SERVICE 6.222.1 E rev.

: a 1998-04-17

Handling, Installation and Maintenance

of Steel Wire Ropes

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SERVICE 6.222.1 E rev.: a 1998-04-17

Unloading steel wire ropes It is advisable to lift a reel by means of a shaft which
is put through its axis bore.
When handling a steel wire rope, the first trouble
often occurs immediately upon receiving it: the fork
of the fork lift truck is either placed under the reel
or inside the coil.

If the fork of the fork lift truck is longer than the

width of the reel, the reel can also be lifted at the
flanges.

In both cases it might damage the surface of the

rope. The damage may not be discovered until much
later and it could happen that the manufacturer of
the wire rope is held responsible.

If possible, the rope, when recieved on cils or reels,

should not have any contact with a metal hook or
the fork of a fork lift truck.

Instead, it should be lifted by means of a wide tex-

Storing steel wire ropes
tile webbing sling.

Steel wire ropes should be stored in a clean, cool,

dry place indoors. The ropes must not be allowed
to rest on the floor. They can be placed on pallets.

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SERVICE 6.222.1 E rev.: a 1998-04-17

If outdoor storage cannot be avoided the ropes must Unwinding steel wire ropes from the reel
be covered in a way that moisture cannot create
corrosion problems. Although plastic foil protects An unreeling stand (turnable) should be used to
the ropes from rain, condensation from beneath unwind a wire rope from its reel.
might not be able to escape and could damage the
ropes permanently. To avoid condensation prob- Another accepted unreeling method is to mount the
lems, it is advisable to use breathable water-proof reel on a shaft supported by two jacks or a stand.
fabric covers readily available from tarpaulin manu-
factures.

When storing a number of spare ropes, the follow-

ing rule should be applied: first in - first out. This
means, the ropes should be used in the order of
delivery. In this way it can be avoided that certain
ropes are only put in service after being stored for
many years.

It is self-evident that the different ropes in stock must

be clearly marked to avoid the possibility of
confusion (e.g. if similar ropes of diffferent tensile
strength are stored).

In addition proper records have to be kept which

make it possible to trace the "history" of any rope
back to the manufacturer on the basis of storing
number, specification, date of order and date of
delivery.

Installing steel wire ropes

When installing steel wire ropes, extra care must

be taken that the ropes are unwound from the ring
or reel without torsions and without any outer dam-
age. The same applies to reeving the ropes into
the system.
Unwinding steel wire ropes from the coil
Rolling the wire rope along the floor, as is some-
times recommended in the relevant literature, does
not work very well in practice because the reel al-
ways unwinds less wire than the distance the reel
travels, so that with this method the rope has to be
dragged along the worker.

If a rope is delivered on a coil, it is either unwound

on a turntable or the coil is rolled along the ground
like a hoop. In the latter case ensure that the sur-
face is clean; sand or grit that sticks to the lubricant
might damage the wires when the rope travels or
sheaves.

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SERVICE 6.222.1 E rev.: a 1998-04-17

Under no circumstances must the rope be pulled If one end of the ropes has a fitting attached, as it
off a coil while it is lying on the ground or looped is mostly the case with deck cranes, there is no
over the head of the reel, because this will inevita- other possibility than pulling the loose rope end
bly induce one torsion per wrap into the rope. through the whole reeving system.

The most common rope fittings for deck cranes are

shown below.

The aluminum ferrule with mechanical splice.

Every torsion will change the lay lengths of the
stands and of the wire rope; at the same time the
proportions of lengths of the rope elements and fi-
nally the distribution of load within the rope are
changed. A rope that is unwound at the sides of a
coil or reel will try to resist the enforced torsions The cast steel ferrule with mechanical splice.
and form loops. When pulled taut these loops will
result in irreparable kinks.

Steel wire ropes with kinks are not safe to operate

and must be discarded.
The spelter socket.

The installation procedure Typical deck crane example

The most advantageous way of installing a steel Below is shown an example of a typical deck crane,
wire rope varies from crane to crane. In any case a where the rope must be spooled from the reel via
procedure should be chosen that (under justifiable sheaves S1 through S9 onto the drum.
expenditure) guarentees the least risk of torsions
and avoids damage to the rope by contact with parts
of the construction.

With some cranes it may be advisable to discard

the old rope first and to install the new one after-
wards. With other cranes, particularly with bigger
ones, it might be better to pull in the new rope at-
tached to the old one. Another possibility is to use
a thinner rope by which the wire rope proper is pulled
into the system. This method is often used with new
equipment.

