boxer king 5600/5600r - snap-on · 7.15 screw support tool: check and adjustment pag. 120 7.16 king...

Service Manual 04/2010 Rev.B 1

Author Stefano Muzzioli

BOXER KING 5600/5600R TRUCK TYRE CHANGER SERVICE MANUAL


UPDATING GUIDE: Release B of 02/04/2010 Removed “50 or 60 Hz” At page 49


TABLE OF CONTENTS 1.0 Introduction Pag. 5 2.0 Tools and special tools required Pag. 5 2.1 Use of digital multimeter Pag. 8 3.0 Diagrams section: electric and hydraulics Pag. 8 3.1 Electric diagram for CE proved King 5600 Pag. 9 3.2 Electric diagram for King 5600 supplied at 200/3/60 Pag. 17 3.3 Electric diagram for CE approved King 5600R Pag. 25 3.4 Electric diagram for King 5600R supplied at 200/3/60 Pag. 33 3.5 Hydraulic diagram for CE approved King 5600 Pag. 41 3.6 Hydraulic diagram for non CE approved King 5600 Pag. 43 3.7 Hydraulic diagram for CE approved King 5600R Pag. 45 3.8 Hydraulic diagram for non CE approved King 5600 R Pag. 47 4.0 Electric function Pag. 49 5.0 Access to electric parts Pag. 50 5.1 Power supply cable and plug: check and replacement Pag. 51 5.2 Main switch Q1: check and replacement Pag. 52 5.3 Circuit Breaker Q2: check and replacement Pag. 53 5.4 Hydraulic motor cable: check and replacement Pag. 54 5.5 Hydraulic motor: check and replacement Pag. 54 5.6 Fuses F1,F2,F3: check and replacement Pag. 56 5.7 Inverter pole switch Q3: check and replacement Pag. 57 5.8 Chuck motor cables: check and replacement Pag. 58 5.9 Chuck motor: check and replacement Pag. 58 5.10 Transformer: check and replacement Pag. 61 5.11 Fuses F4,F5,F6,F7: check and replacement Pag. 61 5.12 Link converter: check and replacement Pag. 62 5.13 Three polar 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 replacement Pag. 66 5.17 Micro switches S2, S3 and S6 holders: check and replacement Pag. 66 5.18 Shut off cable: check and replacement Pag. 67 5.19 Shut off switch S4: check and replacement Pag. 68 5.20 Emergency switch S5: check and replacement Pag. 69 5.21 Robotic safety switch cable: check and replacement Pag. 70 5.22 Robotic safety switch: check and replacement Pag. 72 5.23 Coil connector cable: check and replacement Pag. 72 6.0 Hydraulic function Pag. 73 6.1 Access to hydraulic parts Pag. 75 6.2 Hydraulic oil level: check and levelling Pag. 78 6.3 High hydraulic pressure circuit: check and adjustment Pag. 79 6.4 Low hydraulic pressure circuit: check and adjustment Pag. 79 6.5 Hydraulic pressure of chuck cylinder: check and adjustment Pag. 80 6.6 Saddle cylinder sliding hydraulic pressure: check and adjustment Pag. 83 6.7 Hydraulic pump: check and replacement Pag. 85 6.8 Coil valve: check and replacement Pag. 87 6.9 King 5600 saddle cylinder: check and replacement Pag. 88 6.10 King 5600R saddle cylinder: check and replacement Pag. 90 6.11 King 5600 saddle cylinder seals: check and replacement Pag. 92 6.12 King 5600R saddle cylinder seals: check and replacement Pag. 94 6.13 Chuck arm cylinder: check and replacement Pag. 94 6.14 Chuck arm lowering speed: check and adjustment Pag. 95 6.15 Chuck arm cylinder seals: check and replacement Pag. 96 6.16 Chuck cylinder: check and repairing Pag. 96


6.17 Tool holder cylinder: check and replacement Pag. 99 6.18 Tool holder cylinder seals: check and replacement Pag. 100 6.19 King 5600R robotic cylinder: check and replacement Pag. 101 6.20 King 5600R robotic cylinder seals: check and replacement Pag. 104 7.0 Mechanical section Pag. 104 7.1 Saddle: check and adjustment Pag. 104 7.2 King 5600R saddle slides: check and replacement Pag. 105 7.3 King 5600 saddle slides: check and replacement Pag. 108 7.4 King 5600 saddle bushings: check and replacement Pag. 109 7.5 King 5600R robotic rotation: check and adjustment Pag. 109 7.6 King 5600R robotic rotor: check and replacement Pag. 110 7.7 King 5600R lower robotic cam and spring: check 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 replacement Pag. 117 7.11 King 5600R hook:check and adjustment Pag. 117 7.12 King 5600R hook:check and replacement Pag. 118 7.13 King 5600 hook:check and adjustment Pag. 118 7.14 King 5600 hook:check and replacement Pag. 119 7.15 Screw support tool: check and adjustment Pag. 120 7.16 King 5600 tool holder arm: check and replacement Pag. 120 7.17 King 5600R tool holder arm: check and replacement Pag. 121 7.18 Mount - Dismount tool: check and replacement Pag. 122 7.19 Jaws and claws: check and replacement Pag. 123 7.20 Worm screw: check and replacement Pag. 124 7.21 Worm screw seal: check and replacement Pag. 126 7.22 Chuck seal: check and replacement Pag. 127 8.0 Trouble shooting Pag. 128 9.0 Service Bulletins Pag. 130


1.0 INTRODUCTION This technical manual describes maintenance, check and repair operations of the G.S. range of Boxer King 5600 and 5600R and is for use of qualified personnel only. This manual is also applicable to the following models: BOXER KING 5600/5600R ACCU 4560/4560MR HOFMANN JAPAN GX56 HOFMANN MONTY 4400/4400R TIP TOP PROMONT 956 SUPER EIWA WING 311 COATS 9500/9500R Reproduction, translation and accommodation rights are reserved.

ALL SAFETY REGULATIONS MUST BE STRICTLY FOLLOWED DURING ANY MAINTENANCE, CHECK AND REPAIR OPERATION.

PERSONNEL PERFORMING MAINTENANCE, CHECK AND REPAIR OPERATIONS MUST HAVE BEEN 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 ON A PLATE. UNTILL DECEMBER 31 2001, THE SERIAL NUMBER IS A SEQUENCE OF FIGURES STANDING FOR THE MANUFACTURING MONTH (#1) AND YEAR (#2), FOLLOWED BY A PROGRESSIVE NUMBER (#3) AND #4 SHOWS THE MODEL.

STARTING FROM JANUARY 1 2002, THE SERIAL NUMBER HAS CHANGED SEQUENCE OF FIGURES STANDING FOR THE MANUFACTURING MONTH (#1) AND YEAR (#2), REFERENCE NUMBER OF THE MACHINE (#3) AND PROGRESSIVE NUMBER OF THE MACHINE (#5) MANUFACTURED WITH THIS PART NUMBER. THE #4 STILL SHOWS THE MODEL.

2.0 TOOLS Before starting any repair operation, make sure that all required tools are available: 1 Set of end wrenches from 8 to 30mm

Fig.1 1 Set of screwdrivers (standard and cross type).

Fig.2


1 Set of tube type wrenches from 7 to 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 pliers and scissor.

Fig.7 Rubber and steel hammers.

Fig.8 Extractor

Fig.9


1 Tool for removal of cylinder pin # 4013567

Fig.10 1 Multimeter, Loctite green 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 with adapter # 4006849.

Fig.14 2 Calliper wrenches of 5 and 6mm to open the cylinders.

Fig.15 Spanner wrench


2.1 USE OF DIGITAL MULTIMETER In this manual it is frequently required the use of a digital multimeter. We recommend a digital multimeter instead of an analog model because easier to use and more accurate.

CAREFULLY READ THE INSTRUCTION MANUAL OF YOUR MULTIMETER FOR EVERY INFORMATION CONCERNING ITS FUNCTIONS.

The following short notes are just to remind some important general principles.

ALL SAFETY CAUTIONS MUST BE RESPECTED FOR A CORRECT USE OF MEASUREMENT DEVICES. NEVER APPLY TO YOUR MULTIMETER CURRENT OR VOLTAGE HIGHER THAN MULTIMETER MEASUREMENT CAPACITY.

PAY EXTRA CARE WHEN MEASURING VOLTAGE BEYOND 50 VOLTS.

WHENEVER POSSIBLE DISCONNECT POWER SUPPLY CIRCUIT BEFORE CONNECTING MULTIMETER TERMINALS TO THE CONTACTS.

To measure VDC values (direct current): • Suitably adjust the end of scale selector and

VDC selector . If you don't know the probable value of the voltage to measure, start with the highest end-of-scale value.

• Connect the terminals as per instructions. If - - - is displaied and the terminals are

connected 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 measure, start with the highest end-of-scale value.

• Connect the terminals as per instructions. To measure current magnitude (AC-DC):

• Disconnect power supply. • To measure the current intensity, the

multimeter must be connected in series with the circuit.

• Suitably adjust the end of scale selector and Amp selector . If you don't know the probable value of the voltage to measure, start with the highest end-of-scale value.

• If - - - is displaied and the terminals are connected as per instructions, the polarity (DC) is reversed.

To measure resistance (Ohm) values:

• Disconnect the component to be tested from the rest of the circuit.

• Suitably adjust the end of scale selector and Ω selector . If you don't know the probable value of the voltage to measure, start with the highest end-of-scale value.

3.0 DIAGRAM SECTION: ELECTRIC AND HYDRAULIC The differences between the King 5600 diagrams and the 5600R ones consist in the robotic tool movement only. The electric diagram includes two more switches while the hydraulic one includes one more coil valve and one more cylinder.


3.1 ELECTRIC DIAGRAM FOR CE PROVED KING 5600

Fig.16


Fig.17


Fig.18


Fig.19


Fig.20


Fig.21


Fig.22


Fig.23


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

Fig.24


Fig.25


Fig.26


Fig.27


Fig.28


Fig.29


Fig.30


Fig.31


3.3 ELECTRIC DIAGRAM FOR CE APPROVED KING 5600R

Fig.32


Fig.33


Fig.34


Fig.35


Fig.36


Fig.37


Fig.38


Fig.39


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

Fig.40


Fig.41


Fig.42


Fig.43


Fig.44


Fig.45


Fig.46


Fig.47


3.5 HYDRAULIC DIAGRAM FOR CE APPROVED KING 5600

Fig. 48


Fig.49


3.6 HYDRAULIC DIAGRAM FOR KING 5600

Fig.50


Fig.51


3.7 HYDRAULIC DIAGRAM FOR CE APPROVED KING 5600R

Fig.52


Fig.53


3.8 HYDRAULIC DIAGRAM FOR MACHINE NON CE KING 5600R

Fig.54


Fig.55


4.0 ELECTRIC FUNCTION All King 5600 and 5600R truck tyre changers are equipped by 3 phase motor only. Single phase motors are not available on this style of machines. The machines can be wired at two different voltages: 400 VAC (suitable for 360-415V range). 230 VAC (suitable for 200-250V range).

The voltage at which the machine is wired is printed on the serial number plate and on a tag at the end of the power cord. The electric system of the machine is composed by 3 circuits:

Power circuit. Auxiliary circuit. Protection circuit.

4.1 POWER CIRCUIT. The power cord has 4 wires: L1,L2,L3 = Phases PE (yellow/green) = Ground The main switch Q1 (Fig.16) controls the power to the machine and it supplies the electric power to the circuit breaker Q2 and to the 25A fuses F1,F2,F3 (Fig.16). The pump motor M (Fig.16) is controlled by the circuit breaker Q2. In case of short circuit or excessive heating, the circuit breaker cuts off the power to the motor. IMPORTANT! The circuit breaker must be regulated following the amperage printed on the label of the pump motor. On CE certified machines only, the circuit breaker is controlled by a coil of minimum tension D1,D2 (Fig.16). It provides to cut off the power to the pump motor in case, for any reason, there is no power on the fuses F2,F3 (Fig.16).

The chuck motor M (Fig.17) rotation way is controlled by the three polar meters K1 and K2 (Fig.17) while the inverter pole switch Q3 (Fig.17) 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 AUXILIARY CIRCUIT The auxiliary circuit controls all movements of the machine. Two wires, U and V, connected to T1 and T2 of the breaker circuit Q2 (Fig.17) supply high power to the transformer T (Fig.17). The transformer transforms the high power in 24VAC and 26VAC. 2 Fuses, F4 and F5, of 2A each one (Fig.17) protect the main circuit of the transformer and 2 further fuses,F6 and F7, of 3.15A each one protect the low power circuit. The link converter (Fig.17) is supplied by transformer and it transforms 26VAC in 24VDC to be sent to the coil valves (Fig.18 and 19) for the hydraulic movements. The three polar meters K1 and K2 (Fig. 18), are supplied by the transformer at 24VAC and they control the rotation way of the chuck motor. All movements of the machine are controlled by a remote control where there are 4 switches (Fig.20 and 21): S1 Controls the rotation way of chuck motor (2 pedals). S2 Controls opening and closing of the chuck (2 position switch). S3 Controls chuck arm and saddle movement (8 position switch, 4 position for Hoffmann Japan). S6 Controls the tool holder arm movements (s position switch on King 5600, 4 position switch on King 5600R). 4.3 SAFETY CIRCUIT All machines are equipped by a shut off switch S4 (Fig. 18) on the chuck arm to avoid injuries to personnel or object laying on its pad. The CE certified machines are equipped by an emergency stop switch S5 (Fig. 18), which shut off the 2 auxiliary circuit, 26VAC and 24VDC, in case of emergency.


The three polar meters K1 and K2, are equipped by a mechanical security (Fig.65) to avoid the starting of both meters simultaneously saving the motor from blowing up. On Ce proved machined the chuck motor is also equipped by a thermostat R1 connected to K1 and K2 (Fig.18): in case of overheating it disconnects K1 and K2 automatically. When the chuck motor is cold the thermostat gets closes and K1 and K2 are reactivated automatically. All King 5600R are also equipped by a safety micro switch S7 on the Robotic assy that locks all hydraulic movements, except the toolholder lifting and lowering, whenever the toolholder hook is not well clamped. 5.0 ACCESS TO ELECTRIC PARTS

BEFORE APPROACHING THE ELECTRIC PARTS OF 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 ANY CONTROL AND/OR REPLACEMENT VERIFY IF ALL WIRES AND CONNECTORS ARE WELL FITTED. To access to electric parts of the machine:

Fig.56

ELECTRIC BOX: Turn all switches off and open the box by lifting the lever up (Fig.56). Sometimes the opening may result difficult because of door seal sticking. When this happens the door can be easily opened by pulling it with both hands from top and bottom.

The electric box contains the following electric components (Fig.57): #1 Main switch Q1 #2 Circuit braker Q2 #3 Coil D1,D2 #4 Fuses F1,F2,F3 #5 Transformer T #6 Fuses F4,F5,F6,F7 #7 Link converter #8 Three polar meters K 1,K2 #9 Control wires terminal #10 Inverter pole switch

Fig.57

PORTABLE CONTROL: Remove the 4 screws from the base and lift up the column (Fig.58).


Fig.58

8 AND 2 POSITION SWITCHES ASSIES: Remove the screws 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 DOOR BE CAREFUL NOT TO CRUSH WIRES.

5.1 POWER SUPPLY CABLE AND PLUG: CHECK AND REPLACEMENT


: 1h : Small and medium screwdriver, medium

cross screwdriver, 7mm tube type wrench, faston pliers, scissors, pliers, multimeter.

: Defective power supply cable and plug may cause the following malfunction:

1. Turning the switch on the machine does not run at all.

TO CHECK THE CABLE: Disconnect power supply. Open the electric box ( 5.0). Remove the yellow protection #1 (Fig.64). Check wires continuity from power supply

plug to main switch terminals (Fig.63).

Fig.63 IMPORTANT! TO CHECK GROUND (YELLOW/GREEN) WIRE, DISCONNECT THE WIRE END FROM THE TERMINAL BLOCK. TO REPLACE THE CABLE: Remove the main switch (Fig.65) and

disconnect blue, brown and black wires. Disconnect the ground wire from terminal

block. Release cable strain relief on the electric box. Remove plug from cord and take the wrong

cable away. Insert 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 the switch terminals. Fix the main switch.

Connect the ground wire to ground terminal block.

Fix the switch yellow protection. Install plug. Tighten strain relief FIRMLY .

