FB 455

REPAIR MANUAL

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USE

SWEPAC FB 455is used to pack ballast under foundations, in connection with road building, in trenches, etc. On account of the forward/reverse func-tion, the machine is very suitable for packing in tight spaces and as a complement to larger packing equipment. The infinitely variable speed control makes it possible to move with great precision and to pack without moving.

USE 3SAFETY INSTRUCTIONS 4STANDARDS 4SIGNS 5TECNICAL DATA 6METHOD OF OPERATION 6TECHNICAL DESCRIPTION 7DAILY CHECKS 8BEFORE STARTING 9STARTING 9STOPPING 9OPERATING INSTRUCTIONS 10TRANSPORTATION 10SERVICE AND REPAIR WORK 11BOLT JOINTS 11MAINTENANCE SCHEDULE 12CHANGING ENGINE OIL 13 Other maintenance of the engine 13CHANGING RUBBER DAMPER 14CHANGING THE HOOD 14

CONTENTS

CHANGING LIFTING HAWSERS 15CHECKING THE BASE PLATE 15HYDRAULIC SYSTEM 16 Changing the return oil filter 16 Changing hydraulic oil 16 Dismantling the valve block 16 Cleaning the pressure limiting valve 16 Dismantling the pressure limiting valve 17 Changing hydraulic pump, drive 17 Changing hydraulic pump, adjustment 17 Faults in the hydraulic system 18HYDRAULIC DIAGRAM 19VIBRATION ELEMENT 20 Removing upper part 22 Dismantling the upper part 22 Removing gear wheels 23 Removing actuating rod 24 Assembling vibration element 24ELECTRIC SYSTEM 26 Checking the batteries 26WIRING DIAGRAM 27

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Sound pressure level at the oper- 93 dB (A)ator’s ears, LpA

Permitted sound power level, L WA 108 dB (A) Guaranteed soundpower level, L WA 108 dB (A)

STANDARDSNoiseMeasurement in accordance with the standard EN 500-4 Rev. 1:1998, Annex C:

In accordance with the conditions in Directive 2000/14/EC, Annex VI, the following values are reported:

As the sound pressure level at the operator’s ears exceeds 85 dB (A), ear protectors must be used during operation!

Hand/arm vibrationsThe vibration acceleration was measured in accordance with the ISO 5349 standard during operation on a surface of macadam. The measurement values were translated into the maximum daily exposure time for regular usage. For additional information about vibrations, please confer the regulation AFS 2005:15 from the Swedish Work Environment Authority, effective July 1st 2005.

Exhaust EmissionsThe FB 455 meets the requirements for exhaust emissions in accordance with US-EPA stage 2.

SAFETY INSTRUCTIONS

• Before using the machine, the operator must be informed of the manufacturer’s safety instructions and instructions for use.

• The machine may only be used outdoors.

• The machine may not be used if protection and safety devices are not present or not working.

• The operator may not leave the machine unattended when the engine is on. When the vibrator is connected, the operator must be able to control the movement of the machine using the control handle and the start/stop controls. The machine may be operated only by a trained operator.

• During maintenance work or other interventions in the machine, the engine must always be off.

• Switch the engine off before adding fuel. Avoid fuel spillage and immediately wipe off any spilled fuel. Add fuel only in well ventilated areas.

• Avoid touching hot engine parts, for example the silencer.

• Before lifting the machine, check that the lifting device and its mounting are not damaged and that the rubber dampers on the base plate are undamaged and tightened.

• During transportation and storage, the fuel tank should be empty and the fuel cock switched off.

• When the machine is parked, ensure that it cannot tip over. The machine may not incline more than 20º.

• The operator must use ear protectors when working with the machine.

• The operator must ensure that no unauthorised persons are in the immediate vicinity of the machine.

FB 455

FB 455Hand/arm vibrations, m/s2 2.6

The maximum daily exposure time, h 7.4

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SIGNS

Warning Signs Machine Signs

Before use, carefully read the manual and its safety instruc-tions so that you can handle the machine safely. Ensure that the manual is always accessible.

As the sound pressure level at the operator’s ears exceeds 85 dB (A), ear protectors must be used when working with the machine to prevent hearing damage.

Engine, silencer: to avoid burns or discomfort, do not touch hot engine parts when the engine is on or when the machine has recently been used.

