Crane User's Guide - Union Wire Rope

Crane User’s
Guide

Contents Page(s)
Choosing the right wire rope for your application . . . . . . . . . . 4
Wire rope recommendations for crane applications . . . . . . . . 6
XLT 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ropes for rotational stability . . . . . . . . . . . . . . . . . . . . . 9
Flex-X 7CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Wire rope weights and minimum breaking force for cranes . . . 11
Guidelines for installation and maintenance . . . . . . . . . . . 12
How to inspect and when to replace your wire rope . . . . . . . 14
How to identify and correct problems with your wire rope . . . . 16
Drum spooling . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rope unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Block rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2

let us show you the ropes
It takes more than the right wire
ropes to operate your cranes. It
also takes the right knowledge
and experience. When you know the
ropes – that is, how to choose, use
and maintain each of the many types
of ropes – you’ll know how to assure
maximum service life and performance
for each crane application.
When it comes to showing you the
ropes, no one does it like Union, a
WireCo WorldGroup brand. As the
largest producer of wire rope, we
offer everything you need for your
crane’s wire rope needs. Eight WireCo
WorldGroup manufacturing operations
and seven distribution centers in North
America, plus manufacturing facilities in
Germany and China, give our customers
unparalleled support and global reach.
Union can deliver the right wire ropes
for your machine and application no
matter where your worksite may be. All
the more reason to call us.
This crane user’s guide is only one
example. On the following pages, you’ll
gain valuable information to help you:
Choose the right wire roPes. Knowing
the ropes starts by understanding the
wide variety of wire ropes available for
your many needs. This guide contains
practical information to help you.
Care and maintain wire roPes.
You can help assure maximum service
life and performance by following
the proper care and maintenance
procedures – including regular
inspections – outlined in this guide.
identify and Prevent Common
Problems in the field.
This guide also tells you how to
recognize and prevent some of the more
common causes of wire rope damage
during handling, installation and usage.
broad range. best manufacturer. Unmatched support.
At Union, we understand the crane market . Our years of climbing on the rigs with you,
combined with the latest metallurgical practices and unique design capabilities, have
enabled us to continue to innovate and provide the most cost effective line of crane ropes in
the world . Union is part of the global leader in manufacturing, engineering and distributing
wire rope, wire rope assemblies, high carbon wire, and electromechanical cable: WireCo
WorldGroup . We apply thorough design and manufacturing controls – including complete
material traceability. And we are the only manufacturer in the world that is QPL qualified, API
certified, and registered to both ISO 9001:2000 and AS-9100 Quality Systems. So buy from
the best…WireCo WorldGroup – The world is our worksite .
3

enefit of
fewer oUtside
wires Per strand
abrasion
resistanCe
> Increases with
larger wires .
> Decreases with
smaller wires .
benefit of
more oUtside
wires Per strand
fatigUe
resistanCe
> Decreases with
larger wires .
> Increases with
smaller wires .
Choosing the right wire rope for your application
With each application, your
choices of wire ropes can
be many. How do you know
which one works best for you? Ropes
include a combination of characteristics
that give them specific performance
abilities. Before you choose, it pays
to look closely at each rope’s special
characteristics.
no single wire roPe Can do it all
All wire ropes feature design
characteristic tradeoffs. In most cases, a
wire rope cannot increase both fatigue
resistance and abrasion resistance. For
example, when you increase fatigue
resistance by selecting a rope with more
wires, the rope will have less abrasion
resistance because of its greater number
of smaller outer wires.
When you need wire rope with greater
abrasion resistance, one choice is a rope
with fewer (and larger) outer wires to
reduce the effects of surface wear. But
that means the rope’s fatigue resistance
will decrease. That’s why you need to
choose your wire rope like you would
any other machine. Very carefully. You
must consider all operating conditions
and rope characteristics.
the basiC CharaCteristiCs
of wire roPe
How do you choose the wire rope that’s
best suited for your job? Following are
the most common characteristics to be
considered when selecting a rope for an
application.
Strength Wire rope strength is
usually measured in tons of 2,000 lbs. In
published material, wire rope strength
is shown as minimum breaking force or
nominal (catalog) strength.
4
These refer to calculated strength
figures that have been accepted by the
wire rope industry.
When placed under tension on a test
device, a new rope should break at a figure
equal to – or higher than – the minimum
breaking force shown for that rope.
The published values apply to new,
unused rope. A rope should never operate
at – or near – the minimum breaking
force. The minimum breaking force of the
rope must be divided by the design factor
required for the application to determine
the maximum load allowed on the
rope. During its useful life, a rope loses
strength gradually due to natural causes
such as surface wear and metal fatigue.
FAtIgue reSIStAnce Fatigue
resistance involves fatigue of the
wires that make up a rope. To have
high fatigue resistance, wires must be
capable of bending repeatedly under
stress – for example, as a loaded rope
passes over a sheave during operation.
Increased fatigue resistance is achieved
in a rope design by using a large number
of wires. It involves both the wire
properties and rope construction.
In general, a rope made of many wires
will have greater fatigue resistance
than a same-size rope made of fewer,
larger wires because smaller wires
have greater ability to bend as the rope
passes over sheaves or around drums.
To overcome the effects of fatigue, ropes
must never bend over sheaves or drums
with a diameter so small as to bend
wires excessively. There are precise
recommendations for sheave and drum
sizes to properly accommodate all sizes
and types of ropes.

