Fasep TOP AUTOMATIC 4.0 Operating And Maintenance Manual Download | Manualshive

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OPERATING AND MAINTENANCE MANUAL

RASE.TOP.4028

Code DOC.

UM TOP AUTOMATIC

4.0

Rev. 6

Page 12 of 86

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2

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DESCRIPTION OF THE MACHINE

The tyre changer machine (the subject of this Operating and Maintenance Manual) allows a tyre to
be changed on different types of wheels, in an easy and safe manner for the operator.
Its innovative tilting system of the self-centring unit (where the wheel is positioned) facilitates
bead-breaking operations while decreasing the need for the operator to intervene on the tyre
using manual tools.
The

“RASE.TOP 4028”

machine is completed by a PLC control system and by a dedicated electric

panel.

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Summary of Contents for TOP AUTOMATIC 4.0

Page 1: ...TIC 4 0 FASEP 2000 Srl Via Faentina 96 50032 Ronta Fi ITALIA Sede legale Piazza d Azeglio 39 50121 Firenze Tel 39 055 8403126 Email vendite fasep it Skype fasep2000 orario ufficio 8 12 13 18 GMT 1 sol...

Page 2: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 2 of 86 2 Blank page...

Page 3: ...compartment 17 2 1 5 Self centring unit 18 2 1 6 Upper tool unit 18 2 1 7 Lower tool unit 19 2 1 8 Tecnoservice unit 19 2 1 9 Lifter 20 2 1 10 Pedals 21 2 2 CE plate 22 2 3 Specifications 23 3 SAFETY...

Page 4: ...5 1 Finished work cycle reports 65 5 5 2 Rim geometry diagnostics 69 Connection to the company s computer network 69 6 MAINTENANCE 73 6 1 Safety precautions 74 6 2 Disconnecting and putting out of ser...

Page 5: ...ual risks 28 Figure 18 Machine s dimensions 32 Figure 19 Connection points to power sources 33 Figure 20 Machine hoisting 35 Figure 21 Adjustable leg 36 Figure 22 Touch screen for work cycle monitorin...

Page 6: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 6 of 86 6 Blank page...

Page 7: ...urpose and intended recipients The purpose of this manual is to provide the information required to operate and service the machine Any work on the machine must be performed by a specially trained ope...

Page 8: ...es to be implemented to avoid damaging the machine This symbol is used in the safety messages rules in the manual when potentially hazardous situations exist or it is probable for persons using the ma...

Page 9: ...tives at the time it was put on the market Fig 1 DECLARATION OF CONFORMITY Encl II A Part I Selection A Machinery Directive 2006 42 EC Declares under the sole resposability of its legal representative...

Page 10: ...mile of EC Declaration of Conformity 1 5 WDK CERTIFICATION The RASE TOP 4028 tyre changer complies with the requirements of the German Rubber Association s Wirtschaftsverband der deutschen Kautschukin...

Page 11: ...INTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 11 of 86 11 1 6 WARRANTY The warranty covers the machine for 24 months starting from the date the Manufacturer ships the machine...

Page 12: ...allows a tyre to be changed on different types of wheels in an easy and safe manner for the operator Its innovative tilting system of the self centring unit where the wheel is positioned facilitates b...

Page 13: ...2 1 MAIN UNITS The tyre changer consists of the following units figure 2 Figure 2 Overall view of the machine 7 5 3 1 4 8 2 6 1 Machine frame 2 Control panel 3 Rear cabinet 4 Electric panel compartme...

Page 14: ...es Fig 3 Figure 3 Locking cones The average life under normal operating conditions of the tyre changer is estimated at 20 years Once this period is over the machine may undergo a complete overhaul che...

Page 15: ...e start and emergency buttons and lifter selectors Fig 5 Figure 5 Control panel 1 Touch screen unit 2 UPPER TOOL UNIT RAISE LOWER lever and LH RH TRANSLATION LEVER FOR THE SELF CENTRING UNIT 3 TECNOSE...

Page 16: ...OC UM TOP AUTOMATIC 4 0 Rev 6 Page 16 of 86 16 2 1 3 Rear cabinet and electric panel The cabinet in the back of the machine Fig 6 holds the hydrauliccontrol unit a the upper tool rotation unit b and t...

Page 17: ...RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 17 of 86 17 2 1 4 Electric panel compartment The electric panel compartment Fig 7 holds the PLC a power supply unit b and inverters c Figure 7 E...

Page 18: ...centring unit Fig 8 may be tilted during the tyre extraction step in order to reduce the stress applied to the bead of the tyre during removal Figure 8 Self centring unit 2 1 6 Upper tool unit The upp...

