BOXER KING 5600R - User Manual

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

Summary

2.0 TOOLS

2.1 USE OF DIGITAL MULTIMETER

Provides guidance on using a digital multimeter for measurements.

3.0 DIAGRAM SECTION: ELECTRIC AND HYDRAULIC

3.1 ELECTRIC DIAGRAM FOR CE PROVED KING 5600

Provides the electrical diagram for the CE approved King 5600 model.

3.2 ELECTRIC DIAGRAM FOR KING SUPPLIED AT 200 V-3 PH-60 Hz

Electrical diagram for King machines supplied at 200V-3PH-60Hz.

3.3 ELECTRIC DIAGRAM FOR CE APPROVED KING 5600 R

Electrical diagram for the CE approved King 5600R model.

3.4 ELECTRIC DIAGRAM FOR KING 5600 R SUPPLIED AT 200 V - 3 PH - 60 HZ

Electrical diagram for King 5600R machines at 200V-3PH-60Hz.

3.5 HYDRAULIC DIAGRAM FOR CE APPROVED KING 5600

Hydraulic diagram for the CE approved King 5600 model.

3.6 HYDRAULIC DIAGRAM FOR KING 5600

Hydraulic diagram for the King 5600 model.

3.7 HYDRAULIC DIAGRAM FOR CE APPROVED KING 5600 R

Hydraulic diagram for the CE approved King 5600R model.

3.8 HYDRAULIC DIAGRAM FOR MACHINE NON CE KING 5600 R

Hydraulic diagram for the non-CE King 5600R model.

4.0 ELECTRIC FUNCTION

4.1 POWER CIRCUIT

Details the machine's power circuit, including cable and main switch.

4.2 AUXILIARY CIRCUIT

Describes the auxiliary circuit controlling machine movements and components.

4.3 SAFETY CIRCUIT

Explains the safety circuit and emergency stop functions.

5.0 ACCESS TO ELECTRIC PARTS

5.1 POWER SUPPLY CABLE AND PLUG: CHECK AND REPLACEMENT

Procedure for checking and replacing the power supply cable and plug.

5.2 MAIN SWITCH Q1: CHECK AND REPLACEMENT

5.3 CIRCUIT BREAKER Q2: CHECK AND REPLACEMENT

5.4 HYDRAULIC MOTOR CABLE: CHECK AND REPLACEMENT

5.5 HYDRAULIC MOTOR: CHECK AND REPLACEMENT

5.6 FUSES F1, F2, F3: CHECK AND REPLACEMENT

5.7 INVERTER POLE SWITCH Q3: CHECK AND REPLACEMENT

5.8 CHUCK MOTOR CABLES: CHECK AND REPLACEMENT

5.9 CHUCK MOTOR: CHECK AND REPLACEMENT

5.10 TRANFORMER: CHECK AND REPLACEMENT

5.11 FUSES F4,F5,F6,F7: CHECK AND REPLACEMENT

5.12 LINK CONVERTER: CHECK AND REPLACEMENT

5.13 THREE POLAR METERS K1,K2: CHECK AND REPLACEMENT

5.14 PORTABLE CONTROL CABLE: CHECK AND REPLACEMENT

5.15 SWITCHES S1: CHECK AND REPLACEMENT

5.16 MICRO SWITCHES S2, S3, AND S6: CHECK AND REPLACEMENT

5.17 MICRO SWITCHES S2, S3, AND S6 HOLDERS: CHECK AND REPLACEMENT

5.18 SHUT OFF CABLE: CHECK AND REPLACEMENT

5.19 SHUT OFF SWITCH S4: CHECK AND REPLACEMENT

5.20 EMERGENCY SWITCH S5: CHECK AND REPLACEMENT

5.21 ROBOTIC SAFETY SWITCH CABLE: CHECK AND REPLACEMENT

5.22 ROBOTIC SAFETY SWITCH: CHECK AND REPLACEMENT

5.23 COIL CONNECTOR CABLE: CHECK AND REPLACEMENT

6.0 HYDRAULIC FUNCTION

6.1 ACCESS TO HYDRAULIC PARTS

6.2 HYDRAULIC OIL LEVEL: CHECK AND LEVELLING

Procedure for checking and maintaining the hydraulic oil level.

