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IMS ROBOTICS DRIVEplus Manual

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  • Page 3 Information about the machine Designation: IMS Cutter DRIVEplus Manufacturer: IMS Robotics GmbH Am Bauhof 6 01458 Ottendorf-Okrilla Tel: +49 (0)35205/75550 Fax: +49 (0)35205/53749 Email: info@ims-robotics.de http://www.ims-robotics.de User information: As of 15/03/2022 Translation Item number: 034 17 000...
  • Page 4 Foreword The user information is intended to help the operator to work safely and properly and to maintain the IMS devices. It is therefore essential to pay attention to this manual. Note The accident prevention regulations and general safety rules must be observed when operating the device.

  • Page 5: Table Of Contents

    Table of Contents Intended Use ........................ 9 Technical Information ....................10 Technical data.......................10 Main dimensions ....................11 General Safety Rules ....................12 Description and Setting Instructions ................13 Overview of the assemblies ..................13 General description ....................15 Controller ......................15 4.3.1 Controller in general ..................15 4.3.2 Operating elements on the controller ...............15 4.3.3 Connections on the controller ................18...
  • Page 6 4.4.4.6 "Minimise" button ..................41 4.4.4.7 "Settings" button ..................42 4.4.4.7.1 Basic settings ..................42 4.4.4.7.2 Text overlay ..................43 4.4.4.8 Select Language and unit .................44 4.4.4.9 Service menu ...................44 4.4.4.10 Information menu ..................45 Cable drum ......................46 4.5.1 Overview ......................46 4.5.2 Explanation of the operating elements of the cable drum ........46 4.5.3 Mounting roll arm on the cable drum ...............49 4.5.4...
  • Page 7 5.3.1 Operating the milling robot ................69 Conversion to other nominal diameters ..............70 5.4.1 Extension parts and nominal diameter dependent assembly of the DRIVEplus carriage and the pressure rail ..................70 5.4.1.1 Overview of extension parts of the carriage ..........70 5.4.1.1.1 Assembly corundum and granulated wheels ........72 5.4.1.2...
  • Page 8 6.3.2.1 Ball bearing and fins of the large air motor ..........84 6.3.2.1.1 Ball bearing ..................84 6.3.2.1.2 Replace the fins ...................84 6.3.2.2 Ball bearing and blades of the small air motor ..........86 6.3.2.2.1 Overview of spare parts ...............86 6.3.2.2.2 Disassembling and reassembling the air motor ........87 6.3.3 Milling arm/ swivel drive gear - oil change ............90 6.3.3.1...

  • Page 9: Intended Use

    The IMS milling machine DRIVEplus may be used only for the execution of milling work for the purpose of rehabilitating unpressurised pipes or lines. The device can be used to open inliners after renovation and remove obstacles (roots, protruding seals, small misalignments, etc.).

  • Page 10: Technical Information

    Change of nominal diameters: depending on the nominal diameter, between approx. 10 and approx. 20 min Electricity: 100-240 V +/-1% /50-60 Hz/1000 W Weight: DRIVEplus - milling machine without extensions: approx. 38 kg Extension carriage: approx. 11 kg Extensions complete: approx. 23 kg Cable drum: approx.

  • Page 11: Main Dimensions

    2.2 Main dimensions Carriage with cutting arm: Device designed for pipes of 200 mm nominal diameter: 1114 mm...

  • Page 12: General Safety Rules

    3 General Safety Rules CAUTION! The device may be operated only by persons who have been instructed in its use. Inadequate knowledge can cause damage to the device or danger to the operator. CAUTION! Pull out the mains plug before opening the devices. CAUTION! When lowering the individual parts or the entire robot, it is forbidden for persons to be in the shaft or under the suspended load.

  • Page 13: Description And Setting Instructions

    4 Description and Setting Instructions 4.1 Overview of the assemblies Overall view Carriage Cutter air hose Crane attachment Water nozzle for camera Wheels - pressure rail Electric swivel drive Pressure rail Nitrogen valve - carriage Swivel-head camera with nitrogen Reverse travel sensor valve Cutting arm Electrical connection - reverse travel...
  • Page 14 Nitrogen valve - camera Controller with monitor Nitrogen valve - cutting arm Cable drum Water nozzle Foot pedal Locking screw - swivel drive External control unit...

