spac100

FB 165FB 225FB 250

REPAIR MANUAL

Dok: 101495A-GB 1309

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USE

SWEPAC FB165 / FB 225 / FB 250are used to pack ballast under foundations, in connection with road building, in trenches, etc. On account of the forward/reverse function, the machine is very suitable for packing in tight spaces and as a complement to larger packing equipment in places with poor access

CONTENTS

USE............................................................... SAFETY INSTRUCTIONS.......................... STANDARDS............................................... SIGNS............................................................ TECHNICAL DATA..................................... METHOD OF OPERATION......................... FUEL and OIL RECOMANDATION........... TECHNICAL DESCRIPTION...................... DAILY CHECKS.......................................... V-belt / HYDRAULIC OIL QUANTITY...... BEFORE STARTING.................................... STARTING, petrol engine............................. AFTER STARTING...................................... STOPPING.................................................... BEFORE STARTING.................................... STARTING, diesel engine............................. MANUAL START......................................... STOPPING.................................................... OPERATING INSTRUCTIONS................... TRANSPORTATION.................................... SERVICE AND REPAIR WORK.................

34456667891010101011111212131415

MAINTENANCE SCHEDULE.............CHANGING ENGINE OIL...................CHANGING RUBBER DAMPER........CHECKING THE BASE PLATE..........CHANGING THE LIFTING EYECHANGING HYDRAULIC OILVIBRATION ELEMENTVIBRATIONSELEMENT SKETCHRemoving upper partDismantling the vibrationselementRemoving gear wheelsRemoving actuating rodAssembling vibration elementELECTRIC SYSTEMChecking the batteriesWiring diagram

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STANDARDSNoiseMeasurement in accordance with the standard EN 500-4 Rev. 1:1998, Annex C:Measurement uncertainty ± 0.5 dB (A) in 95% of the measurements.In accordance with the conditions in Directive 2000/14/EC, Annex VI, the following values are reported:

FB 225 FB 250Hatz

FB 250Yanmar

Sound pressurelevel at the operator’s ears, LpA

95 dB (A) 95 dB (A) 95 dB (A)

Permitted sound power level, L WA

108 dB (A) 108 dB (A)

Guaranteed sound power level, L WA

108dB (A) 108 dB (A)

As the sound pressure level at the operator’s ears exceeds 80 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.Measurement uncertainty ± 0.3 m/s2 in 95% of the measurements

SAFETY INSTRUCTIONS

• Before using the machine, the operator must be in-formed 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 sa-fety devices are not present or not working.

• The operator may not leave the machine unattended when the engine is on. When the vibrator is con-nected, the operator must be able to control the mo-vement 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 de-vice 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 per-sons are in the immediate vicinity of the machine.

• Always wear personal protective equipment as heavy, non-slip shoes, ear protectors and approved eye protection. • The machine may not be used in environments with potentionell fire or explosion danger. • Never use the machine if you are tired or have consumed alcohol or are under medication that could affect your vision, your discretion or you coordination ability. • Never use a machine in any way changed from the original design.

Exhaust EmissionsThe FB165 / FB 225 meet the requirements for exhaust emissions in accordance with EU Directive 2002/88EC stage 2. The FB 250 meet the requirements for exhaust emissions in accordance with US-CARB stage 1.

FB 165

91 dB (A)

108 dB (A)

105 dB (A)

108 dB (A)

108 dB (A)

FB 165 FB 225 FB 250Hatz

FB 250Yanmar

Hand/armvibrations, m/s2

The maximum daily exposuretime

2,5 2,7 2,7 2,7

8 h 6,9 h 6,9 h 6,9 h

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8MACHINERY

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

Belt drive: Keep hands, tools and other objects away from the belt drive when the machine is on to avoid injury and damage. See the safety instructions in the manual.

As the sound pressure level at the operator’s ears exceeds 80 dB (A), ear protectors must be used when working with the machine to prevent hearing damage.