IMPORTANT! AT THE END OF THE OPERATION CHECK THE ROTATION WAY OF THE HYDRAULIC MOTOR: IF IT IS WRONG REVERSE TWO PLUG WIRES ONLY. 5.2 MAIN SWITCH Q1: CHECK AND REPLACEMENT

: 30’ : Medium screwdrivers, medium cross

screwdriver, 7mm tube type wrench, pliers. : Defective main switch may cause the

following malfunction: 1. Turning the switch on the machine does not

run at all. TO CHECK THE SWITCH: Disconnect power supply. Open the electric box ( 5.0). Remove the yellow protection #1 (Fig.64).

Fig.64 Remove the main switch and disconnect all

wires (Fig. 64). Turn switch to “Off”. Check that there is no

continuity (Ω =infinity) between any two terminals L1, L1, L2, L 2, L3 and L 3 ( 4.0).


Fig.65 Turn switch to “On”. Check that there is

continuity between terminals L1, L1, L2, L 2, L3 and L 3 (Ω = 0 ~ 0,3) and discontinuity between terminals L1, L2, L3 and L1, L2, L3 ( 4.0). If there is continuity the switch is in short circuit and it must be replaced.

TO REPLACE THE SWITCH: As the main switch must be removed to be

checked, its replacement only requires the removing of the rear support #1 (Fig.66).

Install the rear support on the new main switch.

Connect wires ends FIRMLY to the new switch terminals as shown in the appropriate electric diagram ( 3.0).

Fig.66 Install the switch on the electric box paying

attention to the direction of the spacer #1 (Fig. 67) and mount the yellow protection (Fig.64).

Fig.67 IMPORTANT! 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, multimeter. : Defective power circuit breaker may cause

the following malfunction: 1. Turning the switch on the hydraulic motor does not run at all. 2. Sometimes the breaker shuts off itself

suddenly when the machine is operating. IMPORTANT! BEFORE STARTING WITH ANY CONTROL AND REPLACEMENT VERIFY IF THE BREAKER IS CORRECTLY REGULATED COMPARED TO MOTOR DATAS. TO CHECK THE CIRCUIT BREAKER: Turn the machine on.

MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK

Select the multimeter in VAC. Check voltage

between terminals L1and T1, L2 and T2, L3 and T3 of the circuit breaker Q2.If it is not correct the breaker must be replaced.

NOTE ONLY FOR CE PROVED MACHINES: If the circuit breaker Q2 cannot be switched on, check the following parts:


Check if the fuses F2 and F3 are fine ( 5.6). Check if the coil of minimum tension is fine. Check if the hydraulic motor is fine ( 5.7). TO REPLACE THE CIRCUIT BRAKER: Disconnect power supply. Remove all wires from the breaker.

IMPORTANT! MARK THE WIRES PROPERLY FOR AN EASY AND SAFE INSTALLATION. Pull downward the tab and lift the breaker up

for its removing. Install the new breaker . Connect all wires FIRMLY. Regulate the breaker by turning the wheel #1

(Fig.68) according the amperage printed on the label of the pump motor.

Fig.68 IMPORTANT! AT THE END OF THE OPERATION CHECK THE ROTATION WAY OF THE HYDRAULIC MOTOR: IF IT IS WRONG REVERSE ONLY THE BRAKER WIRES OTHERWISE THE CHUCK MOTOR WILL TURN WRONGLY. 5.4 HYDRAULIC MOTOR CABLE: CHECK AND REPLACEMENT

: 1h : Medium screwdriver, medium cross

screwdriver, 7mm tube type wrench, socket head screw 6mm, end wrench 13mm, multimeter, pliers.

: Defective cable may cause the following malfunction:

1. Low motor and hydraulic power. 2. Circuit breaker shutting off. 3. Noisy motor. 4. Motor damaging (burning).

TO CHECK THE CABLE: Disconnect power supply. Open the electric box ( 5.0). Disconnect the motor wires from circuit

breaker Q2. Remove the 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 the electric box

and on the motor. Take the wrong cable away. Insert the new cable through the strain relief.

IMPORTANT! : USE ONLY APPROVED CABLE AND GROUND WIRE MUST BE LONGER THAN THE OTHER ONES. NOTE: Before connecting the wires ends, tighten all terminals nuts on the motor. Fix new fastons on inside cable ends and

connect them to the motor and breaker terminals.

Check the rotation way of the motor: If it is wrong reverse only two motor wires otherwise the chuck motor will turn wrongly.

Mount the motor terminals cover.

IMPORTANT: WHEN REMOUNTING THE MOTOR TERMINALS COVER BE CAREFUL NOT TO CRUSH WIRES.

5.5 HYDRAULIC MOTOR: CHECK AND REPLACEMENT

: 1h : End wrench 13mm, 7mm tube type wrench,

13mm long tube type wrench (Fig.10), medium standard screwdriver, medium cross screwdriver, socket head screw 6 and 3mm, multimeter, amperometic pliers, rubber hammer, calliper.

: Defective hydraulic motor may cause the following malfunction:

1. Turning the switch on the hydraulic motor does not run at all.

2. Motor stops when high hydraulic pressure is required.

3. Circuit breaker shutting off. 4. Motor noisy. 5. Turning the switch on the motor turns but the

machine does not make any hydraulic movements.

IMPORTANT!


IN CASE OF FAILURE #5 CHECK IF THE ROTATION OF THE MOTOR IS CORRECT AS FIRST. TO CONTROL THE MOTOR WHEN IT DOES NOT RUN: Disconnect power supply. Remove the motor terminals cover. Select the multimeter in Ohm and check if

there is continuity between terminals U, V and W of the motor (Fig.69).

Fig.69 TO CONTROL THE MOTOR WHEN IT IS NOISY: Disconnect power supply. Remove the motor fan protection and check if

the fan is well tightened. Mount the motor fan protection. Remove the motor terminal cover (Fig.69) and

verify if all wires are well fitted on terminals. If the wires are well fitted on terminals mount

the motor terminals cover and remove the 4 motor screws very carefully: the motor may fall down suddenly.

Place the motor on the frame as shown in Fig.71.

Switch the motor on and listen it: if it is noisy replace it by following the next step.

TO CONTROL THE MOTOR WHEN THE CIRCUIT 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 cover (Fig.69) and

verify if all wires are well fitted on terminals. If the wires are well fitted on terminals take

the ammeter pliers.

Regulate the scale according to the maximum amperage reported on the motor.

Connect the pliers to a wire (Fig.70).

Fig.70


Switch the machine on. Make a hydraulic movement and get the

pump under pressure. Press the button to lock the value reported by

the pliers. Perform the above control on all wires. If the amperage required by one or more

phases is 10% higher compared that one reported on the motor tag, increase the breaker adjustment.

If the amperage is higher than 10%, the motor must be replaced.

TO REPLACE THE MOTOR: Remove all wires from the motor. Remove the 4 motor screws very carefully:

the motor may fall down suddenly. Remove the aluminium spacer. Take the distance of joint compared to the

motor by using a calliper (Fig.71).


Fig.71 Lose the 3mm Allen screws of the joint and

remove it from the motor shaft by using two levers (Fig.72).

Fig.72 Take the new motor. Mount the joint following the distance

previously verified and lock it. IMPORTANT! A WRONG REGULATION OF THE JOINTS WILL CAUSE HYDRAULIC PUMP DAMAGING OR DAMAGING OF JOINTS THEMSELVES WITH A CONSEGUENT NO HYDRAULIC MOVEMENTS. Mount the aluminium spacer: There is a little

hole in a face and this face must be mounted

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. Check the rotation way of the motor: If it is

wrong reverse only two motor wires otherwise the chuck motor will turn wrongly.



5.6 FUSES F1, F2, F3: CHECK AND REPLACEMENT

: 30’ : Multimeter : Defective fuse/s may cause the following

malfunction: 1. Chuck motor does not run at all. TO CONTROL AND REPLACE THE FUSES: Disconnect the machine from power supply. Open the electric box ( 5.0). Open the protection and remove the fuse

(Fig.73). Verify if there is continuity between the ends

of each fuse. If necessary, replace them with fuses of the

same value: 25A 500V. IMPORTANT! ON NON CE PROVED VERSIONS, THE CHUCK MOTOR PROTECTION IS REPLACED BY A CIRCUIT BREAKER ( 5.3).

Fig.73


5.7 INVERTER POLE SWITCH Q3: CHECK AND REPLACEMENT

: 1h : Medium and big cross screwdrivers,

multimeter. : Defective inverter pole switch may cause the

following malfunction: 1. Low chuck power. 2. Noisy motor. 3. Motor damaging (burning). 4. Chuck motor does not run in one or both

speeds. TO CHECK THE INVERTER POLE SWITCH: Verify which is the speed that would not work. Remove the chuck motor terminal cover. Switch the machine on.


Turn the inverter switch 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 voltage at which

the machine is supplied. If not the switch must be replaced.

Perform the same controls with terminals U1-V1 and W1-V1.

TO REPLACE THE INVERTER POLE SWITCH:

Turn the machine off. Open the electric box.

Remove screw shown by the arrow to take out the switch handle (Fig.74).

Fig.74 Remove the white spacer (Fig.75).

Fig.75 Remove the screws shown by the arrows to

take out the plastic protection and the speed label (Fig.76).

Fig.76 Remove the screws shown by the arrows to

get the inverter switch free (Fig. 77 and 78).


Fig.77

Fig.78 Remove the wires from defective inverter

switch. Connect the wires to the new switch following

the proper electric diagram. Mount the switch on the electric box. Mount the speed label with its plastic

protection. Mount the white spacer. Mount the handle. Turn the machine on and check the chuck

rotation way in both speed. If the chuck rotation way is not the same in

both speeds verify which is the speed at which the chuck motor is turning wrongly.

Dismount again the inverter pole switch. Take the electric diagram and reverse two

wires of the wrong speed cable. Mount the switch again and check the rotation

way again. Mount the chuck motor terminals cover.


5.8 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. Chuck motor does turn in one or both 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). Select the multimeter in Ohm and check if

there is continuity between the ends of each wire of the same cable.

TO REPLACE THE CABLE: Release cable strain relief on the electric box

and on the motor. Take the wrong cable away. Insert the new cable through the strain relief.

IMPORTANT! USE ONLY APPROVED CABLE AND GROUND WIRE MUST BE LITTLE LONGER THAN THE OTHER ONES. NOTE: Before connecting the wires ends, tighten all terminals nuts on the motor. Fit new fastons on wires ends and connect

them to the motor and to the inverter pole switch Q3 terminals.

Check if the chuck motor rotation way is correct and if it is the same in both speeds: if the motor change direction changing the speed, take the electric diagram and reverse two wires of the wrong speed cable on the motor only. If the chuck motor turns in wrong direction in both speed, reverse the wires 8 and 9 of the remote control cable on the wire terminal into the electric box ( 5.0).



5.9 CHUCK MOTOR: CHECK AND REPLACEMENT

: 1h 30’


: End wrenches 13,17,19mm, medium cross 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. Fuse/s F1,F2,F3 blowing up. 4. Motor is noisy TO CONTROL THE CHUCK MOTOR WHEN IT DOES NOT RUN IN ONE OR BOTH SPEED AND WHEN IT SHOWS LOW POWER: Disconnect machine from power supply. Remove the motor terminals cover. Switch the machine on.


Turn the inverter switch 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).

If the display shows the voltage at which the machine is supplied the motor 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 if all wires are well fitted. If the wires are well fitted on their terminals,

mount the cover and remove the pulleys protections shown in Fig.79.

Fig.79

Lose the 8mm bolt #A (Fig.80).

Fig.80 Lose the 4 12mm bolts shown in Fig.81 and

remove the belts.

Fig.81 Remove the fan protection and verify if the fan

is well tightened on motor shaft. Mount the fan protection, turn the machine on,

make it turning and verify if it s noisy. TO REPLACE THE CHUCK MOTOR: Disconnect machine from power supply. Remove all wires from the motor. Remove the chuck motor assy from the chuck

arm. Lose the 10mm bolts #C (Fig.80) and remove

the motor from its support. Remove the pulley by using an extractor tool

(Fig.82). NOTE: The pulley ONLY may be removed from the motor shaft as shown in the picture. Any other system may cause risk of pulley breakage.


Fig.82 Take the new motor. Install the pulley by using rubber hammer and

fit its screw by using green loctite. NOTE: The mounting of the new pulley must be done very carefully in order to avoid motor bearings damaging.

Install the motor on its support without lock the bolts #C (Fig.80).

Lock the motor support only with 8mm #A (Fig.80) and the 4 12mm bolts (Fig.81).

Make pulleys alignment by moving the motor only and using a straight bar as shown in the picture: there must be 1,5 mm between bar and plastic pulley (Fig.83).

Fig.83

Lock all 4 10mm motor bolts #C (Fig.80). Lose the 8mm bolt #A (Fig.80) and the 4

12mm bolts (Fig.81). Mount the belts Make the belts tension by turning the 12mm

nuts (Fig.81). When the belt tension 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).

Fig.85 Lock the 8mm and 12mm bolts (Fig.80 and

81) FIRMLY. Connect the wires FIRMLY to motor terminals

following the proper electric diagram.

NOTE: Before connecting the wires ends, tighten all terminals nuts. Check if the chuck motor rotation way is

correct and if it is the same in both speeds: if the motor change direction changing the speed, take the electric diagram and reverse two wires of the wrong speed cable on the motor only. If the chuck motor turns in wrong direction in both speed, reverse the wires 8 and 9 of the remote control cable on the wire terminal into the electric box ( 5.0).



Mount the belts protections.


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’ : Multimeter, small and medium cross

screwdrivers, pliers. : Defective transformer may cause the

following malfunction: 1. Smoke gets out from the electric box with

consequent burning of the transformer. 2. Turning the machine on, the hydraulic motor

run but the machine does not make any movement.

TO CONTROL THE TRANSFORMER: Take the multimeter and select it in VAC. Switch the machine on.


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 terminals 0 and 24 and between terminals 0 and 26 (Fig.86).

TO REPLACE THE TRANFORMER: Disconnect the machine from power supply. Open the electric box ( 5.0). Remove all wires from terminals.

Fig.86

IMPORTANT! MARK WIRES PROPERLY FOR AN EASY AND SAFE INSTALLATION.

Lose its four screws. Pull the transformer up and take it out. Install the new transformer and tighten firmly

all wires. 5.11 FUSES F4,F5,F6,F7: CHECK AND REPLACEMENT

: 30’ : Multimeter. : Defective fuse/s may cause the following

malfunction: 1. Turning the machine on, the hydraulic motor

run normally but the machine does not make any movement.

TO CONTROL AND REPLACE THE FUSES: Disconnect the machine from power supply. Open the electric box ( 5.0). Open the protection and remove the fuse

(Fig.87)

Fig.87


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.88

5.12 LINK CONVERTER: CHECK AND REPLACEMENT

: 30’ : Multimeter, Medium cross screwdriver : Defective rectifier may cause the following

malfunction 1. Turning the machine on, the hydraulic motor run but the machine does not make any movement. TO CONTROL THE CONVERTER: Switch the machine on. Take the multimeter and select it in VAC.

MACHINE UNDER TENSION. DANGER OF ELECTRIC SHOCK

Position the multimeter probes on the red

terminals of the converter and verify if the power displayed by the multimeter is 26 VAC (Fig.89).

Position the multimeter probes on the blue

terminals of the converter and verify if the 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 from the converter. IMPORTANT! MARK WIRES PROPERLY FOR AN EASY AND SAFE INSTALLATION. Loosen the defective converter and replace it

with a new one. Fit all wires again. Check if the machine works normally.

5.13 THREE POLAR METERS K1,K2: CHECK AND REPLACEMENT

: 30’ each one : Medium screwdriver, medium cross

screwdriver, pliers. : Defective contactor K1 or K2 may cause the

following malfunction: 1. Chuck does not turn in one direction or both

direction. 2. Low chuck power in one or both direction. 3. Noisy motor. 4. Burning of the motor.

A. TO CONTROL THE METERS: Disconnect the machine from power supply. Open the electric box ( 5.0). Take the multimeter and select it in Ohm. Press the black buttons on top of the meter

K1 and verify if there is continuity between L1-T1, L2-T2, L3-T3 (Fig.90).

Repeat the same operation with K2. B. TO CONTROL THE COIL: Switch the machine on. Take the multimeter and select it in VAC.


Fig.90

MACHINE UNDER TENSION. DANGER OF ELECTRIC SHOCK

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.

