BOXER KING 5600, Service Manual

Page 1: ...Service Manual 04 2010 Rev B 1 Author Stefano Muzzioli BOXER KING 5600 5600R TRUCK TYRE CHANGER SERVICE MANUAL...

Page 2: ...Service Manual 04 2010 Rev B 2 UPDATING GUIDE Release B of 02 04 2010 Removed 50 or 60 Hz At page 49...

Page 3: ...ar meters K1 K2 check and replacement Pag 62 5 14 Portable control cable check and replacement Pag 63 5 15 Switches S1 check and replacement Pag 66 5 16 Micro switches S2 S3 and S6 check and replaceme...

Page 4: ...and replacement Pag 112 7 8 King 5600R tool holder moving cabinet check and replacement Pag 115 7 9 Shutdown pin check and replacement Pag 116 7 10 King 5600R tool holder arm bushings check and repla...

Page 5: ...N DULY TRAINED BY G S AUTHORIZED INSTRUCTORS Keep this manual constantly updated by adding Service Bulletins related to Boxer King 2600 IMPORTANT THE IDENTIFICATION DATAS OF EACH MACHINE ARE PRINTED O...

Page 6: ...o 13mm Fig 3 1 Set of Allen wrenches from 3 to 12mm Fig 4 1 Set of socket wrenches of 17 19 22 24mm and Allen socket wrench of 10 and 12mm Fig 5 Dyanamometric wrench Fig 6 Standard pliers Seeger plier...

Page 7: ...een type Silicon Fig 11 1 Ammeter pliers Fig 12 In addition to a standard set of hand tools the following special tools are required 1 Wrench adjustment of saddle clearance 0013564 Fig 13 1 Manometer...

Page 8: ...d as per instructions the polarity is reversed To measure VAC values alternate current Suitably adjust the end of scale selector and VAC selector If you don t know the probable value of the voltage to...

Page 9: ...Service Manual 04 2010 Rev B 9 3 1 ELECTRIC DIAGRAM FOR CE PROVED KING 5600 Fig 16...

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Page 17: ...Service Manual 04 2010 Rev B 17 3 2 ELECTRIC DIAGRAM FOR KING SUPPLIED AT 200V 3PH 60Hz Fig 24...

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Page 25: ...Service Manual 04 2010 Rev B 25 3 3 ELECTRIC DIAGRAM FOR CE APPROVED KING 5600R Fig 32...

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Page 33: ...Service Manual 04 2010 Rev B 33 3 4ELECTRIC DIAGRAM FOR KING 5600R SUPPLIED AT 200V 3PH 60HZ Fig 40...

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Page 41: ...Service Manual 04 2010 Rev B 41 3 5 HYDRAULIC DIAGRAM FOR CE APPROVED KING 5600 Fig 48...

Page 42: ...Service Manual 04 2010 Rev B 42 Fig 49...

Page 43: ...Service Manual 04 2010 Rev B 43 3 6HYDRAULIC DIAGRAM FOR KING 5600 Fig 50...

Page 44: ...Service Manual 04 2010 Rev B 44 Fig 51...

Page 45: ...Service Manual 04 2010 Rev B 45 3 7 HYDRAULIC DIAGRAM FOR CE APPROVED KING 5600R Fig 52...

Page 46: ...Service Manual 04 2010 Rev B 46 Fig 53...

Page 47: ...Service Manual 04 2010 Rev B 47 3 8 HYDRAULIC DIAGRAM FOR MACHINE NON CE KING 5600R Fig 54...

Page 48: ...Service Manual 04 2010 Rev B 48 Fig 55...

Page 49: ...controlled the speed The chuck motor is protected by three 25A fuses F1 F2 F3 Fig 17 On machines for non CE market there is a further circuit breaker Q3 Fig 24 instead of the fuses F1 F2 F3 4 2 AUXIL...

Page 50: ...THE MACHINE DISCONNECT THE MACHINE FROM ELECTRIC SUPPLY Very often electric failures are only caused by loosened wires or connectors not well fitted Therefore it is VERY IMPORTANT BEFORE STARTING WITH...

