Instructions / Assembly

ManualsBrandsPanellift ManualsBuilding materials11 ft. 150 lbs. Drywall Panel Hoist Cable/Sheave Kit

ASME Standards for wire rope (cable) inspection and replacement

Reprinted with permission from ASME B30.19 Cableways

The following is intended as a helpful guide to the general topic of inspection and replacement

of wire rope (cable). It is not intended to be an exhaustive treatment of the topic.

Frequent inspection (at least daily) by a competent person and prompt replacement of any cable that shows any sign of

wear is the responsibility of the owner and the operator of the PANELLIFT

Drywall Lift.

With reference to the chart below at 19-2.4.3(b)(6) the Panellift® Drywall Lift cable is a nominal 1/8” high tensile cable (rope).

Max. Allowable

Reduction From

Rope Diam. Nominal Diam.

(00) General

...

The use of cableways, cranes, derricks, hoists, hooks, jacks, and slings is

subject to certain hazards that cannot be met by mechanical means but only

by the exercise of intelligence, care, and common sense. It is therefore

essential to have personnel involved in the use and operation of equipment

who are competent, careful, physically and mentally qualified, and trained in

the safe operation of the equipment and the handling of the loads. Serious

hazards are overloading, dropping or slipping of the load caused by

improper hitching or slinging, obstructing the free passage of the load, and

using equipment for a purpose for which it was not intended or designed.

...

Section 19-2.4: Rope Inspection, Replacement, and Maintenance 19-2.4.1

General. Sheave diameters, drum diameters, and rope design factors are

limited because of cableway design configuration. Due to these parameters,

inspection in accordance with para. 19-2.4.2 to detect deterioration and

timely replacment in accordance with para. 19-2.4.3 are essential.

19-2.4.2 Inspection

(a) Frequent Inspection

(1) All running ropes in service should be visually inspected once each

working day. A visual inspection shall consist of observation of all rope that

can reasonably be expected to be in use during the day’s operations. These

visual observations should be concerned with discovering gross damage

that may be an immediate hazard, such as listed below:

(a) distortion of the rope such as kinking, crushing, unstranding, birdcaging,

main strand displacement, or core protrusion. Loss of rope diameter in a

short rope length or unevenness of outer strands should provide evidence

that the rope or ropes are to be replaced.

(b) General corrosion; (c) Broken or cut strands; (d) number, distribution,

and type of visible broken wires [see paras. 19-2.4.3(b)(1), (2), and (7) for

further guidance];

(e) core failure in rotation-resistant ropes; when damage is suspected, the

rope shall either be removed from service or given an inspection as detailed

in para. 19-2.4.2(b).

(2) Care shall be taken when inspecting sections of rapid deterioration, such

as flange points, crossover points, and repetitive pickup points on drums.

(3) Care shall be taken when inspecting certain ropes, such as

rotation-resistant ropes, because of their higher susceptibility to damage and

increased deterioration when working on equipment with limited design

parameters. The internal deterioration of rotation-resistant ropes may not be

readily observable.

(b) Periodic Inspection

(1) The inspection frequency shall be determined by a qualified person and

shall be based on such factors as expected rope life (determined by

experience on the particular installation or similar installations), severity of

enviorment, percentage of capacity lifts, frequency rates of operation, and

exposure to shock loads. Inspections need not be at equal calandar

intervals and should be more frequent as the rope approaches the end of its

useful life. The inspection shall be made at least every 1000 hr of cableway

operation or annually, whichever comes first.

(2) Periodic inspections shall be performed by an appointed or authorized

person. This inspection shall cover the entire length of rope. Only the

surface wires of the rope need be inspected. No attempt should be made to

open the rope. Any deterioration resulting in appreciable loss of original

strength, such as described below, shall be noted, and a determination shall

be made as to whether further use of the rope would constitute a hazard:

(a) points listed in para. 19-2.4.2(a): (b) reduction of rope diameter below

nominal diameter due to loss of core support, corrosion, or wear of outside

wires;

(d) severely corroded, cracked, bent, worn, or improperly applied end

connections.

(3) Care shall be taken when inspecting sections of rapid deterioration, such

as the following:

(a) sections in contact with saddles, equalizer sheaves, or other sheaves,

including track cable sheaves, where rope travel is limited;

(b) sections of the rope at or near terminal ends where corroded or broken

wires may develop.

