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BOXER KING 5600 Service Manual

Truck tyre changer
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Author Stefano Muzzioli
BOXER KING 5600/5600R
TRUCK TYRE CHANGER
SERVICE MANUAL
Service Manual 04/2010 Rev.B
1

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Summary of Contents for BOXER KING 5600

  • Page 1 Author Stefano Muzzioli BOXER KING 5600/5600R TRUCK TYRE CHANGER SERVICE MANUAL Service Manual 04/2010 Rev.B...
  • Page 2 UPDATING GUIDE: Release B of 02/04/2010 Removed “50 or 60 Hz” At page 49 Service Manual 04/2010 Rev.B...

  • Page 3: Table Of Contents

    Pag. Diagrams section: electric and hydraulics Pag. Electric diagram for CE proved King 5600 Pag. Electric diagram for King 5600 supplied at 200/3/60 Pag. Electric diagram for CE approved King 5600R Pag. Electric diagram for King 5600R supplied at 200/3/60 Pag.
  • Page 4 King 5600 hook:check and replacement Pag. 7.15 Screw support tool: check and adjustment Pag. 7.16 King 5600 tool holder arm: check and replacement Pag. 7.17 King 5600R tool holder arm: check and replacement Pag. 7.18 Mount - Dismount tool: check and replacement Pag.

  • Page 5: Introduction

    MANUFACTURING MONTH (#1) AND YEAR check and repair operations of the G.S. range of (#2), REFERENCE NUMBER OF THE MACHINE Boxer King 5600 and 5600R and is for use of (#3) AND PROGRESSIVE NUMBER OF THE qualified personnel only. MACHINE (#5) MANUFACTURED WITH THIS This manual is also applicable to the following PART NUMBER.
  • Page 6 1 Set of tube type wrenches from 7 to 13mm. Standard pliers, Seeger pliers and scissor. Fig.3 Fig.7 1 Set of Allen wrenches from 3 to 12mm. Rubber and steel hammers. Fig.4 1 Set of socket wrenches of 17-19-22-24mm and Allen socket wrench of 10 and 12mm Fig.8 Extractor...
  • Page 7 1 Tool for removal of cylinder pin # 4013567 Fig.13 1 Manometer with adapter # 4006849. Fig.10 1 Multimeter, Loctite green type, Silicon Fig.14 2 Calliper wrenches of 5 and 6mm to open the cylinders. Fig.11 1 Ammeter pliers Fig.15 Spanner wrench Fig.12 In addition to a standard set of hand tools, the...

  • Page 8: Use Of Digital Multimeter

    NEVER APPLY TO YOUR MULTIMETER CURRENT OR AND HYDRAULIC VOLTAGE HIGHER THAN MULTIMETER MEASUREMENT The differences between the King 5600 diagrams CAPACITY. and the 5600R ones consist in the robotic tool movement only. PAY EXTRA CARE WHEN The electric diagram includes two more switches...

  • Page 9: Electric Diagram For Ce Proved King 5600

    3.1 ELECTRIC DIAGRAM FOR CE PROVED KING 5600 Fig.16 Service Manual 04/2010 Rev.B...
  • Page 10 Fig.17 Service Manual 04/2010 Rev.B...
  • Page 11 Fig.18 Service Manual 04/2010 Rev.B...
  • Page 12 Fig.19 Service Manual 04/2010 Rev.B...
  • Page 13 Fig.20 Service Manual 04/2010 Rev.B...
  • Page 14 Fig.21 Service Manual 04/2010 Rev.B...
  • Page 15 Fig.22 Service Manual 04/2010 Rev.B...
  • Page 16 Fig.23 Service Manual 04/2010 Rev.B...
  • Page 17 3.2 ELECTRIC DIAGRAM FOR KING SUPPLIED AT 200V-3PH-60Hz Fig.24 Service Manual 04/2010 Rev.B...
  • Page 18 Fig.25 Service Manual 04/2010 Rev.B...
  • Page 19 Fig.26 Service Manual 04/2010 Rev.B...
  • Page 20 Fig.27 Service Manual 04/2010 Rev.B...
  • Page 21 Fig.28 Service Manual 04/2010 Rev.B...
  • Page 22 Fig.29 Service Manual 04/2010 Rev.B...
  • Page 23 Fig.30 Service Manual 04/2010 Rev.B...
  • Page 24 Fig.31 Service Manual 04/2010 Rev.B...

  • Page 25: Electric Diagram For Ce Approved King 5600R

    3.3 ELECTRIC DIAGRAM FOR CE APPROVED KING 5600R Fig.32 Service Manual 04/2010 Rev.B...
  • Page 26 Fig.33 Service Manual 04/2010 Rev.B...
  • Page 27 Fig.34 Service Manual 04/2010 Rev.B...
  • Page 28 Fig.35 Service Manual 04/2010 Rev.B...
  • Page 29 Fig.36 Service Manual 04/2010 Rev.B...
  • Page 30 Fig.37 Service Manual 04/2010 Rev.B...
  • Page 31 Fig.38 Service Manual 04/2010 Rev.B...
  • Page 32 Fig.39 Service Manual 04/2010 Rev.B...