Page 51: ...and pull up the switches Fig 59 60 and 61 Fig 59 Fig 60 Fig 61 SAFETY SWITCH Remove the screws and pull out the yellow assy Fig 62 Fig 62 IMPORTANT WHEN REMOUNTING SWITCHES AND CLOSING THE ELCTRIC BOX...

Page 52: ...sert the new cable through the strain relief IMPORTANT USE ONLY APPROVED CABLES AND PLUGS AND GROUND WIRE MUST BE LONGER THAN THE OTHER ONES Fix new fastons on inside cable ends and connect them to th...

Page 53: ...ORTANT AT THE END OF THE OPERATION CHECK THE ROTATION WAY OF THE HYDRAULIC MOTOR IF IT IS WRONG REVERSE TWO SWITCH WIRES ONLY 5 3 CIRCUIT BREAKER Q2 CHECK AND REPLACEMENT 30 Medium screwdriver pliers...

Page 54: ...e motor terminals cover and remove all wires from terminals Select the multimeter in Ohm and check if there is continuity between ends of each wire TO REPLACE THE CABLE Release cable strain relief on...

Page 55: ...UIT BREAKER SHUTS OFF IMPORTANT BEFORE STARTING WITH ANY CONTROL AND REPLACEMENT VERIFY IF THE BREAKER IS CORRECTLY REGULATED COMPARED TO MOTOR DATAS Disconnect power supply Remove the motor terminal...

Page 56: ...t which the machine is supplied NOTE Before connecting the wires ends tighten all terminals nuts Check the rotation way of the motor If it is wrong reverse only two motor wires otherwise the chuck mot...

Page 57: ...h on the faulty speed Take the multimeter and select it in VAC Position the multimeter probes on U1 and W1 of the motor terminals and press the rotation pedal Fig 73 Fig 73 The display must show the v...

Page 58: ...speeds TO CHECK THE CABLES Disconnect power supply Open the electric box 5 0 Remove the motor terminals cover and all wires from terminals Remove the inverter pole switch from the electric box 5 7 Se...

Page 59: ...must be replaced Perform the same controls with terminals U1 V1 and W1 V1 TO CONTROL THE MOTOR WHEN IT IS NOISY Disconnect machine from power supply Remove the motor terminal cover Fig 73 and verify...

Page 60: ...on is done make sure that there are still 1 5mm between bar and plastic pulley Fig 84 Fig 84 If the clearance is not correct increase it by turning the nut 1 or decrease it by turning the nut 2 Fig 85...

Page 61: ...RIC SHOCK Verify if the power between terminals 0 and 400 or 230 according to voltage at which the machine is supplied is correct Fig 86 if not see 5 1 and 5 2 Verify if there is power between termina...

Page 62: ...e power displayed by the multimeter is 24 VDC Fig 89 if not replace the converter Fig 89 TO REPLACE THE CONVERTER Disconnect the machine from power supply Open the electric box 5 0 Remove all wires fr...

Page 63: ...ion 1 and lifting it up 2 Fig 91 Remove all wires from terminals IMPORTANT MARK WIRES PROPERLY FOR AN EASY AND SAFE INSTALLATION Pull downward the tab and lift the meter up for its removing Fig 92 Ins...

Page 64: ...wire from the correspondent micro switch and verify if there is continuity between the two ends of the same wire Fig 96 TO REPLACE THE CABLE Disconnect the machine from power supply Open the electric...

Page 65: ...wire from the second 2 position switch Connect the rest of the wires to the third steel wire Pull up all steel wires simultaneously until to get all wires out Remove the steel wires from the rest of t...

Page 66: ...VALVE THE PROBLEM IS DUE TO AN ELECTRIC MALFUNCTION TO CONTROL THE SWITCHES If the wires are fine 5 14 the switches S2 S3 and S6 need to be checked Take the multimeter and select it in Ohm Position t...