1. Manufacturer2. Place, country of manufacture.3. CE mark.4. Model name.5. Year of manufacture.6. Max. engine power.7. Max. weight.8. Serial number.

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FB 455

Net weight .................................463 kgBase plate, w x l ........................700 x 1080 mm Speed .........................................approximately 25 m/minPermitted inclination ................20°Centrifugal force .......................60,000 NVibration frequency ..................70 HzDrive engine ..............................Yanmar L 100AEEngine power ............................7.35 kW Engine RPM ..............................3600 RPMFuel tank volume .......................5.5 literFuel type ....................................DieselHydraulic oil volume ................38 literBattery capacity ........................30 Ah / 40 AhGenerator power ........................180 W (15 A)Oil quantity, crankcase ..............1,65 liter

FUEL and OIL RECOMMENDATIONS

Fuel ...........................................DieselEngine oil ..................................SAE10W-30Hydraulic oil .............................Viscosity Grade ISO VG 32

TECHNICAL DATA METHOD OF OPERATION

The machine consists of a base plate with a vibration element and an upper part cushioned from the base plate. The cushioning between the base plate and the upper part consists of four rubber dampers. The upper part, on which the drive engine is mounted, is also designed as a hydraulic oil tank. The control handle is placed on the upper part and cushioned with rubber dampers. The vibration element is driven and the direction of travel is changed by means of hy-draulics. The hydraulic pump, mounted on the diesel engine, supplies a hydraulic motor on the vibration element with an oil flow. The vibration element consist of two shafts on roller bearings with bias weights that are connected to gear wheels that rotate in opposite directions. One gear wheel can rotate on its shaft by means of a hydraulic cylinder. This changes the mutual phase positions of the eccentric weights and the direction of travel of the machine, and the speed is changed infinitely variably. All parts are well protected against da-mage in connection with use and transportation by a sturdy protective frame with a hood of impact-resistant polythene.

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TECHNICAL DESCRIPTION

FB 455

1. Protective hood2. Lifting eye3. Diesel engine4. Control panel5. Hydraulic tank6. Control handle7. Forward/reverse control8. Vibrator and handle heating switch

Left side view

Right side view

9. Base plate10. Rubber damper11. Vibration element12. Air filter13. Hydraulic pump14. Gas shock absorber15. Hydraulic oil filter16. Transport locking device

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Fuel CheckCheck that there is fuel in the tank. Top up if necessary.

Engine Oil Level CheckCheck the oil level in the crankcase every day. The oil must reach the edge of the filling hole when the machine is on a level surface.

Air Filter CheckThe air filter must be checked at least once every working week.

1. Filter housing2. Safety cartridge3. Filter element4. Cap

Cleaning1. Remove the cap and empty out the dust which has collected. Wipe the cap with a damp cloth.2. Carefully remove the filter element and wipe the inside of the filter housing clean.3. Blow the filter clean with dry compressed air, max. 5 bar, from the inside until no more dust comes out.

Throw the filter element away:− if it has been cleaned five times.− if it is damaged.− after 1000 operating hours or maximum 12 months.

Safety CartridgeThis is normally replaced after around 3000 operating hours or if the main filter is damaged.To replace it, remove the filter set as described above and fit a new safety cartridge.

DAILY CHECKS Oil/Fuel LeakageCheck every day that the engine is not leaking oil or fuel. If a leak is discovered, the machine may not be operated until the fault has been remedied.

Hydraulic Oil Level CheckCheck every day that the hydraulic connections do not leak or wear during operation. Check the oil level with the dipstick on the top of the tank. The level must be between “MIN” and “MAX”.

Vibration ElementCheck regularly that there is no oil leak. If you suspect a leak, check the level at the level screw on the vibration ele-ment. If necessary, add oil up to the lower edge of the level hole when the vibrator is horizontal. Seal any leaks. Note! Machines must never be operated if a leak is suspected.

Rubber DampersCheck the condition of the rubber dampers regularly. Replace damaged dampers.

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In very cold weather or if the battery capacity is low for a different reason, starting can be facilitated using the decompression handle in connection with the valve housing. Press the lever down and hold it down until the flywheel has reached its maximum RPM. Run the engine warm for around 5 minutes.

See Daily Checks on page 8.

BEFORE STARTING

STARTING

STOPPING

Open the hood.

Open the fuel cock.