Every rope is subject to metal fatigue
from bending stress while in operation,
and therefore the rope’s strength
gradually diminishes as the rope is used.
cruShIng reSIStAnce Crushing
is the effect of external pressure on a
rope, which damages it by distorting
the cross-section shape of the rope, its
strands or core – or all three.
Crushing resistance therefore is a rope’s
ability to withstand or resist external
forces, and is a term generally used to
express comparison between ropes.
When a rope is damaged by crushing,
the wires, strands and core are
prevented from moving and adjusting
normally during operation.
In general, IWRC ropes are more crush
resistant than fiber core ropes. Regular
lay ropes are more crush resistant than
lang lay ropes. 6-strand ropes have
greater crush resistance than 8-strand
ropes or 19-strand ropes. Flex-X ® ropes
are more resistant than standard roundstrand
ropes.
reSIStAnce to metAl loSS And
deFormAtIon Metal loss refers to
the actual wearing away of metal from
the outer wires of a rope, and metal
deformation is the changing of the shape
of outer wires of a rope.
In general, resistance to metal loss
by abrasion (usually called “abrasion
resistance”) refers to a rope’s ability to
withstand metal being worn away along its
exterior. This reduces strength of a rope.
The most common form of metal
deformation is generally called
“peening” – since outside wires of
a peened rope appear to have been
“hammered” along their exposed
surface.
Peening usually occurs on drums,
caused by rope-to-rope contact during
spooling of the rope on the drum. It may
also occur on sheaves.
Peening causes metal fatigue, which
in turn may cause wire failure. The
hammering – which causes the metal
of the wire to flow into a new shape
– realigns the grain structure of the
metal, thereby affecting its fatigue
resistance. The out-of-round shape also
impairs wire movement when the rope
bends.
reSIStAnce to rotAtIon When
a load is placed on a rope, torque is
created within the rope as wires and
strands try to straighten out. This is
normal and the rope is designed to
operate with this load-induced torque.
However, this torque can cause both
single part and multiple part hoisting
systems to rotate. Load-induced torque
can be reduced by specially designed
ropes.
In standard 6- and 8-strand ropes, the
torques produced by the outer strands
and the IWRC are in the same direction
and add together. XLT4 ropes use the
torque created by the strand lay and
the rope lay to minimize the total rope
torque. In rotation-resistant ropes,
the lay of the outer strands is in the
opposite direction to the lay of the inner
strands, thus the torques produced are
in opposite directions and the torques
subtract from each other.
5
“sqUared ends”
> Typical example of
breaks due to fatigue .
“CrUshing”
> Typical example of
external pressure on a
wire rope .
Cross-seCtion
of a worn wire
> Original
cross-section
> Worn
surface
Cross-seCtion
of a Peened wire
> Original
cross-section
> Peened
surface

Crawler and trUCk Cranes
wire rope recommendations for crane applications
let us show you the ropes you’ll need to keep your cranes working. On the
following charts, you’ll see the wire ropes we recommend for your many different
applications. Your specific application may vary, of course, and that’s why you can
depend on a world leader such as Union to help you choose the right rope.
important note when changing ropes:
mobile Cranes: When changing wire ropes, ensure the minimum breaking force is equal to or
higher than the rope it replaces. If you change from a standard rope to a rotation-resistant rope,
the required design factor will change. ASME B30.5 requires a design factor of 3.5 for standard
ropes and a design factor of 5.0 for rotation-resistant ropes. If changing from a standard rope to
a low-torque rope, the required design factor will not change . The XLT 4 low-torque rope may be
used with a design factor of 3.5.
tower Cranes: When changing wire ropes, ensure the minimum breaking force is equal to or
higher than the rope it replaces. ASME B30.3 requires a design factor of no less than 5 for all
load hoist ropes .
Anytime you change the construction or grade of the rope on a crane, ensure the crane’s load
charts are verified or updated as needed.
aPPliCation reCommended roPe Comments
main hoist rope flex-X® 6 regular lay iwrC
Xlt 4
flex-X 35
flex-X 19 Ps regular lay
6 x 26 regular lay iwrC
6 x 25 regular lay iwrC
auxiliary Xlt 4
hoist rope flex-X 35
flex-X 19 Ps
19 x 7
8 x 25
boom hoist rope flex-X 9
flex-X 6 regular lay iwrC
flattened strand
6 x 26 regular lay iwrC
tag line 6 x 19 regular lay iwrC
6 x 36 regular lay iwrC
6
Characteristics needed are resistance to bending fatigue,
resistance to crushing and resistance to wear . Flex-X 6
provides the best combination of necessary characteristics,
plus higher strength. If block rotation is a problem and the
drum is grooved, XLT 4 is recommended . For smooth drums,
Flex-X 35 or Flex-X 19 PS should be considered.
Rotation resistance is a primary concern in an auxiliary
hoist and for applications utilizing grooved drums, XLT 4 is
recommended. For smooth drum applications, Flex-X 35
should be considered . Both of these ropes may be used with a
swivel. For less demanding applications, Flex-X 19 PS provides
a good combination of rotation resistant properties and
resistance to crushing .
The primary characteristic needed in a boom hoist rope is
resistance to drum crushing . Flex-X 9 is best suited to handle
this situation . Flex-X 6 also works well in many boom hoist
applications. Though alternate lay ropes may be specified on
your equipment, it generally will not perform as well as those
listed here .
Most standard construction ropes will perform in this
application .

Clamshells and graPPles
aPPliCation reCommended roPe Comments
holding line and flex-X® 6 iwrC
closing line 6 x 26 regular lay iwrC
boom hoist and refer to Crawler Crane section
tag line
tower Cranes
aPPliCation reCommended roPe Comments
hoist rope
flex-X 35
Xlt 4
trolley rope flex-X 7CC
7-flex
6 x 36
boom hoist rope flex-X 9
flex-X 6 regular lay iwrC
flattened strand
6 x 26 regular lay iwrC
These applications need a solid combination of
resistance to fatigue and abrasion. Flex-X 6 fills this need
better than conventional ropes .
Rotation resistance is necessary for block stability in long
block fall distances incurred with tower cranes . Flex-X
35 is recommended for this application. XLT 4 is also
recommended . Both of these ropes may be used with a
swivel .
Fatigue resistance and resistance to wear are important
for trolley ropes . Flex-x 7CC offers the best combination of
these characteristics making it the best choice for trolley
ropes .
The primary characteristic needed in a boom hoist rope
is resistance to drum crushing . Flex-X 9 is best suited
to handle this situation . Flex-X 6 also works well in
many boom hoist applications . Alternate lay ropes may
be specified on your equipment but it generally won’t
perform as well as those listed here .
7

