swepac FB 515 User manual

FB 515
B00001
USER MANUAL IN ORIGINAL
Doc: 101533-GB 2104

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Doc: 101533-GB 2104

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FB 515
Doc: 101533-GB 2104
USE
SWEPAC FB515
This machine may only be used as intended, i.e.,
to pack ballast under foundations, roadwork construction, in pipe
and cable trenches, etc. All other applications are forbidden. Due
to the forward / reverse function, the machine is highly suited for
packing ballast in places with poor access and as a complement
to larger packing equipment in hard-to-reach places. The stepless
speed control makes it possible to operate it with great precision and
also “pack on the spot”.
The machine may not be reconstructed or modied with permission
from Swepac.
USE.......................................................................... 3
SAFETY INSTRUCTIONS..................................... 4
STANDARDS.......................................................... 4
SIGNS...................................................................... 5
TECHNICAL DATA................................................ 6
METHOD OF OPERATION FB 515 ...................... 6
COMPONENT PLACEMENT................................ 7
DAILY SUPERVISION .......................................... 8
BEFORE STARTING............................................ 10
STARTING THE MACHINE................................ 10
STOPPING THE MACHINE ................................ 11
EMERGENCY STOP/ DEAD MAN’S SWITCH. 11
DRIVING INSTRUCTIONS................................. 11
TRANSPORTATION............................................. 12
HYDRAULIC OIL PRESSURE............................ 13
HYDRAULIC SCHEMATIC ................................ 14
ACCESSORIES..................................................... 15
EC DECLARATION OF CONFORMITY............ 19
CONTENTS

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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 de-
vices are not present or not working.
• The operator may not leave the machine unattended when
the engine is on. The machine is equipped with a Dead
Man’s Switch to prevent this. When the vibrator is con-
nected, the operator must be able to control the movement
of the machine using the operating lever and the start/stop
controls. The machine may only be operated by a trained
operator.
• During maintenance work or other interventions in the
machine, the engine must always be o.
• Switch the engine o before adding fuel. Avoid fuel spill-
age and immediately wipe o 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 o.
• When the machine is parked, ensure that it cannot tip over.
The machine must 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 poten-
tial re or explosion danger.
• Never use the machine if you are tired or have consumed
alcohol or are using medication that could aect your vi-
sion, your discretion or your coordination ability.
• Never use a machine that, in any way, has been changed
from its original design.
STANDARDS
Noise
Measurement according to the standard EN 500-4 Rev.1:
1998, Annex C:
Measurement uncertainty ± 0,5dB (A) i 95% of
measurements.
In accordance with the conditions in Directive 2000/14/EC,
Annex VI, the following values are reported:
FB 515
Sound pressure level at the operator’s ears, LpA 93 dB (A)
Permitted sound power level, L WA 108 dB (A)
Guaranteed sound power level, L WA 108 dB (A)
Since the sound pressure level in the operator’s ears
exceeds
80 dB (A), ear protectors must be used during operation!
Hand/arm vibration
Vibration acceleration has been measured according to the
ISO 5349 standard when driving on macadam substrates.
The measured values have been converted to maximum
daily exposure during regular use. Further information
is available in the work environment regulations AFS
2005:15 on vibration, valid from 1 July 2005.
Measurement uncertainty ± 0,3 m/s2 i 95 % of
measurements.
FB 515
Hand/arm vibration, m/s22.6
Maximum daily exposure 7,4h
Exhaust Emissions
FB515 meets the requirements for exhaust emissions in
accordance with Euro V.
Additional information
Environmentally approved for use in large cities.

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SIGNS
Warning Signs
Before use, carefully read through the manual and safety
regulations in order to be able to handle the machine in
a proper manner. Make sure that the manual is always
available
Engine, silencer: In order to prevent burns or discomfort,
make sure not to touch hot motor parts when the motor is
running or when the machine has recently been used.
Belt drive: Keep hands, tools or other objects away from the
belt drive when the machine is in operation in order to avoid
injury. See the safety instructions in the manual.
Machine plate
1. Manufacturer.
2. Country of manufacture.
3. CE label.
4. Model name.
5. Year of manufacture.
6. Maximum motor power.
7. Maximum weight.
8. Serial number.
9. Machine type
Since the sound pressure level in the operator’s ears exceeds
80 dB (A), ear protectors must be used during operation.