Switch the main power switch, located on the instrument panel inside the protective cover, to the position “I”.

Close the hood.

Note! The vibration power switch on the handle must be in the position “vibration off” (red/green marking). Otherwise the machine cannot be started.

Switch the throttle lever (3) to the full RPM position (green marking).

Start the engine with the power switch (1). Place the knob in the central position and check that the charging and oil pressure lamps (2) light up. Then press the power switch down (green marking).

Note! Never run the starter motor for longer than 10 seconds at a time. If the engine does not start, wait 15 seconds before trying to start it again.

Switch the throttle lever (3) to idle and let the engine run for a few minutes.

Press the engine power switch (1) upwards (red marking).

Stop the engine by moving the throttle lever to the stop posi-tion (red marking).

At the End of the Day

Open the hood.

Switch off the main power switch, “O” position.

Close the fuel cock.

Close the hood.

Vibration power switch andhandle heating

Main power switch Decompression handleFuel cock

Instrument panel with;1. Engine power switch2. Control lamps for charging and oil pressure3. Throttle lever

Closed

Open

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The vibrator is started and stopped with the power switch on the handle.When the control hoop on the handle is moved backwards, the machine reverses and when the hoop is moved forwards, the machine moves forwards. The speed is controlled by how long the control hoop is activated.

The machine is only designed to be used outdoors. Work with the machine in daylight or other adequate lighting. Ballast must be wetted or naturally damp. All other use is discouraged.

Note! When moving up a slope, the machine should be reversed.The machine may not incline more than 20º when in use or parked.

Handle HeatingFor increased comfort, the machine has an electrically hea-ted handle. The handle heating is activated with the power switch on the handle and can only be used when the vibrator is connected, which prevents the heating coil from dischar-ging the battery when the machine is not being used.

OPERATING INSTRUCTIONS TRANSPORTATION

The machine is fitted with a lifting hawser that can be folded in under the hood when it is not in use.

Check before lifting that the lifting eye and its mounting on the machine are undamaged. Check also that the base plate’s rubber dampers are undamaged and firmly attached. For transportation by vehicle, the handle must be folded forwards and locked with the transport locking device. The machine must then be secured with, for example, approved straps. Note! Secure it by the base plate and not the rubber-cushioned upper part.

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SERVICE AND REPAIR WORK

For the machine to function optimally the prescribed maintenance and inspection must be carried out regularly and according to the descriptions that are provided in the maintenance schedule. After the first 100-150 hours an initial service is carried out according to the maintenance schedule. Maintenance and repair work must be undertaken by trained personnel or personnel who are well acquainted with the machine. The safety regulations must be followed.Always clean the surrounding area and the respective components before lubrication, changing filters or repairing the hydraulic system. Only use clean containers when refilling lubricant.

BOLT jOINTS

The table below indicates the torque for bolts with metric thread. It is important to check all bolts after the first50/100 working hours. The bolt joints must be tightened with a torque wrench.

BoltTightening torque

Nm 8.8-quality

Nm 10.9-quality

Nm12.9-quality

M6 9,5 13,5 16M8 23 32 38,5M10 45 63,5 76M12 78 110 133M16 192 269 322

SAFETY REGULATIONS FOR SERVICE AND REPAIR WORK

• Only personnel who are well acquainted with the machine should carry out service and repair work.

• Service personnel must ensure that there are no other persons in dangerous proximity when carrying out repair work and test runs.There is a risk of serious personal injury!

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MAINTENANCE SCHEDULE

Measure At every service

When necessary

After the first 100 hours

Every 3rd month or 200 hours

Annually or each 800 hours

After 3 years

Check fuel level p. 8Check for fuel leaks p. 8Check oil level in engine p. 8Check/clean air filter p. 8 p. 8Check battery p. 26Check that the lifting hawsers are undamaged

p. 15

Check hydraulic hoses p. 8Check hydraulic system for leaks

p. 8

Check/change rubber dampers

p. 8 p. 14

Check function of electric system

p. 27 p. 27

Check connector at the governor

p. 26

Check hydraulic system, function

sid. 19 p. 19

Check hydraulic oil level p. 8 see engine supplier’s documentation

Change engine oil p. 13 p. 13Check tightness of visible bolt joints

p. 11 p. 11

Change fuel filter see engine supplier’s documentation

Check/adjust valve clearance see engine supplier’s documentation

Check/clean injectors see engine supplier’s documentation

Check valve seats see engine supplier’s documentation

Check oil level in vibration element

p. 25

Change oil in vibration element

p. 25

Change hydraulic oil /clean hydraulic tank

p. 16

Change return oil filter p. 16Check for crack formation in base plate

p. 15

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CHANGING ENGINE OIL

Draining

- Engine oil should be kept at operating temperature when changing

- Disconnect the draining tube and move it to the side of the machine.

