November 2006
38 AL4000 Light Tower Part No. 833002 Rev A
WIRE ROPE REPLACEMENT
CRITERIA FOR REPLACEMENT OF WIRE ROPE – TEREX LIGHT TOWERS
The wire ropes used to raise and lower the masts on a TEREX Light Tower are probably some of
the most important mechanical parts used in day-to-day operation of the machinery. It is there-
fore very important that the cables be inspected on a frequent basis (once a month) for wear and
tear, and immediately in the event of possible damage due to operator error in using the winch, or
possible damage from other equipment.
NORMAL WEAR AND TEAR
When used properly, the wire ropes should give years of trouble-free service, depending on how
often the masts are raised and lowered. The rule of thumb at TEREX is that if the tower is raised
and lowered an average of once per day, that the cables should be replaced every two
years of service.
NORMAL INSPECTION
The wire ropes are constructed of 7 strands of 19 plow steel wires each twisted together, and
then the assembly galvanized to resist corrosion. Using a wadded-up cloth or heavy leather
gloves (to avoid being pricked by a broken wire), run a hand up and down a length of the cable.
If any exterior wires are broken, they will lift up from main body of the cable and become visible.
For any given 1 foot of cable length; if there are 4 or more wires each, on any 2 or more strands
broken, the suspect rope should be replaced immediately.
DAMAGE INSPECTION
If any nicks (partial strand cut through), kinks (permanent bends), or weld spatter on the cable
(from field service) are observed, the suspect wire rope should be changed immediately. If
there is a crushed spot somewhere on the wire rope, it should be replaced only if the width of
the crushed spot exceeds 1-1/4 times the nominal diameter of the cable (5/16” on a 1/4” cable,
and 7/32” on a 3/16” cable), or if there are broken wires at the point of damage.
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