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TECHNICAL DATA
FB 515
Net weight 495 kg
Base plate, w x l 700 x 1080 mm Operational speed
approximately 25 m/min
Permitted inclination 20°
Centrifugal force 66000 N
Vibration frequency 72 Hz
Driving engine Hatz 1D50Z
Engine power 7.5 kW
Engine RPM 3000 RPM
Fuel tank volume 12 litre
Fuel type Diesel
Hydraulic oil volume 13 litre
Battery capacity 40 Ah
Generator power 180 W (15 A)
METHOD OF OPERATION FB 515
(hydraulically powered only)
The machine consists of a base plate with vibrating elements
and a top-mounted suspended plate. The cushioning between
the base plate and the upper part consists of rubber
dampers. The operating lever is situated on the top plate
and cushioned with rubber dampers. The vibration element
and changing travel direction is powered by hydraulics. The
hydraulic pump, mounted on the internal combustion engine,
supplies the oil ow to a hydraulic motor on the vibrating
element. The vibrating element consists of two roller-
bearing shafts with balance weights which are connected to
cogwheels which rotate against each other. One cogwheel
can be rotated on its axis by means of a hydraulic cylinder,
this changes the mutual phase position of the eccentric
weights and the driving direction and speed of the machine
change steplessly. The engine is well protected against
damage in connection with use and transportation by a
sturdy protective frame with a protective panel.
The machine's steering system is constantly connected online
and can be updated, tracked and positioned over the internet.
Via this system, it can also be geopositioned, i.e. Its
operations can be limited to a certain geographical work area
and connected to several machines in the same workplace to
allow one key to work for several machines.
OIL and FUEL RECOMMENDATIONS
Fuel Diesel Mk1
Engine oil SAE10W-30
Oil quantity, crankcase 1,5 litre
Engine oil change First oil change after 50
hours then every 200 hours of
operation. Change lter each
time.
Type of hydraulic oil
amount
Statoil Hydraway Bio SE 32-
68 13 litre
Hydraulic oil lter,
change
After 3 years
vibrating element, oil/
amount
SAE10W-30
0,4 litre

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COMPONENT PLACEMENT
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Left side view
1. Cap
2. Yoke
3. Connection point, battery charge + (Some machines)
4. Operating lever (forward/reverse lever)
5. Control panel
6. Starter key “dead man’s switch” (some machines)
7. Bottom plate
8. Rubber dampers
9. Vibrating element
10. Engine
B00010
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Right side view
11. Refueling
12. Battery
13. Hydraulic oil lter
14. Protective frame
15. Air lter
16. Hydraulic pump (during hydraulic operation)
Centrifugal coupling (when belt-driven)
17. Hydraulic oil cooler
18. Side protection
19. Transport security

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DAILY SUPERVISION
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.
Note! The engine must be turned o and the engine should
be on a level surface.
The oil should reach the maximum marking.
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.
Air Filter Check
The air lter must be checked at least once every working
week. When working in dusty conditions, check daily.
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B00003
1. Air lter housing
2. Filter element
3. Filter cap
4. Dust collector/Emptying valva
Check hydraulic oil level
Check daily that the hydraulic connections are not leaking or
wear out from driving. The oil level in the hydraulic oil tank
must be as shown, at maximum 2 cm below the tank top.
When lling with hydraulic oil, do as follows:
Remove the fuel cap. Remove the insert lter. Fill up with
hydraulic oil and replace the lter and cap. Make sure that
the cover is properly tightened when reassembling.
B00004
2 cm
Hydraulic oil cooler
The machine is equipped with a hydraulic oil cooler. The
cooler starts when the hydraulic oil temperature reaches +50
˚C. After that, the cooler switches on and o as required.
After switching o the machine, the cooler fan may run for a
short time, which is completely normal.
B00017
Note! Hydraulic Oil Temperature Warning Light, shines red
when the hydraulic oil temperature is too high. Continued
use will lead to the poorer packing capacity. Stop and check
the hydraulic oil cooler.
Thermostats
1. Thermostat for the hydraulic oil cooler fan.
2. Thermostat for high oil temperature warning lamp.