- Undo the draining plug and allow the oil to run into a suitable container. To speed up drainage, take out the dipstick. Dispose of the oil in accordance with environmental requirements. Refilling engine oil

- Plug the hose and secure it to the machine.- Fill up with oil through the filling hole. Volume: 1.65 l.- Check the oil level and fill when necessary.- Screw the filling plug/dipstick back in place Check that

the gasket seals properly.

Cleaning oil sieve

The oil filter is located at the bottom edge of the engine and is cleaned in connection with an oil change.- Screw out the oil sieve (1).- Rinse the sieve in diesel fuel.- Check that the gasket is intact before screwing back in

place.

Other maintenance of the engine

For other maintenance and repairs you are referred to the engine supplier’s documentation.

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CHANGING RUBBER DAMPER

The rubber damper should be changed if the metal plates come loose from the rubber element or if the rubber damper has been damaged by oil and no longer feels elastic.

- Undo the bolts that hold the rubber damper.- Lift the machine slightly.- Remove the bolts completely. NB! The bottom plate will

now become undone as well.- Position new rubber dampers- Put a drop of oil on each bolt and tighten.

NB! Make sure that the rubber damper does not twist when being installed.

Oil-damaged damper

Normal distortion The metal plate has come loose from the rubber

CHANGING THE HOOD

1. Open the hood and undo all 8 bolts with nuts (1).2. Remove the handle (2) by undoing the bolts from the

inside.3. Lift off the hood.4. Check that the rubber expanders are intact. Replace

when necessary.5. Check that the rubber strip around the hood is intact.

Replace when necessary.6. Mount the new hood on the steel frame.7. Screw in place with the 8 bolts/nuts.8. Screw the handle in place.9. Glue on the front insulation piece.

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CHECKING THE BASE PLATE

(to be carried out in connection with removal of the upper part, see Vibration element)

1. Check that there are no crack formations (a) in the base plate.

2. Check that there are no (a) indentations in the base plate.

a

b

CHANGING LIFTING HAWSERS

1. The lifting hawsers are to be changed when the outer cover is damaged.

2. Loosen the bolts using two tools.3. Lift off the worn/damaged strap.

Warning!The lifting hawser must not be reused! Used hawsers must not be refitted.

4. Replace with a new hawser.5. Fit bolts and washers.6. Tighten with a torque according to the table on page 11.

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HYDRAULIC SYSTEM

Changing the return oil filter

1. Carefully clean around the filter to ensure that no contamination gets into the hydraulic system.

2. Undo the return hose at the filter.3. Unscrew the filter unit using filter pliers.4. Check that replacement filter’s gasket is intact and clean.

Lightly lubricate the gasket.5. Screw the filter unit in place.6. Fit the return oil filter.

Dismantling the valve block

The valve block contains a pressure limiting valve and a solenoid valve for vibrations off and on.1. Lift the machine up at the front edge so that the fitting for

hydraulic oil is higher than the hydraulic oil tank to avoid oil running out.

2. Remove the hydraulic hoses.3. Unscrew the four bolts to the hydraulic pump (1).

Changing hydraulic oil

1. Remove the inspection hatch on the top of the hydraulic oil tank

2. Unscrew the draining plug (1).3. Empty out the oil through the draining hole on the bottom

of the tank.

4. Collect the oil in a suitable container and dispose of it in an environmentally appropriate manner. The hydraulic oil can be drained out of the tank by means of suction in order to speed up the process.

5. Clean the tank thoroughly inside.6. Screw the draining plug in place.7. Refill with new hydraulic oil of the same type as there

was in the system.

Only use new hydraulic oil from clean containers with sealed lids. If possible, the oil should be filtered in connection withrefilling.

When changing to another hydraulic oil, your oil supplier should advise as to which procedure is required.

Cleaning pressure limiting valve

Stoppages in the hydraulic system are often due to contamination in the pressure limiting valve.