Page 19: ...ool is used by the operator to break the lower bead of the tyre Fig 10 Figure 10 Lower tool 2 1 8 Tecnoservice unit The Tecnoservice unit is used during the tyre fitting step Three tools are used to s...

Page 20: ...L RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 20 of 86 20 2 1 9 Lifter The lifter is pneumatically operated and used by the operator to load and unload the tyres for removal and fitting ope...

Page 21: ...Clockwise rotation pedal pressing down on this pedal rotates the tyre clockwise in relation to the operator s position 3 Movement pause pedal when this pedal is pressed down during the automatic tyre...

Page 22: ...The data on the plate may not be altered for any reason Figure 14 CE plate Type SMONTAGOMME Type TYRE CHANGER Modello Model RASE TOP 2028 Matricola Serial number XX Alimentazione elettrica Electrical...

Page 23: ...ions of wheel RIM DIAMETER from 1 to 8 MAX TYRE DIAMETER 114 mm 4 MAX TYRE WIDTH 80 mm 1 TYPES OF TYRES Conventional low profile run flat Tilting translating self centring system WHEEL LOCKING Automat...

Page 24: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 24 of 86 24...

Page 25: ...nual Servicemen and operating personnel must be suitably trained and informed before beginning any work Moreover operators are required to comply with the following warnings Do not use the machine for...

Page 26: ...course of the work cycle 3 3 SAFETY GUARDS All components of the tyre changer which may generate risks such as motors and transmission components electric panels pipes and hydraulic and pneumatic comp...

Page 27: ...ency button category 0 is located on the control panel of the machine Fig 16 a 1 The main power switch is located in the back of the machine on the left hand side Fig 16 b Figure 16 Emergency button a...

Page 28: ...er to the machine using the main power switch ref fig 16 b The electrocution hazard may arise if unqualified personnel access the cabinet containing the electric panel and the machine is not disconnec...

Page 29: ...onsible for immediately restoring the proper operation of the components themselves at the end of the work 3 7 1 Safety rules for the operator Use the machine for the purposes and under the operating...

Page 30: ...nd dry and more specifically eliminate any oil or grease spots Do not use petrol or inflammable solvents such as detergent always use non hazardous commercial solvents Do not use compressed air to cle...

Page 31: ...contact the Manufacturer who will provide all the information and support necessary to work in safe conditions Any defects arising from installation not performed according to the rules of the trade r...

Page 32: ...ase lighting must be uniform ensure good visibility of all areas on the machine and must not create dangerous reflections with a stroboscopic effect Lighting must allow the control panels to be easily...

Page 33: ...ine Fig 19 The power supply and pneumatic networks at the customer s premises are to have the following characteristics Electrical energy voltage 230 V frequency 50 60 Hz single phase power supply wit...

Page 34: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 34 of 86 34...

Page 35: ...ttention to the safety regulations below during machine hoisting operations Use hoisting means fork lift trucks or cranes and harness accessories which are suitable for the mass and dimensions of the...

Page 36: ...ocal provisions in force and the rules of the trade indicated by FASEP Unless indicated otherwise the floor must support a specific load of 2 kg cm2 and be of the industrial type smooth and flat Ensur...

Page 37: ...stem both when translating and tilted bead breaker unit during machine operation Also Ensure the tyre changer was not damaged during the assembly or installation step Carefully check the integrity of...

Page 38: ...If the machine is uninstalled in order to be stored for a period of time we recommend emptying the hydraulic control unit or in any case replacing the oil before it is operated again Repeat the initi...

Page 39: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 39 of 86 39 Blank page...

Page 40: ...elements falling within the intended use The machine must ONLY be used by qualified personnel who have read the contents of this manual Only use materials and products indicated by the Manufacturer to...

Page 41: ...D plates ref par 2 2 and danger signs ref par 3 5 Check operation of the safety devices emergency button ref par 3 4 To start the machine perform the following operations 1 Turn the main power switch...

Page 42: ...ion press this button to access the reading of the machine s operation parameters type of tyres changed amount of power consumed diagnostics etc Activity scheduling press the button to access the dail...

Page 43: ...USE pedal during tyre removal Decrease rim diameter press the button to decrease the rim diameter View rim diameter the icon displays the rim diameter setting unit of measure inches Increase rim diame...

Page 44: ...re touch the operator uses levers 2 and 5 ref fig 6 to bring the upper bead breaker and lower bead breaker to touch the respective beads of the tyre To choose option a or option b the operator has to...

Page 45: ...MERGENCY BUTTON IS NOT PRESSED DOWN AND PRESS START ON THE CONTROL PANEL THIS WILL START THE PUMP AND SOLENOID VALVES OF THE HYDRAULIC CIRCUIT POSITION SELECTOR TO AUTO REF FIG PRESS RESET REMOVAL TOO...

