Trouble Shooting Chart

FaultPossible
Reason		CureTypes of Wire Break
BurningSheaves too heavyReplace with lighter sheaves

ABRASION


Wire worn before breaking

Rollers stuckLubricate or replace rollers
Burning and AbrasionSheaves frozenFree sheave, lubricate and regroove
Burning or CrushingRope dragging over obstaclesKeep rope path clear

OVERLOAD


Necked-down part indicates excessive tension

Core of rope chars and breaksExcessive heatUse IWRC
CorrosionAcid, sulphur or salt fumesLubricate frequently
Corrosion and rustRope not lubricatedLubricate more frequently

FATIGUE


Steel became brittle through bending

Corrugation with excessive wearRollers too softFit harder rollers
Sheave and drum material too softFit larger sheaves and drums
CrushingCrosswinding on drumSpool right and use correct rope

COMBINATION


A combination of destructive factors

Drum too fullUse less rope or smaller rope or larger drum
Crushing and nickingRope damaged by impactHandle with greater care
DistortionRope cut badlySeize rope properly before cutting
RESULTS OF ABUSE



RUST BOUND



PINCHED



OVER STRAINED



CORRODED

Under abrasive conditions the wire crowns of the rope are worn down and the diameter of the rope is reduced.

Sheaves grooves too bigReplace sheaves or use larger rope
FatigueSheaves wobbleReplace damaged journals
Straighten or replace bent shafts
Fatigue - prematureReverse bendsIncrease distance between sheaves, use larger sheaves
Fatigue - wires breakSheaves and drums too smallGet larger sheaves and drums
OverloadingFalse starts, false stops and jerking out slack Control speed
Overloading and crushingLoose bearing on drumReplace bearing


ABRASION

Sticky, grabby clutchesMaintain clutches in good working order
Pinching, crushing and burningSheaves grooves too smallReplace or regroove sheaves
Rope breaksOverloads Use proper working loadAVOID KINKING
Do not allow the rope to form into small loops. These may cause kinks - which inflict premanent damage to the rope's wires or strands.

STOP IT SLOWLY!
Slamming the load to a stop, or bouncing it onto the ground, can cause severe rope vibration - with the possibility of rapid bending fatigue. The sudden release of tension combined with rebound can also "bird cage" the rope; an abuse that leads to early failure.

Rope chattersRoller too smallFit larger rollers
Rope jumps off or breaksBroken flange on sheaveReplace sheave immediately
Rope pulls out - high strandFittings improperly attachedAttach fittings properly
Rope - short lifeRope wrong size, construction or gradeFit correct rope - see Section 2
Rope unlaysSwivel fittings on Lang LayChange attachment or use Preformed rope
Rope unlays or Lay tightensRope dragging against stationary objectKeep rope path clear
Rope wear excessiveGrit and sandUse light lubricant frequently
Rope wear and sheave wear excessiveSheaves not alignedRe-align sheaves
Side wear on rope and sheavesExcessive fleet angleReset main sheaves farther out
Spot wear on high strandsKinksHandle rope carefully
If excessive, check for objects embedded in ropeInspect rope frequently