1. Unscrew the pressure limiting valve.2. Press in the rear edge with a screwdriver.3. Check that no contamination is visible in the holes (1).4. Clean using compressed air.

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Changing hydraulic pump, adjustment

Changing hydraulic pump, drive

Dismantling pressure limiting valve

If there is more severe contamination in the valve, dismantle it and carefully wipe off the parts.

Reassemble the pressure limiting valve and reinstall.

1. Remove the return hose from the hydraulic pump (1). Hold it above tank level so that no hydraulic oil runs out. Remove the flange to which the return hose was connected.

2. Undo the hydraulic hoses.3. Remove the valve block from the hydraulic pump (four

bolts).4. Remove the four bolts to the pump flange (2).5. Check the claw coupling (3).6. Remove stop screw and plane washer (4) from the pump

unit before the pump is unfastened from the pump flange.

1. Remove the plastic cover (2)2. Remove the hydraulic hoses at the pump (1). The suction

hoses should be kept above tank level to avoid oil spillage.

3. Remove the metal cross (3) on which the hydraulic pump is located (3 bolts).

4. Remove and fit a new hydraulic pump.5. Move the adaptors and claw coupling over to the new

pump. Check that they are intact. Change damaged parts.6. Put the metal cross and pump in place.

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Faults in the hydraulic system

Two types of faults can occur in the hydraulic system:• those that arise slowly due to wear and• acute faults.

The first-mentioned are due to wear which results in reduced capacity.

Acute faults in the hydraulic system are usually due to some form of contamination stuck in a component which then functions sluggishly or becomes locked in a certain position.

A clear picture of the condition of the hydraulic system, or an indication of the cause of the fault is obtained by simultaneously measuring system pressure, drive motor revs. and vibration frequency. The soil compactor should be in operation and maintain normal working temperature. Hydraulic oil temperature 50-70° C.

The maximum pressure of the hydraulic system is preset on delivery. The set pressure is 200 bar and it can be measured at the moment of starting when the oil in the hydraulic system is cold.

The measurement is taken at the pressure gauge output on the valve block.

When the soil compactor has reached normal working temperature the pressure should be 20-40 bar lower than the system’s max. pressure.

The pressure increases proportionate with the increased load, e.g. if the soil compactor is maintaining low speed or even at a standstill during operation. When max. pressure has been reached the compactor’s speed decreases.

The rate of vibration is reduced somewhat in relation to the engine speed when the hydraulic oil temperature increases.This is due to the fact that the inner leakage in the hydraulic system’s components increases when the oil gets thinner.

Measuring the speed of the drive motor and the vibration rate is carried out by means of a strobe light with a graduated scale. Hydraulic pressure is measured using a pressure gauge connected to the pressure gauge output on the valve block. Strobe light and pressure gauge can be ordered from SWEPAC.

Engine speed ....................3,600 r/min

Vibration rate at hydraulic oil temp. approx. 50 °C ..........68–72 Hz; 4,080–4,320 r/min

Normal pressure when running, hydraulic oil temp. approx. 50 °C ..........160-180 bar

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Vibro element

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Tank

Valve block, adjustment

Return oilfilter

Solenoid valve,vibrationsON/OFF

Hydraulic motorHydraulic cylinder, forward/back

Measuringoutput

Pressure limiting valve

Hydraulic pump,adjustment

S1 = Solenoid valve, adjustment forwardS2 = Solenoid valve, adjustment back

Hydraulicpump,driving

S1

S2

HYDRAULICS DIAGRAM

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THE VIBRATION ELEMENT

Functional description

FB 455 is made up of a base plate with a vibration element and an upper part with a drive motor.

The operating handle is attached at the upper part which also houses the hydraulic oil tank. The upper part and the base plate are joined by powerful rubber dampers which absorb the vibrations. The operating handle is also attached to the upper part with rubber dampers.

The vibration element is powered by hydraulics.The diesel engine drives a hydraulic pump that supplies a hydraulic motor on the vibration element with a flow of oil.

The vibration element consists of two roller bearing shafts equipped with eccentric weights.s The shafts are linked by gear wheels that rotate against each other.

By means of a hydraulic cylinder, one of the gear wheels can be turned on its shaft and be continuously locked in various positions. The mutual phase position of the eccentric weights is then changed and the machine’s speed and direction is thus continuously changed.

