INTRODUCTION TMS700E SERVICE MANUAL
1-18 Published 01-29-2015, Control # 512-01
• Inspect for severely corroded, cracked, bent, worn, or
improperly applied end connections.
• Inspect wire rope in areas subjected to rapid
deterioration such as:
- Sections in contact with saddles, equalizer sheaves,
or other sheaves where wire rope travel is limited.
- Sections of wire rope at or near terminal ends where
corroded or broken wires may protrude.
- Sections of wire rope in contact with stationary
surfaces where abrasion or chafing may take place
as a result of equipment vibration.
• Inspect for damaged or wobbly boom extension and
retraction sheaves that may cause rapid deterioration of
the wire rope.
• Inspect for unusual cable sag/stretch and be sure cables
used in sets all have an equal tension applied. Repeated
need for adjustment of an individual cable is evidence of
cable stretch and indicates the need for additional and
more thorough inspection in order to determine and
correct the cause.
Wire Rope Replacement (All Wire Rope)
No precise rules can be given for determination of the exact
time for replacement of wire rope since many variable factors
are involved. Determination regarding continued use or
replacement of wire rope depends largely upon the good
judgement of an appointed and qualified person who
evaluates the remaining strength in a used rope after
allowance for any deterioration disclosed by inspection.
Wire rope replacement should be determined by the
following information excerpted from a National Consensus
Standard as referenced by Federal Government Agencies
and as recommended by Manitowoc Cranes. All wire rope
will eventually deteriorate to a point where it is no longer
usable. Wire rope shall be taken out of service when any of
the following conditions exist:
• In running ropes, six randomly distributed broken wires
in one lay or three broken wires in one strand in one lay.
• Wear of one-third the original diameter of outside
individual wires. Kinking, crushing, bird caging, or any
other damage resulting in distortion of the rope
structure.
• Evidence of any heat damage from any cause.
• Reductions from nominal diameter of more than 5%.
• In standing ropes, more than two broken wires in one lay
in sections beyond end connections or more than one
broken wire at an end connection.
• Manitowoc Cranes recommends that for cable extended
booms, a single damaged wire rope assembly shall
require replacement of the entire set of extension
cables.
• Manitowoc Cranes recommends for cable extended
booms, that boom extension cables be replaced every
seven (7) years.
Seizing Wire Rope
It is important to seize the ends of rotation resistant wire
ropes to prevent the displacement and unraveling of the
individual wires and strands at the ends. All preformed and
non-preformed styles of wire rope should be seized prior to
cutting. Seizings must be placed on both sides of the point
where the wire rope is to be cut.
The two preferred methods for seizing wire ropes are:
Method 1
Using a length of soft annealed wire, place one end in the
groove between two strands of the wire rope (see
Figure 1-4). Turn the long end of the annealed wire at right
angles to the wire and wrap it tightly over the portion in the
groove.
The two ends of the annealed wire should be twisted
together tightly. Cut off the excess wire and pound the twist
flat against the wire rope.
Method 2
Wind a length of soft annealed wire around the wire rope at
least seven times (see Figure 1-5 thru 1-6). The two ends
should be twisted together in the center of the seizing.
Tighten the seizing by alternately prying and twisting. Cut off
both ends of the wire and pound the twist flat against the
rope.
NOTE: Non-preformed wire rope should have two seizings
located on each side of the cut.
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