift the rated load
■ Safety of design has been prioritised to alleviate unexpected accidents
■ 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 Challenger Chain Blocks are individually load tested in accordance with AS1418.2

A comprehensive range of spare parts is readily available.

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 SPECIFICATIONS

500kg / 1t / 2t

3t / 5t

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 SPECIFICATIONS CONT.
Model CCB103 CCB106 CCB113 CCB116
Rated 500kg 1t
Capacity
Lifting height (m) 3 6 3 6
Test load (kg) 750 1500
Hand force when fully
210 285
loaded (N)
No. of load chain falls 1
Load chain Grade 80 Ф5X23.7
(mm)
Minimum distance be-
tween hooks - Head- 280 330
room (mm) H
Hand chain drop (m) 2 5 2 5
Dimension (mm)
128 142
A
B 75 76
C 130 150
D 20 25
E 22 26
Net weight 9 10 12 16

* 1.5t model chain block not available in Australia.

** optional overload available upon request.

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 SPECIFICATIONS CONT.
Model CCB123 CCB126 CCB133 CCB136 CCB153 CCB156
Rated Capacity 2t 3t 5t
Lifting height (m) 3 6 3 6 3 6
Test load (kg) 3000 4500 7500
Hand force when fully
355 340 400
loaded (N)
No. of load chain falls 1 2 2
Hand chain (mm) Ф5X23.7
Minimum distance be-
tween hooks - Headroom 385 510 615
(mm) H
Hand chain drop (m) 2 5 2 5 2 5
Dimension (mm)
175 158 183
A
B 88 80 90
C 186 220 255
D 33 36 43
E 35 37 43
Net weight 20 25 23 29 39 50

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 PRE-START CHECKLIST
REGULAR INSPECTION OF YOUR CHALLENGER CHAIN 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 chain block is correctly suspended from a suitable support which keeps the load
chain off the ground whilst in storage
■ Ensure the selected chain block is the correct capacity to perform the task required
■ Handle your chain 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 free-wheel knob rotates freely without jamming

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 ON SITE CHECKS
THERE ARE A NUMBER OF CHECKS RECOMMENDED WHEN USING

THE CHALLENGER CHAIN BLOCK ON SITE:

■ Chain blocks must only be used for vertical lifting

instruction manual and understood the operation of the device before its use.
■ Follow all site safety rules where applicable in relation to the movement of suspended loads
■ It is recommended that the chain 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 load capacity rating of the chain block
■ Check that labelling and/or identification is correct and legible
■ Ensure the Pre-Start Check List, as shown previously, has been conducted
■ Make sure that no oil and/or grease makes contact with the braking system of the chain

block
■ Check the environment and locality of the job for hazards to ensure personnel safety for
intended use.
■ Check that the load connection point, where the chain 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 chain 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 chain 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 chain block and load assembly, including any rigging, before continuing the lift
■ The operator should always have a clear view of the complete travel path of the load

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■ Ensure that the load will not be suspended from the chain block for any extended period of time
without secondary restraint. It’s 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

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 GENERAL PRECAUTIONS
■ Always understand the operation of the lifting device before putting it to use
■ Always ensure you are working within the required guidelines of Workplace Health and
Safety regulations relevant to the task being undertaken
■ Never use a chain block to lift a load greater than its rated capacity
■ Always check for personnel within the work area and DO NOT use chain blocks to suspend
loads over people
■ Never use chain blocks for lifting or transporting people under any circumstances
■ Never use the load chain of a chain block to wrap around the load
■ Never operate a chain block with a kinked or twisted load chain
■ Always keep control of the load and do not allow it to swing excessively
■ Avoid shock loading the chain block as it may seriously damage the operating system. If this
occurs, remove the device from use and return it to your supplier for inspection
■ 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
■ Chain blocks are designed for manual use only and must not be converted for power
operation in any way
■ Never modify your chain block from its designed configuration in any way
■ Ensure only the original manufacturers’ spare parts are used in the repair of any chain block
■ Replace any load chain with original manufacturers specified chain only
■ Galvanising or plating of load chain or load bearing parts is not recommended without the
express approval of the supplier
■ Never replace a worn load chain without having the chain block inspected by a qualified

technician.

