Determining the Correct Gauge set to Use

The most common question we are asked is

when to use a a +5% or a +2.5% Sheave
Gauge.
The answer is:

 +5% Sheave Gauges are designed to

determine optimal sheave geometry. They
should fit snugly in new or re-machined
sheaves. If correctly sized wire rope is run
through the sheaves there will be a minimum
of friction which should extend the life of the
wire rope.

 +2.5% API Sheave Gauges are used to

determine when Maximum and Excessive
Wear levels has been reached.

In order to ensure optimal performance of sheaves and wire rope both type of gauges should be
utilized.

+5% NEW SHEAVE GAUGES +2.5% API SHEAVE GAUGES

CORRECT CORRECT
+5% Sheave +2.5% Sheave Gauges
Gauges should fit in should fit in a Sheave
New Sheaves with some space on the
without any gaps on side but without any
the bottom or sides. gaps on the bottom.

TOO LOOSE MAXIMUM WEAR

Sheaves may When a +2.5% Gauge
become wider due fits in a Sheave without
to installation of any space on the side
oversized wire rope, or bottom it has
wobble due to reached it's maximum
bearing collapse or wear point and should
due to excessive be scheduled for
fleet angle. replacement.
 TOO TIGHT EXCESSIVE WEAR
If there is a gap A gap below a
below a +2.5% Sheave Gauge
+5% Gauge it may indicates an excessively
be excessively worn. worn Sheave which
Use a +2.5% should be removed
Sheave Gauge to from service at the
test if Maximum next opportunity.
wear has been
exceeded.

NOMINAL WIRE GAUGES GO NO/GO WIRE GAUGES

MEASURE ACROSS THE CORRECT

OUTER EDGE OF TWO STRANDS Wire Rope should not fit in Gauge

USE SMALLER GAUGE ROUGED WIRE ROPE

Replace if Cable Shows Rust
 USE LARGER GAUGE
USING A NOMINAL
WIRE ROPE GAUGE
Only use a wire rope gauge to determine
approximate wire rope diameter.
1. Align the gauge so that the wire can be
measured from the outer edge of one
strand to the edge of the strand directly
opposite.
2. If the wire rope does not fit in the
gauge, use a larger gauge until the wire
rope fits in the gauge.
3. Shine a light behind the gauge.
4. If you can see light between the gauge
and the wire rope repeat with a smaller
size gauge until no light shows.
For more accurate measurements use a
machinist’s caliper or micrometer.
REPLACE WIRE ROPE
When Cable Fits in Gauge
USING A GO/NOGO
WIRE ROPE GAUGE
Only use a wire rope gauge to determine
approximate wire rope diameter.
1. Align the gauge so that the wire can be
measured from the outer edge of one
strand to the edge of the strand directly
opposite.
2. If the wire rope does not fit in the
gauge it is still above the nominal -
3.125% threshold.
3. If the wire rope fits in the first notch it
should be replaced if the cable shows
rust (rouge).
4. If the wire rope reaches to the bottom
of the gauge it should be replaced.
For more accurate measurements use a
machinist’s caliper or micrometer.