M511-E332 Procedure for Replacing M511-E332 Wire Ropes Introduction Preparation Replacement procedure Inspection and confirmation of movement BR-100 Procedure for Replacing Wire RopesM511-E332 BR-100 Procedure for Replacing Wire Ropes 1, introduction ‘This manual describes the procedure to replace the main wire ropes of BR-100 Series, Serviceman are requested to read this manual carefully before starting the replacement. 2. Preparation 2.1 Tools and repair parts E Tools to prepare @) Spray type WIROL R (PIN 017-90302-01) (Oil exclusively manufactured for wire rope lubrication) General tools (screwdriver, Allen wrench, spanner) @ Blanket or cushion ® Loctite (Blue) Replacement parts '503-64827-02 Suspension rope ... 1 piece (Fig. 1) (026-0060 Split pin, S3 x 30 ~~ 2 pieces (For shaft on the column) @ 026-0038 Spit pin, $2 x 30 2 pieces (For wire rope end) © Working time This replacement work takes about 3 hours I is necessary to remove the anchor bolts during the replacement. Sufficient care must be taken for safety. BR-100 Procedure for Replacing Wire Ropes M511-E3323 Replacement procedure 3 Replacement procedure 3.1 Disassembling the bucky and the column J. Remove the hexagon socket head bolt (Wl x 10, 1 place) from the bottom of front cover. (Fig. 2) 2, Releasing the up/down movement brake, bring down the bucky to the lowest position 3. Bemove the top cover. (Binding screw M4 x 8, 2 places). (Fig. 2) Femove then the front cover. (Hexagon socket head bolt M4 » 10, 1 place) 4 Front cover Bucky 4. Raise the bucky. Fix the weight from the back of column. (Hexagon socket head bolt M10 x 25) (Fig. 3) Ms11-£332 BR-100 Procedure for Replacing Wire RopesM511-E332 BR-100 Procedure for Replacing Wire Ropes Base Bucky unit Bucky cover Weight fixing bolt Column Tum off the power to the system Disconnect the cable connecting the bucky unit to the carriage and the controller. Remove then in the order of the bucky cover (Binding screw M4 x6, 8 places), bucky unit (Hexagon socke! head bolt MS x 8, 4 places) and base (Hexagon socket head bolt MS x 10, 4 places). (Fig. 3) ORS LAN caution Bucky unit waighs approx. 35 kg. 7. Lay down the column on a cushion, (Hexagon socket head bolt M12 » 30, 4 places) ZN caurion Take care sufficiently whan laying down the column. BR-100 Procedure for Replacing Wire Ropes | M511-E3323 Replacement procedure 3.2 Replacement of wire rope 1. Remove the spit pin (¢2 x 80) and nut onthe wire rope end at the carriage side, and remove the wire end from the carriage. (On both wire ropes) (Fig. 4) Wire rope end/ Remove the nut (Remove the spit pin, Fig. 4 cAUTION Replace the split pin with @ new one at the assembly. 2. Remove the split pin ($3 x 30) from the shaff, pull out the shaft from the column and then dismount the pulley unit, (Fig. 5) eed a Shaft Washer Fig. 5 M511-E332 BR-100 Procedure for Replacing Wire Ropes ©M511-E332 BR-100 Procedure for Replacing Wire Ropes caution Replace the split pin with a new one at the assembly. Do not forget to insert the washer when inserting the shaft 3. Remove the weight fixing bolt fram the back of column, Confirm that the column is not inclined, before removing the weight fixing bolt. Otherwise, the weight may slide out off the column, 4, Remove the weight from the top end of column. (Fig. 8) cauTiON This is the replacement of wire rope only. Ifthe hardware of wire rope end can be E removed, itis not necessary to pull out the whole weight, Wire rope Column Fig.6 5. Remove the wire rope. (Fig. 7) Slacken the set screw on the top face of weight (MA » 6), remove the weight shaft and then remove the wie rope. (2 places) BR-100 Procedure for Replacing Wire Ropes M511-E3323 Replacement procedure YE Weight shaft Set screw Wire rope Fig.7 6. Install a new wire rope. (In the reverse order of Steps 1. - 5.) ‘CAUTION } Replace the spilt pin on the wire rope end with a new one at the assembly 3.3 Assembling the bucky and the column J. Assemble the column and the column in the reverse order of 3.1 Disassembling the bucky and the column’ The column and the bucky are heavy. Take sulficient care when assembling the column or mounting the bucky. caution Replace the spit pin with anew one at the assembly, Oo not forget to insert the washer when inserting the shaft M511-£332 BR-100 Procedure for Replacing Wire RopesM511-E332 BR-100 Procedure for Replacing Wire Ropes 8 4. Inspection and confirmation of movement Apply the oil exclusively manufactured for wire rope lubrication on the wire rope. Reier to the Procedure for Application of Lubricant to Wire Ropes (M514-E328), 2. Check movements on each axis. + Is any noise heard? Is there any drag or any section where a large resistance is felt, uring each movement? This is all for the replacement of wire ropes. BR-100 Procedure for Replacing Wire Ropes M511-E332