  • Page 15: General Description

    4.2 General description The IMS milling machine DRIVEplus is a device for execution of milling work for the purpose of cleaning and repairing sewers and for opening inlets after rehabilitation. By using extension parts, the basic version can be upgraded from nominal diameter 150 mm to nominal diameter 600 mm (depending on scope of delivery).
  • Page 16 When faults occur, an acoustic warning signal is sounded. When the fault is acknowledged, the warning signal is turned off. In the event of an accident or fault, press the emergency stop switch. The system is now no longer operational. The red indicator lamp for “emergency stop”...
  • Page 17 The operator interface is a touch panel. All control and regulating elements are activated or deactivated by pressing or swiping on the interface.

  • Page 18: Connections On The Controller

    4.3.3 Connections on the controller Top view of the controller USB port with blind cover (for service technicians only). USB port, to connect a keyboard or computer mouse or a mass storage device to store image or video files.
  • Page 19 Rear view of the controller Analog video signal port 1x USB port, to connect a Monitor HDMI port - Monitor Power supply - Monitor Fastening for Monitor bracket Network port (for service technicians only) Port to connect Controller to Control Box...

  • Page 20: Start Screen

    4.3.4 Start screen After the system has been switched on, the controller is started. This process takes approximately 20 sec. Then the following start screen appears. The following buttons are available: The "Milling" menu opens. A submenu opens from which all settings can be made. A submenu opens in which the language can be set.

  • Page 21: Selecting The Configuration

    4.3.5 Selecting the Configuration First the connected components need to be configured. To do this, open the Configuration menu through the tools icon . The following screen appears: In the "Setup" menu item, press the "Configuration" button. The following screen appears: The basic settings are made here.
  • Page 22 The next step is to select the options connected to the milling machine and the unit conversion. To do this, press the "Down Arrow" button on the top right edge of the screen. The following screen appears: Press the "Milling" icon to enter the Milling menu.

  • Page 23: Milling Menu

    4.3.6 Milling menu 4.3.6.1 Meter counter The meter counter can be reset to 0.00 m by pressing the button. A dialogue box appears asking whether the value should really be reset. You must confirm this dialogue box. Press the button to open a keypad input field, which can be used to enter meters. Press the button to apply the entered value to the meter counter.

  • Page 24: Carriage

    4.3.6.3 Carriage The carriage is equipped with a position sensor. The position of the carriage is graphically displayed. The carriage icon starts to blink if the carriage gets into a precarious tilted position and threatens to tip over. Press the button to make the carriage move slower.

  • Page 25: Milling Arm Position

    4.3.6.6 Milling arm position The position of the milling arm is shown on the milling arm symbol. On the one hand, this is represented analogously, in the form of a clock face. On the other hand, the exact number of degrees can be read in the left field .

  • Page 26: Settings Menu

    It is also possible to switch between the cameras using the right control knob on the left-hand side joystick. The DRIVEplus milling robot is equipped with a headlamp. The headlamp improves the view in the sewer when entering it. The "headlamp" icon is also a button.

  • Page 27: Parameter List

    In the "Setup" submenu, datasets can be created or edited. Furthermore, individual settings such as light intensity, carriage speeds etc. can be made. 4.3.7.1 Parameter list Press the "Parameter list" icon to adjust various parameters of the robot individually. You can scroll between pages 1 and 2 by pressing the arrow icons at the top right edge of the screen.

  • Page 28: Configuration

    In the example shown, the preset, reduced speed is 20%. This speed is applied as soon as the milling motor is started. This is then displayed on the controller via the active icon. With the joystick fully deflected, the maximum speed is only 20% of the maximum speed. Among other things, this facilitates milling at the milling point.

  • Page 29: System Information

    , on the right top edge of the controller. The following selection menu appears: For IMS milling machine DRIVEplus, select "Cutting arm". Settings in the selection item "I/O Module" cannot be changed by the operator. This is necessary only for service work.

