Maintenance for Bridge Crane Wire Rope

1. The service life of steel wire rope is closely related to its usage method. Therefore, it should be used according to the rules, and dragging and throwing should be avoided. Overloading, sharp bending of the steel wire rope, sharp changes in lifting speed, and impact loads should be avoided during use;

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2. When there is rust and dust on the steel wire rope, use a wire brush to brush it off and apply oil;

3. The steel wire rope should be oiled every 4 months, and it is best to use hot oil (around 50 ℃) to penetrate the core of the rope before wiping off excess grease;

4. After the steel wire rope is coiled, it should be placed in a clean and dry place, and the stacking should not be looked at again to prevent twisting;

5. The end of the steel wire rope can be tightly tied with steel wire or welded with a low melting point alloy, or clamped with iron hoops to prevent the rope head from loosening;

6. In use, if there are oil droplets squeezed out from the surface of the steel wire rope, it indicates that the steel wire rope has received considerable force. At this time, the load should be stopped and checked. If necessary, a new steel wire rope should be replaced.

Here is a step-by-step maintenance procedure for the wire rope of a bridge crane:

1. Pre-Use Inspection (Daily)

1. Visually inspect the entire length of the wire rope for:

   • Broken wires

   • Kinks, birdcaging, or flattening

   • Corrosion or rust spots

2. Check the rope’s tension to ensure proper load distribution.

3. Inspect the drum and sheaves for proper alignment and smooth spooling.

   
   

2. Cleaning (As Needed)

1. Use a wire brush, compressed air, or cleaning cloth to remove dust, dirt, and old lubricant.

2. For heavily contaminated ropes, use degreasers suitable for steel wire ropes, followed by wiping with a dry cloth.

   • Avoid high-pressure water that could force contaminants into the core.

     
     

3. Lubrication (Weekly or Monthly)

1. Choose a penetrating lubricant that suits the working environment (moisture-resistant if in wet conditions).

2. Clean the wire rope before applying new lubricant.

3. Apply lubricant evenly along the entire length, focusing on high-friction points (e.g., drum and sheaves).

   • Operate the crane slowly during lubrication to ensure even distribution.

     
     

4. Alignment and Tension Check (Monthly)

1. Verify the alignment of the sheaves and drum to prevent uneven wear.

2. Check for proper tension across all wire ropes. Use a tension meter if available.

3. Ensure the rope spools evenly on the drum to avoid crushing or overlap issues.

   
   

5. Thorough Inspection (Every 3-6 Months)

1. Check for:

   • Broken wires: Replace the rope if more than 10 wires are broken in one lay length.

   • Abrasion or wear: Look for flattened strands or outer wire thinning.

   • Core damage or birdcaging.

2. Inspect the drum and sheaves for damage (sharp edges, grooves, or misalignment).

   
   

6. Environmental Protection (Ongoing)

1. Protect the wire rope from moisture, chemicals, and extreme temperatures.

2. Cover the crane or store the wire rope in a dry area if not in use.

3. Regularly inspect for corrosion if working in marine or corrosive environments.

   
   

7. Replacement Criteria

• Replace the wire rope if:

  • It shows excessive broken wires (as per manufacturer’s guidelines).

  • There is severe corrosion, flattening, or birdcaging.

  • It has stretched beyond allowable limits.

• Follow the manufacturer’s recommendations for periodic replacement.

  
  

8. Record Keeping (Ongoing)

1. Maintain logs of inspections, cleaning, and lubrication activities.

2. Track any defects and document corrective actions.

3. Keep records of replacement intervals for trend analysis and preventive maintenance planning.

   
   

9. Operator Training and Safety (Ongoing)

1. Train crane operators to recognize early signs of wear.

2. Ensure all personnel follow safety guidelines during wire rope maintenance and operation.

   
   

Summary Workflow

• Daily: Visual inspection

• Weekly/Monthly: Cleaning and lubrication

• Monthly: Tension and alignment checks

• Every 3-6 Months: In-depth inspection

• As Needed: Replacement

  
  

Following these steps ensures the safe and reliable operation of your crane’s wire rope, minimizes downtime, and extends the lifespan of the rope.