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Maintenance Manual for Crawler Crane
4.13 Maintenance of wire ropes
The service lives of wire ropes are different basing on the operating condition of the machine.
Both hoisting rope and derricking rope must be strictly inspected regularly to find abrasion and
damage in time.
4.13.1 Inspection of wire ropes
4.13.1.1 Items to be inspected
a) Overall length of a wire rope.
b) The position where the wire rope is frequently bent on the pulley or drum.
c) The position where the wire rope is bent on pulley or drum at the moment when the load is
lifted.
d) In the multi-layer winding system, the position where the wire rope is in contact with the
drum flange, and the transboundary zone where the upper wire rope crosses the lower
wire rope.
4.13.1.2 Inspection interval
a) It is recommended to inspect whether damage exists on wire ropes and its end points.
b) For the first weeks after new wire ropes are installed and the fracture occurs for the first
time, the inspection interval must be shorter than that in other time periods. When the
overloading occurs or suspicious damage which can not be seen is detected, the
inspection interval must be shortened accordingly.
c) In addition, when operation ceasing duration is extended and the wire rope transmission
gear is re-installed, or when the winch is disassembled and re-installed at a new location,
or when an accident happens or damage exists during the operation of wire ropes, the
inspection must be performed.
4.13.2 Maintenance of wire ropes
For dirty wire ropes, their external surface should be cleaned frequently. Especially, for the wire
ropes that are used in a corrosive environment or near chemical substances, dirt on the surface
should be removed in time.
The manufacturer has sufficiently lubricated wire ropes (not only the surface of the wire rope,
but also all the internal space of the wire ropes) during manufacture to prevent corrosion and
reduce friction between wire rope strands, wire ropes and pulleys, and wire ropes and drums.
When black spots or rust exist on the surfaces of wire ropes, the wire ropes need secondary
lubrication. Timely secondary lubrication plays a positive role in extending the operating life of
wire ropes. The lubricating oil for secondary lubrication can hardly penetrate and flow into wire
ropes, so it should not be applied excessively. Excessive lubricating oil will stay on the surface
of a wire rope, making the check for wire rope fracture relatively difficult. It would be best to
adopt acid-free grease and the lubricating oil and the grease should be heated and diluted
before utilization.
4-65
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