Engine and 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.9. Machine type

SIGNS

Warning Signs Machine Signs

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FB 225

Net weight ............................ .....240 kgBase plate, w x l ................... .....550 x 790 mmSpeed ................................... .....approximately 25 m/minPermitted inclination ........... .....20°Centrifugal force .................. .....40.000 NVibration frequency ............. .....80 HzDrive engine ......................... .....Honda GX 270Engine power ....................... .....6.0 kWEngine RPM ........................ .....3200 RPMFuel tank volume .................. .....6 literFuel type ............................... .....Unleaded petrol, 95-98 octane

FB 250 Yanmar

Net weight ............................ .....265 kg Base plate, w x l ................... .....550 x 790 mmSpeed .................................... .....approximately 25 m/minPermitted inclination ............ .....20ºCentrifugal force .................. .....40.000 NVibration frequency ............. .....80 HzDrive engine ......................... .....Yanmar L70NEngine power ....................... .....4.5 kWEngine RPM ........................ .....3200 RPMFuel tank volume .................. .....3.5 literFuel type ............................... .....Diesel MK1Battery .................................. .....12V 40Ah

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 rubber dampers. The power is transmitted from the engine to the vibration element via a V-belt which can be adjusted with a belt tensioner. The engine V-belt pulley is fitted with an integrated centrifugal clutch, which allows the engine to be started and run idle without the vibrator being connected. The engine is well protected against damage in connection with use and transportation by a sturdy protective frame with a protective panel.

FB 250 HATZ

Net weight ............................ .....265 kg Base plate, w x l ................... .....550 x 790 mmSpeed .................................... .....approximately25 m/minPermitted inclination ............ .....20ºCentrifugal force .................. .....40.000 NVibration frequency ............. .....80 HzDrive engine ......................... .....HATZ 1B30Engine power ....................... .....4.8 kWEngine RPM ......................... .....3200 RPMFuel tank volume .................. .....3.5 literFuel type ............................... .....Diesel MK1Battery .................................. .....12V 40Ah

FB 165

Net weight ............................ .....160 kgBase plate, w x l ................... .....430 x 720 mmSpeed ................................... .....approximately 25 m/minPermitted inclination ........... .....20°Centrifugal force .................. .....32.000 NVibration frequency ............. .....79 HzDrive engine ......................... .....Honda GX 200Engine power ....................... .....4,9 kWEngine RPM ........................ .....3150 RPMFuel tank volume .................. .....3.6 literFuel type ............................... .....Unleaded petrol, 95-98 octane

FUEL and OIL RECOMMENDATIONS

Fuel FB165 / FB225..........Unleaded petrol 95-98 octaneFuel FB250.........................DieselEngine oil .............................SAE 10W-30Engine oil change petrol engine: first oil change after 20 hours then every 100 hours of operation.Oil quantity, crankcase FB165............0,5 liter FB225............1 literEngine oil change diesel engine: first oil change after 50 hours then every 200 hours of operation. Oil quantity, crankcase FB250Yanmar...........1 liter FB250Hatz................1 liter

Hydraulic oil ........................ ......HydraWayBIO PA 22Quantity FB165....................1,65 liter FB225....................1,65 liter FB250....................1,65 liter

Oil type/quantity, vibration unit........SAE10W-30 FB165................0,3 liter FB225, FB250...0,4 liter

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TECHNICAL DESCRIPTION

1. Control handle2. Forward/reverse control3. Lifting eye4. Centrifugal clutch5. V-belt6. Vibration element7. Base plate8. Rubber damper9. Engine plate10. Petrol engine / diesel engine11. Transport locking device12. Throttle lever

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Yanmar1

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DAILY CHECKS

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.

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.

Air Filter CheckThe air filter must be checked at least once every working week. When working in dusty conditions, check daily.

1. Paper element2. Foam plastic element

Cleaning1. Remove the foam plastic element and the paper ele-

ment and check that they are undamaged. Replace damaged parts.

2. Wash the foam plastic element in liquid with a high flashpoint and let it dry properly. Dip in engine oil and squeeze dry.

3. Strike the paper element against a hard object a few times to loosen any dirt.

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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”. Fill up when required.

