How To Use A Sheave Gauge

Why Maintain A Sheave
Maintaining a wire rope sheave is much more cost-effective than replacing wire rope. To maximize the life of the wire rope, re-tool or replace a sheave when grooves become:
  • So worn that they allow for excessive wire rope movement OR 
  • So small that they twist and compress the wire rope.
How To Determine The Amount of Wear Using A Wire Rope Sheave Gauge
Use a wire rope sheave gauge to regularly check sheave grooves for wear, which may slow or block a wire rope:
  1. Place the proper size gauge in the sheave.
  2. Shine a light behind the gauge. 
  3. Check for light between the gauge and the root of the groove. If you detect light, replace or re-tool the sheave.
How To Approximate Wire Rope Size
Use a wire rope sheave gauge only to APPROXIMATE wire rope diameter:
  1. Place the wire rope in the proper size gauge. Make sure the wire rope is oriented properly, from the top of one strand to the top of the directly opposite strand.
  2. If the wire rope does not fit in the gauge, repeat with a larger size gauge until the wire rope fits in the gauge.
  3. Shine a light behind the gauge. 
  4. Check for light between the gauge and the wire rope. If you detect light, repeat with a smaller size gauge until no light shows between the wire rope and the gauge. 
How To Accurately Measure Wire Rope Wear
For an ACCURATE wire rope diameter measurement to determine if you should retire the wire rope, use a machinist’s caliper or micrometer. To properly use a caliper to assure accurate measurement:
  1. Note the wire rope diameter, a circumscribed circle that encloses all of the wire rope strands. 
  2. Measure the diameter at the widest points, from the top of one strand to the top of the directly opposite strand. (Measuring two strands side by side will give an inaccurate diameter reading.)
More Information on Wire Rope Measuring Techniques
American Society of Mechanical Engineers