  • Page 33: Electric Diagram For King 5600R Supplied At

    3.4 ELECTRIC DIAGRAM FOR KING 5600R SUPPLIED AT 200V – 3PH - 60HZ Fig.40 Service Manual 04/2010 Rev.B...
  • Page 34 Fig.41 Service Manual 04/2010 Rev.B...
  • Page 35 Fig.42 Service Manual 04/2010 Rev.B...
  • Page 36 Fig.43 Service Manual 04/2010 Rev.B...
  • Page 37 Fig.44 Service Manual 04/2010 Rev.B...
  • Page 38 Fig.45 Service Manual 04/2010 Rev.B...
  • Page 39 Fig.46 Service Manual 04/2010 Rev.B...
  • Page 40 Fig.47 Service Manual 04/2010 Rev.B...

  • Page 41: Hydraulic Diagram For Ce Approved King 5600

    3.5 HYDRAULIC DIAGRAM FOR CE APPROVED KING 5600 Fig. 48 Service Manual 04/2010 Rev.B...
  • Page 42 Fig.49 Service Manual 04/2010 Rev.B...
  • Page 43 3.6 HYDRAULIC DIAGRAM FOR KING 5600 Fig.50 Service Manual 04/2010 Rev.B...
  • Page 44 Fig.51 Service Manual 04/2010 Rev.B...

  • Page 45: Hydraulic Diagram For Ce Approved King 5600R

    3.7 HYDRAULIC DIAGRAM FOR CE APPROVED KING 5600R Fig.52 Service Manual 04/2010 Rev.B...
  • Page 46 Fig.53 Service Manual 04/2010 Rev.B...
  • Page 47 3.8 HYDRAULIC DIAGRAM FOR MACHINE NON CE KING 5600R Fig.54 Service Manual 04/2010 Rev.B...
  • Page 48 Fig.55 Service Manual 04/2010 Rev.B...

  • Page 49: Electric Function

    K1 and K2 (Fig.17) while the inverter pole switch Q3 (Fig.17) All King 5600 and 5600R truck tyre changers are controlled the speed. The chuck motor is equipped by 3 phase motor only. Single phase protected by three 25A fuses F1,F2,F3 (Fig.17).

  • Page 50: Access To Electric Parts

    The three polar meters K1 and K2, are equipped ELECTRIC BOX: Turn all switches off and by a mechanical security (Fig.65) to avoid the open the box by lifting the lever up (Fig.56). starting of both meters simultaneously saving the Sometimes the opening may result difficult motor from blowing up.

  • Page 51: Power Supply Cable And Plug: Check And Replacement

    Fig.60 Fig.58 8 AND 2 POSITION SWITCHES ASSIES: Remove the screws and pull up the switches (Fig.59 , 60 and 61). Fig.61 SAFETY SWITCH: Remove the screws and pull out the yellow assy (Fig. 62). Fig.59 Fig.62 IMPORTANT: WHEN REMOUNTING SWITCHES AND CLOSING THE ELCTRIC BOX DOOR BE CAREFUL NOT TO CRUSH WIRES.

  • Page 52: Main Switch Q1: Check And Replacement

    : 1h Connect the ground wire to ground terminal : Small and medium screwdriver, medium block. cross screwdriver, 7mm tube type wrench, Fix the switch yellow protection. faston pliers, scissors, pliers, multimeter. Install plug. : Defective power supply cable and plug may Tighten strain relief FIRMLY .

  • Page 53: Circuit Breaker Q2: Check And Replacement

    Fig.65 Turn switch to “On”. Check that there is continuity between terminals L 2, Fig.67 and L 3 (Ω = 0 ~ 0,3) and discontinuity IMPORTANT! L1, L2, L3 between terminals and L1, L2, L3 AT THE END OF THE OPERATION CHECK THE ( 4.0).

  • Page 54: Hydraulic Motor Cable: Check And Replacement

    Check if the fuses F2 and F3 are fine ( 5.6). TO CHECK THE CABLE: Check if the coil of minimum tension is fine. Disconnect power supply. Check if the hydraulic motor is fine ( 5.7). Open the electric box ( 5.0). Disconnect the motor wires from circuit TO REPLACE THE CIRCUIT BRAKER: breaker Q2.
  • Page 55 IN CASE OF FAILURE #5 CHECK IF THE Regulate the scale according to the maximum ROTATION OF THE MOTOR IS CORRECT AS amperage reported on the motor. FIRST. Connect the pliers to a wire (Fig.70). TO CONTROL THE MOTOR WHEN IT DOES NOT RUN: Disconnect power supply.

  • Page 56: Fuses F1,F2,F3: Check And Replacement

    downwards in order to show immediately if there is an inner oil leaking. Mount the motor on the hydraulic assy. Connect the wires FIRMLY to motor terminals following the voltage at which the machine is supplied. NOTE: Before connecting the wires ends, tighten all terminals nuts.