V-belt DriveCheck the tension and condition of the V-belt regularly. Replace a damaged V-belt with the new type B 35 for FB 225 / FB250Yanmar, B34 for FB250Hatz and B33/B34 for FB165.

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

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OnOff OpenClosed

Throttle lever FB 225Fuel cock

Oil level Engine power switch

Choke

See Daily Checks on page 8.

BEFORE STARTING

STARTING – Petrol Engine, FB 225

AFTER STARTING

STOPPING

Switch the engine power switch to “1”.

Open the fuel cock.

Switch the throttle lever to “MIN”.

Adjust the choke. If the engine is cold, close the choke completely. Do not use the choke if the engine is warm or if the air temperature is high.

Start by pulling the starting handle. Pull it first until the mecha-nism engages. Then pull it hard and fast.

Switch the throttle lever to idle.

Open the choke gradually.

Run the engine warm for around 5 minutes.

Switch the engine to idle and let it run for a few minutes.

Switch the engine power switch to “0”.

Close the fuel cock.

Throttle lever FB 165Full RPM Idle

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See Daily Checks on page 8.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.

BEFORE STARTING

STARTING – FB 250 HATZ (Electrical Starter)

Switch the throttle lever to “MIN”. A whistle signal is heard when the key is turned to the ignition position.Indicator light for battery charging lights up. Push in the key and turn it. The key springs back after starting.

Fuel cockCharging lamp and engine start switch

Closed

Open

Charging lamp and engine start switch(key)

Throttle lever

FB 250 Yanmar

Open the fuel cock.Switch the engine power switch to “1”.Switch the engine to the idle position idle.Push the start button.

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Decompression handle

Throttle lever Charging lamp and engine start switch

Charging lamp and engine start switch(key)

Handstart HATZ

Turn the key to the ignition position. Pull the starter cord as far as it will go. Let the cord go back in.

Handstart Yanmar

Press the decompression handle down. The handle must remain in the depressed position. Switch the engine power switch to “1”. Take hold of the starter cord with both hands and pull hard. In very cold weather or if the battery capacity is low for a different reason, starting can be facilitated using the decompression device in connection with the valve housing. Press the lever down and hold it down until the flywheel has reached its maximum RPM. Then let it go.

STOPPING

Switch the engine to the idle position idle, let it run for a few minutes, then switch it to stop.

YanmarNever switch the engine off with the decompression handle. Switch the engine power switch to “0”.Close the fuel cock.

HATZTurn the key. A whistlesignal is heard if the key is in the ignition position.

Manual start

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OPERATING INSTRUCTIONS

The machine’s vibration elements start when the throttle is increased. The best packing is achieved at full engine RPM. Avoid running the engine at other RPM. The machine’s vibration element stops when the throttle lever is switched to stop.

To move forwards, do not touch the forward/reverse control. To reverse, pull the hoop towards the control handle.

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.

Reversing

Moving forwards

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TRANSPORTATION

The machine has a lifting eye that can be used for a hook or hawser.

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.

Handle heaterFB 250 has a heated handle for increased comfort. Push the button (1) to activate the heated handle.

Polyuretan PadA polyuretan pad is used for stone paving work to protect against stones and ground clinker

Transport locking

Secure the machine with straps accorrding to illustration during transportationNote! 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.

Maintenance and repair work must be undertaken by trained personnel or personnel who are well acquainted with the machine. Safety regulations must be complied with.

Always clean the area surrounding each component before lubrication, filter change or hydraulic system repair work. Use only clean containers when refilling lubricant.

BOLT JOINTS

The table below indicates the torque for bolts with metric thread. All values are in Nm.It is important to inspect all bolts monthly or after the first 100 hours of operation.The bolt joints must be tightened using a torque wrench.

M5 5,7 8,1 9,7M6 9,8 13 9,8 14 17M8 9,8 14 31 24 33 40M10 24 33 61 47 65 79M12 47 65 100 81 114 134M16 195 277 333

Metric fine threads

ThreadVibrations insulator

Press threads

MF6SK6SMEL6S8.8-10.9

M6SFM6SZM6MF HS N-L

8.8 10.9 12.9

SAFETY REGULATIONS FOR SERVICE AND REPAIR WORK

• Only personnel who are well acquainted with the machine are allowed to 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 for serious personal injury!