6.3 HIGH PRESSURE HYDRAULIC CIRCUIT: CHECK AND ADJUSTMENT

Steps for checking and adjusting the high-pressure hydraulic circuit.

6.4 LOW HYDRAULIC PRESSURE CIRCUIT: CHECK AND ADJUSTMENT

Procedure for checking and adjusting the low-pressure hydraulic circuit.

6.5 HYDRAULIC PRESSURE OF CHUCK CYLINDER: CHECK AND ADJUSTMENT

Steps for checking and adjusting chuck cylinder hydraulic pressure.

6.6 SADDLE CYLINDER SLIDING HYDRAULIC PRESSURE: CHECK AND ADJUSTMENT

Procedure for checking and adjusting saddle cylinder sliding hydraulic pressure.

6.7 HYDRAULIC PUMP: CHECK AND REPLACEMENT

Steps for checking and replacing the hydraulic pump.

6.8 COIL VALVE: CHECK AND REPLACEMENT

6.9 KING 5600 SADDLE CYLINDER: CHECK AND REPLACEMENT

6.10 KING 5600 R SADDLE CYLINDER: CHECK AND REPLACEMENT

6.11 KING 5600 SADDLE CYLINDER SEALS: CHECK AND REPLACEMENT

6.12 KING 5600 R SADDLE CYLINDER SEALS: CHECK AND REPLACEMENT

6.13 CHUCK ARM CYLINDER: CHECK AND REPLACEMENT

6.14 CHUCK ARM LOWERING SPEED: CHECK AND ADJUSTMENT

6.15 CHUCK ARM CYLINDER SEALS: CHECK AND REPLACEMENT

6.16 CHUCK CYLINDER: CHECK AND REPAIRING

6.17 TOOL HOLDER CYLINDER: CHECK AND REPLACEMENT

6.18 TOOL HOLDER CYLINDER SEALS: CHECK AND REPLACEMENT

6.19 KING 5600 R ROBOTIC CYLINDER: CHECK AND REPLACEMENT

7.0 MECHANICAL SECTION

7.1 SADDLE: CHECK AND ADJUSTMENT

Procedure for checking and adjusting the saddle.

7.2 KING 5600 R SADDLE SLIDES: CHECK AND REPLACEMENT

Steps for checking and replacing King 5600R saddle slides.

7.3 KING 5600 SADDLE SLIDES: CHECK AND REPLACEMENT

Procedure for checking and replacing King 5600 saddle slides.

7.4 KING 5600 SADDLE BUSHINGS: CHECK AND REPLACEMENT

7.5 KING 5600 R ROBOTIC ROTATION: CHECK AND ADJUSTEMENT

7.6 KING 5600 R ROBOTIC ROTOR: CHECK AND REPLACEMENT

7.7 KING 5600 R LOWER ROBOTIC CAM AND SPRING: CHECK AND REPLACEMENT

7.8 TOOL HOLDER CABINET MOVING: CHECK AND REPLACEMENT

7.9 SHUTDOWN PIN: CHECK AND REPLACEMENT

7.10 KING 5600 R TOOL HOLDER ARM BUSHINGS: CHECK AND REPLACEMENT

7.11 BOXER KING 5600 R HOOK: CHECK AND ADJUSTMENT

7.12 BOXER KING 5600 R HOOK: CHECK AND REPLACEMENT

7.13 BOXER KING 5600 HOOK: CHECK AND ADJUSTMENT

7.14 BOXER KING 5600 HOOK: CHECK AND REPLACEMENT

7.15 SCREW SUPPORT TOOL HOLDER ARM: CHECK AND ADJUSTMENT

7.16 KING 5600 TOOL OLDER ARM: CHECK AND REPLACEEMENT

7.18 MOUNT - DISMOUNT TOOL

7.19 JAWS AND CLAWS: CHECK AND REPLACEMENT

7.20 WORM SCREW: CHECK AND REPLACEMENT

7.21 WORM SCREW SEAL: CHECK AND REPLACEMENT

7.22 CHUCK SEAL: CHECK AND REPLACEMENT

8.0 TROUBLE SHOOTING

BOXER KING 5600R Specifications

General

Air Supply	8 - 10 bar
Bead Breaker Force	2500 kg
Noise Level	<75 dB
Inside Clamping	12-20"
Wheel Width	3-15"(75-380mm)