Manitowoc Published 09-10-14, Control # 065-24 5-11
14000 SERVICE MANUAL HOISTS
WIRE ROPE LUBRICATION
Refer to the Lubrication Guide in Section 9 of this manual for
recommendations.
WIRE ROPE INSPECTION AND
REPLACEMENT
The inspection and replacement guidelines which follow
comply with United States regulations.
It is impossible to predict when a wire rope will fail; however,
frequent and periodic careful inspection by a qualified
inspector will indicate when the potential for failure exists.
Keeping Records
A signed and dated report of the wire rope’s condition at
each periodic inspection must be kept on file at all times. The
report must cover all inspection points listed in this section.
The information in the records can then be used to establish
data which can be used to determine when a wire rope
should be replaced.
It is recommended that the wire rope inspection program
include reports on the examination of wire rope removed
from service. This information can be used to establish a
relationship between visual inspection and the rope’s actual
internal condition at the time of its removal from service.
Inspecting Wire Rope In Use
Frequent Inspection
Visually inspect all running ropes in service once each work
shift and observe the rope during operation. Pay particular
attention to areas of the rope where wear and other damage
is likely to occur:
• Pick-Up Points — sections of rope that are repeatedly
stressed during each lift, such as those sections in
contact with sheaves.
• End attachments — the point where a fitting is attached
to the rope or the point where the rope is attached to the
drum.
• Abuse points — the point where the rope is subjected to
abnormal scuffing and scraping.
Inspect all rope which can be reasonably expected to be in
use during operation for obvious damage which poses an
immediate hazard, such as the following:
• Rope distortion such as kinking, crushing, unstranding,
bird caging, main strand displacement, and core
protrusion
• Loss of rope diameter and unevenness of the outer
strands indicate that the rope should be replaced
• Corrosion (clean and lubricate)
• Broken or cut strands
• Broken wires (see Periodic Inspection for additional
information)
• Core failure in rotation resistant rope (indicated by lay
lengthening and reduction in diameter)
Periodic Inspection
The periodic inspection interval must be determined by a
qualified inspector and be based on the following factors:
• Expected rope life as indicated by the rope manufacturer
or past experience as determined by the qualified
inspector
• Severity of the environment the rope is operated in
• Size, nature, and frequency of lifts
• The rope’s exposure to shock loading and other abuse
• Rope maintenance practices
Periodic inspection must be performed at least annually.
During the periodic inspection, the entire length of rope must
be inspected for the following types of damage. Any damage
found must be recorded and a determination made as to
whether continued use of the rope is safe.
• All points listed under frequent inspection
• Reduction in rope diameter below the nominal diameter
caused by loss of core support, internal or external
corrosion, or wear of the outside wires
• Severely corroded or broken wires at end attachments
• Severely corroded, cracked, bent, worn, or improperly
applied end attachments
Inspecting Rope Not In Regular Use
Wire rope must be given a complete inspection if it has been
idle for a month or more due to shutdown or storage of the
crane on which the rope is installed. The inspection must be
performed by a qualified inspector looking for the damage
identified under both Frequent and Periodic Inspection.
Replacing Wire Rope
The final decision as to when a wire rope should be replaced
is the responsibility of the qualified inspector. Discovery of
the following conditions is sufficient reason for questioning a
wire rope’s safety and for replacing it.
Wire Rope Diameter
Measure and record the diameter of a new wire rope after
initial loading for comparison with future inspections. A
reduction in rope diameter is often the first outward sign that
the rope core is damaged.
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