In every single case careful consideration is ne-

cessary as to whether the wire rope should be pulled
through the whole reeving system or whether it
should first be wound from the coil or reel onto the
drum and afterwards be reeved into the system.

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SERVICE
Here, special attention must be paid to the hook
block. It must be secured in an upright position so
that the rope can be spooled without any fleet an-
gles occuring between the rope and the block´s
sheaves.
Winding the steel wire rope from the reel
onto the drum
During the manufacturing process every steel wire
rope receives its preferred bending direction when
being drawn from the wire rope closer by means of
a capstan. When delivered to the customer the rope
is bent in that direction. Make certain that it bends
in the same direction when it is wound from the reel
onto the drum.
If the rope is wound at the bottom of the drum, it
should leave the reel at the buttom and vice versa:
i.e., always reel from top to top or from bottom to
bottom.
If this procedure is not strictly followed, the rope
will either try to twist between reel and drum or it
will later try to regain its preferred position when in
practical service. In both cases structural changes
of the rope may occur.
Installing the rope with the help of the old
one or by a thinner rope
If the new rope is pulled in by the old one or by a
thinner rope one must make sure that the connec-
tion between these ropes is absolutely safe. In ad-
dition it must be ensured that the thinner rope can-
not rotate. Rotation-resistant steel wire ropes or
three-strand ibre ropes for instance, can be re-
commended for this purpose. When using conven-
6.222.1 E rev.: a 1998-04-17
tional wire ropes one must at least make sure that
they have the same direction of lay as rope to be
installed.
If the new rope is pulled in with help of the used
one, the two rope ends are often buttwelded to-
gether. A connection of that kind can transfer the
twist of the old rope, built up in the reeving system,
into the new rope. By that method of installation the
new rope may be extremely damaged.
There are even more reasons why that procedure
is highly problematic: It is true, that when using spe-
cial electrodes the welded connection presents
acceptable results in a pull test with a straight rope;
but because of the great length of rigid connection
zone the very same connection could break due to
the enormous bending stresses when running over
sheaves.
If that connection is applied, its safety should be
increased by using a Chinese finger. Fewer prob-
lems are caused by con-
necting wire ropes with
welded-on pad eyes or
chain links, which are
joined by either strands or
thin wire ropes.
This connection provides satisfactory
load capacity, it is flexible and pre-
vents the transfer of twist from the old
rope into the new one. When using
two strands to pull the rope into place,
these will indicate the intensity of twist
in the old rope on the basis of the
number of turns they have made dur-
ing the installation procedure.
Another possibility is connecting the
rope ends with Chinese fingers. These
are tubes made out of braided
strands, which are pulled over the
rope ends and then secured at their
ends with tape or seizing wire. Under
load the Chinese fingers will contract
and hold the rope ends by friction.
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SERVICE 6.222.1 E rev.: a 1998-04-17

When installing a lang lay rope one must take care
that the Chinese finger cannot unwind from the rope
like the nut from a screw. It is recommended to wrap
a tape around the whole rope length to be held by
the Chinese finger to increase the friction.
Under no circumstances should one attempt to gen-
erate the tensioning load by jamming the rope, for
instance between two boards. Structural changes
would deform the rope beyond repair.

Installing under load

To achieve perfect spooling of the rope on the drum

it is very important to apply a tensioning load to the
wire ropes during the installation.

This is particularly important with drums spooling

in two or more layers, which, however, is not very
common with deck cranes. If the first layer(s) are
not under tension, they might be too loose, so that
the top layers might be wedged into the bottom lay-
ers under load. This could seriously damage the
rope. The unwinding rope might even be clamped,
so that the direction of spooling could suddenly be
reversed during the course of unwinding. The re-
sult could be the abrupt lifting of the load that was
actually travelling downwards.
The tensioning load should range from 1% to 2% of
the minimum breaking load of the wire ropes. In
many cases it might suffice to wind the rope quite
normally in order to unwind it and then rewind it
with the help of an outer load.
In other cases, however, the procedure mentioned
above is not possible. In these cases the tensioning
load must already be applied when installing the
rope.
Attaching the rope termination to the fix
point
After the rope has been pulled through the reeving
system, the rope termination (e.g. the mechanical
splice with the aluminum ferrule) must be brought
up to the fix point. A pulling jack can be used to pull
the rope termination to the fix point, where it must
secured with a bolt.
Prior to fixing, if necessary, the rope termination
may be aligned with the fix point by using a steel
bar. The bar should be attached to the rope by
means of a short length of chain. Under no circum-
stances should the rope be gripped with a wrench,
as this will damage the outer wires.