Xlt4: extremely low torque – extremely high strength
From Union comes a revolutionary
crane rope design called XLT 4*.
“XLT” because it has extremely
low torque; “4” because it has the
minimum breaking force of a 6-strand
XXXXIP (4X) IWRC rope.
more lift. less torqUe.
lower Cost.
What sets XLT 4 apart from other ropes
is its unique design, which packs
more high-tensile steel wire into the
rope’s diameter, giving XLT 4 one of the
highest strength-to-diameter ratios ever
achieved – with a minimum breaking
force 33% higher than standard 6-strand
XIP ropes.
Under load, XLT 4 generates near-zero
torque, matching or surpassing the
stability of Category 1 35 x 7 class
rotation-resistant ropes. Yet, thanks to
its unique design, XLT 4 is not classified
as a “rotation-resistant” rope. It can
be used with or without a swivel as a
mobile crane hoist rope at design factors
as low as 3.5 to 1.
And, for value, nothing performs like
XLT 4. Not only does it cost less than a
35 x 7 classification rope, its compact
construction keeps moore steel in
contact with sheaves and drums for
unmatched resistance to crushing and
wear – for lower maintenance, less
downtime and longer service life.
faster, more effiCient Crane
oPeration.
XLT 4’s powerful advantages go
beyond high strength, low torque and
economical cost. With the rope’s high
capacity, lifts may be feasible using
fewer parts of line – boosting the speed,
efficiency and productivity of crane
work.
8
Xlt4 sPeCifiCations
nominal nominal minimUm aPProX
diameter diameter breaking forCe weight
InchES InchES TOnS OF 2000 LBS. LBS./FT.
12 15.8 .045
1/2 17.7 .051
14 21.4 .061
9/16 22.3 .065
5/8 27.4 .079
16 27.8 .079
19 39.0 1.1
3/4 39.2 1.1
22 52.0 1.5
7/8 53.0 1.5
23 56.8 1.6
24 61.7 1.8
1 68.9 2.1
26 72.1 2.1
28 83.3 2.4
1-1/8 86.7 2.6
easy to install. easy to Use.
While XLT4’s unique construction
is different in appearance and feel
compared to other wire ropes, you’ll be
pleasantly surprised by the way it spools
and operates. As with any wire rope,
proper installation is key – particularly
for the base layers and all layers that do
not come off the drum during normal
operation. To maximize performance
and to avoid “pull-in”, the rope must
be spooled on the drum under load,
ensuring that the rope is both tight
against adjacent wraps and tight around
the drum. As with any wire rope, XLT 4
will perform better on a grooved drum.
Although differing in appearance
and feel, field experience has shown
that XLT 4 presents no problems in
terminations using wedge sockets or
wire rope clips. XLT 4 requires no special
end preparation.
*Patent Pending

wire ropes for rotational stability
ropes that provide load stability can often
provide the best and most economical
service in specific applications when you
choose, handle and use them properly.
XLT 4 ropes are specially designed to provide very
low torque, a high minimum breaking force and
high resistance to wear in multi-layer spooling.
This rope is not “rotation-resistant” and can
be used on mobile crane hoist applications at a
minimum design factor of 3.5 and can be used with
a swivel at the dead end.
Contra-helically laid, rotation-resistant ropes are
different from standard ropes because they’re
designed to reduce rope torque. Modes of failure
and wear for rotation-resistant ropes can differ
from those for standard rope constructions.
The very nature of these ropes requires special
handling, selection and usage not encountered
with standard constructions.
rotation-resistant Crane roPes sPeCifiCations
MInIMuM BrEAkIng FOrcES In TOnS OF 2,000 POundS.
These ropes are susceptible to kinking, crushing
and unbalancing in the form of “core pops” and
“birdcages.” Use extreme care to avoid operational
practices that can possibly lead to these conditions.
There are different types of rotation-resistant
ropes, categorized by their resistance to rotation.
Category 1 rotation-resistant rope (Flex-X 35) has at
least 15 outer strands, has three layers of strands
(over a center) and has little or no tendency to
rotate, or, if guided, transmits little or no torque.
Category 2 rotation-resistant rope (Flex-X 19 PS
and 19 x 7) has 10 or more outer strands, has two
or more layers of strands (over a center) and has
a significant resistance to rotation. Category 3
rotation-resistant rope (8 x 19 RTW) has no more
than 9 outer strands, has two layers of strands
(over a center) and has limited resistance to
rotation. For best performance, Category 2 and 3
rotation-resistant ropes should not be used with a
swivel. Category 1 rotation-resistant rope handling,
installation and usage.
Category 1 Category 2 Category 3
fleX-X ® 35 fleX-X ® 19 Ps 19 X 7 XiP ® 8 X 19 XiP ®
diameter approx. minimum diameter approx. minimum approx. minimum diameter approx. minimum
Millimeter weight breaking Inches weight breaking weight breaking Inches weight breaking
lbs. / ft. force lbs. / ft. force lbs. / ft. force lbs. / ft. Force
3/16 0.064 1.57 3/16
1/4 0.113 2.77 1/4
5/16 0.177 4.30 5/16 0.18 4.63
3/8 0.25 6.15 3/8 0.26 6.63
7/16 0.43 11.8 0.35 8.33 7/16 0.36 8.97
13 0.60 20.4 1/2 0.49 15.4 0.45 10.8 1/2 0.47 11.6
16 0.90 30.6 9/16 0.65 19.4 0.58 13.6 9/16 0.60 14.7
18 1.2 38.5 5/8 0.78 23.8 0.71 16.8 5/8 0.73 18.1
19 1.3 42.9 3/4 1.16 34.0 1.02 24.0 3/4 1.06 25.9
22 1.7 57.2 7/8 1.58 46.0 1.39 32.5 7/8 1.44 35.0
25.4 2.2 75.8 1 2.05 59.8 1.82 42.2 1 1.88 45.5
26 2.3 79.3 1 1/8 2.57 75.2 2.30 53.1 1 1/8 2.39 57.3
28 2.7 91.6 1 1/4 2.83 65.1 1 1/4 2.94 70.5
30 3.1 105 1 3/8 3.43 78.4 1 3/8 3.56 84.9
32 3.5 119 1 1/2 4.08 92.8 1 1/2 4.24 100
note: These strengths apply only when a test is conducted with
both ends fixed. When in use, the strengths of these ropes may be
significantly reduced if one end is free to rotate.
9