TO REPLACE THE METER: Disconnect the machine from power supply. Remove mechanical safety from meters by

pulling the locking safety lever in direction 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). Install the new meter. Connect all wires FIRMLY. Mount the mechanical safety.

Fig.91

Fig.92 5.14 PORTABLE CONTROL CABLE: CHECK AND REPLACEMENT

: 2h 30’ : Small and medium screwdriver, medium

cross screwdriver, tube type wrenches 7 and 10mm, end wrenches 10 and 14mm

: Defective portable cable may cause the following malfunction:

1. Machine does not make one or more movements.

2. Sometimes the machine does not make one or more movements.

3. Fuses F6 and F7 blow up. IMPORTANT! FAILURE #1 MAY ALSO BE CAUSED BY HYDRAULIC PROBLEM. TO VERIFY IF THE


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.93

TO CONTROL THE CABLE: Disconnect the machine from power supply. Open the electric box ( 5.0). Remove the wires cover (Fig.94).

Fig.94 Remove all portable control wires from

terminals block (Fig.95). Take a multimeter and select it in Ohm. Position a multimeter probe on a common end

(the n°1 is for the rotation pedals and the n°20 is for hydraulic commands) and the second one on the supposed defective wire.

Press the correspondent command on the portable control and verify if there is continuity between the two ends (Fig.96)

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.

Fig.96 TO REPLACE THE CABLE: Disconnect the machine from power supply. Open the electric box ( 5.0). Remove all remote control wires from

terminals block (Fig.94). Remove all wires from all micro switches Remove the defective cable from the portable

control. Connect by tape the old cable with the new

one to insert the new cable through the inner cabinet holes.

Release cable strain relief on the electric box. Take the defective cable away. Insert the new cable through the strain relief. Connect all wires FIRMLY to the terminals

block of the electric box, following the numbers reported on each one .

Tighten the cable strain relief. Insert 3 steel wires through 8 and 2 position

switches and, only on CE proved machines, emergency switch seats in order to drive easily the new wires to the correct direction inside of the portable control.

Tighten the rotation wire FIRMLY to their switches in the bottom of the portable control.


Mount the rotation switches on their support and tighten handily the nuts

With pedals in rest position, leave 5mm of clearance between them and the switches (Fig.97).

Fig.97 Press the pedals all way down: they do not

have contact with the switches bodies. In case of contact increase the previous 5mm clearance (Fig.98)

Fig.98 Tighten the nuts FIRMLY. Connect by using tape, the wires 4,5,6,7 and

the 4 commons ones all together connected, to the steel wire coming from the 8 position switch previously inserted. On King 5600R connect the wires 12,13,17,18 and further 4 common wires to the steel wire from 4 position switch.

Connect by using tape, the wires 2,3 and 2 commons all together connected, to the steel wire coming from 2 position switch. On King 5600 connect wires 12,13 and two further common wires to the steel 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 the wires.

Connect all wires to the switches. IMPORTANT: THE WIRES MUST BE FITTED ON THE MICRO SWITCH IN OPPOSITE POSITION COMPARED TO THE DRAWING REPORTED ON 8 AND 2 POSITION SWITCH. COMAND WIRES MUST BE FITTED ON PLUG #1 WHILE THE COMMON ONES MUST BE FITTED ON MIDDLE PLUG #2 (Fig.99). Make some turns of tape around the 8 and 4

position switches (Fig.62) in order to avoid short circuit.

Install the cable strain relief in the bottom of the portable control and tighten the ground wire FIRMLY.

Fit the column to the base. Fit 8,4 and 2 position switch and the

emergency switch.

IMPORTANT: WHEN REMOUNTING COLUMN ON THE BASE BE CAREFUL NOT TO CRUSH WIRES.

Fig.99 Check if the machine works fine. If the machine start to work alone when

switching on, it means that command wire/s is/are reversed with the common one/s. Verify which is the movement, dismount the


correspondent switch holder and reverse the wires. Check the machine again.

5.15 SWITCHES S1: CHECK AND REPLACEMENT

: 30’ each one : Medium screwdriver, tube type wrench

10mm, end wrench 14mm : Defective switch/es S1 and S2 may cause

the following malfunction: 1. The chuck does not turn in one or both ways. 2. Fuse F7 blows up. TO CONTROL THE SWITCHES: If the wires are fine ( 5.14) the switches S1

need to be checked. Take the multimeter and select it in Ohm. Position the multimeter probes on the

contacts where the wires were fitted. Press by hand the switch and verify if there is

continuity: If not the switch must be replaced. TO REPLACE THE SWITCHES:

To replace the defective switch loose its screws and fix the new one following the instruction ( 5.14).

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

: 30’ each one : Small and medium cross screwdriver. : Defective switches S2, S3 and S6 may

cause the following malfunction: 1. One or more hydraulic movements do not

work. 2. Fuse F6 blows up. 3. Switching the machine on one or more

movements starts automatically. IMPORTANT! FAILURE #1 MAY ALSO BE CAUSED BY HYDRAULIC PROBLEM. TO VERIFY IF THE FAIULURE IS ELCTRIC 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. 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 the multimeter probes on the contacts where the wires were fitted.

Press by hand the switch and verify if there is continuity: If not the switch must be replaced.

TO REPLACE THE SWITCH:

To replace the defective switch loose its screws and fix the new one following the instruction ( 5.14).

5.17 MICRO SWITCHES S2, S3, AND S6 HOLDERS: CHECK AND REPLACEMENT : 1h : Small and medium cross screwdriver, big

standard screwdriver, pliers, loctite. : Defective switches holders may cause the

following malfunction: 1. One or more hydraulic movements do not work. 2. The holders are damaged or broken. TO CHECK THE HOLDERS:

Disconnect power supply from machine. Remove the holder/s from the portable

control. Remove the tape from the 8 or 4 position

switch assy. Move the lever and check if the switches

make a “click” sound when they are pressed. IMPORTANT! THE SWITCHES CLICK MUST BE GOT WITHOUT MAKE ANY OVERPRESSURE ON THE HOLDERS HANDLE. TO REPLACE THE 2 POSITION HOLDERS: Remove all wires and micro switches from

their holder. Remove the wires and the switches. Install switches and wires on the new holder

( 5.14). IMPORTANT! THE WIRES MUST BE FITTED ON THE MICRO SWITCH IN OPPOSITE POSITION COMPARED TO THE DRAWING REPORTED ON 2 POSITION SWITCH. COMAND WIRES MUST BE FITTED ON PLUG #1 ONLY WHILE THE COMMON ONES MUST BE FITTED ON MIDDLE PLUG #2 ONLY (Fig.100).


Fig.100 Verify if it works fine. 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 SCREWDRIVER IF THE HANDLE IS WELL TIGHTENED (Fig.102). IF IT IS LOOSENED DISMOUNT THE COMPLETE HANDLE AND MOUNT IT AGAIN BY USING LOCTITE ON THE THREAD. Remove the seeger ring #1 and the rubber

protection #2 (Fig.101)

Fig.101 Remove the 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 using loctite on the thread. Install the rubber protection #2 and the seeger

ring #1 (Fig.101). Install the micro switches. Install the top cover. Make some turns of tape all around the 8 or 4

position switch to avoid short circuit. Verify if it works fine Mount the assy on the portable control.

5.18 SHUT OFF CABLE: CHECK AND REPLACEMENT : 1h : Small standard screwdriver, medium cros

screwdriver, multimeter , pliers. : Defective cable may cause the following

malfunction: 1. The chuck arm does not come down. 2. Fuse F7 blows up. IMPORTANT!


FAIULURE #1 ALSO MAY BE CAUSED BE A MECHANICAL MALFUNCTION OF THE SHUT OFF SWITCH PROTECTION. BEFORE STARTING WITH ANY ELECTRICAL CONTROL VERIFY IF THE PROTECTION IS WELL REGULATED AND IF IT MOVES UP AND DOWN FREELY. TO CONTROL THE CABLE: Disconnect the machine from power supply. Open the electric box ( 5.0). Disconnect the wires 10 and 11 from terminal

block into electric box (Fig.104).

Fig.104 Open the shut off switch S4 cover and

disconnect both wires (Fig.105). Take a multimeter and select it in Ohm. Position the multimeter probes on the ends of

same wire and verify if there is continuity (Ω = 0 ~ 0,3).

If there is not continuity the wire must be replaced.

Fig.105 TO REPLACE THE CABLE: Disconnect the machine from power supply. Open the electric box ( 5.0).

Disconnect the wires 10 and 11 from terminal block.

Open the shut off switch S4 cover and disconnect both wires (Fig.105).

Release the strains cable relief on electric box.

Take the defective cable away. Insert the new cable. Tighten the wires on the switch 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 leaving some

cable free (Fig.105). 5.19 SHUT OFF SWITCH S4: CHECK AND REPLACEMENT

: 1h : Small standard screwdriver, multimeter ,

pliers, end wrench 13mm, Allen wrench 4mm, loctite.

: Defective shut off switch may cause the following malfunction:

3. The chuck arm does not come down. 5.0 Fuse F7 blows up. IMPORTANT! FAIULURE #1 ALSO MAY BE CAUSED BY A MECHANICAL MALFUNCTION OF THE SHUT OFF SWITCH SAFETY LEVER. BEFORE STARTING WITH ANY ELECTRICAL CONTROL VERIFY IF THE PROTECTION IS WELL REGULATED AND IF IT MOVES UP AND DOWN FREELY. TO CONTROL THE SWITCH: Disconnect the machine from power supply. Open the electric box ( 5.1). Disconnect the wires 10 and 11 from terminal

block. Open the shut off switch S4 door and

disconnect both wires (Fig.105). Take a multimeter and select it in Ohm. Position the multimeter probes on the switch

terminals and verify if there is continuity (Ω = 0 ~ 0,3).

If there is not continuity the switch must be replaced.

TO REPLACE THE SWITCH: Release the strain cable relief on chuck arm. Remove the defective switch. Install the new switch.


Tighten the wires on the switch S4 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 leaving some

cable free. NOTE: LEAVE 2mm OF CLEARANCE BETWEEN SWITCH S4 AND ITS SAFETY LEVER IN ORDER TO AVOID STOPPING OF THE CHUCK ARM DURING THE LOWERING OPERATION. Verify if the shut off protection is moving up

and down freely with chuck arm completely lowered (Fig.106).

Fig.106 5.20 EMERGENCY SWITCH S5: CHECK AND REPLACEMENT

: 1h : End wrench 8mm, tube type wrench 8mm, small standard screwdriver, small cross screwdriver, multimeter.

: 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 machine. Remove the yellow assy from portable control

( 5.0 Fig.62). Take a multimeter and select it in Ohm. Leave the red emergency button unlocked Position the multimeter probes on the red

terminals wires and verify if there is continuity (Ω = 0 ~ 0,3) (Fig.107).

Do the same control on the blue terminals. If there is not continuity the switch must be

replaced. TO REPLACE THE SWITCH S5: Loosen the screws #1 until to have switch

very free(Fig.107). Loosen the metal ring #1 and turn the red

button #2 (Fig.108) counter clockwise for a quarter of a turn pull it up to take it off.

The red button is now separated from the rest of the switch (Fig.109).

Fig.107

Fig.108

Fig.109


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. Fix the yellow assy to the portable control.

IMPORTANT: WHEN FIXING THE SWITCH ASSY TO THE PORTABLE CONTROL, BE CAREFUL NOT TO CRUSH WIRES.

5.21 ROBOTIC SAFETY SWITCH CABLE: CHECK AND REPLACEMENT

: 1h : Small standard and cross screwdrivers,

3mm allen wrench, 6mm end wrench, pliers, multimeter.

: Defective cable may cause the following malfunction:

1. All hydraulic movements, except tool holder lifting and lowering, do not work. TO CHECK THE CABLE: Disconnect the machine from power supply. Open the electric box ( 5.0). Disconnect the wires from terminal block 20

and 21 (Fig.110).

Fig.110 Remove the robotic safety switch cover

(Fig.111). Take a multimeter and select it in Ohm. Verify if there is continuity between two ends

of the same wire. If one or both wires do not show continuity,

the cable must be replaced.

Fig.111 TO REPLACE THE CABLE: Lose cable strein relief (Fig.112).

Fig.112 Lose the nut shown in Fig.113 and remove

the switch from its support.

Fig.113


Disconnect the wires from the switch. Cut the clip hoses and remove the switch

cover (Fig.114).

Fig.114 Remove the 2 bolts shown by the arrows and

take away the protection (Fig.115).

Fig.115 Remove all plastic protections. Take away the defective cable. Insert the new cable. Connect the cable to the robotic switch. Mount the switch on its support in order to

have all movements running. Connect 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 machined size of the safety rod (Fig.116).

Fig.116 Regulate the switch in order to have its wheel

as closest as possible to the machined safety rod but leaving it free (Fig.117)

Fig.117 Lock the switch nuts FIRMLY. Lower the tool holder a little and check if all

movements are locked: If not decrease a little the clearance between switch wheel and machined safety rod by moving the switch as shown by arrow (Fig.118).

Fig.118


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.119 Tighten the cable strein relief. Mount the switch cover and fit the hoses with

a clip hose (Fig.114).

IMPORTANT: WHEN FIXING THE SWITCH COVER, BE CAREFUL NOT TO CRUSH WIRES.

Move the tool holder ‘till end of the stroke and

leave some hoses free (Fig.120)

Fig.120 Lock the hoses on their protection and mount

the rubber tube (Fig.121) Install the protection (Fig.115). Mount the plastic spring around the hoses.

Fig.121 Check if the machine works fine.

5.22 ROBOTIC SAFETY SWITCH : CHECK AND REPLACEMENT


3mm allen wrench, 6mm end wrench, pliers, multimeter.

: Defective switch may cause the following malfunction:

1. All hydraulic movements, except tool holder lifting and lowering, do not work. TO CONTROL THE SWITCH: Switch the machine on. Lower the tool holder arm and hook it. Make sure to have the hook cylinder at the

end of stroke. Turn off the machine and open the electric

box. Disconnect the wires 20 and 21 from terminal

block (Fig.110). Take the multimeter and select it in Ohm. Verify if there is continuity between the wires

20 and 21. If there is not continuity the switch must be

replaced. IMPORTANT! BEFORE STARTING WITH SWITCH REPLACEMENT VERIFY IF IT IS WELL REGULATED AND VERIFY IF THE WIRE IS FINE. TO REPLACE THE SWITCH: Replace the switch following 5.21

5.23 COIL CONNECTOR CABLE: CHECK AND REPLACEMENT



pliers, multimeter. : Defective cable or connector may cause the

following malfunction: 1. One or more hydraulic movements do not

work. 2. Fuse F7 blows up. TO CONTROL THE CABLE: Disconnect the machine from power supply. Open the electric box ( 5.0). Remove the coil valve protection (Fig.122).

Fig.122 Remove all coil connector from coil valves. Take a multimeter and select it in Ohm. Position the multimeter probes on the ends of

the coil connector (Fig.123) and verify if there is continuity between the terminals: If there is not continuity the wires are defective.

Fig.123 TO REPLACE THE CABLE: Disconnect all wires from the terminals block. Disconnect all connectors from coil valves. Release 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 FIRMLY TO THE TERMINALS, MOUNT THE CONNECTOR AGAIN AND VERIFY IF THE MACHINE WORKS FINE. IF THE PROBLEM IS STILL NOT SOLVED PROCED FOLLOWING THE BELOW INSTRUCTION. Remove all wires from connectors (Fig.125). Take away the defective cable. Insert the new cable. Tighten all wires FIRMLY on the terminals

block and on the coil connectors. Tighten the cable strains relief. Fix the connectors to the coil valve following

the correct order.

Fig.124

Fig.125 6.0 HYDRAULIC FUNCTION The hydraulic working pressure at which each machine is carefully regulated is 160 Bar (2300 P.S.I) and it is reported on the sticker label. The hydraulic system is composed by two different circuits:

High pressure circuit at 160 Bar (2300 psi). Low pressure circuit at 60 Bar (860 psi).


6.0.1 HIGH PRESSURE CIRCUIT: The high hydraulic pressure is controlled by the valve 0.5 (Fig.52) and its range is from 50 to 200Bar (720 to 2880Psi). This valve avoids overstress to hydraulic and mechanical components. The working of this valve is very easy: when the hydraulic pressure inside of a cylinder reaches 160 (2300 P.S.I.), the valve opens and unloads the oil directly into the reservoir. The cylinders operating at high pressure are the following:

Saddle cylinder. Chuck arm cylinder. Chuck cylinder.