  • Page 30: Joystick Config

    4.3.7.4 Joystick Config In the "Joystick configuration" menu item, the robot control can be individually adjust and saved. Each user can create their own dataset (user profile) for the robot controller. These created datasets are displayed in a list and can be loaded as required. The dataset "IMS Standard"...
  • Page 31 Text field with the name of the selected dataset and the date of the last change that was made. Opens the menu for the joystick configuration - Milling Opens the menu for the joystick configuration - UV Restoration Opens the menu for the joystick configuration - Shuttering Opens the menu for the joystick configuration - Spatula Create and save a new dataset To create a new dataset, press the icon...
  • Page 32 Chang a dataset / Adjust the joystick configuration To change any dataset and adjust the joystick configuration, select the desired dataset (user profile) from the list and press the icon The Dataset (user profile) is loaded and the name is displayed in the text field e.g.: Then open the menu for the joystick configuration, e.g.: The following selection menu appears:...
  • Page 33 Functions for joystick axes: --free-- drive turn 4.axis/SAT turn camera camera LED Functions for joystick buttons: --free-- milling milling water switch camera pressure rail wiper If a function is already set on another control element, it is marked in red. NOTES! No function can be assigned twice for the robot controller! The function that was assigned twice must be changed.
  • Page 34 Then press the icon to save the settings. The Icon is displayed to confirm saving. Delete dataset Select the dataset to be deleted from the list by pressing the icon Then press the icon to delete the previously selected dataset. NOTES! A deleted dataset cannot be restored! A dialogue box appears asking: "Do you really want to delete the dataset",...

  • Page 35: Operation Touch Monitor With Video Software

    The IMS video software has a recorder and player function, a function for taking photos and recording data. The IMS video software is supplied with the IMS DRIVEplus. The video software is pre-installed on a Mini PC, which is installed in the controller.
  • Page 36 The video software is started with a double click via the icon The following screen appears:...

  • Page 37: Overview Of The Individual Buttons In The Footer Bar

    4.4.3 Overview of the individual buttons in the footer bar Use the "Video player" button to open the video player. (see point 4.4.4.1 Video player menu) Press the "Record" button to start video recording. The icon turns blue. Press the button to take a photo of the screen display. Press the button to open a submenu at the upper left edge of the screen.

  • Page 38: Explanation Of The Individual Buttons

    4.4.4 Explanation of the individual buttons 4.4.4.1 Video player menu Use the video player button to start the video player. It is used to play back recorded video files and also to view image files. After pressing the button, the following screen opens: The video player has the following buttons: The button opens the "Window Explorer"...

  • Page 39: Loading And Playing A Stored Video Or Image File

    Pressing the button opens a submenu. The keyboard shortcuts for video control are explained here. Press the button to terminate the program. 4.4.4.2 Loading and playing a stored video or image file Press the "Open" button to open the "Window Explorer" of the Mini PC. The files are stored under "windows (C:) →...
  • Page 40 Double-click on the desired file to load it into the video player. The loaded video file can now be started using the icon. The icon is now displayed in blue. Pause playback with the pause icon . When the "Pause" button is pressed, the symbol is blue.

  • Page 41: Record Button

    4.4.4.3 Record button Press the "Record" button to start video recording. The icon now turns blue . Press this icon to stop video recording. 4.4.4.4 "Camera" button Press the "Camera" button to create an image file. The icon changes colour briefly. To view this file, see point 4.4.4.2 Loading and playing a stored video or image file.

  • Page 42: Settings" Button

    4.4.4.7 "Settings" button 4.4.4.7.1 Basic settings Press the "Settings" button to open the settings menu. You will first be taken to the page where various basic settings are made. Most fields are predefined by the manufacturer of the system. Only the fields "Project name" and "Set the Path"...

  • Page 43: Text Overlay

    4.4.4.7.2 Text overlay Press the "Text overlay" button to open a menu in which overlays can be defined and in which text can be written. If a check mark is set in the "Date" and "Time" fields , the current date and time are displayed at the top left edge of the screen.

  • Page 44: Select Language And Unit

    4.4.4.8 Select Language and unit By pressing the “Select language” button , the menu for the language selection opens. Furthermore, the units of measurement can be changed from metric to imperial here. The metric system is preset. By ticking the "convert" field, we switch to the imperial system of measurement.

  • Page 45: Information Menu

    4.4.4.10 Information menu Click on the "Information menu" button to open an information page with all contact details of IMS.