  • Page 57: Inverter Pole Switch Q3: Check And Replacement

    Remove screw shown by the arrow to take 5.7 INVERTER POLE SWITCH Q3: out the switch handle (Fig.74). CHECK AND REPLACEMENT : 1h : Medium and big cross screwdrivers, multimeter. : Defective inverter pole switch may cause the following malfunction: 1.

  • Page 58: Chuck Motor Cables: Check And Replacement

    : 1h : Big and medium cross screwdrivers, 7mm tube type wrench, pliers, multimeter : Defective chuck motor cable may cause the following malfunction: 1. Low chuck power. 2. Noisy motor. 3. Fuses F1,F2,F3 blow up. 4. Motor damaging (burning). 5.
  • Page 59 : End wrenches 13,17,19mm, medium cross Lose the 8mm bolt #A (Fig.80). screwdriver, 7mm tube type wrenches, multimeter, straight bar, extractor,loctite. : Defective chuck motor may cause the following malfunction: 1. Low chuck power. 2. Motor does not run in one or both speed. 3.
  • Page 60 Fig.82 Fig.84 Take the new motor. If the clearance is not correct, increase it by Install the pulley by using rubber hammer and turning the nut #1 or decrease it by turning the fit its screw by using green loctite. nut #2 (Fig.85).

  • Page 61: Fuses F4,F5,F6,F7: Check And Replacement

    NOTE: After mounting the protection turn the chuck to verify if there is contact between pulleys and their protections. In case of contact, the pulleys make noise, the protection need to be readjusted until to have chuck rotation without any noise. 5.10 TRANFORMER: CHECK AND REPLACEMENT : 30’...

  • Page 62: Link Converter: Check And Replacement

    Take a multimeter and select it in Ohm. Verify if there is continuity between the ends of each fuse. If necessary, replace them with fuses of the same values: F4= 2A 250V (4A for supplied at 200V) F5= 2A 250V (4A for supplied at 200V) F6= 3,15A 250V F7= 3,15A 250V Fig.89...

  • Page 63: Portable Control Cable: Check And Replacement

    Fig.90 MACHINE UNDER TENSION. DANGER OF ELECTRIC SHOCK Fig.91 Position the multimeter probes on A1 and A2 of the meter and press the correspondent rotation pedal on the remote control: The multimeter must display 24 VAC. If the multimeter shows the correct voltage but the coil does not get exiting, it means that the coil is defective and it must replaced.
  • Page 64 FAILURE IS ELECTRIC OR HYDRAULIC PRESS THE COIL VALVE CORRESPONDENTS TO THE DEFECTIVE HYDRAULIC MOVEMENT (Fig. 93). IF THE MACHINE WORKS NORMALLY BY PRESSING THE COIL VALVE, THE PROBLEM IS DUE TO AN ELECTRIC MALFUNCTION. Fig.95 If there is not continuity remove the suspected wrong wire from the correspondent micro switch and verify if there is continuity between the two ends of the same wire.
  • Page 65 Mount the rotation switches on their support Pull up all steel wires simultaneously until to and tighten handily the nuts get all wires out. With pedals in rest position, leave 5mm of Remove the steel wires from the rest of the clearance between them and the switches wires.

  • Page 66: Switches S1: Check And Replacement

    correspondent switch holder and reverse the Position the multimeter probes on the wires. Check the machine again. contacts where the wires were fitted. Press by hand the switch and verify if there is continuity: If not the switch must be replaced. 5.15 SWITCHES S1: CHECK AND REPLACEMENT TO REPLACE THE SWITCH:...

  • Page 67: Shut Off Cable: Check And Replacement

    Fig.100 Fig.102 Verify if it works fine. Verify if all components are fine (Fig.103) Fit the assy on the portable control. TO REPLACE THE 8 OR 4 POSITION HOLDERS: Remove all wires and micro switches from their holder. Remove the top cover. IMPORTANT! BEFORE STARTING WITH ANY DISMOUNTIG OPERATION VERIFY BY USING...

  • Page 68: Shut Off Switch S4: Check And Replacement

    FAIULURE #1 ALSO MAY BE CAUSED BE A Disconnect the wires 10 and 11 from terminal MECHANICAL MALFUNCTION OF THE SHUT block. OFF SWITCH PROTECTION. Open the shut off switch S4 cover and BEFORE STARTING WITH ANY ELECTRICAL disconnect both wires (Fig.105). CONTROL VERIFY IF THE PROTECTION IS Release the strains cable relief on electric WELL REGULATED AND IF IT MOVES UP AND...

  • Page 69: Emergency Switch S5: Check And Replacement

    Tighten the wires on the switch S4 FIRMLY. Do the same control on the blue terminals. Lock the switch S4 cover and tighten the If there is not continuity the switch must be screws FIRMLY. replaced. TO REPLACE THE SWITCH S5: IMPORTANT: WHEN CLOSING THE SWITCH DOOR BE CAREFUL NOT TO Loosen the screws #1 until to have switch...