A solenoid valve for starting the vibrator, a pressure limiting valve and a measuring output are collected in aseparate connection block. The solenoid valve is controlled electrically from the operating handle.

The speed and direction are controlled by means of the control hoop on the operating handle which actuates a valve block that is mounted in the engine compartment. The valve block is supplied with oil from the adjustment pump.

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1 Hydraulic motor flange2 Cylinder3 O-ring / 99.5x3 NBR 704 Gear ring5 Plug6 Cover7 Gasket8 Housing9 Clutch shaft10 Bearing bush11 Bearing bush12 O-ring / 99.5x3 NBR 7013 O-ring / 99.5x3 NBR 7014 O-ring / 24.2 x 3 NBR 7015 Ball bearing 6190016 Circlip SGH 2217 Circlip SGA 1018 Washer DIN6340 m819 Roller bearing / Nj 309EcP/c320 Roller bearing / Nj 309EcP/c3

21 Roller bearing / Nj 309EcP/c322 Shaft23 Roller bearing / Nj 309EcP/c324 Back-up ring / SS 45x55x325 Flat key / RK 6x6x30 H926 Pin27 Actuating rod28 Bolt m6S 8x20 8.8 galvanized29 Slide bearing30 Back-up ring / SS 45x55x331 Circlip / SGA 4532 Eccentric weight33 Hydraulic motor34 O-ring / 99.5x3 NBR 7035 Back-up ring / SS 45x55x336 Circlip / SGA 4537 Flat washer38 HS washer39 PUR washer

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Removing upper part

Figures in brackets refer to positions in fig on page 21.

1. Lift the machine by the lifting hawsers2. Remove the two bolts for the rubber elements in the

machine’s rear edge that secure the upper part to the plate.

3. Undo the two front bolts for the rubber elements so that the upper part can be angled slightly upwards.

4. Lift the upper part so that it is angled a few centimetres upwards at the rear edge.

5. Remove the four socket head cap screws to the hydraulic pump – the flange (1). Pull out the hydraulic motor and flange with a hard jerk, so that it comes away from the bearing fitting.

Dismantling the vibration element

CAUTIONCrushing risk! Be careful with your fingers when handling eccentric weights and shafts in the housing for the vibration element

6. Remove the hydraulic hose from the cylinder (2). Plug the hose and the adaptor on the cylinder

NB! A small amount of oil can come out of the hose. Wipe it up.

7. Remove the front bolts to the rubber elements that hold the upper part.

8. Lower the handle.9. Check that the hydraulic motor is running freely and

carefully lift off the upper part.10. Check that o-ring (3), gear ring (4) and plug (5) on the

hydraulic motor flange are undamaged. NB! Allow the o-ring to remain on the hydraulic

motor flange and the gear ring and plug to remain on the clutch shaft.

11. Clean the base plate and the housing for the vibration element.

Make sure that no contamination gets caught in the unprotected bearing race.

1. Remove the bolts for the cover (6).2. Remove and check the gasket (7) for the cover. Change

when necessary.3. Empty out hydraulic oil and clean inside the housing (8).

NB!4. It is important to mark the gear wheels so that they are in

the right position when fitting.

5. Remove the bolts for the clutch shaft’s (9) bearing bush (10). Tap carefully with a plastic hammer so that the bearing bush loosens. Check that the o-ring (34) is intact. Change when necessary.

6. Remove the bolts for the shaft’s bearing bush (11). Tap carefully with a plastic hammer so that the bearing bush loosens. Check that the o-ring (12) is intact. Change when necessary.

7. Remove the bolts for the cylinder (2). Tap carefully with a plastic hammer so that the cylinder comes loose.

8. Carefully pull out the cylinder so that the o-rings on the piston are not damaged.

9. Check that the o-ring (13) for the cylinder is intact. Change when necessary.

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10. Check that there is no damage or scratches inside the cylinder.

11. Check that the o-rings (14) on the piston are intact.12. Check that the hardened washer (18) on the actuating

rod is undamaged.13. Remove the four eccentric weights (32). NB! Each bolt has two washers. When removing the

washers make sure they do not get into the housing.

16. Remove the bearings (21) (closest to the cylinder) for the shaft (22) by tapping with a plastic mallet on the opposite side of the shaft. Check the bearings. Remove washer (35) and circlip (36).