flex-X 7CC, a container crane rope that
guarantees a lift in productivity.
container crane hoist and trolley
ropes are subjected to the
stressful combination of bending
fatigue and abrasion from operating over
a series of intricate sheaves and drums.
Union has developed Flex-X 7cc, a
wire rope for container cranes that’s so
revolutionary it’s guaranteed to provide
you with a significant lift in service life
when compared with standard ropes.
Flex-X 7cc will operate longer – no
matter what load conditions you put it
under. A combination of superior design
and manufacturing technique helps
reduce metal fatigue, internally and
externally, while helping to extend the
life of sheaves and drums.
fleX-X 7CC lasts longer.
Flex-X 7CC’s longer service life will
result in lower maintenance costs due to
fewer rope changes.
All ropes gradually lose strength due
to wear and fatigue but test data has
proven that Flex-X 7cc has superior
fatigue life over standard rope. With the
ropes subjected to the same operating
conditions (load and sheave diameter),
the chart at right illustrates how Flex-X
7cc’s service exceeded standard rope
by 46% when both ropes reached 80% of
the standard rope’s strength.
10
fleX-X 7CC sPeCifiCations
nominal aPProX minimUm
diameter weight breaking forCe
InchES LBS./FT. TOnS OF 2000 LBS.
1/2 0.50 15.3
9/16 0.63 19.3
5/8 0.80 22.7
3/4 1.13 32.4
7/8 1.55 43.8
1 2.01 56.9
1-1/8 2.54 71.5
1-1/4 3.14 87.9
1-3/8 3.80 106
fleX-X 7CC
FLex-x 7CC Standard

wire rope weights and minimum
breaking force for cranes.
standard 6 X 19 Class and
6 X 36 Class Crane roPes.
the 6 x 19 classification of wire ropes
includes standard 6-strand round strand
ropes with 16 through 26 wires per
strand. The 6 x 36 classification of wire ropes
includes standard 6-strand round strand ropes
with 27 through 49 wires per strand. Although
their operating characteristics vary, all have the
same weight per foot and the same minimum
breaking force, size for size.
6 X 19 & 6 X 36 Class SPEcIFIcATIOnS
iwrC / fleX-X 6 and fleX-X 9 / flattened strand roPes
MInIMuM BrEAkIng FOrcES In TOnS OF 2,000 POundS.
6 X 19 and 6 X 36 Class iwrC ComPaCted strand flattened strand
diameter XiP ® XXiP ® fleX-X ® 6 fleX-X ® 9
Inches approx.
weight minimum
lbs. / ft. breaking force
3/16
1/4 0.116 3.40
5/16 0.18 5.27
approx.
weight
lbs. / ft.
The Flex-X ® process compacts each strand,
which improves the rope’s strength, stability,
abrasion resistance, fatigue resistance and
crushing resistance.
These characteristics make Flex-X 6 an
excellent choice for the main hoist rope for
mobile cranes and the hoist rope on most
overhead cranes. Flex-X 9, specifically designed
for boom hoist applications, features compacted
strands and swaging for extra drum crushing
resistance
minimum
breaking
force
3/8 0.26 7.55 8.30 0.32 8.8
7/16 0.35 10.2 11.2 0.41 11.9
1/2 0.46 13.3 14.6 0.55 15.3
approx.
weight
lbs. / ft.
minimum
breaking
force
approx.
weight
lbs. / ft.
minimum
breaking
force
9/16 0.59 16.8 18.5 0.70 19.3
5/8 0.72 20.6 22.7 0.86 22.7 0.95 26.2 0.74 21.7
3/4 1.04 29.4 32.4 1.25 32.4 1.35 37.4 1.06 31.0
7/8 1.42 39.8 43.8 1.67 43.8 1.85 50.6 1.46 41.9
1 1.85 51.7 56.9 2.18 56.9 2.40 65.7 1.89 54.4
1 1/8 2.34 65.0 71.5 2.71 71.5 3.05 82.7 2.39 68.5
1 1/4 2.89 79.9 87.9 3.43 87.9 2.95 84.0
1 3/8 3.50 96.0 106 4.25 106 3.57 101
1 1/2 4.16 114 125 5.01 125 4.25 119
1 5/8 4.88 132 146 4.99 140
1 3/4 5.67 153 169 5.79 161
1 7/8 6.50 174 192
2 7.39 198 217
2 1/8 8.35 221 244
2 1/4 9.36 247 272
note: Many wire ropes are also available in PFV, a plastic
impregnated rope design from Union .
11

when yoU’re
installing wire
roPe, there’s a
Primary ConCern:
Getting the rope on the
equipment without trapping
any twist that may
have been induced during
handling or installation .
make sure the foundation
layer is spooled tightly.
guidelines for installation and maintenance.
the Preferred teChniqUe for
installing roPe onto a Crane.
1. Unload roPe ProPerly and relieve
any twists.
Pull the rope off the shipping reel or
unroll it from a shipping coil as shown.
(If done improperly, you may kink the
rope, which will result in permanent
damage to the rope.) Then lay the rope
on the ground in a direct line with the
boom. This helps release any twist in
the rope.
2. attaCh roPe’s end to drUm. Pull the
rope over the point sheave and attach
the end to the drum. Before making
any end attachment, be sure the rope
strands are free to adjust. (In other
words, make sure the end of the rope
is not welded together.)
3. wind roPe onto drUm slowly and
CarefUlly. At this point, it isn’t
necessary to provide additional load
other than the weight of the rope
being pulled across the ground.
4. sPool first layer tightly.
It’s essential on smooth-faced drums
that the first layer is spooled with
wraps tight and close together since
the first layer forms the foundation for
succeeding layers. If need be, use a
rubber, lead or brass mallet (but never
a steel hammer) to tap the rope in place.
12
Unreel rope from a shaft supported by two jacks.
Uncoil rope by rolling it along ground like a hoop.
5. sPool mUltiPle layers with
sUffiCient tension. It’s very important
to apply a tensioning load to the ropes
during the rope
breaking-in
process. (If not,
the lower layers
may be loose
enough that the
upper layers
become wedged
into the lower
layers under
load, which
can seriously
the result of improper
tensioning is a “pulling in” of
the rope.
damage the rope.) The tensioning load
should range from 2 to 3% of the rope’s
minimum breaking force.
6. for roPes in
mUlti-Part
systems:
Reeve the
traveling
block and
boomtip
sheaves so
the rope incorrect Correct
spacing is
maximized and the traveling (hook)
block hangs straight and level to help
assure block stability. Avoid deadending
the rope at the traveling block
if possible.
7. CheCk roPe for twist. With the rope
slack, pull enough rope out to allow it
to hang in a
loop (right).
If the rope
hangs without
twisting
together,
there is no
twist in rope no twist
twist in the
rope. If the rope twists together (left),
the rope has twist in it. Follow steps
shown on next page to relieve twist
from the rope.