  • Page 70: Robotic Safety Switch Cable: Check And Replacement

    Remove the wires. Take the new switch and fix the wires. Fix the red button by pressing and turning it clockwise for a quarter of a turn. Tighten the metal ring. Tighten the screws #1 (Fig.107). Switch the machine on and verify if it works fine.
  • Page 71 Disconnect the wires from the switch. Cut the clip hoses and remove the switch cover (Fig.114). Fig.116 Regulate the switch in order to have its wheel as closest as possible to the machined safety Fig.114 rod but leaving it free (Fig.117) Remove the 2 bolts shown by the arrows and take away the protection (Fig.115).

  • Page 72: Robotic Safety Switch: Check And Replacement

    Lower all way down the tool holder ‘till to have its cylinder at the end of the stroke: all function of the machine should work normally. If not move a little the switch by following the arrow in Fig.119. Fig.121 Check if the machine works fine.

  • Page 73: Hydraulic Function

    : 1h VERIFY IF THE WIRES ARE FITTED ON THEIR : Small standard and cross screwdrivers, TERMINALS. IF THEY AREN’T TIGHTEN THEM pliers, multimeter. FIRMLY TO THE TERMINALS, MOUNT THE : Defective cable or connector may cause the CONNECTOR AGAIN AND VERIFY IF THE following malfunction: MACHINE WORKS FINE.
  • Page 74 6.0.1 HIGH PRESSURE CIRCUIT: 6.0.5 LEFT / RIGHT OF CARRIAGE: The high hydraulic pressure is controlled by the LEFT: Oil flow reaches the side “B” of the valve 0.5 (Fig.52) and its range is from 50 to cylinder 1.4 through the valve Y1B. Oil in 200Bar (720 to 2880Psi).

  • Page 75: Access To Hydraulic Parts

    0,5 or that one 4.1 open and unload the oil to the reservoir. 6.1 ACCESS TO HYDRAULIC PARTS The access to the hydraulic parts of the Boxer Fig.126 King 2600 is more complicated compared to the electric ones, because in some cases the...
  • Page 76 Fig.128 KING 5600 SADDLE CYLINDER: To access to this cylinder (Fig.130) remove the red hoses protection (Fig.129). Fig.131 CHUCK CYLINDER: This cylinder (Fig.132) is included into the chuck arm and its access is the most complicated one because it requires the dismounting of the gear oil tank, the worm screw assy and chuck components.
  • Page 77 Fig.133 Fig.136 To dismount the cabinet tool holder on the King 5600 remove the 14mm nut in Fig.137 and then those ones of 10mm in Fig.138. Fig.134 To dismount the cabinet tool holder on the King 5600 remove the 14mm nut in Fig.135 and then that one of 20mm in Fig.136.

  • Page 78: Hydraulic Oil Level: Check And Levelling

    6.2 HYDRAULIC OIL LEVEL: CHECK AND LEVELLING : 30’ : Suggested hydraulic oil. : Incorrect oil level may cause the following malfunction: 1. Slow or no hydraulic movements. 2. Possible pump damaging. TO CHECK THE HYDRAULIC OIL LEVEL: Switch the machine on. Close all cylinders.

  • Page 79: High Hydraulic Pressure Circuit: Check And Adjustment

    2. DO NOT OVERFILL THE RESERVOIR BECAUSE THE OIL IN EXCESS WILL COME OFF THROUGH THE STOPPER WHILE MACHINE IS OPERATING . The hydraulic oil does not need to be replaced: It only must be refilled. 6.3 HIGH PRESSURE HYDRAULIC CIRCUIT: CHECK AND ADJUSTMENT : 30’...

  • Page 80: Hydraulic Pressure Of Chuck Cylinder: Check And Adjustment

    Turn the machine on and close the tool holder cylinder ‘till end of the stroke ( 6.1 Fig.133). Turn the machine off. Remove the screw and install the manometer on the steel oil hose (Fig.146). Fig.148 Move to the right the tool holder cylinder ‘till end of the stroke.
  • Page 81 TO ADJUST THE CHUCK CYLINDER PRESSURE: To adjust the maximum pressure 6.3. 6.5.1 LOCKING VALVE TO CHECK THE LOCKING VALVE: IMPORTANT! DO NOT REPLACE THIS PART WITH OPENED CHUCK CYLINDER. Close the chuck cylinder completely. Switch the machine off. Fig.151 Press the coil valve by screwdriver to unload the remaining pressure ( 5.14 Fig.93).
  • Page 82 THE LITTLE HOLE ON THE FLANGE MUST Remove the locking valve from chuck cylinder MATCH WITH THE LITTLE ON THE CHUCK flange following the point1. CYLINDER, OTHERWISE THE CYLINDER WILL Remove the piston shown by the arrow in OPEN BUT IT WILL NOT CLOSE ANYMORE picture 155.

  • Page 83: Saddle Cylinder Sliding Hydraulic Pressure: Check And Adjustment

    IMPORTANT! IN CASE OF FLANGE REPLACEMENT IT IS SUGGESTED THE REPLACEMENT FO THE MANIFOLD “O” RINGS (FIG.160). Fig.157 TO REPLACE THE FLANGE: Remove the small and big flange O rings. Remove the screw #1 and the washer Fig.160 (Fig.158). Mount the manifold revolving on the cylinder flange by using some grease to make the operation easy.
  • Page 84 MOBILE TABLE IS VERY HEAVY: HANDLE IT WITH CARE TO AVOID FEET AND FINGERS CRUSHING. Fig.163 If the sliding pressure shown by the manometer will be considerably higher than 50Bar (720PSI), the saddle needs adjustment. TO ADJUST THE SLIDING PRESSURE: Fig.161 Position the saddle in the middle of the frame on the king 5600R (Fig.164), while the King...