19-2.4.3 Rope Replacement

(a) No precise rules can be givin for determination of the exact time for rope

replacement, since many variable factors are involved. Once a rope reaches

any one of the specified removal criteria, it may be allowed to operate to the

end of the work shift, based on the judgement of a qualified person. The rope

shall be replaced after that work shift, at the end of the day, or at the latest

time prior to the equipment being used by the next work shift.

(b) Removal criteria for rope replacement shall be as follows:

(1) in running ropes, six randomly distributed broken wires in one lay, or three

broken wires in one strand in one lay.

(2) One outer wire, broken at the contract point with the core of the rope, that

has worked its way out of the rope structure and protrudes and loops out out

from the rope structure. Additional inspection of this section is required.

(3) Wear of one-third the original diameter of outside individual wires.

(4) Kinking, crushing, birdcaging, or any other damage resulting in distortion

of the rope structure.

(5) Evidence of heat damage from any cause.

(6) Reductions from nominal diameter greater than those shown below:

Up to 5/16 in. (8mm) 1/64 in. (0.4 mm)

Over 3/8 in. up to 1/2 in. (13 mm) 1/32 in. (0.8 mm)

Over 9/16 in. up to 3/4 in. (19 mm) 3/64 in. (1.2 mm)

Over 7/8 in. up to 1 1/8 in. (29 mm) 1/16 in. (1.6 mm)

Over 1 1/4 in. up to 1 1/2’ in. (38 mm) 3/32 in. (2.4 mm)

(7) In standing ropes, more than two broken wires in one lay in sections

beyond end connections, or more than one broken wire at an end connection.

operating on steel sheaves and drums. The user shall contact the sheave,

drum, or cableway manufacturer, or a qualified person for broken wire

removal criteria for wire ropes operating on sheave and drums made of

material other than steel.

(d) Replacement rope shall have a nominal strength rating at least equal to

the original rope furnished or recommended by the cableway manufacturer or

designer, or a qualified person. Any deviation from the original size, grade, or

construction shall be specified by the rope manufacturer, the cableway

manufacturer or designer, or a qualified person.

(e) Ropes Not in Regular Use. All rope that has been idle for a period of a

month or more due to shutdown or storage of a cableway on which it is

installed shall be given an inspection in accordance with para. 19-2.4.2(b)

before it is placed in service. This inspection shall be for all types of

deterioration and shall be performed by an appointed or authorized person.

(f) Inspection Records

(1) Frequent inspection-no records required.

(2) Periodic Inspection - in order to establish data as a basis for judging the

proper time for replacment, a dated report of rope condition at each periodic

inspection shall be kept on file. This report shall cover points of deterioration

listed in para. 19-2.4.2(b)(2).

(g) A long range inspection program should be established and should include

records on examination of rope removed from service so a relationship can be

established between visual observation and actual condition of the internal

structure.

Sheave Pocket

WRONG

CORRECT

WARNING

4a. Feed the crimped end of the new cable through the “A” section anchoring “V” from the bottom as shown. 4b.

Make sure the anchoring end of the cable is pulled snugly against the anchoring “V” as shown. (NEVER

DISASSEMBLE THE NUT AND BOLT OF CABLE ANCHORING ASSEMBLY)

5. To insert the crimped end of the cable into the TOP end of the “B” section begin by slightly bending the

tip of the cable as shown in image 2A. This should give the cable a neccessary angle for it to slide up into

the Sheave Pocket easier as shown in image 2B. Turn the sheave in the direction indicated in image 2B,

this will help pull the end of the cable through the sheave pocket. If the “B” section is the factory original,

the painted end is the top and the bottom has several inches of unfinished surface. If both ends of the “B”

section are painted, it is either a replacement or you are working on the “F” section of an extension

186-00. In either case, wear marks on the section should indicate which end is the top.

6a. Insert the crimped end of the cable into the sheave pocket at the end nearest the end of the “B”

section as shown. Once the tip of the cable is showing, pull the rest of the cable out all of the way

through.

CABLE REPLACEMENT INSTRUCTIONS cont.

The cable MUST feed in from the top of the “B” exactly as shown in steps 2 - 3 in order to

function properly. Failure to install the cable correctly as shown can cause wearing of the cable

for which it is not designed which can result in failure of the cable. Failure of the cable while the

lift is raised will result in a sudden and rapid lowering of the lift and the load possibly resulting in

serious property damage and/or serious bodily injury.

Sheave Pocket