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UNDERHÅLLSSCHEMA

MeasureDAILY

Fuel level XFuel leaks XOil level in engine XAir filter XBelt pulley XBattery XLifting device XHydraulic system leaks / level XHydraulic oil level XRubber dampers XCheck function of electric system

X

Check function of hydraulic system

X

Change engine oil, bensin engine

First change after 20 hours

X

Change engine oil, diesel engine

First change after 50 hours

X

Check tightness of visible bolt joints

X

Drain fuel tank, diesel XCheck/adjust valve clearance, diesel

X

Cleaning fuel filter XChange fuel filter, diesel XCheck injection angle, diesel XCheck / spark plugg, bensin X

Check / change the cylindric pin

X

Check / change O-ring on the piston

X

Change hydraulic oil X

EVERY MONTH/100 HOURS

EVERY 3 rd MONTH /200 HOURS

EVERY 6 rd MONTH /400 HOURS

YEARLY AFTER 3 YEARS

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CHANGING ENGINE OIL

Draining

- The engine oil should be kept at operating temperature when changing.

- Loosen the drainage pipe and move it to the side of the machine.

- Remove the draining plug and allow the oil to run into a suitable container. Loosen the dipstick to speed up drainage. Dispose of the oil in line with environmental regulations.

NB! The oil draining process is the same for all types of engines.

Cleaning the oil sieve - FB 250 Yanmar / Hatz

The oil filter is located at the bottom of the engine and is cleaned when changing oil.- Screw out the oil sieve (1).- Rinse the sieve in diesel fuel.- Check that the gasket is intact before screwing the

sieve in place.

Refilling engine oil

- Plug thedrainage pipe and secure it to the machine.- Fill up with oil through the filling hole. Oil volume: See page 6.- Check the oil level and fill when necessary.- Screw the filling plug/dipstick back in place. Make

sure the gasket seals tightly.

Other engine maintenance

For other maintenance and repairs, please refer to the documentation provided by the engine supplier.

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REPLACING RUBBER DAMPERS

The rubber damper must be replaced if the metal plates separate from the rubber unit or if the rubber damper has become oil damaged, and is no longer fully elastic.

Normal distortionThe metal plate has separated from the rubber unit.

Oil-damaged damper

- Loosen the bolt that keeps the rubber damper in place.

- Lift the machine slightly.- Remove the bolts completely. NB! The base plate

will come undone also.- Put the new rubber dampers in place.- Put a drop of oil on each bolt and tighten. NB! Make sure the rubber damper does not twist out of place when fitting it.

INSPECTION OF BASE PLATE

(performed when the upper part is removed, refer to Vibration element)

1. Check for any cracks (a) in the base plate.2. Check for any indentations (b) in the base plate.

REPLACING THE LIFTING EYE

1. The lifting eye is replaced if it becomes damaged.

2. Remove the bolts using two tools.3. Lift off the worn/damaged eye.

4. Replace with a new eye.5. Screw back all bolts and nuts.6. Tighten these according to the torque table on page 11.

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Changing hydraulic oil

1. Remove the dipstick (1) on the top of the hydraulic oil tank.

2. Unscrew the hydraulic oil hose (2) at the pump as outlined in

the illustration below.

3. Collect the oil in a suitable container and dispose of it in an environmentally appropriate manner.

The hydraulic oil can be sucked from the tank to speed up the process.

4. Make sure the tank is free from dirt.5. Refill with a similar hydraulic oil to that already in

the system.

Use only a new hydraulic oil from a clean container with a sealed lid. Filter the oil, if possible when refilling.

When changing to another hydraulic oil, the oil supplier is obliged to indicate the required procedure.

HYDRAULICS DIAGRAM

1) Hydraulic motor reset2) Pressure limiting valve, 20 BAR3) Hydraulic cylinder Front/Back4) Manual valve block reset

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THE VIBRATION ELEMENT

Functional description

The machine consists of a base plate with a vibration element and an upper part fitted with an engine. The operating handle is fitted to the upper part. The upper part and the base plate are linked together with a robust rubber damper, which absorbs the vibrations. The operating handle is also fitted to the upper part with rubber dampers.