17. Tap out the bearings (23) on the opposite side. Check the bearings. Remove washer (30) and circlip (31).

Removing gear wheels

NB! Removal of gear wheels for the clutch shaft (9) is only carried out when changing a damaged gear wheel.

1. Remove the gear wheel from the clutch shaft (9) as follows:- Remove (if necessary tap out with a plastic hammer)

the inner bearing of the roller bearing.- Remove the back-up ring (24) and check that it is

undamaged.- Remove the circlip.- Remove the circlip that is located by the gear wheel.- Put the shaft in a pipe that holds against the gear

wheel. Knock out the clutch shaft from the gear wheel. As the gear wheel is hot on the clutch shaft, it might be firmly attached. Make use of the flat key (25) that is located between the gear wheel and the clutch shaft.

- When fitting a new gear wheel, the gear wheel must be heated on.

2. Remove the gear wheel from the shaft (22) as follows:

14. Remove the bearings (19) (closest to the hydraulic motor) for the clutch shaft (9) by tapping with a plastic mallet on the opposite side of the clutch shaft. Check the bearings.

15. Tap out the bearings (20) on the opposite side. Check the bearings.

- Remove the circlip (a). See picture above. - Remove the brass washer (b). - Move the shaft through the gear wheel so that the

pin (c) is in the middle of the hole (d). - Using a mandrel, push the pin out through the

larger hole on the bearings for the gear wheel. - Pull the shaft out. - Check that the slide bearing (teflon) inside the

gear wheel bearing is undamaged. Change when necessary.

- Check that no teeth on the gear wheel are damaged. Change when necessary.

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20

19

32

a b

c

d

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CAUTIONCrushing risk! Be careful with your fingers when handling eccentric weights and shafts in the vibration element housing.

6. Screw on the four eccentric weights (32). Furnish the bolts with flat washer (37) and HS washer (38). Tighten the bolts with a torque of 133 Nm.

13. When necessary, check the piston’s bearing (15).a. Remove the circlip (16).b. Pull out the piston.c. Remove the circlip (17).d. Pull off both the piston’s bearings and inspect.

Fitting the clutch shaft (9)

1. Fit circlips and back-up ring on the clutch shaft.2. Fit bearing on the clutch shaft.3. Fit clutch shaft and gear wheel in the housing.4. Check the marking with the centre punch mark so that

the gear wheels are in the correct position in relation to each other. Mesh the gear wheels together and keep them in this position.

5. Fit the bearings for both shafts by tapping them in with a plastic hammer.

Removing the actuating rod

1. Temporarily insert the pin (26) that locks the actuating rod (27) to the shaft (22).

2. Remove bolt (28) in the rear edge of the actuating rod.3. Remove the pin.4. Pull the actuating rod out of the shaft.5. Check that the slide bearings (29) inside both ends of the

shafts are undamaged. Change when necessary.

Assembling the vibration element

Fitting the shaft (22)

1. Put the shaft (22) in the gear wheel.2. Fit actuator rod in the shaft:

a. Fit the pin (26) in the shaft and the actuating rod.b. Fit the PUR washer (39) and the washer (18) and

tighten the bolts in (28) the actuating rod.3. Fit the brass washer (b) and circlip (a). See previous

picture.4. Fit circlip (31).5. Fit washer (30).6. Check that the shaft turns easily when the actuating rod

is moved forward and back.7. Fit circlip (36) and back-up ring (35) on the shaft.8. Fit the bearing on the shaft.9. Fit the shaft with the gear wheel in the housing (8).

26

15, 16, 17

NB! When fitting the shaft bearings (19 and 21), only fit the bearings in the outer edge and then lift the shafts into place in the bearings. Then tap the bearings into place.

NB! The bearing for the clutch shaft (19) at the hydraulic motor can be put in position by temporarily fitting bea-ring bush (11) over the bearing. Tap on the bearing bush with a plastic hammer so that the bearing comes into position.

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7. Check the angles on the eccentric weights:a. Actuating rod completely extended.b. The weights should be positioned as shown in the

picture.

The picture shows the view from the cylinder and hydraulic motor side.

90°

2 cogs

Refilling oil in the vibration housing

1. Check that the bolts for the draining hole are tight. Pour hydraulic oil into the housing. The oil should come up to the lower edge of the bolts for the draining hole.