  • Page 46: Cable Drum

    4.5 Cable drum 4.5.1 Overview The cable drum is equipped with 2 wheels for mobile use. The water equipment is mounted on the cable drum. It is used for cooling the milling tool as well as cleaning the milling point. Furthermore, the cable drum has a hand crank with gear stage, an optional electric reeling system, operating elements and a media cable routing system.
  • Page 47 If no foot switch is connected, this switch can be used for reeling. The speed of the electric reeling is controlled by a potentiometer. This switch is used to engage and disengage the electric clutch in the cable drum. The clutch can also be operated on the controller. In the event of an accident or fault, press the emergency stop switch.
  • Page 48 1.) The cable drum is connected to a compressor at the compressed air port located on the drum. Before switching on the compressor, check whether the shut-off valve (3) is closed. 2.) Furthermore, the cable drum has a quick coupling to connect an air gun. 3.) Shut-off valve to the compressor.

  • Page 49: Mounting Roll Arm On The Cable Drum

    4.5.3 Mounting roll arm on the cable drum To prevent the media cable from kinking, the cable drum is equipped with a detachable roll arm. It is mandatory to use this roll arm when using the system. The cable drum has 2 mounting plates with 2 suspension points each.

  • Page 50: Water Equipment

    Water equipment 4.5.4.1 Water equipment with 2 liter water tank The IMS – milling machine DRIVEplus has water equipment for cleaning the camera as standard. The water equipment is equipped with a 2 liter water tank. The water tank is pressurized with compressed air via connection “1”.

  • Page 51: Connection Of Water Tank (Optional) To Cable Drum

    The water tank must now be installed in the brackets shown in the illustration and secured with the locking bolt. Now connect the water and compressed air. The water equipment has now been converted for operation in a vehicle installation set. 4.5.4.2 Connection of water tank (optional) to cable drum The water tank is filled via the coupling, which is located below the water tank.

  • Page 52: Safety Regulations

    Now the compressed air supply hose has to be installed between the water tank and the cable drum. Prior to disconnecting the water tank from the cable drum, the water tank must be vented completely. For this purpose, close the shut-off valve on the cable drum. The connection to the compressor is now interrupted.

  • Page 53: Control Box With Operating Elements And Connections

    4.7 Control box with operating elements and connections 4.7.1 Control box in general 13 14 Main switch Analog video output Release button External control unit Operational/ready for use Cable drum motor – no function Emergency stop Renovation system – no function Emergency stop switch Connection of cable drum Key switch - emergency mode...

  • Page 54: Explanation For Control Elements And Connections On Control Box

    4.7.2 Explanation for control elements and connections on control box 4.7.2.1 Fan There are two fans installed on both sides of the control box The fans must not be covered or obstructed. 4.7.2.2 Analog video output Analog video output Option for connecting a separate monitor. 4.7.2.3 Anschluss Handbedienteil Extern A manual control unit can be connected to control the robot.

  • Page 55: Connection Renovation System

    4.7.2.8 Main switch There is a main switch located on the control box of the DRIVEplus. With this switch the entire mains voltage of the system is interrupted. Voltage supply is interrupted by turning off this switch to the "Off"...

  • Page 56: Release Button

    4.7.2.9 Release button After switching on the system using the main switch the Release button must also be pressed. The system is now started. The system cannot be released when the emergency stop switches are pressed. The emergency stop switches need to be released first, before the system can be made operational with the Release button.

  • Page 57: Emergency Mode "Drive

    4.7.2.13 Emergency mode "Drive" Steers the driving movement of the DRIVEplus carriage into manual mode. 4.7.2.14 Emergency mode "Turn" Steers the turning movement of the DRIVEplus cutting arm into manual mode. 4.7.2.15 Emergency mode "Swivel" Steers the swivelling movement of the DRIVEplus cutting arm into...

  • Page 58: Key Switch "Emergency Mode

    4.7.2.16 Key switch "Emergency mode" In case the PLC controller fails or has some other fault, the system can be switched from automatic to manual mode. To do this, switch off the system, set the switch to position 1 and restart the system. The carriage functions "drive, turn, swivel"...

  • Page 59: Explanation External Hand-Held Control Unit

    4.7.3 Explanation external hand-held control unit Connection cable for control cabinet Switch for electrical coupling, cable drum engaged and disengaged Emergency switch Electric clutch signal lamp Shift lever for moving the trolley Joystick for swiveling and rotating the milling arm Shift lever for winding the cable drum on and off 4.7.3.1 Connection cable with plug of the hand-held control unit The connection cable has an 18-pin connector.