The power is transmitted from the engine to the vibration element via a V-belt, which can be adjusted with a belt tensioner. The engine V-belt pulley is fitted with an integrated centrifugal clutch, which allows the engine to be started and run idle without the vibrator being connected.

The vibration element consists of two roller bearing shafts fitted with eccentric weights. The shafts are linked through cog wheels that rotate against each other.

One of the cog wheels can, with the help of a hydraulic cylinder, be turned on its shaft and can be variably locked in different positions. The mutual phase position of the eccentric weights is altered as a result and the speed of the machine and direction is variably altered.

Speed and direction are controlled using the control hoop on the operating handle, which interacts with a valve block that is mounted on the handle. The valve block is supplied with oil from the adjustment pump that is fitted tothe vibration element.

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46

55

1 1217

2216

40

15

57

43 30

2725 20

19

2356

36 37

5039 31 5

35

33 34 36 37

6 7

27

32

53

13

5417

49

27

44145

2

58

5238

110

59 11 9

29

14

41 42

48

26

26

18

47

21

4 8

4 8

4 8

47

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24

28

51

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1 BOLT / M6S 8x20 8.8 fzb; 2 BOLT / M6SZ 6x16 fzb; 3 BOLT / M6SZ 8x25 8.8 fzb; 4 BOLT / MC6S 8x25 8.8 fzb; BOLT / MC6S 8x20 8.8 fzb5 BOLT / MS6SS 4x6 SS; 6 BOLT / MC6S 6x20 8.8 fzb; 7 WASHER / BRB 6,4x12 HB200 fzb; 8 WASHER / BRB 8,4x16 HB200 fzb; 9 BRICKA / BRB 10,5x22 HB200 fzb; 10 WASHER / SRKB 9x35x3 HB200 fzb; 11 WASHER / HS10; 12 WASHER / HS 8; WASHER / HS 613 CYLINDRIC PIN Ø8; CYLINDRIC PIN Ø6 14 FLAT KEY / RK 6x6x30 H9; 15 FLAT KEY / RK 10x8x36; FLAT KEY / RK 10x8x3016 CIRCLIP / SGA 45; CIRCLIP/ SGA 4017 CIRCLIP / SGA 40;CIRCLIP / SGA 3518 CIRCLIP / SGA 50; CIRCLIP / SGA 4519 CIRCLIP / SGH 22; 20 CIRCLIP / SGA 10; 21 FLAT KEY / RK 6x6x16; FLAT KEY / RK 6x6x1022 INNERRING / LRT 20x25x17; 23 ROLLER BEARING NJ 308ECP/C3; ROLLER BEARING NJ 306ECP/C324 SLIDE BEARING 00000299; 25 BALL BEARING / 61900; 26 SLIDE BEARINGPG 40 44 05 F; WASHER27 O-RING / 89,5x3 NBR 70; O-RING / 72,0x3 NBR 7028 RADIAL SEALING 25x35x6 CCP VITON; 29 O-RING / 22,22x2,62 NBR 70; 30 O-RING / 24,2x3 VITON;31 GEAR RIMROTEX 9-99;

32 PLUG R3/8” 7503-00-06; PLUG R1/4” 7503-00-0433 COUPLING /R1/4” UF-R1/4”UF; 34 RUBBER/STEEL WASHER R1/4”; 35 HYDRAULIC PUMP; 36 COUPLING G1/4 UF x M14 x 1,5UF;37 RUBBER/STEEL WASHER M14; 38 BELT PULLEY ; 39 CLAW COUPLING ; 40 COG WHEEL ; 41 LOCK; 42 SEAL;43 PISTON ; 44 WASHER DIN6340 M8;45 WASHER ; 46 SHAFT ; 47 COG WHEEL; 48 CONTROLL SLEEVE; 49 BEARING CAP; 50 BEARING CAP; 51 SHAFT; 52 BEARING CAP; 53 CONTROL ROD ; 54 WASHER ; 55 CYLINDER; 56 HOUSING; 57 WEIGHT; 58 LOCK;59 SKRUV / MC6S 10x48 12,9; BOLT/ MC6S 10x40 12,9

FB225-FB250 FB165 FB225-FB250 FB165

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Removing upper part

Numbers in brackets refer to positions in figure on page 22, as well as for the other clarifying illustrations.

