Table 8. Diagnostic Guide to Common Wire Rope Abuses

Figure 4-43. Types of Breaks in Wire Rope

TM-5-3810-305-10 Crane Wheel Mounted Hydraulic Light 7 1/2 Ton (Rough Terrain Crane) Model LRT 110 Manual
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TM5-3810-305-10 Table 8. Diagnostic Guide to Common Wire Rope Abuses Abuse Symptoms Possible Causes Fatigue Wire break is transverse - either straight across Check for rope bent around too small a radius; or Z-shaped. Broken ends will appear grainy, vibration or whipping; wobbly sheaves; rollers too small; reverse bends; bent shafts; incorrect rope construction; improper installation; poor end attachments. All running rope if left in service long enough will fail by fatigue. Tension Wire break reveals predominantly cup and cone Check for overloads; sticky, grabby clutches; fracture with some 45-degree shear breaks. jerky conditions; loose bearing on drum; fast starts, fast stops; broken sheave flange; wrong rope size and grade; poor end attachments. Check for too great a strain on rope after factors of deterioration have weakened it. Abrasion Wire break mainly displays outer wires worn Check for change in rope or sheave size; change smooth to knife-edge thinness. Wire broken in load; overburden change; frozen or stuck by abrasion in combination with another factor sheaves; soft rollers, sheaves, or drums; will show a combination break. excessive fleet angle; misalignment of sheaves; kinks; improperly attached fittings; grit and sand; objects imbedded in rope; improper grooving. Cut or Gouged Wire ends are pinched down, mashed and/or Check on all the above conditions for mechanical or Rough Wire cut in a rough diagonal shear-like manner. abuse, or either abnormal or accidental forces during installation. Torsion or Wire ends show evidence of twist and/or cork- Check on all the above conditions for mechanical Twisting screw effect. abuse, or either abnormal or accidental forces during installation. Mashing Wires are flattened and spread at broken ends. Check on all the above conditions for mechanical abuse, or either abnormal or accidental forces during installation. Corrosion Wire surfaces are pitted with break showing Indicates improper lubrication or storage. evidence either of fatigue tension or abrasion. Abrasion plus Reduced cross-section is broken off square A long-term condition normal to the operating Fatigue thereby producing a chisel shape. process. Abrasion plus Reduced cross-section is necked down as A long-term condition normal to the operating Tension in a cup and cone configuration. Tensile break process. produces a chisel shape. 4-50

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