Ample rope tension can be provided by a simple

plank bearing against the reel flanges or by a brak-
ing disk attached to the reel.

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SERVICE 6.222.1 E rev.: a 1998-04-17

"Breaking-in" the steel wire rope The rope and this wire end are now wrapped mov-
ing away from the location of the intended cut.
After the rope has been installed and before it is
going to do its proper job, several run-throughs of
the normal operational circle should be carried out
under light load. The new rope
should be "broken-in", so that the
component parts can settle and
adjust themselves to the actual The rope is tightly wrapped for a distance of approx.
operating conditions. It is most un- three rope diameters.
fortunate that in practice only too
often the exact opposite of this
recommendation is performed:
quite frequently after installing the
rope overload tests are carried out
with loads beyond the safe work-
ing load of the system. Both ends of the seizing wire are then pulled tight
and twisted together for a length of one rope diam-
eter.
Cutting steel wire ropes

In some cases the user must cut steel wire ropes.

Hand cutters are sufficient for rope diameters up to
8 mm. Mechanical or hydaulic cutters will be re-
quired for larger sizes. The twisted connection is then hammered into a
gusset between the strands. After preparing the
The best method is to use a high speed disk cutter. other side of the intended cut accordingly the rope
Unless the rope is being scrapped the use of flame can now be cut.
cutting equipment is not recommended.

Careless cutting can result in the balance of ten-

sion in the rope being destroyed. This is particu-
larly important when cutting rotation resistant ropes
where the strands may have been deliberately non-
preformed as part of the manufacturing specifica-
tion.
In every case, each side of the cut must be prop-
erly seized to prevent strand disturbance. Insulat-
ing tape cannot prevent strand movement, so an-
nealed (iron) wire should always be used.
After marking the position of the cut the end of the
seizing wire is laid along the rope axis leaving suf-
ficient length to secure both ends by twisting when
the seizing complete.
Instead of using one long seizing it is also possible
to apply at least three seizing the size of one rope
diameter each on both sides of the intended cut.
The maintenance of steel wire ropes
Steel wire ropes must be serviced regularly, the kind
of maintenance depending on the lifting device, its
use and the selected rope. Regular maintenance
may considerably increase the service life of a steel
wire rope.

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SERVICE
Relubricating steel wire ropes
During production the rope receives intensive lu-
brication. This in-process treatment will provide the
rope with ample protection against corrosion and is
meant to reduce the friction between the elements
which make up the rope as well as the friction be-
tween rope and sheaves or drums. This lubrication,
however, only lasts for a limited time and should be
re-applied periodically.
German Standard DIN 15 020, e. g. specifies: "Steel
wire ropes must be relubricated at regular intervals,
depending on their use, particularly along the zones
subjected to bending. If for operational reasons
relubrication cannot be carried out, shorter service
life of the rope is to be expected and the inspection
intervals have to be arranged accordingly."
When choosing the relubricant, it must be ensured
that it is in accordance with the recommendations
of the rope manufacturer.
There are several techniques of lubricant applica-
tion: The most common ones at present are paint-
ing or swabbing.
Quite often the lubricant is applied at a sheave,
sometimes a continuous drip method is used. If only
a little lubricant is required, pressure spray nozzles
can be applied.
Maximum penetration of the lubricant into the gaps
of the rope, can only be quaranteed if high pres-
sure lubrication is applied with the help of a pres-
sure lubricator.
With this method the two halfs of a sleeve, which is
equipped with rubber sealings, are clamped round
the rope and screwed together. While the rope runs
through the lubricator the lubricant is pressed into
the sleeve at a pressure upto about 30 bars.
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6.222.1 E rev.: a 1998-04-17
It is important with all different methods of
relubrication of steel wire ropes that they are car-
ried out regularly right from the beginning of the
service life of the rope and not only after the first
damage has been ascertained.
Cleaning steel wire ropes
DIN 15 020 recommends: "From time to time very
dirty steel wire ropes should be cleaned externally".
This applies particularly to ropes operating in ex-
tremely abrasive conditions and to those that take
up chemicals.
Effective cleaning without proper tools is quite a
laborious job. For cleaning steel wire ropes the Ca-
nadian Rigging Manual recommends an appliance
with three rotating wire brushes and an air blast
drying system to follow. An American manufacturer
offers a "rope porcupine", a sleeve equipped with
brushes, which is drawn along the steel wire rope.
Removing broken wires
If during an inspection ends of broken wires are
detected which might cross adjacent wires and
destroy them when running over sheaves, these
broken wire ends must be removed.
Under no circumstances should the broken wire
ends be pinched off with a pair of nippers. The best
method is to move the wire ends backwards and
forwards until they break deep in the valley between
two outer strands. With thicker wires a tool should
be moved backwards and forwards on the surface
of the rope, thus bending the wires until they break.
SERVICE 6.222.1 E rev.: a 1998-04-17

