FB 165 FB 225 FB 250 REPAIR MANUAL. spac100. Dok: A-GB 1309

Transcription

1 FB 165 FB 225 FB 250 REPAIR MANUAL spac100

2 FB165 / FB 225 / FB 250 2

3 FB 165 / FB 225 / FB 250 USE SWEPAC FB165 / FB 225 / FB 250 are 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... 4 SIGNS... 5 TECHNICAL DATA... 6 METHOD OF OPERATION... 6 FUEL and OIL RECOMANDATION... 6 TECHNICAL DESCRIPTION... 7 DAILY CHECKS... 8 V-belt / HYDRAULIC OIL QUANTITY... 9 BEFORE STARTING STARTING, petrol engine AFTER STARTING STOPPING BEFORE STARTING STARTING, diesel engine MANUAL START STOPPING OPERATING INSTRUCTIONS TRANSPORTATION SERVICE AND REPAIR WORK MAINTENANCE SCHEDULE CHANGING ENGINE OIL CHANGING RUBBER DAMPER CHECKING THE BASE PLATE CHANGING THE LIFTING EYE 18 CHANGING HYDRAULIC OIL 19 VIBRATION ELEMENT 20 VIBRATIONSELEMENT SKETCH 21 Removing upper part 22 Dismantling the vibrationselement 22 Removing gear wheels 23 Removing actuating rod 23 Assembling vibration element 24 ELECTRIC SYSTEM 25 Checking the batteries 25 Wiring diagram 25 3

4 FB165 / FB 225 / FB 250 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. 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. STANDARDS Noise Measurement in accordance with the standard EN 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: Sound pressure level at the operator s ears, LpA Permitted sound power level, L WA Guaranteed sound power level, L WA FB 225 FB 250 Hatz FB 250 Yanmar 95 db (A) 95 db (A) 95 db (A) 108 db (A) 108 db (A) 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 vibrations The 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 Measurement uncertainty ± 0.3 m/s2 in 95% of the measurements Hand/arm vibrations, m/s 2 The maximum daily exposure time FB db (A) 108 db (A) 105 db (A) FB 165 FB 225 FB 250 Hatz Exhaust Emissions The 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 db (A) 108 db (A) FB 250 Yanmar 2,5 2,7 2,7 2,7 8 h 6,9 h 6,9 h 6,9 h 4

5 FB 165 / FB 225 / FB 250 SIGNS Warning Signs Machine Signs 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. 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. 9 8 MACHINERY Manufacturer 2. 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 4 5 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. 5

6 FB165 / FB 225 / FB 250 TECHNICAL DATA FB 165 Net weight kg Base plate, w x l x 720 mm Speed...approximately 25 m/min Permitted inclination...20 Centrifugal force N Vibration frequency...79 Hz Drive engine...honda G 200 Engine power...4,9 kw Engine RPM RPM Fuel tank volume liter Fuel type...unleaded petrol, octane FB 225 Net weight kg Base plate, w x l x 790 mm Speed...approximately 25 m/min Permitted inclination...20 Centrifugal force N Vibration frequency...80 Hz Drive engine...honda G 270 Engine power kw Engine RPM RPM Fuel tank volume...6 liter Fuel type...unleaded petrol, octane FB 250 Yanmar Net weight kg Base plate, w x l x 790 mm Speed...approximately 25 m/min Permitted inclination...20º Centrifugal force N Vibration frequency...80 Hz Drive engine...yanmar L70N Engine power kw Engine RPM RPM Fuel tank volume liter Fuel type...diesel MK1 Battery...12V 40Ah 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. FUEL and OIL RECOMMENDATIONS FB 250 HATZ Net weight kg Base plate, w x l x 790 mm Speed...approximately 25 m/min Permitted inclination...20º Centrifugal force N Vibration frequency...80 Hz Drive engine...hatz 1B30 Engine power kw Engine RPM RPM Fuel tank volume liter Fuel type...diesel MK1 Battery...12V 40Ah Fuel FB165 / FB225...Unleaded petrol octane Fuel FB250...Diesel Engine oil...sae 10W-30 Engine oil change petrol engine: first oil change after 20 hours then every 100 hours of operation. Oil quantity, crankcase FB ,5 liter FB liter Engine 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 22 Quantity FB ,65 liter FB ,65 liter FB ,65 liter Oil type/quantity, vibration unit...sae10w-30 FB ,3 liter FB225, FB ,4 liter 6