  • Page 60: Switch For The Electrical Coupling Of The Hand-Held Control Unit

    The shift lever controls the movement of the DRIVEplus trolley. 4.7.3.6 Controlling the milling arm with the hand-held control unit The swivel movement of the DRIVEplus milling arm is controlled by moving the joystick up or down. If the joystick is moved to the left or right, the...

  • Page 61: Controlling The Cable Drum With The Hand-Held Control Unit

    4.7.3.7 Controlling the cable drum with the hand-held control unit The cable drum is reeled up / down using this switch lever. 4.7.3.8 Connection of the hand control to the control cabinet CAUTION! If the hand control is not connected to the control cabinet, it is imperative to connect this connection with the dummy plug.

  • Page 62: Robot

    4.8 Robot The driving movement as well as the turning and swivelling of the head is realized through electric drives. CAUTION! All electrically powered axes of the robot (driving, turning, swivelling, 4th axis) as well as the rotation of the camera must not be moved by hand. The couplings of the electrical supply line are waterproof (IP 65) when plugged together.

  • Page 63: Reverse Travel Safety Device

    4.8.1.2 Reverse travel safety device The reverse travel safety device is meant for preventing the robot from driving over the media supply lines. For this purpose, there is a reverse travel sensor located on the rear side of the carriage. The chain of the medial cable will be hung there.

  • Page 64: Swivel-Head Camera

    4.8.3 Swivel-head camera The camera enables the operator to observe the milling process in the direction of entry. When using the camera, the angle of view in the pipe is limited, i.e. while driving in, the parts of the pipe are covered by the motor or the milling tool. From a pipe diameter of DN 250 onwards the camera can be mounted in such a way that the angle of view in the pipe becomes larger.

  • Page 65: Swivel-Head Camera With Wiper (Optional)

    To protect the electronic components in the camera, it is filled with nitrogen. Nitrogen must be checked daily before starting and after completing work (see 6.3.4 Nitrogen filling). CAUTION! The quality of the video image depends largely on uniform illumination of the object to be observed.

  • Page 66: Equipment Options

    Nitrogen valve Camera Wiper To protect the electronic components in the camera, it is filled with nitrogen. Nitrogen must be checked daily before starting and after completing work (see 6.3.4 Nitrogen filling). CAUTION! The quality of the video image depends largely on uniform illumination of the object to be observed.

  • Page 67: Electric Swivel Drive For Milling Motor

    4.8.5.2 Electric swivel drive for milling motor The swivel drive for the milling motor is used for swivelling the tool. It can be swivelled by approx. 120°. The milling motor can be locked by a screw for heavy or precise milling work and on projecting sockets with the electric swivel drive.

  • Page 68: Operating Manuals

    5 Operating manuals 5.1 Energy supply CAUTION! Pay attention to the order! Establish connections from the universal cable drum to the universal controller Connect the power supply to the cable drum Establish the pneumatic supply line to the cable drum. CAUTION Set the operating elements to STOP.

  • Page 69: Start Up

    5.2 Start up Always check the nitrogen pressure before starting up the system (see 6.3.4 Nitrogen filling) CAUTION! Lack of nitrogen can lead to destruction of the DRIVEplus milling machine. 5.3 Operation 5.3.1 Operating the milling robot CAUTION! When inserting and removing the milling robot from the sewer, the milling machine must not touch or bump with the swivel arm.

  • Page 70: Conversion To Other Nominal Diameters

    Pay attention to the position sensor display on the controller. 5.4.1 Extension parts and nominal diameter dependent assembly of the DRIVEplus carriage and the pressure rail 5.4.1.1 Overview of extension parts of the carriage Wheels, diameter 90, 110 and 140...
  • Page 71 Axis extensions AW1, AW4, AW5, EW8 and EW3 (top view) 20 mm 60 mm 90 mm 08 mm 03 mm Undercarriage...

  • Page 72: Assembly Corundum And Granulated Wheels

    Optionally available corundum and granulated wheels To increase the traction in the channel, corundum or granulate wheels can be fitted. The corundum and granulate wheels are not part of the standard scope of delivery and can be optionally ordered from IMS. Attention! The wheels have a very rough surface.

  • Page 73: Mounting The Undercarriage

    5.4.1.2 Mounting the undercarriage First all extension parts of the carriage must be removed. Now mount the 4 toothed wheels, with the hexagon socket head screws M6 x 16 DIN 7984 (flat head). Now place the carriage in the undercarriage. While doing so, the guide pin of the undercarriage must point to the front, in the direction of the cutting arm.