6.0.2 LOW PRESSURE CIRCUIT: The low hydraulic pressure is controlled by the valve 4.1 (Fig.52) and its range is from 0 to 100Bar (0 to 1440Psi). The working of this is the same of above one and its purpose is to supply the minimum hydraulic pressure to allow the tool holder movements. The cylinder operating at low pressure are the following:

Tool holder cylinder. Robotic cylinder on King 5600R only.

NOTE: ALL HYDRAULIC CYLINDERS ARE DOUBLE ACTING TYPE. 6.0.3 DESCRIPTION OF THE FUNCTION: The description of the hydraulic function can be grouped into 7 phases as following:

Machine in rest position. Rise and descent of chuck arm. Left and right of saddle. Opening and closing of the chuck. Left and right the tool holder Rise and descent of the tool holder cylinder

ON KING 5600R ONLY Double movements.

6.0.4 MACHINE IN REST POSITION: When the machine is switched on but not operating, the hydraulic oil (Fig.52) is pumped through all valves in rest position, and then it returns to the reservoir.

6.0.5 LEFT / RIGHT OF CARRIAGE:

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 “A” of the cylinder 1.4 through the valve Y1N. Oil in opposite side “B” gets out and returns to reservoir through the valve Y1B (Fig.52).

6.0.6 RISE AND DESCENT OF CHUCK ARM:

RISE: The oil flow arrives to the valve Y2B, which is opened, and unlocking the valve 2.5, it reaches the side “B” of the cylinder 2.7 making the wheel lifting. Oil contained in opposite side ”A”, returns to the reservoir through all others valves. Safety valve 2.5 prevents any unexpected chuck arm lowering from oil hose breakage or defective coil valve (Fig.52).

DESCENT: Oil flow, before reaching the side “A” of cylinder 2.7 through the valve Y2N, is forced to the safety valve 2.5 to get its unlocking. Oil contained in opposite side “B”, gets out through the valve 2.2, which control the lowering speed of the chuck arm, and returns to reservoir through all other valves (Fig.52).

NOTE: THE SAFETY VALVE 2.5 IS INSTALLED ON CE PROVED MACHINES ONLY.

6.0.7 OPENING AND CLOSING OF THE CHUCK:

OPENING: Oil flow reaches the side “A” of the cylinder 3.5 through the valve Y3N and when the cylinder has reached the maximum pressure, the locking valve 3.4 avoids dropping of hydraulic pressure.

CLOSING: The oil flow is forced to the locking

valve 3.4 through the valve Y3B to get its unlocking. Oil contained in the side “B” of the chuck cylinder 3.5 returns to the reservoir through all other valves (Fig.52).

6.0.8 LEFT / RIGHT OF TOOL HOLDER:

LEFT: Oil flow reaches the side “B” of the cylinder 4.5 through the valve Y5B. Oil in opposite side “A” gets out and returns to reservoir through the valveY5N (Fig.52).


RIGHT: Oil flow reaches the side “A” of the cylinder 4.5 through the valve Y5N. Oil in opposite side “B” gets out and returns to reservoir through the valve Y5B (Fig.52).

6.0.9 RISE AND DESCENT OF ROBOTIC:

RISE: The oil flow reaches the side “B” of the cylinder 5.5 through the valve Y4N making the robotic lifting. Oil contained in opposite side ”A”, returns to the reservoir through all others valves.

DESCENT: Oil flow reaches the side “A” of cylinder 5.5 through the valve Y4B making the robotic lowering. Oil contained in opposite side “B”, gets out through the valve Y4N and returns to reservoir through all other valves (Fig.52).

6.0.10 DOUBLE MOVEMENTS:

Oil flow can reach simultaneously more valves moving more cylinders and making faster operations. As soon as one or more cylinders reach the end of their stroke, machine stops all movements because the valves 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 King 2600 is more complicated compared to the electric ones, because in some cases the dismounting of many parts is required to reach those defective. The most important controls are those ones concerning the different hydraulic pressures at which each cylinder of the machine is working. This controls allow to find out very quickly the reason of any hydraulic malfunction. Another of the purpose of this manual is to reduce as much as possible the oil leaking during the maintenance operation: this will allow to operate on the machine in clean and safe condition. Before approaching the hydraulic parts , the following material needs to be prepared: 2 oil containers: 1 for hydraulic oil and 1 for

gear oil. Oil absorber. Paper towels.

BEFORE APPROACHING THE HYDRAULIC PARTS OF THE MACHINE, DISCONNECT THE MACHINE FROM ELECTRIC SUPPLY.

IN CASE OF OIL LEAKING DRY CAREFULY THE FLOOR TO AVOID SLIPAGE.

IMPORTANT!

HYDRAULIC ASSY: Remove the top cover (Fig.122) and the whole assy is available (Fig.126).

Fig.126

KING 5600R SADDLE CYLINDER: To access to this cylinder (Fig.128) remove the black cover (Fig.127).

Fig.127


Fig.128

KING 5600 SADDLE CYLINDER: To access to this cylinder (Fig.130) remove the red hoses protection (Fig.129).

Fig.129

Fig.130

CHUCK ARM CYLINDER: The access to this cylinder does not require any dismounting of any protection (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 screw assy and chuck components. So far the chuck cylinder has required the replacement of the seals only.

Fig.132

TOOL HOLDER CYLINDER: The access to this cylinder (Fig.135), requires the dismounting of the cabinet-tool holder cabinet (Fig. 133 and 134).


Fig.133

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.

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 cabinet tool holder on the

King 5600 remove the 14mm nut in Fig.137 and then those ones of 10mm in Fig.138.

Fig.137

Fig.138


Fig.139

ROBOTIC CYLINDER: The access to this cylinder (Fig.141) requires the dismounting of the hook protection (Fig.140).

Fig.140

Fig.141

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. Switch the machine off. Remove the reservoir stopper. Verify if oil level corresponds to mark #1 of the

stopper rod (Fig.142)

Fig.142 TO MAKE THE OIL LEVEL: Take the suggested hydraulic oil, reported on

a sticker tag on the reservoir and on the user manual, and fill the reservoir until to reach the mark on the stopper rod.

IMPORTANT! 1. USE SUGGESTED HYDRAULIC OIL ONLY

AS REPORTED ON THE USER MANUAL.


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’ : End wrenches 10,13,19 and 24mm, allen

wrenches of 3 and 6mm, manometer. : This is the first operation to be done when

there is the suspects of hydraulic problem. TO CHECK THE PRESSURE: Switch the machine on and close the jaws. Turn the machine off Install he manometer on the chuck cylinder

flange (Fig.143).

Fig.143 Open the jaws 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 higher than the

above one, remove the red cover on the hydraulic assy shown by the arrow on Fig.126, unlock the nut and try to increase it by turning clockwise the 3mm hex screw (Fig.145).

Fig.145 Close the jaws and switch off the machine. Remove the manometer and install the bolt

with a new copper washer. Mount the red cover.

6.4 LOW HYDRAULIC PRESSURE CIRCUIT: CHECK AND ADJUSTMENT

: 30’ : End wrenches 10, 13, 19 and 24mm, allen

wrench of 6mm, manometer. : Incorrect pressure may cause the following

malfunction: 1. Slow movements of the tool holder. 2. Slow lifting and lowering of the tool holder arm TO CHECK THE PRESSURE:


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.146 Turn the machine on. Move the tool holder arm to the left ‘till end of

stroke and verify if the maximum pressure is 60 bar (900 PSI) (Fig.147).

Fig.147 TO ADJUST THE PRESSURE: If the pressure is lower or higher than the

above one, remove the black coil valve cover on the hydraulic assy shown by the arrow on

5.23 Fig.122, unlock the nut and try to increase or decrease the pressure by turning clockwise or counter clockwise the 6mm hex screw shown in the picture (Fig.148).

Fig.148 Move to the right the tool holder cylinder ‘till

end of the stroke. Turn the machine off. Remove the manometer 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 wrenches of 10,17,19 and 24mm, 3,5

and 10mm Allen wrenches, 24mm socket wrench, small pliers, small cross screwdriver, manometer, green loctite, hydraulic oil container, dynamometric wrench.

: Incorrect chuck hydraulic pressure may cause the following malfunction:

1. Low clamping power of the rims. TO CHECK THE CHUCK CYLINDER PRESSURE: Check the maximum pressure 6.3. Keep the chuck cylinder quite opened for 10’:

the pressure should not decrease below than 140 Bar (2050PSI).

If the pressure drops quickly or considerably over than the above one, the following parts need to be checked and, if necessary, replaced:

1. Locking valve. 2. Locking valve piston release O ring. 3. Rear cylinder flange. 4. Chuck cylinder piston seals ( 6.13). IMPORTANT! IN CASE OF THE ABOVE PROBLEM THE MACHINE DOES NOT SHOW ANY OUTHER OIL LEAKING.


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. Press the coil valve by screwdriver to unload

the remaining pressure ( 5.14 Fig.93). Remove the manometer 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 cylinder. Remove the locking valve #1from the cylinder

flange (Fig.151): if the valve is opened it must be replaced.

Fig.151 IMPORTANT! BEFORE REPLACING THE LOCKING VALVE, VERIFY IF ITS O RING SHOWN IN THE PICTURE 152 IS FINE.

Fig.152 TO REPLACE THE LOCKING VALVE: Install the new valve on the flange. Mount the flange with its shim on the chuck

cylinder (Fig.153).

Fig.153 IMPORTANT!


THE LITTLE HOLE ON THE FLANGE MUST MATCH WITH THE LITTLE ON THE CHUCK CYLINDER, OTHERWISE THE CYLINDER WILL OPEN BUT IT WILL NOT CLOSE ANYMORE Tighten two flange screws paying attention to

avoid the dropping of the shim. Check if the chuck turns free by hand: if not

the shim is dropped and it must be placed correctly.

Tighten the rest of the bolts very carefully by using a dynamometric wrench regulated at 8Kgm (Fig.154).

Fig.154 Mount the anti rotational bolts #2 (Fig.150):

the small plate #4 must be left free. Install the oil hoses Install the manometer. Switch the machine on and open the chuck

arms ‘till having the cylinder with maximum pressure.

Keep the chuck cylinder quite opened for 10’. After 10’ unlock the chuck cylinder pressure

unless close the arms and open it again ‘till having maximum pressure again for further 10’.

Perform the above operation three times IMPORTANT! 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 Bar (2050PSI).

Remove the manometer and install the bolts with a new copper washer.

6.5.2 PISTON RELEASE LOCKING

VALVE “O” RING. TO CONTROL AND REPLACE THE O RING:

Remove the locking valve from chuck cylinder flange following the point1.

Remove the piston shown by the arrow in picture 155.

Fig.155 Check if the piston O ring is fine (Fig.156)

Fig.156 Install the new O ring on the piston. Clean very carefully the flange to avoid that

pieces of “O” ring get in the hydraulic oil circuit.

Mount the piston into the flange. Mount the rest of the parts by following the

point 1. Check if the machine works fine.

6.5.3 REAR CYLINDER FLANGE TO CHECK THE FLANGE: Remove the manifold revolving assy from

cylinder following ( 6.5.1). Remove the release piston from the flange (

6.5.2). Verify if there excess of clearance between

piston and its side into the flange (Fig.157): if there to much clearance the flange must be replaced.


Fig.157 TO REPLACE THE FLANGE: Remove the small and big flange O rings. Remove the screw #1 and the washer

(Fig.158).

Fig.158 Remove the manifold #2 (Fig 158) from the

flange (Fig.159).

Fig.159

IMPORTANT! IN CASE OF FLANGE REPLACEMENT IT IS SUGGESTED THE REPLACEMENT FO THE MANIFOLD “O” RINGS (FIG.160).

Fig.160 Mount the manifold revolving on the cylinder

flange by using some grease to make the operation easy.

Install the washer #2 (Fig.158) and fit the screw #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 cylinder

( 6.5.1). Verify if the machine works fine.

6.6 SADDLE CYLINDER SLIDING HYDRAULIC PRESSURE : CHECK AND ADJUSTMENT

: 1h : End wrenches 10, 17, 19, 17mm socket

wrench, 6mm Allen wrench, rubber hammer, wrench adjustment of saddle clearance, manometer with adapter.

: Incorrect pressure may cause the following malfunction:

1. Low bead breaker power. 2. Slow saddle sliding. TO CHECK THE SLIDING PRESSURE: Remove the pin #1 (Fig.161). Pull out the pin #2 and remove the mobile

table #3 (Fig.161)


MOBILE TABLE IS VERY HEAVY: HANDLE IT WITH CARE TO AVOID FEET AND FINGERS CRUSHING.

Fig.161 Close the saddle cylinder completely. Switch the machine off. Press the coil valve by screwdriver to unload

the remaining pressure ( 5.14 Fig.93). Install the manometer on the saddle hose of

the hydraulic assy (Fig.162).

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 all translation (Fig.163).

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: Position the saddle in the middle of the frame

on the king 5600R (Fig.164), while the King 5600 saddle needs to be open a little (Fig.165).

Fig.164

Fig.165


Unlock the screws, turn counter clockwise of 1/8 of a turn the eccentrics (Fig.166 ,167 and 168) and lock the screws FIRMLY.

Fig.166 IMPORTANT! DO NOT UNLOCK ALL SCREWS TOGETHER: ECCENTRICS MUST BE ADJUSTED AND LOCKED ONE BY ONE. NOTE: FOR KING 5600 ADJUST THE ECCENTRICS OF THE PICTURES 160 ONLY BECAUSE THERE ARE TWO BUSHINGS IN THE BOTTOM.

Fig.167

Fig.168 Check if the sliding pressure is correct. Remove the manometer and install the screw

with two news copper washer. Mount the mobile table.

MOBILE TABLE 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 pliers, manometer with adapter, hydraulic oil container.

: Defective hydraulic pump may cause the following malfunction:

1. Slow moving. 2. Low bead breaker and chucking power. 3. Noisy pump. 4. Oil leaking from the motor spacer. TO CHECK THE HYDRAULIC PUMP WHEN IT SHOWS HYDRAULIC PROBLEM: Check the whole hydraulic pressure ( 6.3). If the pressure does not grow up the hydraulic

pump needs to be replaced. TO CHECK THE PUMP WHEN IT IS NOISY: Remove the hydraulic motor ( 5.5) Switch the motor on and listen it: If it is not

noisy, replace the pump.


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. Disconnect the machine from power supply. Remove the hydraulic motor ( 5.5). Remove the 4 reservoir screws and take it

out. Remove the screws #1 and #2 and take the

pump out (Fig.169).

Fig.169 IMPORTANT! 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 O RING #2 (FIG.170) MAY CAUSE OIL LEAKING FROM THE ALUMINIUM MOTOR SPACER.

BREAKAGE OF SEAL #3 (FIG.171) MAY CAUSE OIL LEAKING FROM THE ALUMINIUM MOTOR SPACER.

Fig.170

Fig.171 TO REPLACE THE SEAL #3 (FIG.171):

1. Remove the bolts #4 (Fig.171) and open the

pump unless take out the pump roots (Fig.172).

Fig.172 2. Remove the Seeger ring from the cover. 3. Push the defective seal out. 4. Grease the seal side and install carefully the

new seal. 5. Install the seeger ring. 6. Replace also the two pump inner seal.


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. Take a new pump and fit it on its support. Tighten the pump bolts FIRMLY. Take a couple of pliers and turn the pump

shaft: it must turn freely. Mount the oil reservoir. Take the oil previously saved in the cleaned

tank and put it into the reservoir. Switch the machine on and check the

maximum hydraulic pressure. Make the hydraulic oil level. Remove the manometer and install the bolt

with two news copper washers. Mount the hydraulic assy top cover.

6.8 COIL VALVE: CHECK AND REPLACEMENT

: 30’ each one : Small cross screwdriver, end wrenches

10,14 and 22mm, hydraulic oil container. : Defective coil valve may cause the following

malfunction: 1. Oil leaking. 2. One or more hydraulic movements start

themselves. 3. The chuck arm lowers itself (machine NON

CE PROVED ONLY). 4. One or more hydraulic movements do not

work. 5. Low chucking pressure. TO CHECK THE COIL VALVE: Remove the coil 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 pressure replace the 3 small “O” rings #A (Fig.173) by following the instruction below reported..

If the there is an oil leaking between the valve body and the aluminium block, the larger “O” ring #B must be replaced (Fig.173) by following the instruction below reported..

If there is an oil leaking through the valve piston, replace the complete valve by following the instruction below reported..