7 FB 165 / FB 225 / FB 250 TECHNICAL DESCRIPTION FB 165 / FB 225 / FB Control handle 2. Forward/reverse control 3. Lifting eye 4. Centrifugal clutch 5. V-belt 6. Vibration element 7. Base plate 8. Rubber damper 9. Engine plate 10. Petrol engine / diesel engine 11. Transport locking device 12. Throttle lever

8 FB165 / FB 225 / FB 250 DAILY CHECKS Fuel Check Check that there is fuel in the tank. Top up if necessary. Engine Oil Level Check Check 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 Check The air filter must be checked at least once every working week. When working in dusty conditions, check daily. Honda 1. Paper element 2. Foam plastic element 1 2 Oil/Fuel Leakage Check 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. Yanmar 1 2 HATZ spac102 Cleaning 1. Remove the foam plastic element and the paper element 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. 8

9 FB 165 / FB 225 / FB 250 V-belt Drive Check 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. Hydraulic Oil Level Check Check 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 MA. Fill up when required. Rubber Dampers Check the condition of the rubber dampers regularly. Replace damaged dampers. spac101 9

10 FB165 / FB 225 / FB 250 spac103 Oil level Engine power switch Off On Fuel cock Closed Choke Open Throttle lever FB 225 Full RPM Idle Throttle lever FB 165 BEFORE STARTING AFTER STARTING See Daily Checks on page 8. STARTING Petrol Engine, FB 225 Switch the engine power switch to 1. Switch the throttle lever to idle. Open the choke gradually. Run the engine warm for around 5 minutes. 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 mechanism engages. Then pull it hard and fast. STOPPING Switch the engine to idle and let it run for a few minutes. Switch the engine power switch to 0. Close the fuel cock. 10

11 FB 165 / FB 225 / FB 250 Closed Open spac108 spac104 Fuel cock Charging lamp and engine start switch spac105 spac107 Throttle lever Charging lamp and engine start switch(key) BEFORE STARTING 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. 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. 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. 11

12 FB165 / FB 225 / FB 250 spac104 spac105 spac107 Throttle lever Charging lamp and engine start switch Charging lamp and engine start switch(key) Decompression handle Manual start spac106 Handstart HATZ STOPPING Turn the key to the ignition position. Pull the starter cord as far as it will go. Let the cord go back in. Switch the engine to the idle position idle, let it run for a few minutes, then switch it to stop. 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. Yanmar Never switch the engine off with the decompression handle. Switch the engine power switch to 0. Close the fuel cock. HATZ Turn the key. A whistlesignal is heard if the key is in the ignition position. 12

13 FB 165 / FB 225 / FB 250 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. NOTE! When moving up a slope, the machine should be reversed. The machine may not incline more than 20º when in use or parked. To move forwards, do not touch the forward/reverse control. To reverse, pull the hoop towards the control handle. Reversing Moving forwards spac110a spac110b 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. 13

14 FB165 / FB 225 / FB 250 Handle heater FB 250 has a heated handle for increased comfort. Push the button (1) to activate the heated handle. TRANSPORTATION The machine has a lifting eye that can be used for a hook or hawser. 1 spac109 Polyuretan Pad A polyuretan pad is used for stone paving work to protect against stones and ground clinker 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. Transport locking Secure the machine with straps accorrding to illustration during transportation Note! Secure it by the base plate and not the rubbercushioned upper part. 14

15 FB 165 / FB 225 / FB 250 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. Vibrations Thread insulator Press threads Metric fine threads MF6S K6S MEL6S M6SF M6SZ M6MF HS N-L M5 5,7 8,1 9,7 M6 9,8 13 9, M8 9, M M M 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! 15

16 FB165 / FB 225 / FB 250 UNDERHÅLLSSCHEMA Measure DAILY EVERY MONTH/100 HOURS EVERY 3 rd MONTH /200 HOURS EVERY 6 rd MONTH /400 HOURS YEARLY AFTER 3 YEARS Fuel level Fuel leaks Oil level in engine Air filter Belt pulley Battery Lifting device Hydraulic system leaks / level Hydraulic oil level Rubber dampers Check function of electric system Check function of hydraulic system Change engine oil, bensin engine First change after 20 hours Change engine oil, diesel engine First change after 50 hours Check tightness of visible bolt joints Drain fuel tank, diesel Check/adjust valve clearance, diesel Cleaning fuel filter Change fuel filter, diesel Check injection angle, diesel Check / spark plugg, bensin Check / change the cylindric pin Check / change O-ring on the piston Change hydraulic oil 16