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Vibrating element
Check for oil leaks regularly. Seal any leaks. NOTE! the
machine must under no circumstances be operated if there
are any indications of leakage.
Note! Oil amount in the vibration element is 0,4 L.
1B00015
1. Draining / relling openings
Rubber dampers
Check the condition of the rubber dampers regularly.
Replace damaged dampers.
Hatz decompression lever
In cold weather or if the machine has trouble starting, try
opening the decompression valve, then try again.
Remove the front cover to access the decompression valve,
the decompression lever will return to its original position
when the engine starts.
Charging the battery
B00018
If the “Charging” warning light on the control panel shines
red or if the machine is left unused for a long period, the
battery needs to be charged.
Machine with external charging point
This is done by pulling out the lever (1) that provides
connection to the positive terminal of the battery (connect
the charger’s positive cable here) and connect the charger’s
negative cable to the machine chassis.
Machine with no external charging point
This is done by removing the rear cover (2) to allow access
to the battery. Connect the charger cables to the battery
terminals.
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BEFORE STARTING
See “DAILY SUPERVISION”, page 8.
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Attach the strap (1) that is located together with the ignition
key (2) in a suitable place in the operator’s clothing.
This is an important safety feature, since the key acts as a
dead man’s switch and will be pulled out of position and
stop the machine if the operator loses control.
The key is unique and only works for your machine if it is
not programmed to work for other machines, e.g. within a
work area.
Control panel
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1. Vibration switch, push the switch to increase the engine
speed and begin compaction.
2. Start/Reset switch, press and hold the switch there for 1
second, the machine will begin to idle.
3. Switch for handle heating, push in the switch to heat the
handle when the engine is running (Some machines).
4. Indicator lamp “Charging”, red when battery is low.
5. Oil pressure Warning Light, red when oil pressure is low
(after having displayed red, the control system must be re-
set by holding down the Start/Reset switch for 7 seconds).
6. Fuel Level Warning light, green when full, yellow when
half-full and red when the tank is empty. When the light
is red, rell fuel. Tap the machine’s operating lever lightly
and the last measured value will be displayed even when
the engine is switched o (Some models).
(NOTE! The engine is switched o before the fuel tank is
completely empty, which means that the fuel system does
not need to be vented after stopping due to lack of fuel).
7. Air Filter Warning Light, shines red when the air lter is
clogged (some models).
8. Hydraulic Oil Temperature Warning Light, shines red
when the hydraulic oil temperature is too high (the warn-
ing light is present on all models, but is only used on cer-
tain models).
9. Swepac Compaction Indicator (SCI). The lights are turned
on from left to right as compaction progresses (some mod-
els).

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The machine is only intended for outdoor use. Operate the
machine in daylight or other adequate lighting. Ballast must
be wetted or naturally damp. All other uses are advised
against.
Note! When driving uphill, the machine should be driven in
reverse.
The machine may not incline more than 20º sideways or
during installation.
B00011
Lever heating
B00020
Some machines are equipped with lever heating. The lever
heating is activated by the lever heating switch on the control
panel: The lever heating can only be used when the engine is
running in order to prevent the heating coil from wasting the
battery when the machine is not in use.
Driving in reverse
Driving forward
STARTING THE MACHINE
Put the key in its slot on the control panel. Press the Start/
Reset switch, press and hold the switch there for 1 second,
the machine will then start. Let the machine idle for at least
30 seconds before pressing the vibration switch to activate it
and begin working.
If the machine has diculty starting, e.g., in cold weather,
keep the Start/Reset switch down for a period of time and
the starter motor will start up in 15 seconds
If the machine still won’t start, check the following:
• is there fuel in the tank?
• is the battery charged?
• if the machine is programmed to be used within a specic
area, make sure you are not outside the area.
• if the machine still will not start, try resetting the machine’s
control system by holding down the Start/Reset switch (2)
for 7 seconds.
• contact service repairman
STOPPING THE MACHINE
Press the vibration switch (1) once to stop vibrations
and then press the Start/Reset switch (2) once to stop the
machine. Retract the starter key.
EMERGENCY STOP/ DEAD MAN’S
SWITCH
(Some machines)
Retract the starter key to stop the machine immediately.
B00019
DRIVING INSTRUCTIONS
Start and stop the machine’s vibration element with the
vibration switch on the control panel.
When the control bar on the handle is pulled backwards, the
machine reverses and when the bar is pressed forward, the
machine moves forward.
Note! When packing, always run the engine at full throttle.
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TRANSPORTATION
The machine has a lifting yoke.
Note! Only use the lifting point (1) of the protective frame
when lifting the machine.
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Check before lifting that the lifting yoke and its mounting on
the machine are undamaged. Check also that the base plate’s
rubber dampers are undamaged and rmly attached.
Transport security
For transportation by vehicle, the lever must be in the
forward position and secured with, for example, approved
straps. Note! Secure it to the lifting yoke on the base plate
and not the rubber-cushioned upper part.
Always secure the machine with a strap as shown in the
illustration or the lifting yoke on the base plate during
transport.
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HYDRAULIC OIL PRESSURE
MEASURING AND SETTINGS
It is possible to obtain a clear understanding of the condition of the hydraulic system or indication of cause of interference by
simultaneously measuring the system pressure, driving engine speed and vibration frequency. The plate compactor must be
in operation and maintain a normal working temperature. Normal hydraulic oil temperature during operation is 50–70°C.
The maximum pressure of the hydraulic system is preset upon delivery. The set pressure is 200 bar and can be measured
when starting up the machine
if the oil in the hydraulic system is cold.
When the plate compactor has reached normal operating temperature, the pressure should be 30-50 bar lower than the
system’s maximum pressure.
The pressure increases proportionally with increased load, eg if the plate compactor is kept at a low speed or is kept still
during operation. When at maximum pressure, the vibrator speed is decreased.
Measurement of driving engine speed and vibration frequency is carried out with a stroboscope lamp with a graduated scale.
Hydraulic pressure is measured with a manometer with a manometer outlet on the valve block, see image. Strobe lamp and
manometer can be ordered from SWEPAC.
Engine speed ......................................... 2900 r / min loaded Hatz
Vibration frequency at hydraulic oil temp. approx. 50°C ........... 70–72 Hz; 4200–4320 RPM
Normal pressure when driving, hydraulic oil temp. approx. 50°C ....... 150–170 bar
B00014
Measuring point, hydraulic system