1. Remove belt guard, loosen the belt tensioner and remove the belt. Lift the machine slightly using the lifting eye.

2. Remove the four bolts for the rubber units that secure the upper part to the base plate.

3. Lift the upper part approximately 5 cm.4. Remove the hydraulic hose from the cylinder (55). Plug the hose and the coupling on the cylinder, 3/8 plug for the FB225 and the FB250 models and a 1/4 plug for

FB165.5. Remove the four hex socket bolts for the hydraulic motor

- the flange (50). Pull out the hydraulic motor and flange with a hard jerk, so that it comes away from the bearing fitting.

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

6. Tilt down the handle.7. Check that the hydraulic motor has come free and carefully

lift off the upper part.8. Check that the o-ring (27) and sprocket (31) on the

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

flange and the sprocket on the pump.9. Clean the base plate and the housing for the vibration

element. Make sure that any dirt does not get into the unprotected

bearing race.

Dismantling the vibration element

CAUTIONRisk of crushing!

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

1. Remove the bolts for the cover (41).2. Check the gasket (42) for the cover. Replace if

necessary.3. Empty out the 10W 30 oil and clean inside the

housing (56).

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 cylinder (55). Tap carefully with a plastic hammer so that the cylinder loosens.6. Carefully pull out the cylinder so that the o-rings on the piston are not damaged.7. Check that the o-ring (27) for the cylinder is intact. Replace if necessary.8. Check that there is no damage or scratches inside

the cylinder.9. Check that the o-rings (30) on the piston are intact

and that the piston is not worn.10. Check that the PUR washer (39) on the actuating

rod is undamaged.11. Remove the four eccentric weights (57). NB! Each bolt has two washers. When removing

the washers, make sure they do not fall into the housing.

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9

Disassembly of the vibration element

1. Remove the cover (58) from the transmission cap (52). Disassemble the V-belt pulley and the key. Remove the five bolts for the transmission cap. Pull out the transmission cap carefully. Check that the o-ring (27) for the transmission cap is intact. Check that the O-ring for the transmission cap is intact. Replace if necessary.2. Press out the bearing (a). Press at ”A”.3. Press out the bearing (b). Press at ”B”.4. Remove the shafts (46, 51) with the cog wheels still on the shafts.

Removing cog wheels clutch shaft

NB! Removal of cog wheels for the clutch shaft (46) is only carried out when changing a damaged cog wheel.

1. Remove the cog wheel from the clutch shaft (46) as follows:- Remove (if necessary, tap out with a plastic

hammer) the inner bearing of the roller bearing.- Remove the circlip.- Remove the circlip that is located by the cog

wheel.- Put the shaft in a pipe that presses against the cog

wheel. Knock out the clutch shaft from the cog wheel. As the cog wheel is hot on the clutch shaft, it can be hard to remove. Keep track of the flat key (25) that is located between the cog wheel and the clutch shaft.

- When fitting a new cog wheel, it must be heated on.

2. Remove the cog wheel from the control shaft (51) as follows:- Remove the circlip (a). See figure above.- Move the shaft through the cog wheel so that the

pin (c) is in the middle of the hole (b).- Using a punch, push the pin out through the larger

hole on the bearings for the cog wheel.- Pull the shaft out.- Check that the bushing (teflon) inside the

cog wheel bearing is undamaged. Replace if necessary.

- Check that the teeth on the cog wheel are intact. Replace if necessary.

3. When necessary, check the piston’s bearing (25).a. Remove the circlip (19).b. Pull out the piston.c. Remove the circlip (20).d. Pull off both the piston’s bearings and inspect

them.