  • Page 85: Hydraulic Pump: Check And Replacement

    ECCENTRICS MUST BE ADJUSTED AND HEAVY: HANDLE IT WITH LOCKED ONE BY ONE. CARE TO AVOID FEET AND FINGERS CRUSHING. NOTE: FOR KING 5600 ADJUST THE ECCENTRICS OF THE PICTURES 160 ONLY BECAUSE THERE ARE TWO BUSHINGS IN Mount the top cover. THE BOTTOM.
  • Page 86 IMPORTANT! SOMETIMES THE NOISY IS CAUSED BY A BAD REGULATION OF THE JOINTS. WHEN THEY ARE NOT WELL REGULATED THE MOTOR FAN STOPS VERY QUICKLY. TO REPLACE THE HYDRAULIC PUMP: Switch the machine on. Open all cylinders completely. Switch the machine off. Take a cleaned recipient.

  • Page 87: Coil Valve: Check And Replacement

    7. Mount both covers very carefully in order to avoid damaging to the new seals. 8. Tighten the screws FIRMLY. 9. Take a couple of pliers and turn the pump shaft: it must turn freely. In case all seals and O ring will result fine, the pump needs to be replaced.

  • Page 88: King 5600 Saddle Cylinder: Check And Replacement

    Fig.175 leaking or mechanical breakages. Open the body valve by using 14mm end TO REPLACE THE CYLINDER ON KING 5600 wrench (Fig.176). Clean very carefully all parts from slag and Open the saddle cylinder ‘till end of stroke.
  • Page 89 Remove the pin by using the tool for removal of cylinder pin (Fig.179). Fig.181 Mount the cylinder pin from the bottom. Install the top washer #2 and split pin #1 (Fig.180). Fig.179 Fit the oil hoses by using new copper washers.

  • Page 90: King 5600R Saddle Cylinder: Check And Replacement

    Mount the washers and the screw of Fig.177. Remove the pin by using the tool for removal Open and close the cylinder to verify if it is of cylinder pin (Fig.185). working fine. Mount the oil hoses protection ( 6.1 Fig.129). Make the hydraulic oil level ( 6.2).
  • Page 91 INSTALLATION ON THE SADDLE ( 6.9 FIG.181). Install the top washer and a new split pin. Install the longer oil hose (Fig.187). Insert the oil hose through its guide and connect it to the hydraulic assy. Turn on the machine. Mount the saddle pin 6.9.

  • Page 92: King 5600 Saddle Cylinder Seals: Check And Replacement

    Mount the hose plastic separators (Fig.184). Mount the oil hose protection 6.1 Fig.127. Check the hydraulic oil level 6.2. 6.11 KING 5600 SADDLE CYLINDER SEALS: CHECK AND REPLACEMENT : 2h : End wrench 13, 19mm, 8mm Allen wrench, socket wrench of 27mm, medium standard screwdriver, pliers, calliper wrench, steel and Fig.191...
  • Page 93 Fig.193 Fig.196 Remove the seal and the plastic guides. Verify the condition of all components. Remove the piston (Fig.194). Clean very accurately all parts, wash the rod thread by using solvent and dry it carefully. Install the new O ring and the new lip seal on the ring screw.

  • Page 94: King 5600R Saddle Cylinder Seals: Check And Replacement

    Check if the machine works fine. 6.13 CHUCK ARM CYLINDER: CHECK AND REPLACEMENT : 1h 30’ : Steel hammer, rubber hammer, long lever, end wrenches 9, 13 and 19mm, piece of wood, hydraulic oil container. : Defective chuck arm cylinder may cause the following malfunctions: 1.

  • Page 95: Chuck Arm Lowering Speed: Check And Adjustment

    SIZENED ON THE PIN OF THE CABINET AND THERE IS NO WAY TO UNLOCK THEM. Remove the greasers #8 (Fig.199) from the defective cylinder. Clean the pin and grease them. Take the new cylinder and fix the greasers. Grease the cylinder bushings. Fix the hoses by using news copper washers.

  • Page 96: Chuck Arm Cylinder Seals: Check And Replacement

    TO CHECK RING NUT “O” RING AND THE PISTON ROD LIP SEAL: Check oil leaking following 6.10. TO CHECK THE PISTON SEALS: Take a wheel and lock it on the chuck. Lift the wheel ‘till end of stroke. Leave the wheel quite lifted for 5’. If 5’...
  • Page 97 If there is an oil leaking between the flange Remove the upper oil hose from the manifold and the chuck arm, the small “O” ring #2 revolving (Fig.206). (Fig.204) is damaged and it must be replaced. Fig.206 Fig.204 Press the command “Open” on portable TO CHECK THE MANIFOLD REVOLVING “O”...
  • Page 98 When the piston seal is just out of the cylinder hold ‘till to have the opposite liner completely empty from the hydraulic oil. Remove the piston from the cylinder. Remove the screw #1 (Fig.210). Remove the piston #2 by using the calliper wrench.

