Installing Flex-X 35 Wire Rope; Procedures For Cutting And Preparing Flex-X 35 - Manitowoc Grove 5540F Service Manual

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Installing Flex-X 35 Wire Rope

CAUTION
Any cutting of this specific wire rope is not recommended.
If FLEX-X 35 wire rope must be cut for any reason, it is
necessary to follow the following instructions. Also, unlike
other types of wire rope, the ends on this wire rope must
be welded.
1. Unload properly and relieve any twists. Pull the rope off
the shipping reel or unroll it from a shipping coil. (If done
improperly, you may kink the rope, which will result in
permanent damage to the rope.) Then, lay the rope on
the ground in direct line with the boom. This helps
release any twist in the rope.
2. Pull the rope over the point sheave and attach the end to
the hoist drum. Be sure not to remove the welded end.
3. Wind rope onto drum slowly and carefully. At this point, it
isn't necessary to provide additional load other than the
weight of the rope being pulled across the ground.
4. Spool first layer tightly. It is essential on smooth-faced
drums that the first layer is spooled with wraps tight and
close together since the first layer forms the foundation
for succeeding layers. If need be, use a rubber, lead or
brass mallet (but never a steel hammer) to tap the rope
into place.
5. Spool multiple layers with sufficient tension. It's very
important to apply a tensioning load to the ropes during
the rope breaking-in process. (If not, the lower layers
may be loose enough that the upper layers become
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FIGURE 1-18
Published 10-21-2010, Control# 198-04
5540F/YB5515 SERVICE MANUAL
wedged into the lower layers under load, which can
seriously damage the rope.) The tensioning load should
range from 1 to 2% of the rope's minimum breaking
force.
6. For ropes in multi-part systems: Reeve the traveling
block and boom tip sheaves so the rope spacing is
maximized and the traveling (hook) block hangs straight
and level to help assure block stability.
7. Breaking in new Flex-X 35—After installation, properly
break in the rope, which allows the rope's component
parts to adjust themselves to the operating conditions:
With the boom fully raised and fully extended, attach a
light load at the hook and raise it a few inches off the
ground. Allow to stand for several minutes. Then cycle
the load between the full "up" and "down" positions
several times. Observe the drum winding and rope travel
for any potential problems.
After making the lifts with a light load, increase the load
and cycle it up and down a few times. This procedure will
train the rope and help assure smooth operation during
its useful life.
Ideally, you should run these loads with reeving that lets
you place the loads on the block with all rope off the
drum except the last three wraps. If this is not possible,
alternate methods must be used to assure proper
tensioning of the rope on the drum.
Procedures for Cutting and Preparing Flex-X
35
Flex-X 35 is a special wire rope that must be handled
differently than any other rope manufactured. One
characteristic that makes this rope special is that the outer
strands are not preformed. It is because of this that the
following procedures for cutting and preparing Flex-X 35
must be followed:
1. The welded ends prepared by the manufacturer are not
to be removed.
2. Before cutting the rope, make three separate bands with
seizing strand on each side of where the cut is to be
made (total of six bands for each cut). Each band is to
have a minimum length of one and one half times the
rope diameter. The two bands closest to the cut should
be located at a distance equal to one rope diameter
away from the cut. The four remaining bands should be
evenly spaced at a distance equal to three rope
diameters.
a. If a welder is available, the cut should be made with
an abrasive saw. Immediately after the cut, both
ends of the rope are to be cap welded so that all
inner and outer strands are welded together,
preventing any movement between them.