Fig.173 To verify the point 4, switch the machine on. Press the coil valve correspondent to the

locked movement by screwdriver ( 5.13 Fig.93): if the machine works normally verify coil connector cable 5.23 and portable control cable 5.14 .

If 5.23 and 5.14 will be fine, the malfunction is due to a defective coil #C (Fig.173).

TO CLEAN THE COIL VALVE: IMPORTANT! DO NOT DISMOUNT ANY COIL VALVE WITH OPENED CHUCK CYLINDER AND LIFTED CHUCK ARM. Switch the machine off. Press the coil valve by screwdriver to unload

the remaining pressure ( 5.13 Fig.93). Remove the coils connectors shown by the

arrows (Fig.174).

Fig.174 Remove the plastic nut #1 (Fig.173). Remove the O ring #2 (Fig. 173). Remove the coil #3 (Fig.173). Remove the O rings #4 (Fig.173). Remove the coil #5 (Fig.173). Remove the O ring #6 (Fig.173).


Remove the valve from aluminium block (Fig.175)

Fig.175 Open the body valve by using 14mm end

wrench (Fig.176). Clean very carefully all parts from slag and

dirty by air pressure.

Fig.176 Mount the body valve. Install the valve on its aluminium block. Install the O ring #6 (Fig.173). Install the coil #5 (Fig.173). Install the O rings #4 (Fig.173). Install the coil #3 (Fig.173). Install the O ring #2 (Fig. 173). Tighten the plastic nut #1 (Fig.173). Fit the coils connectors following the electric

diagram if the original position has been forgotten.

Check if the machine works fine. Mount 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.

: Defective cylinder may cause the following malfunctions:

1. Oil leaking from welding. 2. Mechanical breakage.

NOTE: THE REPLACEMENT OF THE WHOLE CYLINDER IS ONLY SUGGESTED IN CASE OF MECHANICAL DEFECTS. TO CHECK THE CYLINDER Remove the hoses protection ( 6.1 Fig.129) Switch the machine on. Move to the left and to the right the saddle ‘till

end of strokes and verify if there are oil leaking or mechanical breakages.

TO REPLACE THE CYLINDER ON KING 5600 Open the saddle cylinder ‘till end of stroke. Remove the screw and the washers shown in

Fig.177.

Fig.177 Remove the plate locking (Fig.178)

Fig.178


Remove the pin by using the tool for removal of cylinder pin (Fig.179).

Fig.179 Close the cylinder. Turn off the machine. Press the coil valve by screwdriver to unload

the remaining pressure ( 5.13 Fig.93). Remove the oil hoses. Remove the top split pin #1and washer #2

(Fig.180). Remove the cylinder pin from the 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.181 Mount the cylinder pin from the bottom. Install the top washer #2 and split pin #1

(Fig.180). Fit the oil hoses by using new copper

washers. Switch the machine on. Take a tyre lever, open the cylinder and drive

its piston by lever into the saddle bracket (Fig.182).

Fig.182 Install the pin (Fig.183).

Fig.183 Mount the plate locking (Fig.178).


Mount the washers and the screw of Fig.177. Open and close the cylinder to verify if it is

working fine. Mount the oil hoses protection ( 6.1 Fig.129). Make the hydraulic oil level ( 6.2).

6.10 KING 5600R SADDLE CYLINDER: CHECK AND REPLACEMENT

:1h30’ : End wrenches 13,19 and 27mm, Allen

wrench of 8mm, 8 and 13mm tube type wrenches, pliers, medium cross screwdriver, steel and rubber hammer, pliers, hydraulic oil container, loctite, sylicon.

: Defective cylinder may cause the following malfunctions:

1. Oil leaking from welding. 2. Mechanical breakage. NOTE: THE REPLACEMENT OF THE WHOLE CYLINDER IS ONLY SUGGESTED IN CASE OF MECHANICAL DEFECTS. TO CHECK THE CYLINDER: Remove the cylinder protection ( 6.1

Fig.127) Switch the machine on. Move to the left and to the right the saddle ‘till

end of strokes and verify if there are 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 end of stroke. Turn off the machine. Remove the screw and the washers shown in

6.9 Fig.177. Remove the locking plate 6.9 Fig.178.

Remove the pin by using the tool for removal of cylinder pin (Fig.185).

Fig.185 Turn on the machine. Close the cylinder ‘till end of stroke. Turn off the machine. Remove the coil valve cover ( 5.23 Fig.122). Press the coil valve to unload the hydraulic

pressure in the circuit 5.13 Fig.93). Remove the hose protection 6.1 Fig.127. Loose the nut #1 (Fig.186). Tighten the screw #2 ‘till have it free from the

cabinet (Fig.186). Unscrew the screw #3 and #4 to remove the

cylinder supports (Fig.).

Fig.186 NOTE: VERY OFTEN THERE ARE ONE OR MORE SHIMS BETWEEN SUPPORT #4 (FIG.186) AND CABINET. THESE SHIMS MUST INSTALLED AGAIN DURING THE MOUNTING OPERATION. Remove the short oil hose from the hydraulic

assy. Remove the oil hose #A (Fig.187)


Fig.187 Remove the top split pin and washer and

push out the cylinder pin (Fig.188).

Fig.188 Remove the defective cylinder. Remove the short oil hose from the cylinder. Take the new cylinder and install on it the

shorter oil hose. Install the new cylinder by placing the

eventual washers in the lower side. IMPORTANT! THE PISTON MUST BE ORIENTED AT 90° COMPARED TO THE FRAME FOR AN EASY

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. Install the support #4 by using loctite on the

screw (Fig.186). Tighten the screw FIRMLY. NOTE: THE ROUNDING OFF (FIG.189) MUST BE INSTALLED TOWARDS THE WELDING.

Fig.189 Install the shim/s and lock them by using

silicon (Fig.190).

Fig.190 Install the lower support #3 without tighten

firmly the screw #2 with loctite (Fig.186). Turn the screw #1 ‘till to have completely

removed the clearance between cylinder and support.

NOTE: IF THE CLEARANCE CANNOT BE EASILY REMOVED, INSERT MORE SHIMS BETWEEN CYLINDER AND SUPPORTS.


Lock FIRMLY the support screw. Lock FIRMLY the nut #1 (Fig.186). Mount the cylinder protection 6.1 Fig.127. Turn on the machine. Open the saddle. 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 rubber hammer, hydraulic oil container.

Defective seals may cause the following malfunction:

1. Oil leaking from the piston rod. 2. Oil leaking from ring screw. 3. Low bead breaker power. TO CHECK THE RING NUT “O” RING AND THE PISTON ROD LIP SEAL: Switch the machine on. Close the saddle cylinder. When it is at the end of stroke, keep it under

pressure and verify if there is oil leaking from the piston rod or from ring nut.

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 both way. Switch the machine on. Close the saddle cylinder ‘till end of the

stroke. Press the coil valve by screwdriver to unload

the remaining pressure ( 5.13 Fig.93). Take the oil container and remove the hose

“A” (Fig.191).

Fig.191 Take the portable control and press the

movements left of the saddle to have the hose “B” (Fig.191) under pressure.

If the side “A” will leak considerably oil, the piston seal is defective.

Some drops of oil leaking are considered absolutely normal.

Perform the same operation on the side “B”. TO REPLACE THE “O” RINGS AND THE SEALS: IMPORTANT! WHEN THE CYLINDER NEEDS TO BE OPENED THE REPLACEMENT OF WHOLE SET OF SEALS IS HARDLY SUGGESTED. Remove the cylinder from the machine 6.9. Lock the cylinder on a vice. Remove the ring nut (Fig.192).

Fig.192 When the ring screw is completely off, unload

the oil into the oil container. Lock the piston head on the vice. Remove the nut (Fig.193).


Fig.193 Remove the seal and the plastic guides. Remove the piston (Fig.194).

Fig.194 Remove the O ring #1 (Fig.195) inside of the

piston.

Fig.195 Take away the ring screw. Remove the O ring and the lip seal from the

ring screw (Fig.196).

Fig.196 Verify the condition of all components. 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. NOTE: WHEN INSTALLING THE “O” RING ON THE RING SREW BE CAREFUL TO NOT TWIST IT. Grease the seal and insert the ring screw on

the piston rod. Mount the piston on the rod.

IMPORTANT! THE “O” RING MUST BE PLACED IN OPPOSITE POSITION COMPARED TO THE THREAD (Fig.197)

Fig.197 Install the new seals and the new plastic

guides. IMPORTANT: TO MOUNT THE NEW PISTON SEALS DO NOT USE ANY SCREWDRIVER OR ANY SHARPENED TOOL. USE HANDS ONLY (FIG198).


Fig.198 Lock the nut FIRMLY by using loctite. Clean the piston from loctite. Insert the piston into the cylinder.

IMPORTANT: WHEN INSERTING THE PISTON INTO THE CYLINDER, BE CAREFUL NOT TO CRUSH SEALS.

Tighten the ring screw to the cylinder.

IMPORTANT: WHEN TIGHTENING THE RING SCREW TO THE CYLINDER, BE CAREFUL NOT TO CRUSH THE “O” RING.

Lock the ring nut FIRMLY. Mount the cylinder on the machine 6.9. Check the hydraulic oil level 6.2. Verify if the cylinder works fine.

6.12 KING 5600R SADDLE CYLINDER SEALS: CHECK AND REPLACEMENT

: 2h30’ : End wrench 13, 19mm, 8mm Allen wrench,

socket wrench of 27mm, 8 and 13mm tube type wrenches, medium standard screwdriver, pliers, calliper wrench, steel and rubber hammer, hydraulic oil container.

Defective seals may cause the following malfunction:

1. Oil leaking from the piston rod. 2. Oil leaking from ring screw. 3. Low bead breaker power. TO CHECK THE CYLINDER SEALS: 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 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. Oil leaking from welding. 2. Mechanical breakage. 3. Bushings wearing. 4. The cylinder is noisy while lifting up and

lowering down.

NOTE: THE REPLACEMENT OF THE WHOLE CYLINDER IS ONLY SUGGESTED IN CASE OF MECHANICAL DEFECTS AND OIL LEAKING THROUGHT THE WELDINGS. TO CHECK THE CHUCK ARM CYLINDER: Switch the machine on. Lift and lower the chuck arm ‘till end of stroke

several times and verify if it show the malfunction above reported.

TO REPLACE THE CHUCK ARM CYLINDER: Lift up the chuck arm. Remove the safety lever. Remove the pin #1 and #2 (Fig.199 and 200).

Fig.199 Take a piece of wood and place it under the

chuck arm. Lower the chuck arm on the wood. Switch the machine off.


Fig.200 Remove the washers #3 and 4(Fig.199 and

200). Press the coil valve by screwdriver to unload

the remaining pressure ( 5.13 Fig.93). Take the oil container. Remove the hose #5 (Fig.199). Remove the screw #6 to take away the safety

valve #7 (Fig.200) Take a lever. Push out the cylinder (Fig.201).

Fig.201 NOTE: IF THE CYLINDER WOULD NOT GET OUT, CUT ITS BUSHINGS BY USING GRINDING MACHINE. THEY ARE PROBABLY

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. Switch the machine on. Place the bottom bushing of the cylinder on

the pin of the frame. Verify if the greaser 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. Insert the washer and fix the pins. Install the safety valve. Mount the hoses. Remove the piece of wood. Install the safety lever. Check if there is any oil leaking. Make hydraulic oil level 6.2.

6.14 CHUCK ARM LOWERING SPEED: CHECK AND ADJUSTMENT

: 30’ : End wrench 10 and 19mm, pliers, hack-saw,

hydraulic oil container. : Slow lowering speed of the chuck arm.

TO CHECK THE LOWERING SPEED: Switch the machine on. Verify if the lifting and the lowering speeds, ‘till

end of stroke, are both the same or very similar.

If the lowering speed is considerably slower, it needs to be adjusted.

TO ADJUST THE LOWERING SPEED: Lower the chuck arm ‘till end of stroke. Switch the machine off. Remove the top cover. Press the coil valve by screwdriver to unload

the remaining pressure ( 5.13 Fig.93). Remove the hose shown by the arrow

(Fig.202)


Fig.202 Remove the valve with the spring. Dry the valve from the oil and lock it on a vice. Take the hack-saw and make a little bigger

unloading channel shown by the arrow (Fig.203).

Fig.203 Clean the valve accurately by using air

pressure. Mount the valve into the spacer. Mount the hose. Switch the machine on and verify if there are

oil leaking. Mount the top cover.

6.15 CHUCK ARM CYLINDER SEALS: CHECK AND REPLACEMENT

: 3h : End wrench 19mm, steel hammer, rubber

hammer, calliper wrench, piece of wood, hydraulic oil container.

: The defective seals may cause the following malfunctions:

1. Oil leaking from the piston rod. 2. Oil leaking from the ring screw. 3. The chuck arm lowers itself.

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’ later the wheel will considerably lower,

the seals 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 machine 6.13. Replace the cylinder seals 6.11.

6.16 CHUCK CYLINDER: CHECK AND REPAIRING

: 2h to replace the piston and cylinder seals. 30’ to replace the flange O rings.

: End wrenches 19,22mm, 40mm socket wrench, 4, 5 and 8mm Allen wrenches, 8mm tube type wrench, calliper wrench, rubber hammers, manometer, dynamometric wrench, green loctite, hydraulic containers oil.

: Defective chuck cylinder may cause the following malfunctions:

1. Low clamping power. 2. Oil leaking from chuck bell. 3. Oil leaking from cylinder rear flange. TO CHECK THE REAR FLANGE LARGE “O” RING: Switch on the machine. Close the jaws. Install the manometer on the chuck cylinder

( 6.3 Fig.143). Open the chuck arms and keep the cylinder

under pressure 6.3. If there is an oil leaking between the flange

and the chuck arm and the hydraulic pressure drops quickly, the large “O” ring #1 (Fig.204) is damaged and it must be replaced.

TO CHECK THE REAR FLANGE SMALL “O” RING Switch on the machine. Close the jaws and keep the cylinder under

pressure.


If there is an oil leaking between the flange and the chuck arm, the small “O” ring #2 (Fig.204) is damaged and it must be replaced.

Fig.204 TO CHECK THE MANIFOLD REVOLVING “O” RINGS: Switch on the machine. Open and close the chuck arms and keep the

cylinder under pressure in both positions. If there is an oil leaking from the manifold

nuzzle shown in Fig.205, the inner O rings are defective and they must be replaced.

Fig.205 TO CHECK THE FRONT FLANGE SEALS: Switch on the machine. Close the chuck arms and keep the cylinder

under pressure. If there is an oil leaking chuck piston rod, the

flange seals are defective and they must be replaced.

TO CHECK THE PISTON SEALS: Switch on the machine. Open the chuck arms.

Remove the upper oil hose from the manifold revolving (Fig.206).

Fig.206 Press the command “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 REAR FLANGE LARGE AND SMALL “O” RINGS: Remove the rear flange from the chuck

cylinder 6.5. Replace the O rings. Install the rear flange on the chuck cylinder

6.5. Check if the machine works fine.

TO REPLACE THE MANIFOLD REVOLVING “O” RINGS: Remove the manifold revolving following 6.5

without dismount the whole rear flange from chuck cylinder.

Replace the defective O rings (Fig.160). Install the manifold revolving on the cylinder

flange 6.5. Check if the machine works fine.

TO REPLACE THE PISTON SEALS: Turn on the machine and open the chuck

arms completely. Position the chuck in cross way (Fig.207). Turn the machine off. Remove the protection #1 (Fig.207). Remove the nut #2 (Fig.207). Remove the cross #3 (Fig.207). Remove the spacer between the crosses. Lock FIRMLY the bolt #A (Fig.208) of all 4

arms to keep them opened without the crosses.


Fig.207

Fig.208 Remove the cross #4 (Fig.207). Turn the machine on and close the chuck

piston completely. Turn the machine off. Remove the rear flange from the chuck

cylinder 6.5. Turn the chuck cylinder ‘till to have the small

hole at 6 o’clock (Fig.209).

Fig.209 Push out the piston by using 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 (Fig.210). Remove the piston #2 by using the calliper

wrench.

Fig.210 Replace the piston seals (Fig.211) following

6.11.

Fig.211 IMPORTANT! WHEN THE CYLINDER NEEDS TO BE OPENED THE REPLACEMENT OF WHOLE SET OF SEALS IS HARDLY SUGGESTED. Remove the front flange seals and ring. Mount the rear ring by using hands only

(Fig.212).