17 FB 165 / FB 225 / FB 250 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. 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. 1 Yanmar - 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. Hatz Refilling engine oil 1 - 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. 17

18 FB165 / FB 225 / FB 250 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 distortion The metal plate has separated from the rubber unit. 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. 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. 4. Replace with a new eye. 5. Screw back all bolts and nuts. 6. Tighten these according to the torque table on page 11. 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. b a 18

19 FB 165 / FB 225 / FB 250 Changing hydraulic oil HYDRAULICS DIAGRAM 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. VIBRO 3 1 TANK VENTIL.. 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.. 2 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. 4 1) Hydraulic motor reset 2) Pressure limiting valve, 20 BAR 3) Hydraulic cylinder Front/Back 4) Manual valve block reset 19

20 FB165 / FB 225 / FB 250 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. 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 to the vibration element. 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. 20

21 FB 165 / FB 225 / FB FB225-FB250 FB165 FB225-FB250 FB165 1 BOLT / M6S 8x fzb; 2 BOLT / M6SZ 6x16 fzb; 3 BOLT / M6SZ 8x fzb; 4 BOLT / MC6S 8x fzb; BOLT / MC6S 8x fzb 5 BOLT / MS6SS 4x6 SS; 6 BOLT / MC6S 6x 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 6 13 CYLINDRIC PIN Ø8; CYLINDRIC PIN Ø6 14 FLAT KEY / RK 6x6x30 H9; 15 FLAT KEY / RK 10x8x36; FLAT KEY / RK 10x8x30 16 CIRCLIP / SGA 45; CIRCLIP/ SGA CIRCLIP / SGA 40;CIRCLIP / SGA CIRCLIP / SGA 50; CIRCLIP / SGA CIRCLIP / SGH 22; 20 CIRCLIP / SGA 10; 21 FLAT KEY / RK 6x6x16; FLAT KEY / RK 6x6x10 22 INNERRING / LRT 20x25x17; 23 ROLLER BEARING NJ 308ECP/C3; ROLLER BEARING NJ 306ECP/C3 24 SLIDE BEARING ; 25 BALL BEARING / 61900; 26 SLIDE BEARINGPG F; WASHER 27 O-RING / 89,5x3 NBR 70; O-RING / 72,0x3 NBR RADIAL SEALING 25x35x6 CCP VITON; 29 O-RING / 22,22x2,62 NBR 70; 30 O-RING / 24,2x3 VITON; 31 GEAR RIMROTE 9-99; 32 PLUG R3/ ; PLUG R1/ 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 21

22 FB165 / FB 225 / FB 250 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 FB 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. Dismantling the vibration element CAUTION Risk 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 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 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. 22

23 Disassembly of the vibration element FB 165 / FB 225 / FB 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. B b a b Removing cog wheels control shaft c 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. 13 Removing cog wheels clutch shaft A 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 Removing the actuating rod 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. 23

24 FB165 / FB 225 / FB 250 Assembling the vibration element 0 till 1 kugg 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. 90 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. 7. Check the angles on the eccentric weights: a. Actuating rod completely extended. b. The weights should be positioned as shown in the figure. 24

25 FB 165 / FB 225 / FB 250 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 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 freezing in 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. Check that cables and connector are intact. Clean and lubricate electrical terminals with contact spray. WIRING DIAGRAM FOR THE FB250 YANMAR MACHINE CABEL 10 PANEL CABEL 5 CHARGING LAMP MAIN SWITCH CABEL CABEL 7 OILPRESSURE LAMP CABEL 2 + STARTSWITCH CABEL 11 CABEL 4 CABEL 8 HANDLE BUZZER CABEL 9 HANDLE HEAT ENGINE CABEL 6 CABEL CABEL Oilpressure sensor HANDLE HEAT ON / OFF 4 PIN CONTACT FROM THE CABEL SIDE 25

26 SWEPAC AB Address Blockvägen 3, Ljungby, Sweden, tel. +46 (0) , fax +46 (0) , Internet