  • Page 99: Tool Holder Cylinder: Check And Replacement

    Fig.212 Fig.215 Mount the lip seal (Fig.213). Grease the cylinder and piston seals and mount the piston by using rubber hammer. IMPORTANT! Install the rear flange 6.5. INSTALL THE LIP SEAL WITH THE RING SIDE Turn on the machine. TOWARDS THE OUTER SIDE OF THE Open and close the chuck cylinder and verify FLANGE.

  • Page 100: Tool Holder Cylinder Seals: Check And Replacement

    25 Bar (350 PSI) remove the EXTRA CARE TO AVOID cabinet-tool holder cabinet ( 6.1 Fig.133 for FINGERS CRUSHING. King 5600 and Fig.134 for King 5600R). IMPORTANT! VERY OFTEN THERE ARE WASHERS BETWEEN TOOL HOLDERS AND THEIR CABINETS SUPPORT. THEY MUST BE PLACED IN THE SAME ORIGINAL POSITION.

  • Page 101: King 5600R Robotic Cylinder: Check And Replacement

    Open the cylinder ‘till end of the stroke 6.19 KING 5600R ROBOTIC CYLINDER: (Fig.218). CHECK AND REPLACEMENT : 2h : End wrenches of 6,9,13,14,15,17,22 and 24, 3,4 and 5mm Allen wrenches, rubber hammers, manometer, green loctite, hydraulic containers oil. : Defective chuck cylinder may cause the following malfunctions: 1.
  • Page 102 Fig.221 Fig.223 Remove the pin #1 (Fig.222). Remove the nut #2 (Fig.222). Remove the nut and the screw #1 (Fig.216) Lower the rod #3 and remove the nut #4 Push out the pin #2 to take out the cylinder (Fig.214). (Fig.224).
  • Page 103 Remove the greasers #3 and #4 (Fig.224 and Fig.226) Remove the screw #5 (Fig.226). Fig.227 If the cylinder piston reaches the end of stroke before the hook (Fig.228), remove the pin #6 Fig.226 (Fig.222) and turn counter clockwise of a turn the piston rod head (Fig.229).

  • Page 104: King 5600R Robotic Cylinder Seals: Check And Replacement

    Lock the screw #5 (Fig.226) FIRMLY by 6.20 KING 5600R ROBOTIC CYLINDER loctite. SEALS: CHECK AND REPLACEMENT Lift up the hook and install the spring. Lower the hook all way down. : 2h Turn off the machine. : End wrenches of 22, 4 Allen wrench, calliper Install the safety rod #3 (Fig.222).

  • Page 105: King 5600R Saddle Slides: Check And Replacement

    : Incorrect saddle adjustment may cause the following malfunctions: 1. Excess of saddle play. 2. Incorrect distance between tool and rim. 3. Low bead breaking power. TO CHECK THE ADJUSTMENT: To control the adjustment 6.6. TO ADJUST THE SADDLE WHEN THE SLIDES ARE TOO TIGHTENED: To adjust the saddle sliding 6.6.
  • Page 106 Fig.234 Remove the tool holder cylinder 6.18. Disconnect the steel oil hose from standard Fig.236 one. Remove the tool holder oil hoses support shown by the arrow (Fig.235) from the saddle. Fig.237 The slides are bolted on their bars with 8mm Fig.235 screws and toothed washers (Fig.238 and 239).
  • Page 107 Mount the saddle on the cabinet. Mount the pin #5 ( 6.9 Fig.177 and 178). Mount all bars with slides by tightening the screws and the eccentrics by hands only. IMPORTANT! THE BARS HAVE THE FIRST HALF OF THE 10mm THREADED HOSES LARGER THAN THE SECOND ONE (Fig.242).

  • Page 108: King 5600 Saddle Slides: Check And Replacement

    Mount the mount – dismount tool. Mount the mobile plate. Check the machine. Fig.245 7.3 KING 5600 SADDLE SLIDES: Take out the bar of Fig.250 and when both bushings are out of the bar, the saddle can be CHECK AND REPLACEMENT removed from the machine.

  • Page 109: King 5600 Saddle Bushings: Check And Replacement

    Install the steel oil hose. Install the mount dismount tool. Install the mobile plate on the saddle Check if the machine works fine. 7.4 KING 5600 SADDLE BUSHINGS: CHECK AND REPLACEMENT : 5h : End wrenches 9,10,13,17,19,22,24,30mm, 17 and 22mm socket wrench, manometer,...

  • Page 110: King 5600R Robotic Rotor: Check And Replacement

    2. Overstress or breakage of the lifting cylinder. If not turn the screw #2 (Fig.243) ‘till the correct adjustment. TO CHECK THE ROTATION: Lock the nut #2 FIRMLY. Turn on the machine. Lift up the tool holder and perform a complete tool rotation.
  • Page 111 Fig.251 Fig.254 Remove the spring, the washer and the ball Check if the hole #1 is too wide in case of bearing (Fig.252). malfunction 1 (Fig.255). Check if the rotor cam #2 is broken in case of malfunction 2 (Fig.255). Fig.252 Remove the set screw #2 (Fig.251).