eaking in yoUr new wire roPe.
After installation, you should properly
break in your rope, which allows the
rope’s component parts to adjust
themselves to your operating conditions.
With the boom fully raised – and fully
extended if you’re using a hydraulic boom
– attach a light load at the hook and raise
it a few inches off the ground. Allow to
stand for several minutes. Then cycle the
load between the full “up” and “down”
positions several times. Stand back and
watch the drum winding and rope travel
for any potential problems.
After making the lifts with a light load,
increase the load and cycle it up and down
a few times. This procedure will train the
rope and help assure smooth operation
during its useful life.
Ideally, you should run these loads with
reeving that lets you place the loads on
the block with all rope off the drum except
the last three wraps. If this isn’t possible,
alternate methods must be used to assure
proper tensioning of the rope on the drum.
always leave three wraPs on drUm.
Although ASME B30.5 states that two
wraps must remain on the drum when the
hook is in the extreme low position, we
recommend at least three wraps always
remain on the drum.
rigging in tight qUarters.
If you can’t lay the new rope out on the
ground before rigging – and you need to
pull it directly from the reel – further steps
are necessary. First, you should mount the
reel on a shaft through flange holes and
on jack stands, making sure you spool as
illustrated below. While unspooling, do
not allow the reel to “free-wheel.” Brake
the reel by applying pressure to a flange.
Never apply braking pressure to the rope
on the reel – or pass the rope between
blocks of wood or other material.
install from reel top over the point sheave.
relieving twist.
To relieve twist that may be trapped
in a rope spooled directly off a reel to
the drum, raise the boom to its highest
position while letting out the rope until
the rope almost touches the ground. Let
the rope hang free without added load
while standing clear. When twist is fully
relieved, proceed with rigging the crane.
lUbriCate roPes often for long life.
To properly maintain your rope, the first
place to check is for obvious signs of
abuse from other parts of the rope system.
But the biggest part of maintenance
involves regular lubrication to reduce
friction between the rope’s components
as well as the friction between rope and
sheaves or drums.
Your rope receives internal lubricant at
the factory, but it’s not enough to last the
rope’s entire life due to constant bending
over sheaves and drums. The need to
keep ropes properly lubricated can’t be
overemphasized.
Clean roPes first.
Remove excess dirt, rock dust or other
materials that can prevent field-applied
lubricants from properly penetrating into
the ropes.
lUbriCate Using one of two methods.
One is called manual lubrication such as
spray or drip systems that apply lubricant
when you want. You can also swab or
paint lube into your moving rope by hand,
or pour lube onto your rope as it passes a
certain point.
The other is called automatic lubrication
that drips or sprays lube onto your rope
as it passes over a sheave at preselected
intervals.
13
what lUbriCant
shoUld yoU Use?
There are two lubricants
you should not use. never
apply heavy grease to
the rope because it can
trap excessive grit and
dust, which can externally
damage the rope or be
forced inside, causing
hidden damage. nor
should you apply used
“engine oil” because it
contains materials that
can damage your rope .
The kind and amount of
lubricant will vary according
to the type and use of your
wire rope . But the lubricant
should have these traits:
> Penetrate to the rope core .
The best way is to apply
at a place where the rope
bends, such as over a
sheave, exposing the wires
and strands to provide a
better opening to the core .
> Contain enough adhesive
and film strength to stick
to wires in the rope and
the spaces around the
wires .
> Be free of acids and
alkalis .
> Resist corrosion .
> Stay put without being
easily washed away .

how to inspect your wire ropes.
despite their durability and
strength, wire ropes used
on cranes will wear out and
need to be retired from service. That’s
why regular inspection is so crucial to
your long-term success. It’s important
to appoint a qualified trained
person to conduct the inspection
and understand the mechanics of
inspection. This section offers you
general guidelines, but for more
detailed information, please consult
our Techreport 107.
how often to insPeCt.
Obviously, the more you use a wire
rope, the more often you need to inspect
it. According to the ASME standards,
owners or users are required to visually
inspect all wire ropes at least once every
day when in use. A qualified, trained
person should be appointed to conduct
the inspection. That person is also
required to periodically inspect all wire
ropes and keep a written record, noting
any damage and recording when ropes
are replaced. This will give you a basis
for judging the proper time to replace
your ropes.
We recommend you set up a longrange
inspection program, including
examination of ropes removed from
service.
14
foCUs on yoUr roPe’s CritiCal Points.
While you’re required to inspect the
entire rope length, we recommend
you pay particular attention to the
critical points of a wire rope. These are
the points subject to greater internal
stresses, greater external forces or
are more susceptible to damage. Rope
deterioration normally occurs more
quickly at these points, so it pays
to expand your inspection in these
important areas:
PiCk-UP Points. These are sections of
ropes repeatedly placed under stress
when you apply the initial load of each
lift such as those sections contacting the
sheaves or on the drums.
end attaChments. Attachments at the
dead end and drum restrict the free
movement of wires, normally leading to
broken wires that are more difficult to
detect. Inspect with an awl to expose
them, and if you find more than one
broken wire, replace the rope or cut
off the affected area and reattach the
fitting. Corrosion can be more prevalent
in this area. Be sure to also inspect the
fitting itself.
drUms. Check for signs of wear that
could damage wire rope. For grooved
drums, inspect the grooves for
smoothness and absence of corrugation.
For smooth drums, check for wire rope
corrugation. It’s also important to verify
that the required minimum number of
dead wraps remain on the drum and to
check the condition of the drum flanges.
sheaves. The grooves on sheaves usually