Cutting or shifting steel wire ropes

Very often wire ropes must be discarded although

only short rope sections, e. g. the one that climbs
to the second layer on the drum, are seriously dam-
aged, while the rest of the rope is still in perfect
condition.

In cases such as this the service life of wire ropes

can be enormously increased by shortening, shift-
ing them at the fixing point by a span that removes
the section of the rope which has had most abuse
out of the critical zone.

After this procedure an adjacent section will be sub-

jected to the abuse.

Another typical local damage occurs on the drum

at those sections where the rope rubs against the
adjacent winding (crossover point) and must be
deflected to the side. If the damage caused in these
sections is the main reason for discarding the rope,
several cuttings or shiftings will move the stresses
to different rope zones and possibly multiply the
service life of the rope.

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SERVICE 6.222.1 E rev.: a 1998-04-17

Examples of damage to steel wire ropes

The following pages illustrate some typical exam-

ples of damage to steel wire ropes which should
always decree immediate rejection of the rope.

Surfacelayer wires frayed by abrasion; wire ropes

has been running over sharp edges under load.

Localized wear caused by chafing against adjacent

steel structures possibly because of vibrations of
the length of wire rope laying between drum and
sheave.

Heavy wear caused by high contact pressure in

sheave groove.

Severe corrosion.

Typical wire rupture caused by bending fatigue.

Typical example of localized wear and indentation

caused by a kink in the rope.

Nonrotating multi-strand wire rope with outer strand

partially disengaged because of nonuniform tor-
sional stress.

High shock loads have caused outer layer to split

open exposing steel wire rope core between strands
that have come apart.

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SERVICE 6.222.1 E rev.: a 1998-04-17

Some examples of wire rupture

Contraction rupture caused by excessive stress, Wear and identations of surface wires also promote
(e.g., if a slack line suddenly snaps taut under full fatigue and lead to premature wire rupture.
load).

Crown wires of outer strands may wear so thin that Corrosion may cause wire ropes to break. As a
the residual cross sectional area of steel in the rope safety measure, inspect ropes regularly and care-
will not support the normal design load and con- fully to prevent catastrophes; observe manufactur-
traction rupture may ensue. er's instructions

Rupture from fatigue will often occur when under-

size sheaves are used. Vibrations and torsional
stress loads in the rope accelerate fatigue rupture.

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SERVICE 6.222.1 E rev.: a 1998-04-17

THIS PAGE IS INTENTIONALLY LEFT BLANK

12 (12)
SERVICE
Replacement of Wires, Two Fall Rigging
General
The procedure is general and should be seen as a
guidance only. It is important to read and understand
the instructions below before replacement of wires.
- Rope Reeving Diagram for Cranes Type GLBE-2,
section 6.2.
- Preparation for Rig Mode, section 6.3.
- Handling, Installation and Maintenance of Steel
Wire Ropes, section 6.2.
WARNING!
Rig mode will disable stop and overload limits.
There is a risk of severe damage to the crane and
personal injury.
WARNING!
Jib must be supported, lifting of load is not permitted.
There is a risk of severe damage to the crane and
personal injury.
Hoisting winch / wire
For cranes with two fall rigging proceed as follows:
- Place the jib in the jib rest.
If applicable, park the crane, slewing position locked
with cylinders, and the jib at maximum outreach.
If applicable see also special instruction "Parking
of Crane in Wires" in section 4.
- Place the lifting block in a position where the wire
runs freely in the lifting block, see Fig. 1.
C-00262
Fig. 1. Lifting block in right position.
6.223.26 E rev.: b 2012-02-15
- Disengage the slack wire switch by blocking the
spring tensioned roller, which can be done with a
piece of wood, see Fig. 4.
- Loosen the hoisting wire rope socket attached to
the load cell on crane house top with the help of
a shore crane or other suitable crane. Attach the
hoisting wire rope socket to the reel before the
hoisting winch wire is wind from the hoisting winch
drum to the reel. See Fig.13.
- Run the hoisting winch to pay out the hoisting wire,
and at the same time pull on the loose wire end.
- Stop the winch just before it enters into the empty
drum limit.
- Stop the crane. Use pushbutton S13 Start/Stop on
the control panel in cabin.
- Mark the position of the wire drum in relation to the
bracket, this to avoid setting of all hoisting limits
again after installing the new hoisting wire.
- Remove the cover from the limit switch box.
- Mark the position of the shaft in relation to the limit
switch box. See Fig. 8.
- Remove the limit switch box.
- Measure the empty drum measure AL. See Fig. 2.
AL
AL = Empty drum flange
side/ At least three locking
turns/Tank top
Fig. 2. Hoisting winch.
- Secure the wire so the wire can not pay out and
make sure that the wire clamps that holds the end
of the wire can be removed safely.
- Attach a long rope (longer than the wire rope) to
the wire end and place it 4 to 5 turns around the
wire drum.
1 (8)
SERVICE 6.223.26 E rev.: b 2012-02-15