Page 67: ...pins the spacer and the spring from the holder Fig 102 Fig 102 Verify if all components are fine Fig 103 Fig 103 Take the new holder Install the pins the spacer and the spring on the new holder by usi...

Page 68: ...S4 and on the terminals block FIRMLY Lock the switch S4 cover and tighten the screws FIRMLY IMPORTANT WHEN CLOSING THE SWITCH DOOR BE CAREFUL NOT TO CRUSH WIRES Tighten the strain cable relief leavin...

Page 69: ...ltimeter Defective switch S5 may cause the following malfunction 1 Switching the machine on the hydraulic motor turns but the machine does not work TO CONTROL THE SWITCH Remove power supply from the m...

Page 70: ...mm allen wrench 6mm end wrench pliers multimeter L Defective cable may cause the following malfunction 1 All hydraulic movements except tool holder lifting and lowering do not work TO CHECK THE CABLE...

Page 71: ...t the cable to the terminal block 20 and 21 into the electric box Turn on the machine and open the saddle until end of the stroke Fig 115 Lift up the tool holder till to have the switch wheel on the m...

Page 72: ...OBOTIC SAFETY SWITCH CHECK AND REPLACEMENT 1h Small standard and cross screwdrivers 3mm allen wrench 6mm end wrench pliers multimeter L Defective switch may cause the following malfunction 1 All hydra...

Page 73: ...ease the cable strains relief Lift up the connectors by using a screwdriver to have access to the wires Fig 124 IMPORTANT VERIFY IF THE WIRES ARE FITTED ON THEIR TERMINALS IF THEY AREN T TIGHTEN THEM...

Page 74: ...ARRIAGE LEFT Oil flow reaches the side B of the cylinder 1 4 through the valve Y1B Oil in opposite side A gets out and returns to reservoir through the valveY1N Fig 52 RIGHT Oil flow reaches the side...

Page 75: ...RAULIC PARTS The access to the hydraulic parts of the Boxer King 2600 is more complicated compared to the electric ones because in some cases the dismounting of many parts is required to reach those d...

Page 76: ...tection Fig 131 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...

Page 77: ...nut in Fig 135 and then that one of 20mm in Fig 136 NOTE SOMETIMES THERE ARE SHIMS BETWEEN CABINET AND NUT THESE SHIMS MUST BE PLACED AGAIN IN THE SAME POSITION Fig 135 Fig 136 To dismount the cabine...

Page 78: ...draulic movements 2 Possible pump damaging TO CHECK THE HYDRAULIC OIL LEVEL Switch the machine on Close all cylinders Switch the machine off Remove the reservoir stopper Verify if oil level correspond...

Page 79: ...ws and put the chuck cylinder under pressure Verify if the maximum hydraulic pressure shown by the manometer is 160 Bar 2300 PSI Fig 144 Fig 144 TO ADJUST THE PRESSURE If the pressure is lower or high...

Page 80: ...anometer and install the bolt with two new copper washer Check if the machine works fine and if there is any further oil leaking 6 5 HYDRAULIC PRESSURE OF CHUCK CYLINDER CHECK AND ADJUSTMENT 1h End wr...

Page 81: ...eter from the flange Remove the oil hoses 1 Fig 149 Fig 149 Remove the anti rotational bolts 2 Fig 150 Remove the 8 flange screws 3 Fig 150 Fig 150 Remove the rear flange with manifold from the chuck...

Page 82: ...RTANT DO NOT TAKE CARE OF THE PRESSURE SHOWN BY THE MANOMETER AFTER THE 1ST AND THE 2ND CONTROLS At the end of the third test the pressure shown by the manometer should not be decreased below than 140...

Page 83: ...crew 1 Fig 158 by using green loctite Mount the piston release locking valve 6 5 2 Install the locking valve 6 5 1 Replace the small and big cylinder flange O rings Mount the rear flange on the chuck...

Page 84: ...2 Fig 162 Switch the machine on Make a saddle translation till end of stroke watching the manometer the pressure shown by the manometer must be included between 30 and 50 BAR 430 and 720 PSI during al...

