Manitowoc Published 09-09-16, Control # 229-09 5-75
MLC650 SERVICE/MAINTENANCE MANUAL HOISTS
WIRE ROPE INSPECTION AND
REPLACEMENT
The following information is from various wire rope
manufacturers and includes inspection, replacement, and
maintenance guidelines for wire rope as established by
ANSI/ASME B30.5, federal regulations, and Manitowoc
Cranes.
Wire Rope Lubrication
Refer to the lube folio for lubrication techniques.
A high-quality wire rope lubricant is available from the
Manitowoc Crane Care Lattice Team. Otherwise, consult
your wire rope supplier.
Maintain a Wire Rope Condition Report
Always keep on file a signed and dated periodic inspection
report of the wire rope’s condition. The report must cover all
inspection points discussed in this section. The information
in the reports can then be used to determine when a wire
rope should be replaced.
After initial loading of a new rope, measure and record its
diameter for comparison with future inspections. Measure
the rope’s diameter across the crowns of the strands so the
true diameter is measured (Figure 5-43
).
Wire rope removed from service should be examined and a
corresponding report should be kept. 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. See Replacement Criteria on page 5-
77 for inspection guidelines.
Required Inspection Intervals
The frequency of wire rope inspection must be:
• Daily (see Daily Inspection on page 5-75
) and
• Yearly (at minimum) (see Periodic Comprehensive
Inspection on page 5-77)
Wire Rope Care and Replacement Guidelines
• When replacing fixed-length wire rope assemblies (such
as pendants) having permanently attached end fittings,
use only pre-assembled lengths of wire rope as supplied
from Manitowoc Cranes. Do not build lengths from
individual components.
• Replace an entire wire rope assembly. Do not attempt to
rework damaged wire rope or wire rope ends.
• Never electroplate a wire rope assembly.
• Do not weld any wire rope assembly or component
unless welding is recommended by the wire rope
manufacturer.
• Welding spatter must never be allowed to come in
contact with the wire rope or wire rope ends. In addition,
make sure that the wire rope is not an electrical path
during other welding operations.
• Wire ropes are manufactured from special steels. If
heating a wire rope assembly is absolutely necessary for
removal, the entire wire rope assembly must be
discarded.
• On systems equipped with two or more wire rope
assemblies operating as a matched set, they must be
replaced as an entire set.
• Do not paint or coat wire ropes with any substance
except approved lubricants.
Daily Inspection
Wire rope should be inspected in accordance with ANSI/
ASME B30.5 and OSHA 29 CFR 1926.1413. A running
record of the condition of each wire rope should be noted in
the equipment inspection log.
• Each work day, prior to crane work, visually inspect all
rope that can reasonably be expected to be used that
day. Check for obvious damage, including the following:
- Rope defects such as shown in Figure 5-42
CAUTION
Prevent Wire Rope Damage!
Do not use grease to lubricate the wire rope. Grease will
not penetrate the rope properly and will build up in the
valleys between the wires and strands. This buildup will
inhibit rope inspection and could trap moisture in the
rope’s interior.
WARNING
Personal Injury Hazard!
Prior to conducting an inspection of wire rope:
• Lock out the equipment power when removing or
installing the wire rope assemblies.
• Use safety glasses for eye protection.
• Wear protective clothing, gloves, and safety shoes as
appropriate.
• Use supports and clamps to prevent uncontrolled
movement of the wire rope, parts, and equipment.
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