WARNING! - Run the hoisting winch to pay out the old (damaged)
Rig mode will disable stop and overload limits. wire until it is on the deck.
It is not permitted to have any load in the hook. - Attach the new hoisting wire to the same rope by
There is a risk of severe damage to the crane and using tool 662 0754-000, see Fig. 5.
personal injury.

Preparation for Rig Mode

- Set the key switch RIG/OL Test (inside cabinet CT2)
in position RIG. See Fig.3.

Error
Input
07 18
MP SP
Output
27
Error

07
Input
MP
Output
33 36
SP Error MP

07
Input
SP
Output
33 36
Error

07
Input
MP

33
SP
Output
36
Error

07
Input
MP SP
Output
33 36
Fig. 5 Tool, wire rigging sock, 662 0754-000.
08 19 28 39 43 39 43 39 43 39 43
09 20 29 34 37 34 37 34 37 34 37
08 08 08 08
10 26 30 40 45 40 45 40 45 40 45
11 49 31 09 31 09 31 09 31 09 31
30 30 30 30
12 51 32 10 32 10 32 10 32 10 32
13 56 33 19 Sw19 19 Sw19 19 Sw19 19 Sw19
14 57 34 20 Sw20 55 20 Sw20 55 20 Sw20 55 20 Sw20 55
15 58 35 11 14 Sw14 11 14 Sw14 11 14 Sw14 11 14 Sw14
16 59 36 56 Sw56 56 Sw56 56 Sw56 56 Sw56
17 60 37 12 15 Sw15 12 15 Sw15 12 15 Sw15 12 15 Sw15
24V 38 26 27 26 27 26 27 26 27
Com 39 58 59 58 59 58 59 58 59
40 49 17 29 49 17 29 49 17 29 49 17 29

- Attach the wire rope end to the wire drum with the
53 51 18 53 51 18 53 51 18 53 51 18 53
61 52 54 52 54 52 54 52 54
57 57 57 57

Com Com Com Com

SC
C3
IO
C3
SC Supervisory
A1 C1
HOHoisting
A1 C1
LU Luffing
A1 C1
SL Slewing
A1 C1
AU Auxiliary
A1 C1
IO
A1
Input/Output

C1
wire rope clamps and tighten the bolts. For tighten-
HO_C1
SC_C3

SC_C1

AU_C1
LU_C1

SL_C1
IO_C3

IO_C1
HO_A1
SC_A1

AU_A1
LU_A1

SL_A1

IO_A1

C4 C4 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2 A2 C2

ing torques, see instruction "Tightening Torques..."

HO_C2
SC_C2

AU_C2
LU_C2

SL_C2

IO_C2
HO_A2
SC_C4

SC_A2

AU_A2
LU_A2

SL_A2
IO_C4

IO_A2

485.2 485.2 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1 A3T 485.1
HO_485.1
SC_485.1