  • Page 112: King 5600R Lower Robotic Cam And Spring: Check And Replacement

    TO REPLACE THE ROBOTIC ROTOR: Remove the shim of Fig.254 from rotor. Remove the half ball bearings rings by using a screwdriver (Fig.257). Fig.259 Install the bearing ball, the washer (Fig.252) and the ball bearing nut #1 (Fig.251). Turn on the machine lower the hook to verify if the rotor hole #1 (Fig.255) matches with Fig.257 rotation proof pin.
  • Page 113 Remove the rotor 7.6. Replace the cam and/or the spring (Fig.262 Verify if the cams are broken 7.5 (Fig.256). and 263). TO CHECK THE SPRING: Turn on the machine. Lower the tool holder arm. Turn off the machine. Remove the seeger ring #1 and take away the cover #2 (Fig.260) without remove the screw.
  • Page 114 Fig.264 Fig.267 Pull and turn clockwise of ½ of a turn the spring (Fig.268) and at the same time insert the pin #4 (Fig.269). Fig.265 Fig.268 Mount the stopper #2 and its screw #1 (Fig.261). Fig.266 Insert the pin #3 for 1/3 of its length and with the sign #4 (Fig.269) towards the top.
  • Page 115 7.8 TOOL HOLDER CABINET MOVING: CHECK AND REPLACEMENT : 1,5h : End wrenches of 13,17,19 and 30mm, Allen wrench of 4,5 and 6mm, rubber hammer , green loctite. : The defective cabinet tool holder moving may cause the following malfunctions: 1.

  • Page 116: Shutdown Pin: Check And Replacement

    BE SURE TO HAVE WELL HOOKED THE TOOL HOLDER IN ORDER TO UNLOAD THE SPRING UNDER THE COVER (FIG.277). Fig.274 Adjust the cabinet in order to avoid its contact with the shims when the tool holder assy is completely hooked (Fig.275). Fig.276 Remove the nut #1 and take out the screw #2 (Fig.277).

  • Page 117: King 5600R Tool Holder Arm Bushings: Check And Replacement

    : End wrench of 13,15,17,19 and 22mm, Allen Check if the machine works fine. wrenches of 4, 6 and 8mm, seeger pliers, rubber hammer. 7.11 BOXER KING 5600R HOOK: : Worn bushings may cause the following malfunctions: CHECK AND ADJUSTMENT 1.

  • Page 118: King 5600R Hook:check And Replacement

    ‘till to have the adjustment SHIMS BETWEEN THE HOOK AND ITS above reported (Fig.282). SUPPORT. AFTER REPLACING THE HOOK INSTALL THESE SHIMS IN THE SAME POSITION AGIN. 7.13 BOXER KING 5600 HOOK: CHECK AND ADJUSTMENT Service Manual 04/2010 Rev.B...

  • Page 119: King 5600 Hook:check And Replacement

    FITTED THE TUBE WITH SPRING BECAUSE BOLT MISSING MAY CAUSE SERIOUS INJURY TO THE OPERATOR. Mount the mount dismount tool. 7.14 BOXER KING 5600 HOOK: CHECK AND REPLACEMENT : 1h Fig.283 : End wrench of 10,13, and 30mm, tube type wrenches of 10mm, medium screwdriver, Lower the tool holder on the saddle bar.

  • Page 120: King 5600 Tool Holder Arm: Check And Replacement

    TO CHECK THE ADJUSTMENT: is well adjusted. Turn the machine on. 7.16 KING 5600 TOOL OLDER ARM: Move the tool holder arm from the left to right ‘till end of the stroke and verify if the screw CHECK AND REPLACEEMENT head gets a contact with the saddle.

  • Page 121: King 5600R Tool Holder Arm: Check And Replacement

    Fig.289 Mount the cabinet tool holder movement 6.1. Make the screw support tool holder adjustment 7.13. Turn on the machine an verify if all screws are well adjusted. 7.17 KING 5600R TOOL OLDER ARM: CHECK AND REPLACEEMENT Fig.287 : 5h Mount the mount –...
  • Page 122 Mount the robotic rotor 7.6. IMPORTANT! Mount the rotation proof pin 7.9. IF THE PLATE HOLE #2 DOES NOT MATCH Mount the mount – dismount tool. WITH THE 8mm THREADED HOLE, TURN THE Make the screw support tool holder PLATE. adjustment 7.13.

  • Page 123: Jaws And Claws: Check And Replacement

    Remove the pin #1 (Fig.292). Unscrew the nut #2 and remove the screw #3 (Fig.292). Fig.293 Fig.292 Install the new hook and tighten the screw#3 and nut #2 FIRMLY (Fig.292). Mount the bead breaker disk. Unscrew the nut #2 ‘till to move the tilting tool by hands.

