TL;DR

Remove the rope from service if 6 or more broken wires appear in any rope lay length, or if the rope diameter is reduced by more than 10% from nominal. Do not attempt to repair a damaged wire rope.

What you might see

visible broken wires protruding from the rope
kinks or birdcaging in the rope length
rope diameter visibly reduced at a point
corrosion or rust on rope strands

Likely causes

Tap to mark as ruled out

Fatigue from cyclic bending over the sheaves, especially at the dead-end termination
Corrosion from moisture, chemicals, or inadequate lubrication attacking individual strands
Abrasion from contact with the sheave grooves when rope is misgrooved or sheave is worn
Kinking from a previous improper unreeling or from a load swing event

Required tools

Wire rope calipers
Clean rag
Konecranes-specified wire rope lubricant
LOTO kit
Replacement rope per CXT nameplate specification

Safety first

Wear heavy leather gloves when handling wire rope. Broken wire ends cause serious lacerations.
Lock out the crane before performing any rope inspection or replacement.
Never repair a damaged wire rope. Replace it as a unit.
Do not return the hoist to service after a rope replacement without a witnessed proof test.

Procedure

7 steps · ~30 min

1
Lock out the crane at the main disconnect. Lower the hook block to the floor before starting rope inspection.
2
Clean the rope with a rag to remove surface grease. Walk the full rope length while rotating it to inspect all sides.[1]
3
Count broken wires in any rope lay length (approximately 6-8 times the rope diameter). Six or more broken wires in one lay is the discard threshold per applicable standards.[1]
4
Check rope diameter at multiple points with calipers. A 10% reduction from nominal indicates severe internal wear.
5
Inspect the rope end terminations and swaged fittings for corrosion, cracking, or evidence of slip.
6
If the rope passes inspection, apply Konecranes-specified rope lubricant over the full length from a dropper or brush, do not spray onto other components.
7
If rope replacement is required, use only the exact rope specification from the CXT hoist nameplate. Install and perform a proof test before returning to service.

Sources

Konecranes CXT Wire Rope Hoist & Crane Maintenance Manual, Konecranes
Konecranes CXT Wire Rope Hoist Maintenance Manual, wire rope inspection discard criteria and lubrication procedures (general)
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