2. Fit the gasket (7) for the cover. Fit the cover (6) and tighten the bolts with a torque according to the table.

Fitting the upper part

1. Secure the upper part at the forward edge of the rubber elements. NB! Check that the bolts for the rubber elements are angled slightly downwards.

2. Check that the gear ring (4) and plug (5) are situated on the clutch shaft (9).

3. Screw on the hydraulic motor flange (1) with the hydraulic motor (33) in the housing. Tighten the bolts with a torque of 23 Nm.

4. Screw the hydraulic hose onto the cylinder (2).5. Check that the hydraulic hoses to the cylinder and the

hydraulic motor and throttle are running freely and are not able to rub against anything.

6. Affix the upper part in the rear rubber elements. Tighten the bolts for the four rubber elements.

8. Fit the bearing bushes (10 and 11). Check that the o-rings are in place. Tap in the bearing bushes with a plastic hammer. Screw on the cover with a torque according to table.

9. Carefully fit the cylinder (2) on the piston. Check that the cylinder’s o-ring (13) is in place. Tap on the cylinder with a plastic hammer so that the bearing is in the correct position. Fit the bolts and tighten them with a torque according to the table.

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ELECTRIC SYSTEM

The electric system functions with 12V current.

Depending on year of manufacture, the FB455 is available with two different battery options.

- Battery 30 Ah- Battery 40 Ah

NB!Always take the earth cable first when disconnecting the batteries. Connect the earth cable last when connecting the battery.

When using an electric welder for welding work, disconnect the battery’s earth cable. Attach the welding apparatus’s earth cable to the part that is to be welded, or in the immediate vicinity of it. If the welding current passes through a bearing it can be damaged!

Checking batteries

It is only the level of electrolyte that has to be checked on the 30 Ah battery. The electrolyte level is visible on the outside of the battery.

- Check the charge by measuring the electrolyte density:

1.28 g/cm3 = fully charged 1.20 g/cm3 = semi charged 1.12 g/cm3 = discharged

Refilling battery water

- Undo the intake hose from the engine’s air filter.- Unscrew the entire air filter unit complete with the

attachment.- Use a short, stubby screwdriver to open the battery cells

for refilling with distilled water.

Battery 40 Ah

The 40 Ah battery is maintenance-free.

General, battery maintenance

- Clean the battery, the poles and the connection cables regularly.

- Check the battery’s attachment.

Keep the battery well charged to prevent it from freezingin the winter. A flat battery freezes at temperatures as high as -10° c. A fully charged battery does not freeze until about -65° c. The battery should therefore be kept fully charged during the winter.

Inspection and maintenance of the electric system

Check that cables and connector are intact.

Clean and lubricate electrical terminals with contact spray.

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WIRING DIAGRAM

VIB

RA

TIO

NO

N/O

FF

11A

5150

SO

LEN

OID

VA

LVE

FRO

NT

SO

LEN

OID

VA

LVE

BA

CK

HA

ND

LE H

EA

TER

ON

/OFF

SWIT

CH

HA

ND

LEH

EA

TER

2 3

13A

13

HAN

DTA

G

15

5

6

1A13

4

_ + _ + 1 2 3 4 5

1A

GR

EE

N

YE

LLO

W

GR

EE

N/

WH

ITE

GR

EE

N/

WH

ITE

WH

ITE

+_

BA

TTE

RY

4 5 6

14

PO

WE

RS

WIT

CH

OIL

PR

ES

SU

RE

LIG

HT C

HA

RG

ELI

GH

T

REL

AYH

OLD

ER

7

2 2A

6A 6B

3

3

6A

12PA

NEL

4 38 9

6B

22A

11

11A

RE

DB

LAC

K

12

15 A

mp

STA

RT

BR

YTA

RE

SO

LEN

OID

VA

LVE

VIB

RA

TIO

NO

N/O

FF

o

o

STA

RTE

RM

OTO

RG

EN

ER

ATO

RC

HA

RG

ER

EG

ULA

TOR

OIL

PRES

SUR

ES

EN

SO

R

CO

NTA

CT

YA

NM

AR

o

2

o

oo

21

21

16

BUZZ

ERC

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SWEPAC INTERNATIONAL ABAddress Box 132, SE-341 23 Ljungby, phone +46 372-156 00, fax +46 372-837 41, E-mail mail@swepac.se, Internet www.swepac.se