  • Page 124: Worm Screw: Check And Replacement

    Fig.296 Remove the chuck motor and place it on the back side of the chuck arm. Unlock the nut #1 and unscrew the set screw #2 of a turn (Fig.297). Fig.295 7.20 WORM SCREW: CHECK AND REPLACEMENT : 2h : End wrenches 13,19,22mm, socket wrench 22 and 24mm, 13mm tube type wrench, 12mm Allen wrench, rubber hammer, silicon.
  • Page 125 Clean the gear oil tank and all oil protection from old silicon very accurately and wash them by using alcohol. Clean the worm screw assy screws and bracket holes from dry loctite. Mount the worm screw on the crown gear and insert the shims, if there are.

  • Page 126: Worm Screw Seal: Check And Replacement

    Turn the machine off and remove the belts protection 5.9. Check if there is oil leaking around the pulley. TO REPLACE THE SEAL: Remove the front worm screw support (Fig.305) by removing the screws #3 and #4 ( 7.20 Fig.298). Fig.303 Fig.305 Lock the support on a vice and remove the...

  • Page 127: Chuck Seal: Check And Replacement

    Remove the chuck from the arm (Fig.308) by using a fork lift. Fig.307 Stop to push the seal in when the wood has reached the support. Fig.308 Mount the support again following 7.20 without perform any worm screw adjustment. Replace the chuck seal by locking the new Check if the machine works fine.

  • Page 128: Trouble Shooting

    Mount the worm screw assy 7.20. MOVEMENTS BUT THE CHUCK MOTOR Mount the safety lever 5.19. DOES NOT TURN AT ALL: Mount the gear stopper by using Teflon tape. Fill the gear by using only suggested gear Check the fuses F1,F2,F3 5.6.
  • Page 129 FAULT 11: THE CHUCK ARM DROPS: Check the tool holder arm 7.16 and 7.17. Check the saddle bushings 7.4. Replace the retainer valve 6.13. Call GS. Check the chuck arm piston seals 6.15. On machines non CE proved replace the coil FAULT 18: THE MACHINE SHOWS SLOW valve 6.8.

  • Page 130: Service Bulletins

    9.0 SERVICE BULLETINS : 378 Date : 08/05/1998 Models Affected : BOXER KING 5600-ACCU4560 Subject HYDRAULIC PLANT - NEW TYPE As from : 12977203 The hydraulic plant has been replaced with a new model easily recognised by the electric valves attached to the block.
  • Page 131 : 379 Date : 08/05/1998 Models Affected : BOXER KING 5600-ACCU4560-WING 311 Subject HYDRAULIC PLANT - NEW TYPE As from : 12977702 The hydraulic plant has been replaced with a new model easily recognised by the electric valves attached to the block.
  • Page 132 : 380 Date : 08/05/1998 Models Affected : BOXER KING 5600-5600R-5610-5610R - ACCU 4560- 4560R-4450 - WING 888-311-511 - KING 23 Subject MODIFICATION OF TUBELESS ROLL As from : JANUARY 1998 The tubeless roll #4014974 has been replaced with #4022287.
  • Page 133 : 389 Date : 17-02-99 Models Affected : BOXER KING 5600 - ACCU 4560 - GX56 Subject : Toolholder Case Starting from : 12981287 The toolholder case #4013116, the hook #4013131, the case drive support #4013107, the case assy #4017013 and the double tool #4006271 have been replaced respectively by #4023642, #4023638, #4023637, #4023773 and #4021567.
  • Page 134 #4024982 BOXER KING 5610R. WING 511 #4024983 In models Boxer King 5610- ACCU4450 (with effect from 04982944), Boxer King 5610R ACCU4560MR and Wing 511 (with effect from 06985378) the hydraulic circuit has also been optimised with consequent replacement of the valve #0022485 and the coil #0022486 with #0023510 and #0022491 respectively.
  • Page 135 Operation of the machine has remained unchanged. • The filter can be installed on the machines where it is not present using the relative parts kit. • It is not necessary to make the modification on machines already sold. Service Manual 04/2010 Rev.B...
  • Page 136 : 414 Date : 15-01-01 Models Affected : Boxer KING 5600R – ACCU 4560, 4560MR Subject : Turntable adjustment washer – modified With effect from 12003412 The adjustment washer#0002092, on the rear of the turntable cylinder, has been replaced by the adjustment washer #0025232, having a thickness of mm.3 (double than the previous one).
  • Page 137 : 430 Date : January 8, 2002 Models Affected : Boxer king 5600R – ACCU 4560MR Starting from s/n : 09018665 Subject : #4012117 tool holder with cam Due to a manufacturing reasons we made a modification to the dimensions of the tool holder with cam #4012117, which has been replaced by the one #4021411.
  • Page 138 BLANK PAGE Service Manual 04/2010 Rev.B...
  • Page 139 BLANK PAGE Service Manual 04/2010 Rev.B...
  • Page 140 AUTHOR: Stefano Muzzioli Copyright statement This manual and the materials contained within are copyright protected. The manual, or any section, page, drawing, or diagram, may not be reproduced by any means without the written consent. The information and specifications in this manual are based on the latest information available at the time of publication. We reserve the right to change the specifications at any time without notice.

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