Best Hoist Material Winch
Operation and Maintenance Manual
15
135062 rev01, 31AUG2020
7.2.4.2 Wire Rope Inspection Procedure
•
Have a helper slowly crank the winch to pay out the entire
length of the wire rope while maintaining approximately 33
lbs (15kg) tension on the line. Use a stiff wire brush to
clean any built up lubricant and other contaminants from
the cable as you are winding it off the drum. Carefully
inspect the attachment point of the wire rope to the winch
drum for any wear, fraying, loose fittings, or other damage.
•
Wear heavy gloves to prevent injury from any loose or
broken wires and inspect the wire rope along its entire
length by running it through your hands while visually
checking its condition. Flexing the cable can help expose
hidden damage. Look for any of the types of damage as
shown in Figures 10, 11, 12, 13, 14, 15.
A wire rope with flattened sections where the diameter across the
damaged section is less than five sixths of the original diameter
MUST BE removed from service and sent to a factory authorized
service center for repair.
Also look for:
•
Heat damage or electrical arc damage (indicated by blue or
other discoloration, melting, weld spatter, or apparent loss
of lubrication),
•
Excessive contamination which can prevent lubrication
from penetrating the wire rope, increasing internal friction
and corrosion
A wire rope winch line exhibiting any of the above conditions MUST
BE removed from service and sent to a factory authorized service
center for repair.
The presence of one or more broken wires in one rope lay length or
one or more broken wires near an attached fitting is cause for
replacement.
If a broken wire is the result of corrosion or if the wire rope is
excessively corroded, the cable must be replaced. Corrosion often
develops from the inside out and may have seriously weakened the
wire rope by the time it becomes visible.
Location of all broken wires MUST BE recorded in the Winch Line
Inspection Log for reference during future inspections.
The protruding end of any broken wires should be removed as they
occur by bending backwards and forwards using a pair of pliers until
they break deep in the valley between two outer strands. Wear gloves and protective eyewear during this operation.
Figure 10, Core Protrusion, Indicating Shock Loading
Figure 11, Crushing of the Wire Rope
Figure 12, Corrosion of the Wire Rope
Figure 13, Fatigue Damage Resulting in Broken Wires
Figure 14, Abrasion Damage
Bulges or reduction in diameter (See Figure 15).
Figure 15, Measuring the diameter of a wire rope.