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 OPERATING INSTRUCTIONS
The Challenger Chain Block has been designed for manual operation only. It utilises a hand chain
to drive a series of gears via a unique braking system to raise and lower a load vertically.

■ Suspend the chain block into the required position to perform the lifting operation, ensuring
the top hook is positioned correctly with the safety latch engaged as required
■ To raise the bottom hook, pull down on the hand chain to rotate the hand chain wheel in a
clockwise direction (looking from the hand wheel cover side)
■ Continuously pulling the hand chain in this direction using a “hand over hand” method will
raise the bottom hook until you have it in the required position
■ To lower the bottom hook, pull down on the hand chain to rotate the hand chain wheel in a
anti-clockwise direction, (looking from the hand wheel cover side)
■ Continuously pulling the hand chain using the above mentioned “hand over hand” method
will either raise or lower the bottom hook into the position required to fix the load
■ Fitment of the load to the lower hook needs care to ensure the safety latch is engaged into
the closed position, thereby securing the load to the chain block
■ Start the lifting process carefully, and once the load is just clear, stop and check the integrity
of the chain block, the load assembly (including any rigging gear) and that the load path is
clear before continuing the lift
■ Lift the load until the required height is achieved
■ Before commencing lowering of the load, ensure that the load path is clear and unobstructed
■ Releasing the hand chain in either direction will stop the load movement and the braking
system will hold the load in that position
■ The desired operation is a smooth hand over hand movement when raising or lowering a load
and excessive speed is not recommended in either direction
■ Once the load is in the desired position, release the pressure on the load chain further by
pulling the hand chain to rotate the hand wheel in the anti-clockwise direction
■ After ensuring the load has been placed safely and securely, release the safety latch of the
bottom hook and remove it from its suspension point
■ After removing the chain block from use, a visual inspection should be performed to cover
the points listed in the Pre-Start Check List previously described

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 SPARE PARTS
FOR 500KG - 5 TONNE
MODELS

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 SPARE PARTS
FOR 500KG MODEL
CODE NO DESCRIPTION CODE NO DESCRIPTION
710050 1 Gear cover assy 710071 27 Positioned plate
710051 2 Disc gear assy 710072 32 Nameplate
710052 3 Drive shaft CHN100 41 Load Chain mm 5 x 15
710053 4 Splined gear 710073 42 End anchor
710054 5 Right side plate assy 710074 43 End anchor pin
710055 6 Load chain sprocket 710075 44 Protected plate
710056 9 Top hook shaft 710076 45 Warning plate assy
710057 11 Chain stripper 710077 46 Top hook assy
710058 13 Guide roller 710078 47 Safety latch assy
710059 14 Left side plate assy 710079 61 Bottom hook assy
710060 15 Pawl spring 710080 62 Hook shaft
710061 16 Pawl 710081 63 Steel wire retainer
710062 17 Brake seat 710082 64 Bush
710063 19 Friction plate 710083 71 Metal lock nut M8
710064 20 Ratchet wheel 710084 72 Metal lock nut M8
710065 21 Brake cover 710085 73 Circlip 22
710066 22 Hand chain wheel 710086 74 Circlip 10
710067 23 Thrust washer 12x26x1 710087 75 Cross head screw M4x10
710068 24 Thrust bearing 12x26x2 710088 76 Split retainer 5
710069 25 Step washer 710089 78 Nameplate 2.5x6
710070 26 Hand chain cover 710090 79 Split pin 2x16
710091 80 Hexagon recess nut M8
710092 81 Cross head nut M6x22
710093 82 Metal locked nut M6