Fig.212 Mount the lip seal (Fig.213).

IMPORTANT! INSTALL THE LIP SEAL WITH THE RING SIDE TOWARDS THE OUTER SIDE OF THE FLANGE.

Fig.213 Install the plastic ring (Fig.214).

Fig.214 Install the dustproof seal (Fig.215).

Fig.215 Grease the cylinder and piston seals and

mount the piston by using rubber hammer. Install the rear flange 6.5. Turn on the machine. Open and close the chuck cylinder and verify

if it works fine and there is any oil leaking. Close the chuck cylinder and mount the cross

#4 and the spacer (Fig.207). Open the chuck cylinder ‘till end of the stroke. Mount the cross #3 and tighten 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, manometer, green loctite, hydraulic containers oil.


1. Slow or locked tool holder movement. 2. Oil leaking. IMPORTANT! BEFORE STARTING WITH ANY DISMOUNTING OPERATION, VERIFY IF THE MAXIMUM HYDRAULIC PRESSURE IS CORRECTLY REGULATED 6.4. NOTE: THE REPLACEMENT OF THE WHOLE CYLINDER IS ONLY SUGGESTED IN CASE OF MECHANICAL DEFECTS. TO CHECK THE CYLINDER: Install the manometer on the cylinder ( 6.4

Fig.142). Switch the machine on. In case of slow movement, move to left the

tool holder by keeping it clamped: during the movement verify that the hydraulic pressure


shown on the manometer must be within 25 Bar (350 PSI).

If the pressure shown by the manometer is higher than 25 Bar (350 PSI) remove the cabinet-tool holder cabinet ( 6.1 Fig.133 for 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. Perform again a complete movement to the

left and verify again the pressure: if it is still higher than 25 Bar (350 PSI), the cylinder must be replaced. If the pressure shown by the manometer is within this pressure, adjust the hook registration 7.9.

In case of oil leaking move to the left and to the right the tool holder cylinder ‘till end of stroke and verify if there are oil leaking or mechanical breakages.

TO REPLACE THE TOOL HOLDER CYLINDER: Close the piston. Turn off the machine. Remove the oil hoses protection ( 6.1

Fig.129). Remove the manometer from the steel oil

hose. Remove the 3 screws that lock the cylinder on

the saddle (Fig.216). IMPORTANT! VERY OFTEN THERE ARE WASHERS BETWEEN 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 oil hose (Fig.217).

WHEN REMOVING THE TOOL HOLDER CYLINDER PAY EXTRA CARE TO AVOID FINGERS CRUSHING.

Fig.217 Remove the defective cylinder. Install the new cylinder. Install the oil hose (Fig.217). Fit the cylinder on the saddle by using loctite

on the screws and placing the shims in the original position.

Install the steel oil hose. Turn on the machine. Open and close the cylinder to verify if there is

any oil leaking. Turn off the machine Mount the oil hoses protections ( 6.1

Fig.129). Mount the cabinet-tool holder. Turn on the machine. Check if the tool holder is moving normally. Check the hydraulic oil level 6.2.

6.18 TOOL HOLDER CYLINDER SEALS: CHECK AND REPLACEMENT

: 1h : End wrenches 19,22,24 and 30mm, 8mm

Allen wrenches, rubber hammers, calliper wrench, manometer, hydraulic containers oil.

: Defective chuck cylinder seals may cause the following malfunctions:

1. Slow or locked tool holder movement. 2. Oil leaking from welding. TO CHECK THE CYLINDER SEALS: Check if there is oil leaking or if there is a slow

tool holder movement by following 6.16. TO REPLACE THE CYLINDER SEALS:


Open the cylinder ‘till end of the stroke (Fig.218).

Fig.218 Turn off the machine. Remove the steel oil hose and hold few

minutes ‘till the cylinder liner will be empty. Remove the ring nut by using the calliper

wrench (Fig.219).

Fig.219 Replace the seals by following 6.11. Mount the ring nut. Install the steel oil hose. Turn on the machine Open and close the cylinder to verify if there is

any oil leaking. Turn off the machine Mount the oil hoses protections ( 6.1

Fig.129). Mount the cabinet-tool holder. Turn on the machine. Check if the tool holder is moving normally. Check the hydraulic oil level 6.2.

6.19 KING 5600R ROBOTIC CYLINDER: 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.


1. Slow or locked tool holder movement. 2. Oil leaking from welding. IMPORTANT! BEFORE STARTING WITH ANY DISMOUNTING OPERATION, VERIFY IF THE MAXIMUM HYDRAULIC PRESSURE IS CORRECTLY REGULATED 6.4. NOTE: THE REPLACEMENT OF THE WHOLE CYLINDER IS ONLY SUGGESTED IN CASE OF MECHANICAL DEFECTS. TO CHECK THE CYLINDER: Remove the hook protection ( 6.1 Fig.140). Check the cylinder following 6.16 and

moving the cylinder up and down. TO REPLACE THE CYLINDER: Lift up the hook #1 ‘till to have it in contact

with the tool holder arm #2 (Fig.220).

Fig.220 Switch the machine off. Remove the safety switch from the cylinder

5.21. Remove the spring (Fig.221).


Fig.221 Remove the pin #1 (Fig.222). Remove the nut #2 (Fig.222). Lower the rod #3 and remove the nut #4

(Fig.214). Remove the rod #3 from the cylinder. Lose the screw #5 (Fig.214). Push out the pin # 6 (Fig.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 take out the cylinder

(Fig.224).

Fig.224 IMPORTANT! TO ADJUST THE CYLINDER POSITION COMPARED TO THE HOOK THERE THE SHIMS IN THE BOTTOM OF THE CYLINDER (FIG.225). THESE SHIMS MUST BE MOUNTED IN THE SAME ORIGINAL POSITION.

Fig.225


Remove the greasers #3 and #4 (Fig.224 and Fig.226)

Remove the screw #5 (Fig.226).

Fig.226 Take the new cylinder. Install the greasers #3 and #4 (Fig.224 and

226). Install the cylinder on its cabinet with the shim

in the original position (Fig.226). Lock the cylinder pin by screw and nut #

(Fig.224). NOTE: THE HOLE IN THE PIN #2 MUST MATCH WITH THE SCREW #1 (FIG.224). Install the nipless fittings and the oil hoses

(Fig.223). Turn on the machine. Open the cylinder. Install 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 reaches the end of stroke before

the cylinder piston (Fig.227), remove the pin #6 (Fig.222) and turn clockwise of a turn the piston rod head (Fig.229).

Fig.227 If the cylinder piston reaches the end of stroke

before the hook (Fig.228), remove the pin #6 (Fig.222) and turn counter clockwise of a turn the piston rod head (Fig.229).

Fig.228

Fig.229 Mount the cylinder on the hook and verify if

both parts reach the end of their stroke at the same time.

Lock the screw #5 (Fig.222) FIRMLY by loctite.


Lock the screw #5 (Fig.226) FIRMLY by loctite.

Lift up the hook and install the spring. Lower the hook all way down. Turn off the machine. Install the safety rod #3 (Fig.222). Install the nut #4 (Fig.222). Install the nut #2 (Fig.222). Tighten manually nuts #2 and #4 (Fig.222)

keeping the safety rod machined section towards the safety switch.

Install the safety switch and leave its nuts free.

Turn on the machine. Lift up the tool holder arm ‘till to have the

machined section working on the safety switch wheel.

Regulate the switch in order to have its wheel as closest as possible to the machined safety rod but leaving it free ( 5.21 Fig.117).

Lock the switch nuts FIRMLY. Turn on the machine. Lower the hook ‘till end of stroke. Turn off the machine. Leave 2mm of clearance between switch and

safety rod (Fig.230) by adjusting the nuts #2 and #4 (Fig.222).

Fig.230 Lock the nuts #2 and #4 FIRMLY by loctite. Turn on the machine. Check if the safety device works properly. Turn the machine off. Install the safety switch cover. Make a new 3mm hole on the piston head

through the previous one on the safety rod. Insert the pin #1 (Fig.222). Mount the hook protection. Check the hydraulic oil level 6.2. Check if the machine works fine.

6.20 KING 5600R ROBOTIC CYLINDER SEALS: CHECK AND REPLACEMENT

: 2h : End wrenches of 22, 4 Allen wrench, calliper

wrench, rubber hammers, manometer, green loctite, hydraulic containers oil.


3. Slow or locked tool holder movement. 4. Oil leaking from welding. TO CHECK THE SEALS: IMPORTANT! WHEN THE CYLINDER NEEDS TO BE OPENED THE REPLACEMENT OF WHOLE SET OF SEALS IS HARDLY SUGGESTED. Check the cylinder seals following 6.18.

TO REPLACE THE SEALS: VERY IMPORTANT! THIS OPERATION DOES NOT REQUIRE THE DISMOUNTING OF THE WHOLE SAFETY DEVICE AS REQUIRED FOR THE CYLINDER REPLACEMENT. Remove the cylinder from the hook 6.18. Open completely the cylinder. Turn the machine off. Remove the ring nut. Take off the piston rod from the cylinder liner

together with safety rod. Replace all cylinder seals 6.11. Insert the piston into the cylinder liner and the

safety rod in its hose. Tighten the ring nut FIRMLY 6.11. Mount the cylinder on the hook 6.18. Check if the machine works fine. Check the hydraulic oil level 6.2.

7.0 MECHANICAL SECTION The mechanical section is mainly connected to the saddle and to the tool holder arm regulations. Usually this parts do not require the replacement and in any case their replacement is required after years of intensive working. 7.1 SADDLE: CHECK AND ADJUSTMENT

: 1h : End wrenches 10,17, 19 and 24mm, allen

wrench 6mm, manometer, Wrench adjustment of saddle clearance, Tool for removal of cylinder pin.


: 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.

TO ADJUST THE SADDLE WHEN THE SLIDES ARE TOO LOSENED: To adjust the saddle sliding 6.6, but the

eccentrics and the hex screws must be turned clockwise of 1/8 of a turn (Fig.231),(Fig.232 and 233 for King 5600R only).

Fig.231

Fig.232

Fig.233 7.2 KING 5600R SADDLE SLIDES: CHECK AND REPLACEMENT

: 4h : End wrenches 10,13,17,19, 22, 24mm, 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

: 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 tool and rim. TO CHECK THE SLIDES: To check the saddle sliding pressure 6.6. If the pressure shown by the manometer is

always lower than 30 bar (430 psi) 7.1 If the eccentrics make a complete turn without

tighten the saddle the slides need to be replaced.

TO REPLACE THE SLIDES: Turn the machine on and close the saddle

cylinder ‘till end of stroke. Lift up the hook (Fig.220). Turn the machine off. Remove the mobile plate from the saddle

6.6 Remove the mount dismount tool #1 from tool

holder arm (Fig.234).


Fig.234 Remove the tool holder cylinder 6.18. Disconnect the steel oil hose from standard

one. Remove the tool holder oil hoses support

shown by the arrow (Fig.235) from the saddle.

Fig.235 Take out the tool holder assy from the saddle

without remove the safety switch and the oil hoses from the cylinder.

TOOL HOLDER ASSY IS VERY 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 the bars with the slides #1, #2, #3

from the saddle (Fig.236 and 237).

Fig.236

Fig.237 The slides are bolted on their bars with 8mm

screws and toothed washers (Fig.238 and 239).

IMPORTANT! 1. THE REPLACEMENT OF THE SLIDES

ALSO REQUIRES THE REPLACEMENT OF THE TOOTHED WASHERS.

2. DO NOT OVER TIGHTEN THE 8mm SCREWS IN ORDER TO AVOID DAMAGING TO THE PLASTIC SLIDES.

Fig.238


Fig.239 Remove the saddle from the cabinet and

replace its plastic slides (Fig.240) by removing the 8mm screws shown by the arrows in Fig.241.

SADDLE IS VERY HAEVY AND IT MUST BE HANDLEDED WITH DECISION. ITS DROPPING MAY CAUSE FEET INJURIES.

Fig.240

Fig.241 Grease both guides welded on the cabinet by

using black grease.

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). THE LARGEST SIZE MUST BE KEPT TOWARD THE ECCENTRICS.

Fig.242 Turn the machine on and position the saddle

in the middle of the cabinet. Turn the eccentrics #1 and #2 (Fig.243) up to

the point you find resistance (without forcing) and lock the screws. Perform the same operation with eccentrics #3 and #4 (Fig.235) and #5 and #6 (Fig.244).

Fig.243


Fig.244 Verify that pressure when sliding carriage

toward the left is within 30-50 bar. If higher, turn just a little bit the eccentrics screws in such a way to create more play 6.6.

When pressure is OK, turn and tighten the other eccentric nuts the same way as the first two and check pressure again.

Remove the manometer. Mount the coil valve protection. Mount the robotic assy. Mount the robotic hoses support. Mount the tool holder cylinder 6.18. Mount the steel hose. Mount the hoses protection. Mount the mount – dismount tool. Mount the mobile plate. Check the machine.

7.3 KING 5600 SADDLE SLIDES: CHECK AND REPLACEMENT

: 3h30’ : End wrenches 10,13,17,19, 22, 24mm, allen

wrench 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

: 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 tool and rim. TO CHECK THE SLIDES: To check the saddle sliding pressure 6.6. If the pressure shown by the manometer is

always lower than 30 bar (430 psi) 7.1 If the eccentrics make a complete turn without

tighten the saddle the slides need to be replaced.

TO REPLACE THE SLIDES: Turn the machine on and open the saddle

cylinder ‘till end of stroke. Close the tool holder cylinder. Turn off the machine. Remove the mount dismount tool. Remove the tool holder cylinder 6.16 Remove the tool holder assy from the

machine. Remove the steel hose. Remove the mobile plate from the saddle

6.6 Remove all eccentrics and all hex screws

from the saddle. Remove the saddle pin #5 ( 6.9 Fig.177 and

178). Remove the screw shown in Fig.245.

Fig.245 Take out the bar of Fig.250 and when both

bushings are out of the bar, the saddle can be removed from the machine.

Fig.246


SADDLE IS VERY HAEVY AND IT MUST BE HANDLEDED WITH DECISION. ITS DROPPING MAY CAUSE FEET INJURIES.

IMPORTANT! AS THE SADDLE IS DISMOUNTED THE CONTROL OF ITS BUSHINGS IS RECOMMENDED. Replace the defective slides 7.2. Lubricate the cabinet guide and the bushings

with black grease while the bar must lubricated with standard grease.

Install the saddle on the cabinet and lock the bolt of Fig.245 with green loctite.

Install the saddle pin #5 ( 6.9 Fig.177 and 178).

Close the saddle ‘till end of the stroke. Install the bar with the slides and make the

saddle regulation 7.2. Install the tool holder assy on the machine. Install the tool holder cylinder 6.16 Install the steel oil hose. Install the mount dismount tool. Install the mobile plate on the saddle 6.6 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, steel and rubber hammers, Tool for removal of cylinder pin, Wrench adjustment of saddle clearance.

: Incorrect saddle adjustment may cause the following malfunctions:

1. Excess of saddle play. 2. Incorrect distance between tool and rim. TO CHECK THE BUSHINGS: Turn on the machine. Open the saddle ‘till end of stroke. Take a long tyre lever and lift up the saddle

(Fig. 247): if it shows a lot of play the bushings are worn and they must be replaced.

Fig.247 TO REPLACE THE SADDLE BUSHINGS: Remove the saddle from the cabinet 7.3. Remove the rings #1 from the bushings

(Fig.248). Remove the defective bushings #2 (Fig.241).

Fig.248

Install the new bushings. Insert the seeger rings. Make the hole #3 (Fig.248) for the greaser. Make sure that the bar can be easily

inserted through both bushings. If not provide to machine the bushings by using 55mm diameter tool.

Install the saddle on the cabinet 7.3. Regulate the saddle 7.2. Check if the machine works fine.

7.5 KING 5600R ROBOTIC ROTATION: CHECK AND ADJUSTEMENT

: 1h : End wrench of 30mm,Allen wrench of 4,

green loctite. : The incorrect robotic rotation may cause the

following malfunctions: 1. Incomplete mount dismount tool rotation.


2. Overstress or breakage of the lifting cylinder. TO CHECK THE ROTATION: Turn on the machine. Lift up the tool holder and perform a complete

tool rotation. The tool must ends the rotation when the

lifting cylinder is at the end of the stroke. A. If the lifting cylinder still moving after the end

of tool rotation, the bolt in holder arm bottom needs to be adjusted.