AU_485.1
LU_485.1

SL_485.1

IO_485.1
SC_485.2

IO_485.2

HO_A3
SC_A3

AU_A3
LU_A3

SL_A3

IO_A3

485.3 485.3 Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI Sp SSI

SC_485.3

IO_485.3

HO_SSI
SC_SSI

AU_SSI
LU_SSI

SL_SSI

IO_SSI
HO_Sp
SC_Sp

AU_Sp
LU_Sp

SL_Sp

IO_Sp

in section 6.2.
- Run the hoisting winch by pulling in the new hoist-
Key switch ing wire, so that the AL measure is the same as
RIG/OL Test noted earlier and that the winch corresponds to the
Fig. 3. RIG/OL Test key switch in cabinet CT2. position marked earlier.
- Stop the crane. Use pushbutton S13 Start/Stop on
- Start the crane again. the control panel in cabin.
- A login window will now appear on the cabin display. - Before operating the hoisting winch read prepara-
See Fig 3. tion for rig mode, page 2.
- Exit Rig mode. Set key switch in position Normal.
- Assemble the limit switch box in its proper place,
the marking on the shaft/box must correspond.
- Start the crane again.
- Run in the rest of the wire. Leave enough slack to
secure the wire rope socket.
- Secure the hoisting wire rope socket to the load
cell on the crane house top. See Fig. 15.
- Remove the wooden piece holding the slack wire
roller.
- Run the hoisting winch and check all limits and
examine that the limit switch settings are correctly,
If necessary, adjust the limits according to instruc-
tion "Limit Switches in..." in section 6.3, instruction
Fig. 4. Login window. "Technical Data" in section 2, and calibrate the
encoder according to instruction "Absolute Encoder
- Write the password to accept rig mode, use the Calibration" in section 6.3.
software keyboard on the cabin display.
Adjustment of pressure roller on the
Note! hoisting winch
The password is normally the last four digits of the See instruction "Rope Reeving Diagram for Cranes
Mfg No which can be found in the table of contents. Type GLBE-2" section 6.1

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SERVICE 6.223.26 E rev.: b 2012-02-15

Luffing winch / wire - Mark the position of the wire drum in relation to the
- Place the jib in the jib rest or move the lifting block bracket.
up against the jib top. - Remove cover from the limit switch box.
- Disengage the slack wire switch by blocking the Note!
spring tensioned roller, which can be done with a Mark the position of the shaft in relation to the box.
piece of wood, see Fig. 6. See Fig. 8.

Piece of wood
100 x 200

Piece of wood
 100 x 200

Fig. 8. Marking inside limit switch box.

- Remove the limit switch box.

- Loosen the luffing wire rope thimble attached to the
crane house top or jib top with the help of a shore
crane or other siutable crane, and lower wire to
deck by means of a rope, see Fig. 11 or 16.
Fig. 6. Disengage of slack wire safety switch. - Secure the wire so that the wire can not pay out
and that the wire clamps that holds the end of the
- Pay out the luffing winch wire and stop just before wire can be removed safely.
it enters into empty drum limit. - Attach a long rope to the wire end (longer than the
- Stop the crane. Use pushbutton S13 Start/Stop on wire rope) and place it 4 to 5 turns around the wire
the control panel in cabin. drum.
- Note how many revolutions of the wire there are - Start the crane again.
left on the drum at this position. Make a mark on - Before operating the luffing winch read preparation
the drum. Measure the empty drum measure AT, for rig mode, page 2.
see Fig. 7. - Activate Rig mode.
- Run the winch to pay out the old luffing wire, and
Wire lock AT
side at the same time pull on the loose wire end until it
is on the deck.
- Attach the new luffing wire to the rope, by using
tool 662 0754-000, see Fig. 5.
- Run the winch by pulling in the wire so that the wire
rope end just enters into the crane house.
- Secure the luffing wire rope socket on crane house
AT = Empty drum flange top or jib top. See Fig.11,12 and 16.
side/ Stop lowest position/ - Run the winch by pulling in the wire, so that the
At least three locking turns empty drum AT measure is the same as noted
earlier and that the luffing winch drum corresponds
to the position marked when the limit switch box
Fig. 7. Luffing winch. was disconnected.

3 (8)
SERVICE 6.223.26 E rev.: b 2012-02-15

- Attach the wire rope end to the wire drum by the

wire rope clamps and tighten the bolts. For tighten-
ing torques see instruction "Tightening Torques..."
in section 6.2. Limit
switch box
- Stop the crane. Use pushbutton S13 Start/Stop on
the control panel in cabin.
- Exit Rig mode. Set key switch in position Normal.
- Assemble the limit switch box in its correct place.
- Start the crane again.
- Run in the rest of the wire.
Winch drum
- Remove the wooden piece holding the slack wire
roller.
- Run the hoisting winch and check all limits and ex-
Fig.9. Limit switch box, hoisting winch.
amine that the limit switch settings are correctly. If
necessary, adjust the limits according to instruction
in section 6.3 and calibrate the encoder according
to instruction "Absolute Encoder Calibration" in
Winch drum
section 6.3.
Limit switch
box
Tightening torque: See the winch part picture or in-
struction "Tightening torques, studs and screws" in
section 6.2 in the instruction and spare parts manual.