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1) Hydraulic pump 6, 45cc 2900 RPM (Hatz)
2) Pressure relief valve max 200 Bar
3) Solenoid valve vibrations On/O󰀨
4) Hydraulic engine 4.09 4300 RPM
5) Hydraulic cylinder Front/Back
6) Measuring outlet
7) Return oil lter
8) Hand lever
HYDRAULIC SCHEMATIC
TANK
VIBRO
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ACCESSORIES
Swepac Compaction Indicator (SCI)
The SCI consists of an accelerometer sensor mounted on the right side of the vibration element and a display unit equipped
with LED lights that light up as compaction progresses. The sensor and the display are connected
via a cable.
Principle:
The base plate movements vary depending on increased or decreased soil compaction. The sensor in the sensor part
continuously measures variations in the base plate’s movement patterns. Movement values are analyzed by the processor
which in turn sends signals to the display to indicate progress via the light signals.
B00008
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When starting:
When starting up, diodes 1,3,5,7 will light up rst, then diodes 2,4,6,8 will light up.
The diodes remain lit until communication with the sensor has started. This usually takes 1 second. Should the power
supply be interrupted or communication breaks o for more than 20 seconds, the ashing LED pattern will begin again until
communications have been resumed. Then all the diodes will turn o and the indicator will signal that the machine is ready
for operation.
When starting the machine or turning on vibration mode, it takes 2-3 seconds before the indicator registers movements in the
base plate. This is because the sensor does not start measuring until the vibrator generates the correct frequency at the base
plate. Neither will the display indicate anything if the engine speed is decreased because the vibrator then runs at a slower
pace and the base plate does not reach the required frequency.
No calibration of the indicator is required when starting the machine.
During operation:
The LED lights are turned on from left to right during operation. The number of lights that ash while driving depends on
the quality and condition of the substrate. When the number of lit lamps does not increase, the substrate will not be further
compacted at any more road crossings. This means that not all the lights will necessarily light up during compaction.
The lights indicate the compaction status of the substrate during operation. If no more lights ash, maximum compaction
of the substrate has been reached. Swepac Compaction Indicator does not replace conventional test methods for degree of
packing and is intended to provide the operator with useful information, such as nding areas that are not compacted or to
avoid overcompaction which risk causing damage to the machine.

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NOTES

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NOTES

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NOTES

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EC DECLARATION OF CONFORMITY
Manufacturer
Swepac AB
Bergvägen 7
34132 Ljungby
1. Category: Plate compactor
2. Type: FB515
3. Motor power: 7.5 kW
The product complies with the following directives:
2006/ 42 / EC
2000 / 14 /EC
2004/108/EC
EN 500-1
EN 500-4
Technical documentation available from:
Swepac AB, Bergvägen 7 34132 Ljungby SE
Tomas Johansson/Product Engineer

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SWEPAC AB
Address Bergvägen 7, 341 32 Ljungby, tel [phone], fax [phone], Email [email protected],
Internet www.swepac.com