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Correct Way to Take Out a Kink in Wire Rope
Seaman - Military manual for the Seaman rate
If wire rope is being run off one reel to a winch drum or another reel, run it from top to top or from bottom to bottom, as shown in figure 3-27. Make up short lengths of wire rope in coils and stop off tightly for stowage. When uncoiling wire rope, stand the coil on edge and roll along the deck, uncoiling as you go, as in figure 3-28. Whenever  possible,  drums,  sheaves,  and  blocks used with wire rope should be placed so as to avoid reverse  or  S-shaped  bends.  Reverse  bends  cause  an unnecessary amount of shifting of the individual wire strands, increasing wear and fatigue. Where a reverse bend is needed, the blocks and drums effecting the reversal should be of larger diameter than ordinarily used and should be spaced as far apart as possible. If a wire rope becomes kinked, never try to pull it out by putting a strain on either part. As soon as a kink is noticed, uncross the ends by pushing them apart. See step 2 in figure 3-29. Performing these steps reverses the process that started the kink. Now turn the bent portion over and place it on your knee or some firm object and push downward until the kink straightens out somewhat. Then lay it on a flat surface and pound it smooth with a wooden mallet. If a heavy strain is put on a wire rope with a kink in it, the rope no longer can be trusted. Cut out the kinked part  and  splice  the  ends  together. Frequently, abrasion or reverse or sharp bends cause individual wires to break and bend back. These broken wires are known as fishhooks. Wire  rope  should  be  inspected  frequently,  checking for fishhooks, kinks, and worn and corroded spots. Worn spots show up as shiny flattened surfaces. To determine the wear, you must know (1) the original diameter of the wire rope, (2) the present diameter of the wire rope at the worn place, and (3) the diameter of a single wire in one of the strands of the wire rope. The original diameter of the rope is shown in the ship's allowance list or in the first lieutenant's records. The actual diameter of the rope is found by measuring it with a micrometer or vernier caliper, as shown in figure 3-30. One  or  more  of  the  following  conditions  is sufficient reason for questioning the rope's safety and considering replacement: 1. The normal rope diameter is reduced by more than the amount shown in table 3-2 for the applicable size rope. See figure 3-30 for the correct method of measuring  diameter. 2.   Six broken wires in one rope lay length, or three broken wires in one strand lay length. See figure 3-30 for definition of a lay length. Figure  3-30.–Measuring  wire-rope  diameter. Table 3-2.–Wire-Rope Allowable Diameter Reduction Maximum   Allowable Nominal Diameter Rope Diameter (inches) Reduction  (inches) 5/16  and  smaller 1/64 3/8 to 1/2 1/32 9/16 to 3/4 3/64 7/8 to 1 1/8 1/16 1 1/4 to 1 1/2 3/32 19/16 to 2 1/8 2 1/8 to 2 1/2 5/32 3-21

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