B. If the tool does not make a complete rotation when the lifting cylinder is at the end of the stroke, the bolt in holder arm bottom needs to be adjusted.

TO ADJUST THE ROTATION IN CASE OF SITUATION A: Turn on the machine. Lower the tool holder arm. Turn off the machine. Unlock the 20mm nut #1 and turn clockwise

the screw #2 of a turn (Fig.249). Tighten the 20mm nut by hands. Turn on the machine and verify if the tool

ends the rotation when the lifting cylinder is at the end of the stroke.

If not turn the screw #2 (Fig.249) ‘till the correct adjustment.

Lock the nut #2 FIRMLY.

Fig.249 TO 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 machine and verify if the tool

ends the rotation when the lifting cylinder is at the end of the stroke.

If not turn the screw #2 (Fig.243) ‘till the correct adjustment.

Lock the nut #2 FIRMLY.

Fig.250 IMPORTANT! IF THE TOOL ROTATION CANNOT BE ADJUSTED WITH THE ADJUSTEMENT SCREW, PROCEDE WITH POINTS 7.6, 7.7,

7.8. 7.6 KING 5600R ROBOTIC ROTOR: CHECK AND REPLACEMENT

: 1,5h : End wrenches of 19,24 and 30mm, Allen

wrench of 4, green loctite. : The robotic rotor may cause the following

malfunctions: 1. Excess mount dismount tool play. 2. Incomplete mount dismount tool rotation. 3. Slow or locked mount dismount tool rotation. TO CHECK THE ROTOR: IMPORTANT! BEFORE STARTING WITH ROTOR DISMOUNTING, BE SURE THAT RING NUT AND ROTATIONAL BOLT ARE WELL REGULATED 7.5 AND THE HYDRAULIC PRESSURE IS CORRECT 6.4. Turn on the machine. Lift up the hook #1 ‘till to have it in contact

with the tool holder arm #2 (Fig.220). Turn off the machine. Remove the mount dismount tool. Remove the ball bearing nut #1 (Fig. 251).


Fig.251 Remove the spring, the washer and the ball

bearing (Fig.252).

Fig.252 Remove the set screw #2 (Fig.251). Remove the ring nut (Fig.253).

Fig.253 Pull out the rotor from the holder arm together

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 broken in case of

malfunction 2 (Fig.255).

Fig.255 Check if the rotor surface or the inner holder

arm are scratched in case of malfunction 3 (Fig.255 and 256).

IMPORTANT! VERIFY IF THE LOWER CAMS OF FIG.249 ARE FINE.

Fig.256


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.257 NOTE: PAY ATTENTION BECAUSE DUE TO THE GREASE, SOME BALL BEARINGS COULD REMAIN ATTACCHED TO THE HALF RINGS AND THEY CAN DROP TO THE FLOOR. Remove the ring nut with the ball bearings

and verify if there are all 44 balls (Fig.258).

Fig.258 Take the new rotor. Insert the ring nut with the ball bearings. Install the half rings. Install the shim. Grease the rotor. Install the rotor on the holder arm by

tightening the ring nut. IMPORTANT! THE THREADED RING NUT HOLE MUST MATCH WITH THAT ONE #A ON THE HOLDER ARM THREAD (FIG.259).

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 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 following the same procedure.

Tighten the set screw #2 (Fig.251) by using loctite.

Mount the tool. Check if the machine works fine. In case of malfunction 3, remove the

scratches from rotor and inner holder arm by using file and sand paper.

Clean very accurately both parts. Grease both parts. Mount the rotor with washer following the

previous instruction. Check if the machine works fine.

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

: 3h : End wrenches of Allen wrench of 3 and

4mm, seeger pliers, steel and rubber hammer, green loctite.

: The robotic rotor may cause the following malfunctions:

1. Incomplete mount dismount tool rotation. 2. Slow or locked mount dismount tool rotation. IMPORTANT! BEFORE STARTING WITH ROTOR DISMOUNTING, BE SURE THAT RING NUT AND ROTATIONAL BOLT ARE WELL REGULATED 7.5 AND THE HYDRAULIC PRESSURE IS CORRECT 6.4. TO CHECK THE CAM:


Remove the rotor 7.6. Verify if the cams are broken 7.5 (Fig.256).

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.

Fig.260 If the spring is free, it is broken and it must be

replaced. TO REPLACE THE CAM AND THE SPRING: Turn on the machine and lift the tool holder. Turn off the machine. Remove 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 top the cam assy. Lock the cam assy on a vice and remove the

cam pin.

Replace the cam and/or the spring (Fig.262 and 263).

Fig.262 NOTE: THE OPENED END SPRING MUST FITTED ON THE CAM PIN AS SHOWN IN FIG.263.

Fig.263 Grease the cam assy and the holder arm. Insert the cam assy into the holder arm.

IMPORTANT! THE ASSY HAS TWO DIFFERENT WINDOWS SIZES (FIG.264 AND 265): IT MUST BE INSERTED INTO THE HOLDER ARM WITH THE SMALL ONE TOWARD THE TOP (FIG.266).


Fig.264

Fig.265

Fig.266 Insert the pin #3 for 1/3 of its length and with

the sign #4 (Fig.269) towards the top. Take a hook like that one of Fig.267.

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.268 Mount the stopper #2 and its screw #1

(Fig.261).

Fig.269 Mount the lower cover with bolt and lock by

the seeger ring (Fig.260). Mount the rotor 7.6. Check if the robotic assy works fine and if

necessary make the rotation adjustment 7.5.


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. Incomplete mount dismount tool rotation. TO CHECK THE CABINET TOOL HOLDER: Turn on the machine. Move the tool holder arm ‘till end of the stroke. Check if the cabinet is worn (Fig.270 and

271).

Fig.270

Fig.271 TO REPLACE THE CABINET TOOL HOLDER: Remove the lifting tool holder cylinder from

the 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 robotic rotor ring nut ( 7.6 Fig.253).

Replace the cabinet with the new one by greasing accurately the new bushing.

Tighten the ring nut #2. IMPORTANT! THE THREADED RING NUT HOLE MUST MATCH WITH THAT ONE ON THE HOLDER ARM THREAD LIKE THAT ONE OF 7.6 FIG.259. Tighten the set screw #1 by using green

loctite and verify that it moves free. Remove the screws shown in Fig.273.

Fig.273 Replace the shims (Fig.275). Tighten FIRMLY the screw of Fig.273. Mount the tool holder assy on the saddle

7.3. Mount the lifting tool holder cylinder 6.18. Adjust the bolts of Fig. 274.


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.275 Keep the tool holder assy hooked and verify

that there is no contact between cabinet and shims on all tool holder stroke.

7.9 SHUTDOWN PIN: CHECK AND REPLACEMENT

: 1h : End wrench of 22mm, Allen wrench of 4 and

5mm, rubber hammer. : 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 the hook protection 7.1. Remove the spring top cover (Fig.276).

BE SURE TO HAVE WELL HOOKED THE TOOL HOLDER IN ORDER TO UNLOAD THE SPRING UNDER THE COVER (FIG.277).

Fig.276 Remove the nut #1 and take out the screw #2

(Fig.277).

Fig.277 NOTE: WHEN REMOVING THE SCREW #2 PAY ATTENTION NOT TO DROP THE PIN INTO ROBOTIC ASSY. Remove the pin: if the lower section is

seriously worn it must be replaced (Fig.278).


Fig.278 Grease and mount the new pin. Tighten the screw #1 and the nut #2 (Fig.277)

‘till their locking and then loosening the nut #2 ‘till to have the screw #1 free to be moved by hands.

Grease and mount the spring and the cover with hook protection support, tightening their screws FIRMLY.

Check if the machine works fine. Mount the hook protection.

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

: 3h : End wrench of 13,15,17,19 and 22mm, Allen

wrenches of 4, 6 and 8mm, seeger pliers, rubber hammer.

: Worn bushings may cause the following malfunctions:

1. Excess of saddle play. 2. Incorrect distance between tool and rim. TO CHECK THE BUSHINGS: Remove the cabinet tool holder moving

6.16. Turn on the machine. Lift the robotic arm up. Handle the mount dismount tool and tilt the

assy: if it show a significant play the bushings need t be replaced.

TO REPLACE THE BUSHINGS: 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 DECISION AND CARE OR ITS DROPPING MAY CAUSE FEET INJURIES.

Remove the seeger ring #1 (Fig.279). Push out the worn bushings #2 (Fig.279).

Fig.279 Insert the new bushings by using the rubber

hammer. Lock the bushings by the seeger rings. Mount the whole assembly on the saddle. Mount the lifting cylinder. Check if the machine works fine.

7.11 BOXER KING 5600R HOOK: CHECK AND ADJUSTMENT

: 30’ : End wrench of 13,22 and 30mm, Allen

wrenches of 4mm, rubber hammer. : Incorrect hook adjustment may cause the

following malfunctions: 1. Slow or locking of the tool holder movement. 2. Difficult hook clamping to the saddle bar. NOTE: BEFORE STARTING WITH HOOK ADJUSTMENT VERIFY IF THE TOOL HOLDER ARM SCREW SUPPORT IS WELL ADJUSTED

7.16. TO CHECK THE HOOK ADJUSTMENT: Turn on the machine and lower the hook. Remove the mount dismount tool. Remove the rotational proof pin 7.9. Disconnect the lifting cylinder from the hook

6.18.


Lift and lower by hand the hook to verify that it has a slight contact with saddle bar: If the hook needs to be forced 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: Remove the nut #1 (Fig.280).

Fig.280 Push out the screw #2 for at least 7/8mm

(1/4”) (Fig.281)

Fig.281 Remove the eccentric plate #3 and #4

(Fig.280 and 281). Turns clockwise or counter clockwise one or

both eccentrics ‘till to have the adjustment above reported (Fig.282).

Fig.282 Install the eccentric plates #3 and #4. Tighten the nut #1 FIRMLY and the 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.

7.12 BOXER KING 5600R HOOK: CHECK AND REPLACEMENT

: 1h : End wrench of 13,22 and 30mm, Allen

wrenches of 4mm, rubber hammer, green loctite.

: Defective hook may cause the following malfunctions:

1. Damaging of the tool holder assy. 2. Tool holder lifting cylinder damaging. 3. No eccentrics adjustment. NOTE: BEFORE STARTING WITH HOOK ADJUSTMENT VERIFY IF THE TOOL HOLDER ARM SCREW SUPPORT IS WELL ADJUSTED

7.15. TO CHECK THE HOOK: Check the following 7.11.

TO REPLACE THE HOOK: Replace the hook following 7.11.

NOTE: VERY OFTEN THERE ARE SOME SHIMS BETWEEN THE HOOK AND ITS SUPPORT. AFTER REPLACING THE HOOK INSTALL THESE SHIMS IN THE SAME POSITION AGIN. 7.13 BOXER KING 5600 HOOK: CHECK AND ADJUSTMENT


: 30’ : End wrench of 10,13, and 30mm, tube type

wrenches of 10mm, medium screwdriver, rubber hammer.

: Incorrect hook adjustment may cause the following malfunctions:

1. Slow or locking of the tool holder movement. 2. Difficult hook clamping to the saddle bar. 3. Mechanical breakage. NOTE: BEFORE STARTING WITH HOOK ADJUSTMENT VERIFY IF THE TOOL HOLDER ARM SCREW SUPPORT IS WELL ADJUSTED

7.15. TO CHECK THE HOOK ADJUSTMENT: Lift up the tool holder assembly. Remove the mount dismount tool #1

(Fig.283). Remove the tube with spring #2 (Fig.283).

Fig.283 Lower the tool holder on the saddle bar. Remove the hook spring (Fig.284).

Fig.284 Lift and lower by hand the hook to verify that it

has a slight contact with saddle bar: If the 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 hook adjustment by following 7.11 Check the hook on five different position of

the saddle. Lift up the tool holder. Mount the hook spring. Mount the tube with spring #2 (Fig.283).

IMPORTANT! MAKE SURE TO HAVE WELL 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 : End wrench of 10,13, and 30mm, tube type

wrenches of 10mm, medium screwdriver, rubber hammer.

: Defective hook may cause the following malfunctions:

1. Damaging of the tool holder assy. 2. No eccentrics adjustment. 3. Mechanical breakage. NOTE: BEFORE STARTING WITH HOOK ADJUSTMENT VERIFY IF THE TOOL HOLDER ARM SCREW SUPPORT IS WELL ADJUSTED

7.15. TO CHECK THE HOOK:


Check the hook following 7.13. TO REPLACE THE HOOK: Replace the hook following 7.13.

7.15 SCREW SUPPORT TOOL HOLDER ARM: CHECK AND ADJUSTMENT

: 30’ : End wrenches of 22. : Incorrect screw adjustment may cause the

following malfunctions: 1. Unsuccessful hook clamping. 2. Slow or locking of tool holder arm movement. TO CHECK THE ADJUSTMENT: Turn the machine on. Move the tool holder arm from the left to right

‘till end of the stroke and verify if the screw head gets a contact with the saddle.

If there is contact the screw must be adjusted. TO ADJUST THE SCREW Turn on the machine. Lose the support screw and clamp the tool

holder (Fig.285).

Fig.285 Position the screw on the closest point to the

saddle. Turn the screw ‘till to have its head in contact

with the saddle and then turn it back ¾ of a turn (Fig.286).

Check if the hook clamps the saddle easily: if not turn the screw ¼ more of a turn in order to increase the clearance.

Fig.286 Lock firmly the nut. Move the tool holder arm to verify if the screw

is well adjusted. 7.16 KING 5600 TOOL OLDER ARM: CHECK AND REPLACEEMENT

: 3h : End wrenches 13,19,22 and 30mm, Allen

wrench of 4 and 6mm, rubber hammer. : The tool holder arm must be change in case

of mechanical breakage only. TO CHECK THE ARM: If the tool holder arm cannot be easily

clamped or if it shows mechanical breakages, it must be replaced.

TO REPLACE THE ARM: Remove the mount – dismount tool, the tube

with spring and the hook 7.13. Remove the tool holder cylinder 6.16. Take out the defective arm. Install the new arm (Fig.287). Mount the tool holder cylinder 6.16. Place the arm on the saddle guide. Move by hands the arm from left to right: if it is

hard to be moved the half –cap needs to be adapted by grinding machine (Fig.287).

Mount and make the hook adjustment 7.13. Mount the tube with spring 7.13.


Fig.287 Mount the mount – dismount tool 7.13. Adjust the tool support screws as following

(Fig.288): 1. Place the tool holder arm in vertical position. 2. Turn the screw #1 ‘till remove all clearance

between pin #2 and tool support #3. 3. Turn the screw #1 back of a ¼ of a turn and

lock FIRMLY the nut #4.

Fig.288 Adjust the lower support screws as following

(Fig.289): 1. Lock the tool holder arm on the saddle. 2. Turn the screws ‘till have them in contact with

the saddle. 3. Turn both screws back of ½ of a turn and lock

the nuts FIRMLY.

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

: 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.

: The tool holder arm must be change in case of mechanical breakage only.

TO CHECK THE ARM: If the tool holder arm cannot be easily

clamped or if it shows mechanical breakages, it must be replaced.

TO REPLACE THE ARM: Remove the mount – dismount tool. Remove the hook protection ( 6.1 Fig.140) Remove the robotic rotor 7.6. Remove the lower robotic cam 7.7. Remove the rotation proof pin 7.9. Remove the hook 7.13. Remove the cabinet tool holder moving 7.8. Remove all greasers. Take the new tool holder arm. Place the arm on the saddle guide. Move by hands the arm from left to right: if it is

hard to be moved the half –cap ( 7.16 Fig.287) and the lower support ( 7.16 Fig.288) need to be adapted by using grinding machine

Mount all greasers. Mount the cabinet tool holder moving 7.8. Mount and adjust the hook 7.13. Mount the lower robotic cam 7.7.


Mount the robotic rotor 7.6. Mount the rotation proof pin 7.9. Mount the mount – dismount tool. Make the screw support tool holder

adjustment 7.13. Mount the hook protection ( 6.1 Fig.140). Verify if the machine works fine and if all

screws are well adjusted. Grease all parts through the greasers.