Page 46: ...E WHEEL IN PLACE PLACE THE WHEEL ON THE SELF CENTRING UNIT AND THE LOCKING CONE INTO POSITION PRESS DOWN ON THE TOP OF THE LOCKING CONE AND TURN SELECTOR 6 ON THE CONTROL PANEL TO THE RIGHT ROTATE THE...

Page 47: ...INE S OPERATING MODE SELECT AUTOMATIC OPERATING MODE BY PRESSING THE RESPECTIVE BUTTON RIM TOUCH LEFT BUTTON WITH RIM DESIGN THE BEAD BREAKERS AUTOMATICALLY COME INTO CONTACT WITH THE RIM OR TYRE TOUC...

Page 48: ...HANGER AUTOMATICALLY BREAKS THE TYRE S UPPER AND LOWER BEADS DURING BEAD BREAKING THE OPERATOR SHOULD ADEQUATELY GREASE BOTH THE UPPER AND LOWER BEADS OF THE TYRE THE OPERATOR HAS TO KEEP THE PAUSE SA...

Page 49: ...ARD AT THE SAME TIME THE LOWER BEAD BREAKER PULLS THE TYRE S LOWER BEAD UPWARD DURING THE UPWARD TRANSLATIONAL MOTION OF THE REMOVAL TOOL AND LOWER BEAD BREAKER THE OPERATOR NEEDS TO GUIDE THE VERTICA...

Page 50: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 50 of 86 50 FIRST TYRE WITH TYRE TOUCH OR RIM TOUCH AND USE REPEAT CYCLE FOR THE SECOND THIRD AND FOURTH TYRES...

Page 51: ...AINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 51 of 86 51 FITTING OPERATIONS GREASING THE NEW TYRE GREASE THE NEW TYRE ADEQUATELY INSERTING THE TYRE LOAD THE TYRE MANUALLY O...

Page 52: ...BEAD USE LEVER 2 ON THE CONTROL PANEL TO MOVE THE TECNOSERVICE UNIT b DOWNWARD AND MANUALLY POSITION THE FIRST BEAD PRESSER c AND THE SECOND BEAD PRESSER d CLOSE TO THE EDGE OF THE RIM GUIDE THE BEAD...

Page 53: ...LVE PRESS ON THE AIR PEDAL REF FIG 1 UNTIL REACHING THE DESIRED PRESSURE THE AIR PRESSURE CAN BE MONITORED VIA THE PRESSURE GAUGE LOCATED NEXT TO THE CONTROL PANEL RELEASING THE WHEEL PLACE THE LEFT H...

Page 54: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 54 of 86 54 UNLOADING THE WHEEL UNLOAD THE WHEEL VIA THE LIFTER USING CONTROL PANEL SELECTORS 9 AND 10 6 9 10...

Page 55: ...EMERGENCY BUTTON IS NOT PRESSED DOWN AND PRESS START ON THE CONTROL PANEL THIS WILL START THE PUMP AND SOLENOID VALVES OF THE HYDRAULIC CIRCUIT MOVE SELECTOR TO MAN REF FIG PRESS RESET REMOVAL TOOLS...

Page 56: ...E WHEEL IN PLACE PLACE THE WHEEL ON THE SELF CENTRING UNIT AND THE LOCKING CONE INTO POSITION PRESS DOWN ON THE TOP OF THE LOCKING CONE AND TURN SELECTOR 6 ON THE CONTROL PANEL TO THE RIGHT ROTATE THE...

Page 57: ...TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 57 of 86 57 SETTING THE RIM DIAMETER USE THE AND KEYS TO DECREASE AND INCREASE RESPECTIVELY THE DIAMETER OF THE WHEEL RIM THE CHOSEN DIAMETER WILL DIS...

Page 58: ...ER 5 ON THE CONTROL PANEL BRING THE UPPER BEAD BREAKER INTO CONTACT WITH THE UPPER BEAD OF THE TYRE BY USING LEVER 2 ON THE CONTROL PANEL IDENTIFY THE APPROPRIATE POSITION OF THE LOWER BEAD BREAKER IN...

Page 59: ...L RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 59 of 86 59 BREAKING OPERATION BY PRESSING ON THE CLOCKWISE ROTATION PEDAL DURING THE BEAD BREAKING OPERATION THE OPERATOR SHOULD GREASE THE TY...

Page 60: ...UNDER THE RIM S UPPER EDGE AND HOOK UP THE TYRE EXTRACT THE TYRE S UPPER BEAD WITH LEVER AND KEEPING THE CLOCKWISE ROTATION PEDAL PRESSED DOWN AID THE EXTRACTION OF THE TYRE S LOWER BEAD BY RAISING T...