Page 85: ...BLE IS VERY HEAVY HANDLE IT WITH CARE TO AVOID FEET AND FINGERS CRUSHING Mount the top cover 6 7 HYDRAULIC PUMP CHECK AND REPLACEMENT 2h End wrenches 10 13 19 and 24mm allen wrenches 3 5 and 6 seeger...

Page 86: ...MPORTANT BEFORE REPLACING THE PUMP VERIFY IF THE O RINGS 1 2 FIG 170 AND THE SEAL 3 FIG 171 ARE FINE BREAKAGE OF O RING 1 FIG 170 MAY CAUSE SLOW HYDRAULIC MOVEMENTS AND LOW HYDRAULIC POWER BREAKAGE OF...

Page 87: ...oil valve assy top cover Remove the coil connectors Switch the machine on if a hydraulic movement start it self the coil valve needs to be opened and cleaned If the machine shows low hydraulic pressur...

Page 88: ...unt the coil valve assy cover 6 9 KING 5600 SADDLE CYLINDER CHECK AND REPLACEMENT 1h End wrenches 13 19mm Allen wrench of 8mm 8 and 13mm tube type wrench rubber hammer pliers hydraulic oil container L...

Page 89: ...he bottom Fig 180 Fig 180 Remove the defective cylinder Install the new cylinder IMPORTANT THE PISTON MUST BE ORIENTED AT 90 COMPARED TO THE FRAME FOR AN EASY INSTALLATION ON THE SADDLE FIG 181 Fig 18...

Page 90: ...e oil leaking or mechanical breakages TO REPLACE THE CYLINDER Close the saddle cylinder till end of stroke Remove the hose plastic separators Fig 184 Fig 184 Turn on the machine Open the saddle till e...

Page 91: ...nd 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 Install the support 4 by...

Page 92: ...Open the cylinder till end of stroke and verify that the piston rod would not show marks or other kind of damaging TO CHECK THE PISTON SEAL Defective seals may cause low bead breaker power in one or...

Page 93: ...ash the rod thread by using solvent and dry it carefully Install the new O ring and the new lip seal on the ring screw NOTE WHEN INSTALLING THE O RING ON THE RING SREW BE CAREFUL TO NOT TWIST IT Greas...

Page 94: ...EALS Remove the cylinder following 6 10 Check the seals following 6 11 TO REPLACE THE CYLINDER SEALS Replace the seals following 6 11 Install the cylinder again on the machine following 6 10 Check if...

Page 95: ...reaser on the bushings are in the correct direction Fig 199 and 200 Take the portable control Open the cylinder till reach the pin of the chuck arm Take the rubber hammer and insert the new cylinder I...

Page 96: ...als needs to be replaced IMPORTANT ON MACHINE NON CE PROVED THE LOWERING OF THE CHUCK ARM MAY BE CAUSED BY A DEFECTIVE COIL VALVE 6 8 TO REPLACE THE O RINGS AND THE SEALS Remove the cylinder from mach...

Page 97: ...mmand Open on portable control to keep under pressure the chuck cylinder If the manifold will show a considerable oil leaking the piston seals are defective and they must be replaced TO REPLACE THE RE...

Page 98: ...ing rubber hammer 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 F...

Page 99: ...ghten the nut 2 FIRMLY Install the protections 1 Fig 207 6 17 TOOL HOLDER CYLINDER CHECK AND REPLACEMENT 1h End wrenches 19 22 24 and 30mm 6 and 8mm Allen wrenches 13mm tube type wrench rubber hammers...

Page 100: ...WEEN CYLINDER AND SADDLE SUPPORT THEY MUST BE PLACED IN THE SAME ORIGINAL POSITION FIG 216 Fig 216 Push out the defective cylinder a little bit by using the rubber hammer only in order to remove the o...

Page 101: ...INDER 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 L Defective chuck cylinder may cause...

Page 102: ...214 Fig 222 Turn the machine on Close the cylinder Turn off the machine Remove the oil hoses 1and the nipless fittings 2 Fig 223 Fig 223 Remove the nut and the screw 1 Fig 216 Push out the pin 2 to ta...