  • Page 74: Overview Of Extension Parts Of The Pressure Rail

    5.4.1.3 Overview of extension parts of the pressure rail The wheels of the pressure rail can be screwed directly to the pressure rail in smaller dimensions. From nominal diameter DN 235 onwards, additional extension plates are screwed to the pressure rail. There are 3 extension plates available for this. DN 235 –...

  • Page 75: Nominal Diameter Dependent Assembly

    DN 150 to DN 600 can be realised. The assembly variants listed in the following table are to be used as reference points. Depending on the pipe situation, the DRIVEplus milling machine can also be assembled smaller or larger. This is achieved by using different axis extensions or by mounting the position of the pressure rail plates and their wheels in a different position.
  • Page 76 Pipe Axis extensions - Undercarriage + Extension plates - Position of extension plate on the pressure rail Position of wheels on the pressure Wheels diameter carriage gears pressure rail from the top rail/extension plate from the top 90 mm M6x20 flat EW 8 3rd hole head...

  • Page 77: Crane Connection

    5.5 Crane Connection The IMS milling machine DRIVEplus has a crane connection, which enables the device to be easily inserted into the shaft. The crane connection can be used from a nominal diameter of DN 225. If smaller nominal widths are used, the sheet metal mounted at the rear end of the carriage must be used.

  • Page 78: Changing The Milling Motor

    5.6 Changing the milling motor The IMS DRIVEplus milling machine has 2 different air motors. For the nominal diameter DN 150 mm, the smaller air motor should be used. How to change the larger air motor for the smaller air motor is described in the following.

  • Page 79: Milling Tools

    O-ring 5.7 Milling tools The large air motor of the milling machine operates at an idle speed of about 9,000 rpm. The smaller air motor operates at an idle speed of about 20,000 rpm. For this reason it is necessary to have the most exacting requirements for the concentricity properties of the milling tool.

  • Page 80: Changing Milling Tool Of The Small Air Motor

    5.7.1 Changing milling tool of the small air motor To change the milling tool of the small air motor, it must be dismantled as described in the point 5.7.2 Changing the milling tool of the large air motor. The milling tool can now be unscrewed using the hardened metal pins supplied in the package contents.

  • Page 81: Pressure Monitoring

    5.8 Pressure monitoring The interior of the carriage and the cutting arm are filled with nitrogen and the pressure is continuously monitored during operation. The overpressure in the device prevents ingress of moisture and thus protects the device from damage caused by wetness. The swivel-head camera is not equipped with any pressure monitoring and needs to be checked manually.

  • Page 82: Checking The Carriage And Cutting Arm After Completing The Work

    5.8.2 Checking the carriage and cutting arm after completing the work After completing the milling work, the function of the pressure monitoring must be rechecked. Fill the carriage and the cutting arm with approx. 1.5 bar nitrogen. The lamps must blink After this, remove the nitrogen from the carriage and the cutting arm (press on the valve until the nitrogen has escaped and repeat after 1 minute).

  • Page 83: Repair And Maintenance

    6 Repair and Maintenance 6.1 Cleaning The milling robot should be cleaned externally after each use. CAUTION! Do not use any high pressure devices. Only wipe the air motor or hose it down without high pressure when the motor is running, otherwise dirt will penetrate through exhaust air openings and destroy the motor.

  • Page 84: Milling Motor

    6.3.2 Milling motor 6.3.2.1 Ball bearing and fins of the large air motor 6.3.2.1.1 Ball bearing Milling leads to wear of the ball bearings of the air motor. This one can be purchased as an exchange assembly from the manufacturer. The wear can be seen from the axial play of the bearings, "hook"...
  • Page 85 After dismantling, everything must be cleaned thoroughly. The air motor contains 6 pieces of fins and 3 pieces of hardened metal pins. The rotor has 3 holes. The 3 metal pins are inserted there. So that the pins do not fall out again during assembly, they can be inserted with a little grease.

  • Page 86: Ball Bearing And Blades Of The Small Air Motor

    6.3.2.2 Ball bearing and blades of the small air motor 6.3.2.2.1 Overview of spare parts 006 30 001 Ball bearing with shim ring and circlip 021 01 027 Cylinder 006 30 002 Rotor with air motor ring 021 01 053 Set of blades 030 01 070 Ball bearing...