Page 61: ...AINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 61 of 86 61 FITTING OPERATIONS GREASING THE NEW TYRE GREASE THE NEW TYRE ADEQUATELY INSERTING THE TYRE LOAD THE TYRE MANUALLY O...

Page 62: ...USE LEVER 3 TO MOVE THE TECNOSERVICE UNIT b DOWNWARD AND MANUALLY POSITION THE FIRST BEAD PRESSER c AND THE SECOND BEAD PRESSER d CLOSE TO THE EDGE OF THE RIM GUIDE THE BEADING OF THE TYRE BY HOLDING...

Page 63: ...EL S AIR VALVE PRESS ON THE AIR PEDAL REF FIG 1 UNTIL REACHING THE DESIRED PRESSURE THE AIR PRESSURE CAN BE MONITORED VIA THE PRESSURE GAUGE LOCATED NEXT TO THE CONTROL PANEL RELEASING THE WHEEL PLACE...

Page 64: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 64 of 86 64 UNLOADING THE WHEEL UNLOAD THE WHEEL VIA THE LIFTER USING CONTROL PANEL SELECTORS 9 AND 10 6 6 10...

Page 65: ...ation parameters and errors if any By pressing the Configuration key on the touch screen Fig 23 the operator gains access to a window from which three operations are possible Fig 24 select the identit...

Page 66: ...25 Report Window a Report key When the Report key is pressed the operator displays the summary of Tyres Completed showing the tyres removed since the machine was installed Fig The Tyres Completed summ...

Page 67: ...ressed the operator displays the amount of power consumed and the machine activity time Fig 27 Figure 27 Consumption and Times Key c Inverter Diagnostics key When the Diagnostics key is pressed the op...

Page 68: ...pressed the operator displays the software version installed on the machine s PLC unit Fig 9 Figure 29 System Info Window e Reset counters key When the Reset Counters key is pressed the operator gain...

Page 69: ...ring unit Rim geometry defects are detected by the lower bead breaker Fault Z and or by the upper bead breaker Fault Y Fig 1 against a reference Diagnostic Offset value in mm chosen by the operator Fi...

Page 70: ...to a PC with wired or wireless connection to the company network Fig 33 Figure 33 Machine connection to company network 2 Open an Internet browser Internet Explorer Mozilla Safari Google Chrome etc an...

Page 71: ...ng the relevant button the control window with the machine s main parameters is displayed automatically Fig 35 Figure 35 Remote machine operation control window 4 For remote access to the machine s as...

Page 72: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 72 of 86 72...

Page 73: ...used to access the Programmazione Attivit window where the customer can remotely enter the vehicle information on which the tyre s change has to be performed Fig 38 Once the tyre s change has been com...

Page 74: ...materials Pay careful attention not to leave lubricants or cleaning products in the area Make sure all system components have come to a complete stop When maintenance is complete restore and properly...

Page 75: ...OSO 46 oil X Clean the mobile mechanical parts guide elements for lower and upper tool unit and sliding elements for self centring unit and spray them with oil X Replace the oil in the control unit EN...

Page 76: ...39 Self centring unit pin 6 4 EXTRAORDINARY MAINTENANCE Contact the Manufacturer immediately for any extraordinary maintenance required so it can send specialized technicians to the machine premises...

Page 77: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 77 of 86 77 Blank page...

Page 78: ...does not correspond with the value indicated 1 2 Ensure the electric panel on the machine is connected to the company network and that the isolating switch is turned to ON 3 Check the mains voltage T...

Page 79: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 79 of 86 79 Blank page...

Page 80: ...g process involves emptying any fluids lubricating products from the machine Collect the oil in dedicated containers and dispose of it according to current regulations The second step involves removin...

Page 81: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 81 of 86 81 Blank page...

Page 82: ...ntling and Disassembly and ensure the warnings concerning their disposal are complied with In Italy the machine must be taken to a qualified disposal consortium in compliance with WEEE provisions More...

Page 83: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 83 of 86 83 Blank page...

Page 84: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 84 of 86 84 10 ATTACHMENTS 1 Pneumatic diagram 2 Hydraulic diagram 3 Spare parts list...

Page 85: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 85 of 86 85 10 1 PNEUMATIC DIAGRAM FASEP Rase top 4028...

Page 86: ...OPERATING AND MAINTENANCE MANUAL RASE TOP 4028 Code DOC UM TOP AUTOMATIC 4 0 Rev 6 Page 86 of 86 86 10 2 HYDRAULIC DIAGRAM 10 3 SPARE PARTS LIST...

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