Removing the actuating rod

1. Temporarily insert the pin (13) that locks the actuating rod (53) to the shaft (51).

2. Remove bolt (1) in the rear end of the actuating rod.

3. Remove the pin.4. Pull the actuating rod out of the shaft.5. Check that the slide bearings (24) inside both

ends of the shafts are undamaged. Replace if necessary.

Removing cog wheels control shaft

24

FB165 / FB 225 / FB 250

90°

0 till 1 kugg

Dok

: 101

495A

-GB

130

9

Assembling the vibration element

Fitting the shaft (51)

1. Put the shaft (51) in the cog wheel.2. Fit actuating rod in the shaft:

a. Fit the pin (13) in the shaft and the actuating rod.b. Fit the PUR washer (45) and the washer (44) and

tighten the bolts (1) in the actuating rod.3. Fit the circlip (a). See the previous figure.4. Fit the circlip (17).5. Fit the washer (54).6. Check that the shaft turns easily when the actuating

rod is moved back and forth.7. Fit the circlip (17) on the shaft.8. Fit the bearing on the shaft.9. Fit the shaft with the cog wheel in the housing (56).

Fitting the clutch shaft (46)

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

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

5. Fit the bearings for both shafts by tapping them in with a plastic hammer.NB! When fitting the shaft bearings (23), 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 (46) at the hydraulic motor can be put in position by temporarily fitting the bearing cap (52) over the bearing. Tap on the bearing cap with a plastic hammer so that the bearing fits into place.

CAUTION

Risk of crushing!Be careful with your fingers when handling eccentric weights and shafts in the housing for the vibration element.

6. Screw the four eccentric weights back in place (57). Fit the

bolts with a flat washer (9) and a HS washer (11). Tighten the bolts with a torque of 79 Nm.

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

figure.

The figure shows the view from the cylinder and hydraulic motor end.

8. Fit the bearing caps (49 and 52). Check that the o-rings are in place. Tap in the bearing caps with a plastic hammer. Screw on the cap with a torque according to the table.

9. Carefully fit the cylinder (55) on the piston. Check that the cylinder’s o-ring (27) 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.

Refilling oil in the vibration housing

1. Check that the bolts for the drainage hole are tight. Fill the housing with 10W-30 oil. Refer to the table on page 3 for the correct oil volume.

2. Fit the gasket (42) for the cover. Fit the cover (41) and tighten the bolts with a torque according to the table.

Fitting the upper part

1. Secure the upper part at the front edge of the rubber units.

NB! Check that the bolts for the rubber units are angled slightly downwards.

2. Check that the sprocket (31) is positioned on the clutch shaft (46).

3. Screw on the hydraulic motor flange (50) with the hydraulic motor (35) in the housing. Tighten the bolts with a torque of 23 Nm.

4. Screw on the hydraulic hose for the cylinder (55).5. Check that the hydraulic hoses to the cylinder and the

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

6. Fix the upper part to the rear rubber units. Tighten the bolts for the four rubber units.

25

FB 165 / FB 225 / FB 250 D

ok: 1

0149

5A-G

B 1

309

+

STARTSWITCH

63

7

2

8

5

-CHARGING LAMP

OILPRESSURELAMP

-

+

PANEL

BUZZER

MAIN SWITCH

4 PIN CONTACTFROM THE CABEL SIDE

CABEL 1

CABEL 8

CABEL 9

CABEL 7

CABEL 11

CABEL 4CABEL 2

CABEL 3

CABEL 5CABEL 10

HANDLE HEAT ON / OFF

3

2

HANDLE HEAT

HANDLE

CABEL 6

ENGINE

CABEL 303127

Oilpressure sensor

WIRING DIAGRAM FOR THE FB250 YANMAR MACHINE

ELECTRIC SYSTEM

The electric system functions with 12V current.

- 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!

Inspection and maintenance of the electric system

Check that cables and connector are intact.Clean and lubricate electrical terminals with contact spray.

Checking batteries

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.

SWEPAC ABAddress Blockvägen 3, 341 32 Ljungby, Sweden, tel. +46 (0)372-156 00, fax +46 (0)372-837 41, E-mail mail@swepac.se,

Internet www.swepac.se