Page 103: ...nstall the cylinder on the hook with the pin 6 Fig 222 NOTE THE HOLE IN THE PIN 6 MUST MATCH WITH THE SCREW 5 FIG 222 Lower the hook completely till end of cylinder stroke IMPORTANT If the hook reache...

Page 104: ...IC CYLINDER SEALS CHECK AND REPLACEMENT 2h End wrenches of 22 4 Allen wrench calliper wrench rubber hammers manometer green loctite hydraulic containers oil L Defective chuck cylinder may cause the fo...

Page 105: ...m allen wrench of 4 5 and 6mm socket wrenches 17 and 22mm 13mm tube type wrench manometer rubber hammer Wrench adjustment of saddle clearance Tool for removal of cylinder pin L Broken or worn saddle s...

Page 106: ...ERY HAEVY IT MUST BE HANDLEDED WITH DECISION BECAUSE ITS DROPPING MAY CAUSE FEET INJURIES Remove all eccentrics and all hex screws from the saddle Remove the saddle pin 5 6 9 Fig 177 and 178 Remove th...

Page 107: ...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 HOS...

Page 108: ...cylinder pin L Broken or worn saddle slides may cause the following malfunctions 1 The eccentrics make a complete turn without tighten the saddle 2 Excess of saddle play 3 Incorrect distance between...

Page 109: ...el and rubber hammers Tool for removal of cylinder pin Wrench adjustment of saddle clearance L Incorrect saddle adjustment may cause the following malfunctions 1 Excess of saddle play 2 Incorrect dist...

Page 110: ...ADJUST THE ROTATION IN CASE OF SITUATION B Turn on the machine Lower the tool holder arm Turn off the machine Unlock the 20mm nut 1 and turn counter clockwise the screw 2 of a turn Fig 250 Turn on the...

Page 111: ...ogether with ball bearings NOTE PAY ATTENTION TO THE ROTOR SHIM S SHOWN BY THE ARROW IN FIG 254 Fig 254 Check if the hole 1 is too wide in case of malfunction 1 Fig 255 Check if the rotor cam 2 is bro...

Page 112: ...rotation proof pin Perform the control on both sides of the rotor If the rotation proof pin does not match with the rotor hole remove the rotor and take away the shim of Fig 254 Then remount the rotor...

Page 113: ...emove the set screw 1 and take away the stopper 2 Fig 261 Remove the pin 3 Fig 269 from the arm Fig 261 Turn on the machine and lower the tool holder Turn off the machine Push out from bottom to the t...

Page 114: ...one of Fig 267 Fig 267 Pull and turn clockwise of of a turn the spring Fig 268 and at the same time insert the pin 4 Fig 269 Fig 268 Mount the stopper 2 and its screw 1 Fig 261 Fig 269 Mount the lowe...

Page 115: ...tool holder assy 6 18 Remove the tool holder assy from the saddle 7 3 Remove the set screw 1 from ring nut Fig 272 Fig 272 Remove the ring nut 2 by using the same specific wrench used to remove the r...

Page 116: ...L The defective pin may cause the following malfunctions 1 Excess moving of mount dismount tool TO CHECK THE PIN Turn on the machine Hook the tool holder assy to the saddle Turn off the machine Remove...

Page 117: ...USHINGS Remove the lifting cylinder from the robotic assy without disconnect oil hoses and safety switch 6 18 Remove the whole assembly 7 3 TOOL HOLDER ASSY IS VERY HAEVY AND GREASED HANDLE IT WITH DE...

Page 118: ...turn it back till to have the hook free Mount the lifting cylinder 6 18 Mount the rotation proof spring 7 9 Mount the mount dismount tool Check if the machine works fine 7 12BOXER KING 5600R HOOK CHE...

Page 119: ...he hook needs to be force when lifting or lowering or if it jumps up and down freely it must be adjusted Perform the same control on five different position of the saddle TO ADJUST THE HOOK Make the h...