Fig. 10 Limit switch box, luffing winch.

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SERVICE 6.223.26 E rev.: b 2012-02-15

Rigging of the luffing wire to crane

CAUTION!
house top
The wire rope thimble must be safely secured by
bending the lock washers, see Fig. 12.
NOTE!
Make sure to grease the wire rope thimble refer to
instructions "Lubricating Chart" and "Lubricants for
Deck Machinery" in section 5.

Luffing

Hoisting

Fig. 11. Example. Rigging of hoisting/luffing wire rope socket/ thimbles to crane house top.

Fig. 12. How to secure the lock washers for the wire Fig.13. How the wire is spooled from the winch drum
ropes and loadcell. on to the reel on deck.

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SERVICE 6.223.26 E rev.: b 2012-02-15

Assembly of the hoisting wire/ load cell

on crane house top

It is important to install new split pins when they are

removed. See Fig. 15 and 17.

Fig.14. Example. Assembly of the load cell for hoisting wire.

Install a new split pin

when replacing wire

Hoisting wire rope socket

Fig.15. Example. Securing of the hoisting wire rope socket to the loadcell.

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SERVICE 6.223.26 E rev.: b 2012-02-15

Securing of luffing wire rope thimble to

jib top.

Luffing wire rope thimble

Fig.16. Example. Securing of the luffing wire rope thimble to jib top.

Securing of the hoisting wire rope sock-

et to jib top, applicable to cranes with
load-cell.

Hoisting wire rope socket Load cell Install a new split pin
when replacing wire

Fig.17. Example. Securing of the hoisting wire rope socket to jib top with load cell

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SERVICE 6.223.26 E rev.: b 2012-02-15

THIS PAGE IS INTENTIONALLY LEFT BLANK

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 S E RV I C E I N F O R M AT I O N

625/1473 E rev.: c 2010-06-23

Indentation and Wear on Wire Sheaves

General
To ensure safe working conditions and long lifetime The wear, see Table 1, can certainly occur on every
of the wire rope it is important to inspect the condition spot where the wire rope is in contact with the wire
of the wire sheaves. sheave, not only on places shown in Fig. 1.

Wear criterias Indentation

When the wear on the wire sheave exceeds 3mm, it
will according to our experience decrease the lifetime
of the wire rope. The wear of the wire sheave will also
reduce the load capacity. Maximum wear is therefore
25% of the wire sheave thickness (t) with a limit to
maximum 3mm, see Fig. 1.
A new wire rope and wire sheave are in contact on
certain spots, see Fig. 2. After some time the
indentation will have the shape shown in Fig. 3. This
is considered as normal wear.

Fig. 1. Wear on wire sheave. Fig. 2. Contact spots.

t a
max
16 3
12 3
10 2.5
8 2
6 1.5

Fig. 3. Good contact between an old wire rope and

Table 1. the wire sheave.

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 S E RV I C E I N F O R M AT I O N

625/1473 E rev.: c 2010-06-23

An old wire rope and a worn wire sheave might have

good contact condition, see Fig. 3, but when a new
wire rope is installed the contact condition might be
very bad, see Fig. 4. This will decrease the lifetime of
the wire rope and wire sheave.

It is therefore important to inspect the wire ropes

according to paragraph "Wear criterias".

Fig. 4. Bad contact between a new wire rope and the

wire sheave.

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 S E RV I C E I N F O R M AT I O N

625/1560 E rev.: f 2010-01-14

Lifting Block/Beam

Warning!
Where equipment has swivelling and moving parts
there are potential safety hazards. Care should be
taken when working with or repairing equipment. If
used incorrectly, breakage could occur injury or
death.

General safety
Eyes for stabilizing
wires (extra equipment)
When equipment is in use, do not put hands:
1. Between sheaves, sideplates, and guards.
2. In area of hook, hook nut, and swivel.
Fig. 1. Lifting block for crane with two sheaves.
Take great care to avoid clothing becoming trapped.

Repair and reeving should be carried out by trained

personnel only. Power should be switched off be-
fore operations are carried out. Work should only
take place when equipment is supported on a firm
surface.

Maintenance and service

Inspection should be carried out on every possible

occasion before taking into operation. Fig. 2. Lifting block for crane with one sheave.

Particular attention should be paid to the items

below:
1. Wear in hook, centre pin, steel structure, and
threads.
2. Play in sheave bushes or bearings.
3. Spacer bolts and nuts.
4. Examine for cracks in welds in steel structure.
5. Condition of safety latch and grease nipples.
6. Wear in holes in sideplates and links.