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 SPARE PARTS
FOR 1 TONNE MODEL
CODE NO DESCRIPTION CODE NO DESCRIPTION
710100 1 Gear cover assy 710121 27 Positioned plate
710101 2 Disc gear assy 710122 32 Nameplate
710102 3 Drive shaft CHN112 41 Load Chain mm 6.3 x 19.1
710103 4 Splined gear 710123 42 End anchor
710104 5 Right side plate assy 710124 43 End anchor pin
710105 6 Load chain sprocket 710125 44 Protected plate
710106 9 Top hook shaft 710126 45 Warning plate assy
710107 11 Chain stripper 710127 46 Top hook assy
710108 13 Guide roller 710128 47 Safety latch assy
710109 14 Left side plate assy 710129 61 Bottom hook assy
710110 15 Pawl spring 710130 62 Hook shaft
710111 16 Pawl 710131 63 Steel wire retainer
710112 17 Brake seat 710132 64 Bush
710113 19 Friction plate 710133 71 Metal lock nut M8
710114 20 Ratchet wheel 710134 72 Metal lock nut M8
710115 21 Brake cover 710135 73 Circlip 26
710116 22 Hand chain wheel 710136 74 Circlip 10
710117 23 Thrust washer 15x28x2 710137 75 Cross head Screw M4x10
710118 24 Thrust bearing15x28x2 710138 76 Split retainer 6
710119 25 Step washer 710139 78 Nameplate 2.5x6
710120 26 Hand chain cover 710140 79 Split pin 2.5x25
710091 80 Hexagon recess nut M10
710092 81 Cross head nut M6x25
710093 82 Metal locked nut M6

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 SPARE PARTS
FOR 2 TONNE MODEL
CODE NO DESCRIPTION CODE NO DESCRIPTION
710200 1 Gear cover assy 710221 27 Positioned plate
710201 2 Disc gear assy 710222 32 Nameplate
710202 3 Drive shaft CHN107 41 Load Chain mm 8x24
710203 4 Splined gear 710223 42 End anchor
710204 5 Right side plate assy 710224 43 End anchor pin
710205 6 Load chain sprocket 710225 44 Protected plate
710206 9 Top hook shaft 710226 45 Warning plate assy
710207 11 Chain stripper 710227 46 Top hook assy
710208 13 Guide roller 710228 47 Safety latch assy
710209 14 Left side plate assy 710229 61 Bottom hook assy
710210 15 Pawl spring 710230 62 Hook shaft
710211 16 Pawl 710231 63 Steel wire retainer
710212 17 Brake seat 710232 64 Bush
710213 19 Friction plate 710233 71 Metal lock nut M10
710214 20 Ratchet wheel 710234 72 Metal lock nut M8
710215 21 Brake cover 710235 73 Circlip 30
710216 22 Hand chain wheel 710236 74 Circlip 10
710217 23 Thrust washer 17x30x1 710237 75 Cross head screw M6x10
710218 24 Thrust bearing 17x30x2 710238 76 Split retainer 8
710219 25 Step washer 710239 78 Nameplate 2.5x6
710220 26 Hand chain cover 710240 79 Split pin 2.5x25
710241 80 Hexagon recess nut M12
710242 81 Cross head screw m6x25
710243 82 Metal locked nut M6

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 SPARE PARTS
FOR 3 TONNE MODEL
CODE NO DESCRIPTION CODE NO DESCRIPTION
710250 1 Gear cover assy 710271 27 Positioned plate
710251 2 Disc gear assy 710272 32 Nameplate
710252 3 Drive shaft CHN415 41 Load Chain mm 7.1 x 21
710253 4 Splined gear 710273 42 End anchor
710254 5 Right side plate assy 710274 43 End anchor pin
710255 6 Load chain sprocket 710275 44 Protected plate
710256 9 Top hook shaft 710276 45 Warning plate assy
710257 11 Chain stripper 710277 46 Top hook assy
710258 13 Guide roller 710278 47 Safety latch assy
710259 14 Left side plate assy 710279 48 Bottom hook pin
710260 15 Pawl spring 710280 61 Bottom hook assy
710261 16 Pawl 710281 63 Bottom hook connector
assy
710262 17 Brake seat
710282 64 Idler sheave assy
710263 19 Friction plate
710283 71 Complete metal locked
710264 20 Ratchet wheel
nut M8
710265 21 Brake cover
710284 72 Complete metal locked
710266 22 Hand chain wheel nut M8
710267 23 Thrust washer 15x28x1 710285 73 Circlip 30
710268 24 Thrust bearing 15x28x2 710286 74 Circlip 10
710269 25 Step washer 710287 75 Cross recess head screw
M6x10
710270 26 Hand chain cover
710288 76 Split retainer 6
710294 86 Metal locked nut M8
710289 78 Nameplate 2.5x6
710295 87 Metal locked nut M8
710290 79 Split pin 2.5x25
710296 88 Hexagon head bolt M8x20
710291 80 Hexagon recess nut M10
710292 81 Cross head screw M6x25
710293 82 Metal locked nut M6