Page 120: ...k of a turn Fig 286 Check if the hook clamps the saddle easily if not turn the screw more of a turn in order to increase the clearance Fig 286 Lock firmly the nut Move the tool holder arm to verify if...

Page 121: ...LACEEMENT 5h End wrenches 13 14 17 19 22 and 30mm Allen wrench of 4 6 and 8mm pliers spanner wrench loctite rubber and steel hammer L The tool holder arm must be change in case of mechanical breakage...

Page 122: ...ghtening the disk still show the play it needs to be replaced If after tightening the disk does not show play anymore mount the plate 2 and lock it firmly with 8mm screw 1 Fig 290 IMPORTANT IF THE PLA...

Page 123: ...how mechanical breakages they must be replaced TO REPLACE THE JAWS Turn on the machine Open the chuck arms Turn off the machine Remove the screw 1 and remove the jaw 2 Fig 293 Remove the pin A Fig 295...

Page 124: ...ne on and make a chuck motor rotation if it is run normally it means that the worm screw is noisy and it must be replaced TO REPLACE THE WORM SCREW Remove the plastic pulley Remove the tang 1 and the...

Page 125: ...wise again the screw 2 Fig 297 Remove the screw 1 Fig 298 put loctite on it and tighten it FIRMLY by using the impact air gun Tighten the 8mm set screw 2 Fig 297 till have it in contact with the 12mm...

Page 126: ...M SCREW SEAL CHECK AND REPLACEMENT 2h End wrenches 13 19 22mm socket wrench 22 and 24mm 13mm tube type wrench 12mm Allen wrench big standard screwdriver rubber hammer silicon L The defective worm scre...

Page 127: ...e seal is defective and it must be replaced IMPORTANT BEFORE STARTING WITH ANY OPERATION VERIFY IF THE CHUCK CYLINDER HAS AXIAL PLAY BECAUSE IN THIS CASE THE PROBLEM CAN BE SOLVED BY INSERTING ONE OR...

Page 128: ...heck the portable control cable 5 14 Check the high hydraulic pressure 6 3 Check the hydraulic motor joints 6 7 Check the hydraulic pump 6 7 Call GS FAULT 5 TURNING THE SWITCH ON THE MACHINE MAKES THE...

Page 129: ...is loosened 5 9 Check the chuck motor cable 5 8 Check the chuck motor 5 9 Check the warm screw 7 20 Call GS FAULT 16 THE HYDRAULIC ASSY IS NOISY Check the hydraulic oil level 6 2 Check the hydraulic...

Page 130: ...the connecting pipes EC Version Non EC Version 0011769 replaced by 0021799 0006470 replaced by 0021797 0011770 replaced by 0021798 0011769 replaced by 0021799 0019081 replaced by 0021796 0011770 repla...

Page 131: ...by 0021799 0006470 replaced by 0021797 0011770 replaced by 0021798 0011769 replaced by 0021799 0019081 replaced by 0021796 0011770 replaced by 0021798 0019083 replaced by 0021793 0019083 replaced by...

Page 132: ...23 Subject MODIFICATION OF TUBELESS ROLL As from JANUARY 1998 The tubeless roll 4014974 has been replaced with 4022287 The new tubeless roll differs from the former one by virtue of the bearings fitt...

Page 133: ...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 Modification is due to productio...

Page 134: ...tion has been introduced in response to a number of reports of solenoid valves becoming blocked CAUTION it is essential to replace the filter at least once a year after switching off the machine and d...

Page 135: ...135 Operation of the machine has remained unchanged Old New 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 modificati...

Page 136: ...This change has been carried out to avoid the gripping of the back flange of the turntable cylinder due to the washer s wear In order to house the washer 0025232 it was necessary to reduce the support...

Page 137: ...than the 4021411 one Also the internal part of the tube carry tool holder 4016501 part number unchanged is machined This have an impact on spares since the new items are not interchangeable with old o...

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Page 140: ...tions 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 Snap on Equipment Srl unipers...