  • Page 87: Disassembling And Reassembling The Air Motor

    6.3.2.2.2 Disassembling and reassembling the air motor First disassemble the entire air motor from the cutting arm. To do this, loosen 4 screws M6 and pull the milling motor upwards and out of the housing. Screws, M6 x 30 The next step is to dismantle the milling tool as shown in 5.7.1 Changing milling tool of the small air motor.
  • Page 88 Remove circlip from small ball bearing. Remove rotor with pin or mandrel. Rotor with air motor ring or bearing with shim ring and circlip can be replaced. The assembly is carried out in reverse order. Place the shim ring on the rotor, fit the small ball bearing with a plastic hammer as far as it will go and fit the circlip.
  • Page 89 Notch Insert the cylinder and rotor simultaneously into the air motor housing. To do this, brake the cylinder using 2 fingers and press the rotor into the air motor housing using the other hand. The notch on the cylinder must point to the outside of the left hole. Notch in cylinder Outside left hole Then screw on the cover with the 3 M4 screws and mount a milling tool (see point 5.7.1...

  • Page 90: Milling Arm/ Swivel Drive Gear - Oil Change

    6.3.3 Milling arm/ swivel drive gear - oil change The gear oil of the rotary actuator must be changed every 4 months. The gear is located behind the swivel head camera of the milling arm. When changing the gear oil, a minimum temperature of 10 ° C must be maintained so that the gear oil can flow better out of the gear housing.

  • Page 91: Open The Screw Plug

    6.3.3.1 Open the screw plug Screw plug G Open the screw plug with an Allen key (size 6) and screw it on carefully. The sealing ring must not be damaged! CAUTION! No foreign bodies or dirt may get into the gear unit. Sealing ring of the screw plug...

  • Page 92: Drain The Transmission Oil

    6.3.3.2 Drain the transmission oil To empty the gearbox, the milling robot must be slowly turned through 180 °. The old gear oil that runs out must be collected in a suitable oil-resistant container or tub. CAUTION! The old gear oil must be disposed of in accordance with current legal regulations (Directive 75/439 / EEC waste oil disposal and waste oil ordinance (AltölV)).

  • Page 93: Fill Transmission Oil

    6.3.3.3 Fill transmission oil To fill the gearbox, the milling robot must be turned back 180 ° and all 4 wheels must stand horizontally on a straight and stable surface. The amount of oil is 40 ml! Gear oil type Usability Amount CASTROL Alphasyn GS 220...

  • Page 94: Close The Screw Plug

    6.3.3.4 Close the screw plug Check the screw plug with the sealing ring for damage. If damage is found, it is necessary to use a new screw plug with a sealing ring. Slowly screw the screw plug into the gear housing by hand. The maximum tightening torque of 10 Nm must not be exceeded.

  • Page 95: Nitrogen Filling

    IMS filling device) must be used. The nitrogen filling must be carried out in a dry place. The IMS DRIVEplus milling machine has 3 nitrogen valves. There is a valve located in the carriage, another valve in the cutting arm and a third valve is installed in the swivel-head camera.
  • Page 96 Filling with IMS filling device: First, the pressure at the pressure reducer must be set correctly (0.8 bar). For this purpose, briefly press on the ram of the filling device. Pressure drops briefly. The pressure must then be reset to 0.8 bar. Then unscrew the valve cap and place the filling device on the valve and wait a few seconds until the filling is complete.

  • Page 97: Set Up Internet Access For Remote Maintenance "Pc

    6.3.5 Set up Internet access for remote maintenance "PC" First step: please switch the system on. Further on press the "PC video software" button on the control panel of the cable drum. The following desktop appears on the video monitor: Please activate now the "Mobile Hotspot and Tethering"...

  • Page 98: Additional Regulations To Be Followed

    In the shown case, select the "AndroidAP" mobile phone and click "Connect". A new dialog box appears asking you to enter a network security key. The network security key is provided by the mobile phone. After entering and confirming, the PC now connects to the mobile phone. You are now connected to the Internet.

  • Page 99: Overview Accessories

    8 Overview accessories...

  • Page 100: Ec-Declaration Of Conformity

    9 EC-Declaration of Conformity...

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