GENMA Maintenance · Parts Replacement & Lifecycle | Wire Rope: When to Replace?

Wire ropes are critical load-bearing components on your GENMA machine. Their condition directly affects operational safety. Beyond counting broken wires, changes in rope diameter, corrosion, and deformation are just as important when deciding whether it's time for replacement.

According to the GENMA maintenance manual, the rope must be replaced if any of the following conditions occur:

1. Diameter reduction exceeds 10%

If the rope diameter decreases by more than 10% (i.e., measured diameter is less than 90% of the nominal diameter) due to friction, corrosion, or other causes — replacement is required, regardless of whether any broken wires are visible.

How to measure: take measurements at intervals of about 1 meter, measure twice at each point, and calculate the average.

2. Specific deformations appear

• Strand loosening — outer strands are loose and longer than inner strands

• Core distortion — one or more strands protrude separately from the rope core

• Kinking — if the rope is kinked, replace it immediately

• Spiral distortion — if the deformation exceeds 1/3 of the rope diameter, replace it

Wire rope service life varies greatly depending on operating conditions — heavy dust, salt spray, and frequent bending all accelerate wear. If you're unsure about the inspection criteria, feel free to reach out to your GENMA service engineer.