Proper Usage and Maintenance

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Wire Rope & Cable

WIRE ROPE IS A MACHINE. Understand and respect it.
Like any machine, it needs proper care and maintenance for optimal safety and long service life. For a better understanding of wire rope, we highly recommend the Wire Rope User's Manual by the Wire Rope Technical Board.

Refer to the General Warnings Here

These warnings also apply to wire rope. Only additional warnings and information are listed below.

Rated Capacity

Rated capacity is the load which a new wire rope may handle under given operating conditions and at assumed design factor. A design factor of 5 is chosen most frequently for wire rope. (Operating loads not to exceed 20% of catalog Breaking Strength.) Operating loads may have to be reduced when life, limb or valuable property are at risk or other than new rope is used. A design factor of 10 is usually chosen when wire rope is used to carry personnel. (Operating loads not to exceed 10% of catalog Breaking Strength.)
Responsibility for choosing a design factor rests with the user.

Matching Attachment's Working Load Limit

Attachments must have at least the same Working Load Limit as the wire rope used
Clips, sockets, thimbles, sleeves, hooks, links, shackles, sheaves, blocks, etc. must match in size, material and strength to provide adequate safety protection. Proper installation is crucial for maximum efficiency and safety.

Keep out from under a raised load.

Do not operate load over people. Do not ride on load. Conduct all lifting operations in such a manner that if equipment were to fail or break, no personnel would be injured. This means KEEP OUT FROM UNDER A RAISED LOAD, DO NOT OPERATE LOADS OVER PEOPLE AND KEEP OUT OF THE LINE OF FORCE OF ANY LOAD.

Avoid Shock Loads

Avoid impacting, jerking or swinging of load. Working Load Limit will not apply in these circumstances because a shock load is generally significantly greater than the static load.

Inspect wire rope regularly

Use inspection instructions as guidelines only. Two of the most important prerequisites for inspecting wire rope are technical knowledge and experience.
Check the general condition of the wire. Also, look for localized damage and wear, especially at wire rope attachments. Inspect all parts that come in contact with the wire rope. Poor performance of wire rope can often be traced back worn or wrong-sized sheaves, drums, rollers, etc. Looks for kinks, broken wires, abrasions, lack of lubrication, rust damage, crushing, reduction of diameter, stretch or other obvious damage. If any of these conditions exists or if there is any other apparent damage to the wire rope, retire the wire rope according to the instructions below.
When in doubt about the extent of the damage, retire the wire rope in question immediately. Without laboratory analysis, it is impossible to determine the strength of damaged or used wire. Thus, you will not be able to tell whether wire rope with any amount of damage is safe to use. Retire the wire rope that is damaged. For specific inspection procedures check various OSHA and ANSI publications.

Destroy, Rather than Discard, Wire Rope to be Retired

Wire rope that is not destroyed might be used again by someone not aware of the hazard associated with that use. Destroying wire rope is best done by cutting it up into short pieces.

Measuring Wire Rope Diameter

Below is an illustration that displays the correct method to measure wire rope diameter.
Measure Wire rope

Wire Rope Clip Installation

It is important to ensure wire rope clips are installed properly. Incorrect installation can reduce the working load limit by 40%. Below are general guidelines for installing wire rope clips.

Parts of a Wire Rope Clip & Assembly 
Parts of a Wire Rope Clip

Clip Installation Diagram

Below is a diagram showing proper clip installation it is imperative that you install the saddle on the live end of the wire rope. An easy to remember saying to help remember proper clip installation is: NEVER SADDLE A DEAD HORSE!
Wire Rope Clip Installation

Hit Tools Swaging Instructions

  1. Before using this tool, examine and ensure that the bolt and nut of the swager are tight.
  2. Cut cable to the required length and lace the cable through the sleeve so that the end will still protrude after crimping.
    Hit Tools Swaging Instructions
  3. Properly insert sleeve into he correct cavity and line up the sleeve between the swager jaws with the long axis perpendicular to the jaws.
    Cable Crimping Instructions
  4. Swaging Sleeves
    1. Swage each sleeve with the correct number of swages listed in the in the table below following the swage sequence shown below.
      Wire Rope Crimp Instructions
      Cable Diameter Swagers Per Oval Sleeve
      1/32" 1
      3/64" 1
      1/16" 1
      3/32" 2
      1/8" 3
      5/32" 3
      3/16" 3
      1/4" 3 or 4
      5/16" 3 or 4
      3/8 3 or 4
    2. Lap splices can be made by 2 oval sleeves. Keep a short space between the sleeves.
      Cable Lap Splice Instuctions
    3. A stopper can be made by crimping a button stop sleeve.
      Cable Button Stop Swaging Instructions
  5. Each HIT Swager has a gauge. Check a crimped sleeve with the gauge. If the presses portion won't go into the gauge freely, press the sleeve completely again.
    Cable Crimping Gauge Instructions

Cable Puller General Warnings

Failure to understand and follow these warnings and instructions could result in property damage, serious personal injury or loss of life. Use of this product demonstrates an understanding of these warnings / instructions and the risks involved. Below is a list of general warnings.

  • DO NOT EXCEED RATED CAPACITY for pulling or lifting.
  • Do not use for overhead lifting. Do not lift any material above shoulder height. Keep all persons clear of load while suspended. Never allow persons beneath a suspended load.
  • Cable pullers are not designed for cargo tie down or load measurement. They are not approved for use as such by any government agency.
  • Inspect puller and its components prior to each use. Do not use if any part of the cable puller is visually damaged.
  • Never use handle extensions (cheater bars).
  • Do not use puller around sharp corners as this may damage the cable, greatly reducing strength.
  • Never load the hooks on the tips of the hook.
  • Do not use if the cable is kinked or knotted.

Fraction / Decimal / Metric Conversions

Fraction Decimal Metric
1/64 0.015625 0.397 mm
1/32 0.031250 0.794 mm
3/64 0.046880 1.191 mm
1/16 0.062500 1.588 mm
5/64 0.078130 1.985 mm
3/32 0.093750 2.381 mm
7/64 0.109380 2.778 mm
1/8 0.125000 3.175 mm
9/64 0.140630 3.572 mm
5/32 0.156250 3.969 mm
3/16 0.187500 4.763 mm
7/32 0.218750 5.556 mm
1/4 0.250000 6.350 mm
9/32 0.281250 7.144 mm
5/16 0.312500 7.938 mm
3/8 0.375000 9.525 mm
7/16 0.437500 11.113 mm
1/2 0.500000 12.700 mm
9/16 0.562500 14.288 mm
5/8 0.625000 15.875 mm
11/16 0.687500 17.463 mm
3/4 0.750000 19.050 mm
7/8 0.875000 22.225 mm
1    1.000000 25.400 mm