wear smaller over time. With a groove
gauge, check each sheave for proper
groove size and contour, as well as
smoothness. Grooves that are too small
or tight can cause pinching and increased
wear while grooves that are too wide
can cause flattening of the rope – both of
which can reduce your rope’s life.
heat eXPosUre. Watch for evidence of
heat exposure which can damage the
rope and its lubricant. Any contact
how to find broken wires.
One of the most common signs of rope deterioration is broken wires, normally the outside
wires at the crowns of the strands . During your inspection, it’s very important to search for
broken wires, especially the areas of the rope in contact with sheaves and drums when
loads are picked up .
typical valley wire breaks.
typical crown wire breaks.
with an electrical arc such as welding
is reason for removal of the entire rope.
Never use the rope as the ground for an
arc welder.
abUse Points. Check for “bright” spots
where ropes are subjected to abnormal
scuffing and scraping. Look for any
condition that causes the rope to be
asymmetrical.
1. The first step is to relax your rope to a stationary position, move the pick-up points off the
sheaves . Clean the grease from the rope with a cloth – a wire brush, if necessary – so
you can see any breaks .
2 . Flex the rope to expose any broken wires hidden in the valleys between the strands .
3. Visually check for any broken wires. One way is to run a cloth along the rope to check for
possible snags .
4 . With an awl, probe between wires and strands and lift any wires that appear loose .
Evidence of internal broken wires may require a more extensive rope examination.
15
> It’s important to
remember there are
minor – sometimes
major – differences
among applications,
even on machines with
similar designs .
That’s why it takes the
best judgment of a
trained, knowledgeable
inspector to choose the
critical points on each
rope application for
closer inspection .

when to replace your ropes.
According to the ASME B30.5
standard for mobile cranes,
there are no precise rules to
determine the exact time to replace
rope because so many variables
are involved. Once a rope reaches a
specified removal criteria, it may be
allowed to operate to the end of the
work shift, based on the judgement of
a qualified person. The rope should be
replaced after that work shift at the
end of the day – or at the latest prior
to the equipment being used by the
next work shift.
The following required standards
established by ASME B30.5 that
provide specific reasons to replace
wire ropes.
broken wires. For running ropes
including XLT 4 ropes, replace when
you see six randomly distributed
broken wires in one lay – or three
broken wires in one strand in one lay.
For rotation resistant ropes categories
1, 2 and 3, replace when you see two
randomly distributed broken wires in
six rope diameters – or four randomly
distributed broken wires in 30 rope
diameters.
Broken wire removal criteria apply
to wire ropes operating on steel
sheaves and drums. The user should
contact the sheave, drum or crane
manufacturer for broken wire removal
criteria for wire ropes operating on
sheaves and drums made of material
other than steel.
16
one broken wire eXtending from
roPe’s Core. When you see one outer
wire broken at the point of contact
with the rope’s core which has worked
its way out or looped out from the
rope structure, you’ll need to conduct
additional inspection of that section of
rope.
eXtensive roPe wear. When wear
reaches one-third the original
diameter of the outside individual
wires, it’s time to replace the rope.
roPe distortion. Replace any rope
with evidence of kinking, crushing,
birdcaging or any other damage
resulting in distortion of the rope
structure.
heat damage. Because heat exposure
can damage the rope and its lubricant,
always remove ropes damaged by heat
from any cause.

edUCtions in nominal diameter.
Replace any rope when its measured
diameter has decreased more than 5%
below its nominal diameter.
what rePlaCement roPe to Use.
Your replacement rope should have a
minimum breaking force at least as
great as the original rope furnished
or recommended by the crane
manufacturer. Any deviation from the
original size, grade or construction
must be specified by the wire rope
manufacturer, crane manufacturer or a
qualified person. See pages 6-7.
what aboUt idle roPes? All wire
ropes that have been idle for one
month or longer due to shutdown
or storage of the crane on which
they’re installed should be inspected
according to ASME standards before
you place them in service. Make sure
an authorized person inspects for all
types of rope deterioration.
always measure the largest dimension
when measuring your rope.
Proper method of measuring ropes with odd
number of outer strands, using caliper with
plates.
17

how to determine
the ProPer
direCtion of drUm
winding.
Overwind left to right, use
right lay rope .
right lay overwind
Underwind right to left,
use right lay rope .
right lay Underwind
Overwind right to left, use
left lay rope .
left lay overwind
Underwind left to right,
use left lay rope .
left lay Underwind
how to identify and correct three
common problems in the field.
drUm sPooling: a tight sitUation for
Crane oPerators.
When you’re installing a new
rope onto a crane, there’s
a primary objective: spool
the rope onto the equipment tightly
without trapping any twist in the
rope on the drum. (See installation
guidelines for details.)
For multiple-layer spooling, it’s
essential to get the first layers of
rope spooled with sufficient tension.
Particularly with smooth-faced drums,
the first layers must be tight with
each wrap snug against the preceding
wrap. Since the first layer provides
the “grooving” for upper layers, wraps
must be placed tightly together. If not,
wraps in upper layers will pull down
between wraps already on the drum,
which can cause crushing damage and
reduced rope strength and service life.
When you encounter spooling
problems, check the following list
to identify the possible cause. If any
of these are incorrect, the result
can include open (or loose) spooling,
random spooling or stacking of rope
against drum flanges.
drUm alignment.
Before spooling, make sure the drum
is level and at right angles to the
boom. Many drums are mounted on
the frame so that adjustment can be
made in alignment.
drUm winding.
Wire rope should wind onto the
smooth-faced drum as shown. Make
sure you wrap the rope left or right
and over or under as recommended.
18
Use of a swivel.
Except for Category 1 rotation-resistant
ropes and XLT 4, a swivel end termination
will let the rope lay lengthen when loaded.
As the rope spools onto a drum, the
unlaid rope travels over the point sheave
and accumulates between the drum and
point sheave. This leads to block rotation,
erratic spooling,
unbalancing and
decreased rope
service. Category
1 rotation
resistant ropes
and XLT 4 may
be used with a
swivel without
these concerns.
fleet angle.
One of the most
important factors
in proper winding
of rope on drums.
For smooth-faced
drums, this
angle should be
between 1/2°
and 1-1/2”. For
grooved drums,
it should be
between 1/2”
and 2”. Fleet
angles larger
than these can
cause spooling
problems and
the rope to rub
against the flanges of the sheave – plus may
lead to rope crushing and abrasion on the
drum. Fleet angles smaller than these may
cause the rope to pile up at the flanges.
Point sheave.
When more than one sheave is in use
at the boomtip, make sure the lead line
presents the optimum fleet angle to the
drum.