If cracks or heavy gouges appear, the equipment

should not be used until a qualified person examines
the equipment. Contact MacGREGOR Cranes,
Service Division.

NO welding should be carried out unless prior

authority is obtained. Fig. 3. Lifting beam for 4-rope crane.

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 S E RV I C E I N F O R M AT I O N

625/1560 E rev.: f 2010-01-14

If the holes in the sideplates, eyes, and swivels are Important!

enlarged by more than 5%, the part should be When replacing genuine parts an overload test of
replaced or maybe repaired, see Fig. 4. Contact the complete unit must be performed and new cer-
MacGREGOR Cranes, Service Division, for tificate must be issued. See Table 1.
instructions.

Lubrication

As a general rule sheaves, shafts, and swivels

should be greased through nipples every 100
working hours, see also separate lubrication chart.
Pins without nipples should be removed and
lubricated with a brush.

Limitation of use

1. Safe working load should never be exceeded, see

Table 1.
2. Crane blocks should be used in vertical lift only.
3. Shock or side loading should not be applied, un-
Fig. 4. Lifting eye.
less equipment is desigend for that purpose.
4. Load should always be in seat of hook or eye.

All repairs should be carried out by responsible

personnel, and great care should be taken in the
reassembly of the equipment and retaining parts,
i. e., grub screws, pins, etc. Make sure they have
the correct sizes and threads and refit them.

Table 1.

Proof load for lifting blocks with 2-part rigging

Class Working load limit Proof load
ABS PL = 2 x WLL
BV WLL < 25 T PL = 2 x WLL
25 T < WLL < 160 T PL = (0.933 x WLL) + 27
WLL > 160 T PL = 1.1 x WLL
DNV PL = 2 x WLL
GL WLL < 25 T PL = 2 x WLL
WLL > 25 T PL = (1.22 x WLL) + 20
LRS WLL < 25 T PL = 2 x WLL
WLL > 25 T PL = (1.22 x WLL) + 20
WLL = Working Load Limit (SWL)
T = 1 metric ton = 1000 kg
PL = Proof Load

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 S E RV I C E I N F O R M AT I O N
Measuring Procedure for Wear in Slewing Bearings
General
Below measuring procedure is valid for the crane
types G, TG, GL, TGL, GLB, H, TH, L, and TL.
Note!
The procedure is not valid for measuring the slewing
bearing under the twin platform.
The slewing bearing is an essential part of the crane
and must be well maintained. Over the years the slew-
ing bearing will have some wear, and to be able to
know if there is a need for changing the slewing bear-
ing records of the wear are needed.
The initial measurements should be taken when
the crane is installed at yard or within 2 months
from crane installation.
If the wear measurement shows wear, grease samples
can be taken for analysis.
For slewing bearing grease sampling procedure see
inspection instruction 625/1651 E.
Measuring
The measurements should be taken regularly, every
6 months. Measurements can be sent to Cargotec
Service Organisation for evaluation.
Note!
When measurements are to be taken the ship shall
have as little list/trim as possible.
Neither a load nor cargo handling equipment should
be attached to the hook.
Procedure
First time a measurement is to be taken two reference
points on the crane's bottom plate must be grinded
and marked. These reference points shall then always
be used at any future measuring, see Fig. 4. Write "A"
625/1579 E rev.: k 2011-10-28
at the reference point in the front of the crane and
"B, C" at the reference point at the back of the crane.
Remove excessive wear (burr) from slewing gear teeth
before measuring.
Measurements shall be taken at four positions of the
slewing bearing, if possible. With the jib pointing:
- Forward to the ship
- Starboard
- Aft
- Port side
It is important to use the same position for all further
measurements to be able to compare the measure-
ments.
With the jib at maximum outreach two measurements
are to be taken, see Fig. 1.
With the jib at minimum position one measurement is
to be taken, see Fig. 2.
Enclosed table can be used to record the measure-
ments.
Allowed play for slewing bearing
Measurements should be recorded with an accuracy
of 0.1 mm.
As a guidence the maximum allowed play is:
- for roller bearings 1.5 mm
- for ball bearings 3.0 mm.
Contact Cargotec Service Organisation for exact maxi-
mum slewing bearing play for your crane.
See Slewing Specification spare part picture or Slew-
ing Bearing drawing for type of bearing in your crane,
section 9.3 in spare parts manual.
Deviation
The deviation is related to differences in production
tolerances and material. For Cargotec a part for a more
accurat evaluation of the bearing play.
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