7.18 MOUNT – DISMOUNT TOOL

: 1h : End wrenches 11,13mm, socket wrench

30mm, rubber hammer. : The mount – dismount tool is composed by

the hook and the bead breaker disk. 1. : The hook needs to be replaced in cases of

mechanical breakage only. 2. : The bead breaker disk may show the

following inconveniences: A. : Excess of play. B. : Mechanical breakage. TO CHECK THE BEAD BREAKER DISK: Move up and down the disk by hands. If the disk shows a considerable play, try to

reduce this play as following (Fig.290): Remove the 8mm screw #1. Remove the plate #2 . Tighten the screw #3 by using impact

machine.

Fig.290 If after tightening 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 PLATE HOLE #2 DOES NOT MATCH WITH THE 8mm THREADED HOLE, TURN THE PLATE. TO REPLACE THE BEAD BREAKER DISK: Take away the defective disk (Fig.291). Remove the washers #1 and #2 (Fig.291) Remove the hardened bushing #3 from the

disk (Fig.291). Remove the greaser. Take the new one and grease it by using

white grease. Install the greaser. Insert the bushing #3 (Fig.291). Place the disk on the hook. Place a washer #1 (Fig.291) on top of the

disk. Place a washer #2 (Fig.291) over the #1 one. Insert half screw #3 (Fig.290) Place a washer #1 (Fig.291) on the bottom of

the disk. Place a washer #2 (Fig.291) under the #1

one. Insert second half of screw #3 (Fig.290) and

tighten it. Check if the disk turns free and if there is yet

play.

Fig.291 In case the disk does not turn free, check if

one or both washers #2 (Fig.291) have been locked between the bushing 3# and the washers #2 (Fig.291).

TO REPLACE THE HOOK: Remove the disk by following the above

instructions.


Remove the pin #1 (Fig.292). Unscrew the nut #2 and remove the screw #3

(Fig.292).

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. 7.19 JAWS AND CLAWS: CHECK AND REPLACEMENT

: 30’each one. : End wrench 19 and 22mm, socket wrench

19 and 22mm, rubber hammer. : The defective jaws and claws may cause the

following inconvenience: 1. Low clamping power. TO CHECK THE JAWS AND CLAWS: Clean the jaws by using a brush and check if

their teeth are fine. If they are worn the jaw/s need to be replaced.

If the claws show 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) and take out the

jaw #3 (Fig.293). Mount the new jaw #3 (Fig.293).

NOTE: THE PIN #A (FIG.294 AND 295) MUST FITTED WITH ITS MACHINED SECTION FORWARDED TO THE TOP TO BE LOCKED BY THE JAW #2 (FIG.293).

Fig.293

Fig.294 Install the jaw #2 by tightening FIRMLY the

screw #1 (Fig.293). TO REPLACE THE CLAWS: Remove the jaws following the above

instruction. Remove the nuts #1 and #2 (Fig.295). Remove the screws #3 and #4 (Fig.295) and

take away the defective claw. Mount the new claw by fitting the screws #3

and #4 (Fig.295). Tighten the nut #2 FIRMLY (Fig.295). Tighten the nut #1 FIRMLY and then turn it

back of ½ of a turn (Fig.295). Turn on the machine and verify if it works fine.


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.

: The defective worm screw may cause the following inconvenience:

1. Noise during chuck rotation. 2. Mechanical breakage. TO CHECK THE WORM SCREW: Turn the machine off and remove the belts

5.9. Turn the machine 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 protection #2,

#3 and #4 (Fig.296).

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.297 Remove all screws #1, #2, #3, #4 and take

away the defective worm screw assy (Fig298).

IMPORTANT: PAY ATTENTION WHEN REMOVING THE WORM SCREW ASSY: SOMETIME THERE ARE SHIMS BETWEEN WORM SCREW SUPPORTS AND CHUCK ARM BRACKET.

Fig.298


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.

Tighten the screws #1, #2, #3 and #4 by hands.

Turn clockwise of a turn the screw #2 (Fig.297).

Take a tyre lever and push up the worm screw (Fig 299).

Fig.299 Take the wrench and tighten the screws #2,

#3 and #4 (Fig.298),by keeping the worm screw pushed up with the tyre lever (Fig.299).

Turn counter clockwise 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 screw #1 (Fig.298).

Lock the nut #1 (Fig.297). Remove one by one the other three 12mm

worm screw bolts and tighten them FIRMLY by using loctite and impact air gun.

Mount the chuck motor. Take the protection #2, place on it the silicon

(Fig. 300) and mount it on the worm screw.

Fig.300 Take the protection #3 and place on it the

silicon (Fig.301) and mount it on the worm screw.

Fig.301 Take the protection #4 and place on it the

silicon (Fig.302) and mount it on the worm screw.

Fig.302 Remove the silicon in excess and use it to

cover the holes on all over the worm screw assy (Fig.303 and 304).


Fig.303

Fig.304 Install the tang #1 (Fig.296). Mount the plastic pulley and the belts. Make the pulleys alignment and belts tension

following 5.9. Turn on the machine. Make the chuck running and check if the it

turns quietly. Check in four points of the chuck if there is

play between crown and worm screw. Lift the chuck arm ‘till end of the stroke. Make the chuck running and check that there

is any oil leaking through the silicon. Install the belts protection 5.9.

7.21 WORM 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.

: The defective worm screw seal may cause the following inconvenience:

1. Oil leaking. TO CHECK THE SEAL:

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.305 Lock the support on a vice and remove the

seal (Fig.306).

Fig.306 Take the new seal and place it on the support. Take a piece of wood of the same seal width

and insert the new seal in the support (Fig.307).


Fig.307 Stop to push the seal in when the wood has

reached the support. Mount the support again following 7.20

without perform any worm screw adjustment. Check if the machine works fine.

7.22 CHUCK SEAL: CHECK AND REPLACEMENT

: 6h : End wrenches 13,17,19,22mm, socket

wrench 22 and 24mm, 13mm tube type wrench, 4,10 and 12mm Allen wrenches, rubber hammer, silicon, loctite, glue.

: The defective worm screw seal may cause the following inconvenience:

1. Gear oil leaking from chuck cylinder rear flange. TO CHECK THE SEAL: Turn on the machine. If the chuck cylinder rear flange shows oil

leaking during the rotation, the 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 MORE SHIMS BETWEEN FLANGE AND CYLINDER. ALSO VERIFY IF THE HYDRAULIC OIL LEVEL IS FINE JUST TO BE SURE THAT THE OIL IS GETTING OUT IS REALLY FROM THE GEAR. TO REPLACE THE SEAL:

Remove the gear oil Remove the safety lever 5.19. Remove the worm screw assy 7.20. Remove the bigger tank. Remove the rear cylinder flange 6.14.

Remove the chuck from the arm (Fig.308) by using a fork lift.

Fig.308 Replace the chuck seal by locking the new

one with silicon in the back side (Fig.309).

Fig.309 Mount the chuck without forget to install the

shim. Mount the rear cylinder flange 6.14. Mount the big tank by placing the silicon as

shown in Fig.310

Fig.310


Mount the worm screw assy 7.20. Mount the safety lever 5.19. Mount the gear stopper by using Teflon tape. Fill the gear by using only suggested gear

reported, together with the quantity, on label stuck on top of the tank or in the user manual.

Check if the machine works fine. 8.0 TROUBLE SHOOTING FAULT 1: TURNING THE SWITCH ON THE MACHINE DOES NOT WORK AT ALL.

Check power supply cable and plug 5.1 . Check the main switch Q1 5.2. Check the circuit breaker Q2 5.3. Check the hydraulic motor cable 5.4. Check the hydraulic motor 5.5. Check the emergency switch S5 5.20. Check the shop power supply line and plug. Call GS.

FAULT 2: TURNING THE SWITCH ON THE HYDRAULIC MOTOR DOES NOT RUN WHILE THE CHUCK MOTOR WORKS NORMALLY:

Check the circuit breaker Q2 5.3. Check the hydraulic motor cable 5.4. Check the hydraulic motor 5.5. Check fuses F2 and F3 5.6. Call GS.

FAULT 3: TURNING THE SWITCH ON THE HYDRAULIC MOTOR RUNS WHILE THE MACHINE DOES NOT MAKE ANY HYDRAULIC MOVEMENT AND THE CHUCK MOTOR TURNS IN WRONG WAY:

Check the rotation way of the hydraulic motor 5.5.

FAULT 4: TURNING THE SWITCH ON THE HYDRAULIC MOTOR RUNS WHILE THE MACHINE DOES NOT MAKE ANY HYDRAULIC MOVEMENT AND THE CHUCK MOTOR TURNS IN THE CORRECT WAYS:

Check the hydraulic oil level 6.2 . Check the fuses F4,F5,F6,F7 5.11. Check the transformer T 5.10 . Check the link converter 5.12. Check 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 HYDRAULIC

MOVEMENTS BUT THE CHUCK MOTOR DOES NOT TURN AT ALL:

Check the fuses F1,F2,F3 5.6. Check the transformer T 5.10. Check the fuses F7 5.11. Check the three polar meters K1 and K2

5.13. Check the portable control cable 5.14. Check the switches S1 5.15. Check the inverter switch 5.7. Check the chuck motor cable 5.8. Check the chuck motor 5.9. Call GS

FAULT 6: TURNING THE SWITCH ON THE HYDRAULIC MOTOR RUNS BUT THE MACHINE CANNOT MAKE ANY MOVEMENT:

Check if the emergency switch S5 is pressed 5.20.

Check the fuses F1,F2,F3 5.6. Check the fuses F4,F5,F6,F7 5.11. Check the transformer T 5.10. Check the portable control cable 5.14. Call GS.

FAULT 7: THE CIRCUIT BREAKER SHUTS OFF:

Check the circuit breaker Q2 regulation 5.3. Check the hydraulic motor cable 5.4. Check the hydraulic motor 5.5. Check the shop power supply.

FAULT 8: THE CHUCK MOTOR DOES NOT TURN IN ONE DIRECTION:

Check the three polar meters K1 and K2 5.13.

Check the portable control cable 5.14. Check the switches S1 5.15. Check the chuck motor 5.9.

FAULT 9: CHUCK ARM LIFTS UP BUT IT DOES NOT LOWER:

Check if the protection is well regulated 5.19.

Check the shut off cable 5.18. Check the shut off switch S4 5.19. Check the coil connector cable 5.23. Check the coil valve 6.8. Call GS.

FAULT 10: THE CHUCK ARM LOWERS TOO SLOW:

Check the valve control speed 6.14. Check if hoses and hydraulic screws are well

cleaned.


FAULT 11: THE CHUCK ARM DROPS:

Replace the retainer valve 6.13. Check the chuck arm piston seals 6.15. On machines non CE proved replace the coil

valve 6.8. FAULT 12: THE CHUCK DOES NOT CLAMP THE WHEELS:

Check the jaws 7.19. Check the chuck cylinder pressure 6.5. Check the chuck cylinder 6.16. Check the manifold revolving 6.5. Call GS.

FAULT 13: THE MACHINE SHOWS SLOW HYDRAULIC MOVEMENTS:

Check the hydraulic oil level 6.2. Check the high pressure circuit 6.3. Check the hydraulic pump 6.7. Call GS.

FAULT 14: THE MACHINE SHOWS LOW BEAD BREAKER POWER:

Check the hydraulic oil level 6.2. Check the high pressure circuit 6.3. Check the saddle adjustment 6.6. Check saddle cylinder 6.9 and 6.10. Check saddle cylinder seals 6.9 and

6.10.

FAULT 15: THE CHUCK IS NOISY:

Check the gear oil level. Check if there is contact among pulleys and

their steel protection 5.9. Check the belts 5.9. Check motor pulley 5.9. Check if chuck motor fan 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 motor fan 5.5. Check the hydraulic motor cable 5.4. Check the hydraulic motor 5.5. Check the joints 5.5. Check the hydraulic pump 6.7. Call GS.

FAULT 17: DURING THE MOUNTING –DISMOUNTING OPERATION THE CHUCK ARM ALWAYS REQUIRES ADJUSTMENT:

Check saddle adjustment 6.6.

Check the tool holder arm 7.16 and 7.17. Check the saddle bushings 7.4. Call GS.

FAULT 18: THE MACHINE SHOWS SLOW TOOL HOLDER ARM MOVEMENT:

Check the low pressure circuit 6.4. Check tool holder cylinder 6.17. Check if the hook is well adjusted 7.11

and 7.13. Check if the screw support tool is well

adjusted 7.15. Check if the tool holder arm is fine 7.16

and 7.17. Call GS.

FAULT 19: THE ROBOTIC DOES NOT MAKE A COMPLETE ROTATION:

Check the robotic rotation 7.5. Check the robotic rotor 7.6. Check the lower robotic cam 7.7. Check the cabinet tool holder moving 7.8. Call GS.

FAULT 20: MACHINE SHOWS OIL LEAKING FROM THE GEAR BOX:

Check the tank sealing 7.21. Check the worm screw seal 7.21. Call GS.


9.0 SERVICE BULLETINS

No. : 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. This modification has entailed replacing the plant housing #4006424 with #4021819 and substituting 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 replaced by 0021798 0019084 replaced by 0021800 0019084 replaced by 0021800 0019095 replaced by 0021795

The complete hydraulic plant (Tab. 686) (excluding the motor) is interchangeable only if the connecting pipes are changed. The components of the new hydraulic plant, including the electric valves, are not interchangeable with those of the old plant, and vice versa. See Tabs. 688-689-686 enclosed.


No. : 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. This modification has entailed replacing the plant housing #4012841 with #4021819 and substituting 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 replaced by 0021798 0019083 replaced by 0021793 0019083 replaced by 0021793 0019095 replaced by 0021795 0019082 replaced by 0021794 0019082 replaced by 0021794 0019097 replaced by 0021801 0019097 replaced by 0021801

The complete hydraulic plant (Tab. 686) (excluding the motor) is interchangeable only if the connecting pipes are changed. The components of the new hydraulic plant, including the electric valves, are not interchangeable with those of the old plant, and vice versa. See Tabs. 688-690-686 enclosed.


No. : 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. The new tubeless roll differs from the former one by virtue of the bearings fitted on the rotation pin. The modification has been effected in order to improve rotation of the roll.

The new roll is interchangeable with the old one.


No. : 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. Modification is due to production reasons.

•The case, the hook, the case drive support and the double tool are interchangeable only if they are replaced with new items. •The old case assy and the new one are interchangeable.


No. : 408 Date : 29-08-00 Models Affected : BOXER KING 5600-5600R-5610-5610R-ACCU 4560-

4560MR-4450-WING 511 – Fontec 5056 – JBEG T8056 – T8056R – SUN STC 8000 – STC 8500

Subject : HYDRAULIC FLUID FILTER – INSERTION IN THE HYDRAULIC POWER UNIT

With effect from 01000398 BOXER KING 5600, ACCU 4560 12999828 BOXER KING 5600R, 4560MR 02001228 BOXER KING 5610, ACCU 4450, JBEG T8056, SUN STC 8000 10997718 BOXER KING 5610R. WING 511, JBEG T8056R, SUN STC 8500

A 25 micron delivery line hydraulic fluid filter has been installed at the base of the solenoid block #0024468. The modification 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 disconnecting the power supply. To install the filter on machines where it is not present, the spare part kits listed below must be fitted. Machine model Parts kit code BOXER KING 5600, ACCU 4560 #4024980 BOXER KING 5600R, 4560MR #4024981 BOXER KING 5610, ACCU 4450 #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.


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 modification on machines already sold.


No. : 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). 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’s length on the chuck support arm #4020214, which anyway does not have a new part number.

• The new adjustment washer is not interchangeable with the old one,

and vice versa. • The new chuck support arm #4020214 is interchangeable with the old

one, provided the new adjustment washer is used. The new washer cannot be fitted on the unmodified chuck support arms.


No. : 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. The #4012117 external diameter is 0,55 mm (0,02 inches) less 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 ones and in case of order we inform that:

• The old #4012117 is still available as a spare • The tube carry tool holder #4016501 is now ground inside and because

that it needs to be assembled only with the new #4021411 • Both tool holder, #4012117 or either #4021411 will be supplied in

combination with the cam #0012115 to guarantee the perfect matching with the cam welded on the tool holder.


BLANK PAGE


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.

Snap-on Equipment Srl unipersonale Via Provinciale per Carpi, 33 42015 CORREGGIO (RE) ITALY Tel. +39-(0)522-733489 Fax +39-(0)522-733610 E-mail: [email protected] Internet: http://www.gsboxer.com - gft... © 2010 Snap-on Equipment. - All Rights Reserved - Rev.B April 2010 P/N: TEEWH602A4

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boxer king 5600/5600r - snap-on · 7.15 screw support tool: check and adjustment pag. 120 7.16 king...

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