grooved drUms.
Groove spacing must be adequate to
prevent the rope from crowding out
adjacent wraps as the rope spools
across the drum. In addition, groove
spacing must not be excessive, which
can allow wraps of the next layer to pull
down between wraps of the previous
layer, causing abrasion and crushing.
drUm flanges.
Flanges should be perpendicular to the
drum face and not worn, deformed or
spread outward. These conditions can
cause spooling problems at the changeof-layer
point as additional layers are
spooled.
Also called “wavy rope,” unbalance is an
indication or result of abnormal movement of
strands in an operating rope. It usually involves
two or more outer strands of rope rising out of
position, standing higher than remaining strands
with no apparent cause or evidence of external
physical force .
Anytime you see an unbalanced rope, you should
increase your rope inspection frequency . Find out
the cause and correct the problem before you
install your next rope .
the causes.
Unbalance often shows up in the middle of a
rope system where you don’t expect it. It’s usually
caused by “milking” of the rope – in other words,
a lay change in the rope . The causes are many:
swivels, small diameter sheaves, improper-sized or
worn sheave grooves or sheave misalignment, to
name a few .
Standard 6-strand regular lay ropes are generally
more resistant to unbalance than other ropes .
how to correct unbalance problems.
There are several practices you can implement
to minimize rope unbalance problems . These
include:
ELIMInATE SWIVELS AT dEAd EndS. A swivel end
termination will lengthen the lay in the rope when
imProPer installation.
When a rope has been installed in such
a way that twist has been introduced
into the rope, spooling problems can
result. (See installation guidelines for
details.)
riser striPs and kiCk Plates.
If spooling problems persist after you’ve
considered the above conditions, try
using riser strips and kick plates. For
details on these accessories, check with
your crane manufacturer or call Union
for technical service.
Rope unbalance: a problem of unequal proportions .
loaded, which can cause an unbalance in the
rope .
rEMOVE WELdEd EndS OF rOPES. Where a
rope has been torch cut, make sure the strands
are free to adjust before the rope is clamped or
seated in an end termination . However, this does
not apply to Flex-X 35. Leave the welded ends on
Flex-X 35
LOOk FOr Any ShEAVE MISALIgnMEnT.
Misalignment of sheaves in multi-part reevings
and improperly aligned idler sheaves can also
contribute to unbalance problems .
ASSurE PrOPEr grOOVE cOnTOurS. Use a
groove gauge to inspect sheave and drum grooves
for proper contour. If sheave grooves are too small
or are worn deeper and narrower by an old rope,
they’re too tight for new ropes. If grooves are too
wide, the ropes tend to flatten out and become
oval-shaped . Any of these conditions can restrict
strand movement and cause twist to build up in
the rope .
cOnSIdEr A 6-STrAnd rOPE cOnSTrucTIOn.
Standard 6-strand regular lay ropes are less
susceptible to unbalance than other ropes .
rEMOVE Any TWIST In rOPE. See rope
installation guidelines for details .
19
150˚
Cross-seCtion views
of three sheave
groove Conditions.
A B C
Using a gauge, a is correct, b
is too tight and C is too loose.

lock rotation: a very entangling problem.
Also called cabling, block
rotation occurs when multipart
reeving twists together
at a certain height, entangling the
parts of rope between the traveling
block and boomtip. It can happen with
little warning, making it virtually
impossible to lift or lower a suspended
load. Twisted hoist lines can bring a
construction project to a sudden halt,
resulting in downtime.
But the good news is this. You can
minimize block rotation through proper
installation and handling, as well as take
corrective measures
the key is Understanding torqUe.
Every wire rope – regardless of type,
classification, grade or manufacturer
– will develop torque when loaded.
Torque is normal and natural, caused
by the way wire ropes are made. Wires
are first laid together in a spiral to form
strands, then several strands are laid
together in a spiral to form the rope.
When loaded, wires and strands try to
straighten out, thus creating torque.
Another source of torque is any change
in the rope lay length. This is normally
caused by “milking” or rotation at the
end of the rope.
Torque in a rope affects the tendency of
the traveling block to rotate. Thus, it’s
important to minimize any torque.
how to helP redUCe bloCk rotation.
There are at least seven different
operating practices you can use to
minimize block rotation on your crane.
Change the rigging geometry. This
includes the following operating
practices:
20
– Use larger diameter traveling block
sheaves to increase the rope spacing.
As the diameter of the traveling
block sheave increases, the chances
for block rotation are reduced.
– Use the outer (farthest apart)
sheaves – traveling block and boom.
– Dead-end the rope at the boomtip
to increase the spread between the
wire rope parts.
Use the shortest fall length Possible.
The length of fall, or the distance from
the pick point to the point sheaves,
is critical. Longer fall lengths are less
stable and more likely to lead to block
rotation.
avoid odd-Part reeving. An even number
of parts is more stable.
Use taglines on lifts. Attach a tagline to
restrain the load block and keep the load
from rotating.

