CHAPTER5 How to replace wire rope

Preparations:
Material:
1. New wire ropes according to the drawing’s requirement.

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 2. Some jute ropes diameter is about 20 mm.
3. Some soft wires diameter is about 2.5mm.
4. Some rope clamps.

Tools & Equipment:

1. Pliers & commen tools
2. Wire rope cutter
3. Forklift; Man lifter (or Mobile crane)

Personnel:
4-5 people

Caution:
1. Pay attention to any moveing wrire ropes.
2. While falling down the used wire rope by gravity freely is prohibited.
3. The suspended wire rope end shuld be binded with jute rope and holded by
manual.

Drum Wire rope

connector 4

Skewing Skewing thruster

Lever Wire rope
connector 3

Wire Wire rope

Rope 1 connector 2
Wire rope
connector 1
Wire rope 3
headblock Wire rope 4 Wire rope 2

Performance: (Suppose that wire rope 2 will be replaced)

1. Move the trolley to the proper position on the gantry girder.

2. Set an enough working area under the trolly with flager lines arounde which.
3. To lower the spreader onto the ground and let the wire ropes loosening
completely. (Fig. 1)

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 4. To lower the hoist wire ropes continued until their fixed end remainded one
and half loop on the drum.
5. After above, cut off the control system.
6. Pull jute ropes on the top of the trolley.
7. Tied each end of the used wire rope with jute ropes on the proper position
temporary as a security, (Fig. 2)

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 8. Cut the used wire rope at the middle part near the sheave of the headblock in
to two parts, then connected their end with jute ropes and holding them by
manual separately. (Fig.3). If not cut the used wire rope, it is allowable, but
the time is needed longer.

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 9. Remove the presse plates of the bolts which fixed the wire rope’s end on the
drum, then take off the used wire rope from the drum carefully.
10. To connected the used wire rope’s end and a long jute rope with wires.
(Fig.4)

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 11. People who on the trolley holding the upper end of the used wire rope by
jute rope and let which down slowly by it’s gravity, at the same time, people
who on the ground pulling the lower end of the used wire rope on to the
ground safely.
12. Disassemble the wire rope connector 2 which is connected between the
other end of the used wire rope and the skewing lever, and then connect the
rope’s end with jute rope by wires. (Fig.5)

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 13. Whire holding the jute rope let the used wire rope down slowly on to the
ground.
14. Disconnect the two sections of used wire rope from the jute ropes which
have fallen down to near the headblock and take them away.
15. Take the new wire rope pass through the sheave which is placed on the
headblock, and then connected their end to that two jute ropes which have
had fallen down from the trolley by wires.
16. After all above, you can pull the new wire rope up pass through relative
sheaves and with the halp of man lifter or forklift on the ground, and then
fixed one rope’s end on the hoist drum and the other connected to the wire
rope connector2 separately. So that replacement of the wire rope No 2 is
finished.