Trouble Shooting Checklist for Broken Wire Ropes

Type	Sample Image	Cause
Abrasion		Frozen sheaves or rollers
		Tight grooves
		Excessive fleet angle
		Oversized or undersized rope
		Corrugated sheave or drum
		Sheave overspin
		Rope jumping the sheave
		Poor spooling
		Misaligned sheaves
		Site contaminants
Core Protusion and Slippage		Shockloading
		Poor seizing techniques
		Poor installation techniques
Corrosion		Lack of lubrication
		Environmental damage
		Improper storage
Crushing		Poor installation techniques
		Poor installation techniques
		Crosswinding
		Poor spooling
		Incorrect wire rope construction
		Poor break-in procedure
		Excessive fleet angle
		Excessive rope length
Fatigue		Out of round sheaves
		Tight grooves
		Misaligned sheaves
		Undersized sheaves
		Worn bearings
		Vibration
		Slapping
		Whipping
		Reverse bends
Diameter Reduction		Lack of lubrication (fiber core)
		Excessive abrasion
		Corrosion, internal and/or external
High Stranding		Poor seizing techniques
		Tight grooves
		Undersized sheaves
		Poor installation techniques
Jumping the Sheave		Poor spooling
		Excessive rope length
		Broken flange
Kinking		Poor unreeling procedures
		Poor installation techniques
		Undersized sheaves
Lay Lengthening & Tightening		Poor installation techniques
		Poor unreeling procedures
		Corrosion
		Core failure
Looped Wires		Poor installation techniques
		Undersized sheaves
Unbalanced Rope		Oversized sheaves