Use a different roPe ConstrUCtion.
Standard 6-strand ropes do not provide
any rotation resistance. There are
different levels of rotation resistance
that can be obtained from specialty
ropes. For maximum block stability
use XLT 4. The unique design of XLT 4
results in extremely low torque under
load. This characteristic makes XLT 4
one of the most stable ropes in multiple
part reeving comparable to Category 1
rotation-resistant ropes. Both XLT 4 and
Category 1 ropes are also used in single
part hoisting.
There are other specialty ropes
that provide lower levels of rotation
resistance. These ropes have been
divided into categories based on their
rotation resistance. The lowest level
of rotation-resistant ropes is Category
3 which include our 8 x 25. Our Flex-X
19 PS and 19 x 7 ropes are Category 2
rotation-resistant ropes. They provide
greater rotation resistance than
Category 3 ropes. Flex-X 19 PS is very
resistant to crushing in multiple layer
spooling and is frequently used in multipart
hoisting applications.
Use a swivel only with Xlt4 and
Category 1 roPes. XLT 4 and Category
1 ropes, due to their special design, may
be used with a swivel. Other wire ropes
should not be used with a swivel.
With standard ropes, Category 2 (Flex-X
19 PS and 19 x 7) rotation-resistant rope
and Category 3 (8 x 25) rotation-resistant
rope, a swivel in an end termination
will allow rotation in a direction that
unlays the outer strands when the rope
is loaded. This can cause a reduction in
rope strength, unbalance in the rope and
spooling problems.
While the rope rotation only occurs
between the swivel and the first sheave,
the unlaid rope travels over the sheave
as the load is lifted and introduces
unlaying to the section of the rope
beyond the sheave. This unlaying
becomes trapped and will not come out
of the rope when the load is removed.
The trapped unlaying causes twist in
the rope, which leads to block rotation,
erratic spooling, unbalancing and
decreased rope service. Remove the
swivel from the rope termination and
follow steps to remove twist from the
rope to optimize rope service.
CheCk sheave alignment and groove
size. Improper sheave alignment or
groove size can “milk” the lay in a rope
and cause torque.
21

The band for XLT 4 and
Category 1 rotationresistant
ropes is based
on torque values . The
bands for 6-strand,
Category 2 and Category
3 rotation-resistant
ropes were developed
in field research jointly
conducted by Wire Rope
Technical Board and the
Power crane and Shovel
Association .
how to evaluate block stability
due to rigging geometry.
Industry testing has been conducted
to help you assess the block stability
of your rigging configuration and
rope selection. The bands on this graph
approximate the block stability for
four types of wire ropes in multi-part
systems:
– 6-strand, right regular lay, IWRC
– Category 3 (8-strand,
rotation-resistant)
– Category 2 (19-strand,
rotation-resistant)
– XLT4 & Category 1 (35 x 7
rotation-resistant.
22
L
D
four independent variables are used in pairs
to locate a reference point on the graph that
indicates the stability of the lift being made. the
ratios used include:
L/S = Length of fall (ft.) ÷ Spacing of the rope (ft.).
L = Length of fall measured from the centerline of the
point sheave to the centerline of the traveling block
sheave as shown in the diagram .
S = Average diagonal spacing of the rope at the boom
point and the traveling block sheaves as shown in the
diagram .
d/d = (d) Average pitch diameter of point and block
sheaves (in.) ÷ (d) nominal rope diameter (in.).
For 2-part reeving, S = average pitch diameter of
point and block sheave
For 3-part reeving, S = 2/3 of 2-part
For 4-part reeving, S = diagonal distance of rope
parts
For 5-part reeving, S = 4/5 of 4-part
For 6-part reeving, S = diagonal distance of rope
parts
For 7-part reeving, S = 6/7 of six-part system
Some graphs were developed in field research
jointly conducted by Wire Rope Technical Board
and the Power crane and Shovel Association.
when the reference point on the graph lies
above the appropriate band, block rotation will
probably occur. if the reference point lies below
S

warning
In the real world, accidents do happen,
and that’s why you need to take special
precautions. Before installing wire rope
warranty
in your applications, always read and
follow the warning label attached to
each product.
Any warranty, expressed or implied as to quality, performance or fitness for use of wire rope products is always premised
on the condition that the published strengths apply only to new, unused rope, that the mechanical equipment on which
such products are used is properly designed and maintained, that such products are properly stored, handled, used and
maintained, and properly inspected on a regular basis during the period of use .
Seller shall not be liable under any circumstances for consequential or incidental damages or secondary charges including
but not limited to personal injury, labor costs, a loss of profits resulting from the use of said products or from said products
being incorporated in or becoming a component of any other product .
23

wireCo worldgroUP: ThE WOrLd IS Our WOrkSITE
engineering wire rope for your
application is a highly specialized
field – with exacting standards
– that we gladly live by. Across the
entire WireCo WorldGroup organization,
we draw from our global pool of talented
engineers to drive results for your
application.
Eight WireCo WorldGroup
manufacturing operations and seven
distribution centers in North America,
plus manufacturing facilities in
Germany and China, give our customers
unparalleled support and global reach.
Our manufacturing standards typically
exceed the minimum design standards
for a wire rope. We take an active role in
industry associations that develop wire
rope specifications and standards, such
as ASTM A1023.
We apply thorough design and
manufacturing controls – including
complete material traceability. And we
are the only manufacturer in the world
that is QPL qualified, API certified, and
registered to both ISO 9001:2000 and
AS-9100 Quality Systems.
816.270.4700
info@wirecoworldgroup.com
12200 NW Ambassador Dr
Kansas City, MO 64163–1244
fax: 816.270.4707
WireCoWorldGroup.com
wireCo worldgroup world headquarters, located in kansas City, missouri.
So, look to the best: The Union brand
backed by the WireCo WorldGroup
organization. We’re dedicated to
matching and advancing wire rope to
your dynamic applications throughout
the world.
With a global manufacturing and
distribution base, along with our
unmatched technical expertise, the
world is our worksite.
©2008 Wireco Worldgroup Form no. 1009d