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 SPARE PARTS
FOR 5 TONNE MODEL
CODE NO DESCRIPTION CODE NO DESCRIPTION
710300 1 Gear cover assy 710321 27 Positioned plate
710301 2 Disc gear assy 710322 32 Nameplate
710302 3 Drive shaft CHN435 41 Load Chain mm 9x27
710303 4 Splined gear 710323 42 End anchor
710304 5 Right side plate assy 710324 43 End anchor pin
710305 6 Load chain sprocket 710325 44 Protected plate
710306 9 Top hook shaft 710326 45 Warning plate assy
710307 11 Chain stripper 710327 46 Top hook assy
710308 13 Guide roller 710328 47 Safety latch assy
710309 14 Left side plate assy 710329 48 Top hook pin
710310 15 Pawl spring 710330 61 Bottom hook assy
710311 16 Pawl 710331 63 Bottom hook connector
assy
710312 17 Brake seat
710332 64 Idler sheave assy
710313 19 Friction plate
710333 71 Metal locked nut M12
710314 20 Ratchet wheel
710334 72 Metal locked nut M8
710315 21 Brake cover
710335 73 Circlip 30
710316 22 Hand chain wheel
710336 74 Circlip 10
710317 23 Thrust washer 17x30x1
710337 75 Cross head screw M6x10
710318 24 Thrust bearing 17x30x2
710338 76 Split retainer 9
710319 25 Step washer
710339 78 Nameplate 2.5x6
710320 26 Hand chain cover
710340 79 Split pin 2.5x25
710344 86 Metal locked nut M10
710341 80 Hexagob recess nut M10
710345 87 Hexagon head bolt M10x25
710342 81 Hexagon head bolt M8x35
710346 88 Metal locked nut m10
710343 82 Metal locked nut M8

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 MAINTENANCE
It is the responsibility of the owner/operator to ensure chain blocks are maintained and tested in
accordance with AS1418.2. Regular maintenance is vital in upkeeping the efficiency of the chain
blocks and also maximises their lifetime.
■ Only authorised personnel should undertake to do 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 chain block should be referred to an authorised
or qualified person for a more thorough examination, servicing and testing:

■ Evidence of possible wear to hooks and fittings

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 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
qualified to undertake Service, Repairs and Testing

GENERAL SERVICE
ITEM CHECK INSPECTIONS INSPECTIONS
Slipping under load or difficulty
Brake Assembly X X
of release
Glazing or score marks. Oil or
Brake Disc X
contamination
Pawl: Ratchet Worn or damaged X
Engagement, corrosion,
Pawl: Spring X
stretching
Top and Bottom Hooks Corrosion, deformation X X
Hook Retaining Components
Not tight or secure X X
Nuts, Bolts, Pins
Hook Latches Damaged, do not engage X X
Suspension Members, Sheaves,
Hand Wheels, Chain Guides,
Wear, cracks, elongation X X
Attachments, Suspension Pins
and Bolts
Distortion, worn or broken
Gears X
teeth, lack of lubrication
Grade, wear, elongation,
Load Chain twisted or damaged, lack of X X
lubrication
Bent, damaged, select lever
Handle, Assembly X X
functional
Covers, Labelling Removed, damaged or illegible X X

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 INSPECTION LOG

INITIAL SERVICE DATE: SERIAL NO:

DATE NOTES AUTH SIGNATURE

Imported exclusively by Pacific Hoists Pty. Ltd. and Pacific Hoists Ltd.
For further information in relation to this product,
please contact the branch where the product was purchased.

HEAD OFFICE
24 Foundry Road, Seven Hills NSW 2147
National Sales & Service P: 02 8825 6900
www.pacifichoists.com.au

Thank you for choosing the Challenger brand. Not only are you
choosing a quality and reliable brand but you are also helping
to support cancer charities in Australia & New Zealand.

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