dvh 550 l - 2 - artemis
TRANSCRIPT
DVH550/600 1
OPERATING ANDMAINTENANCE MANUAL
0408
/eng
lisch
DVH 550 L - 2DVH 550 R - 2
Weber Maschinentechnik GmbHPostfach 21 53, 57329 Bad Laasphe-Rückershausen
Telephone + 49 27 54 / 398-0Fax + 49 27 54 3 98-101 (switchboard) & 3 98-102 (spare parts)
DVH 600 L - 2
2 DVH550/600
DVH550/600 3
IntroductionThis operating and maintenance manual provides instructions for safe handling of type DVH 550 L, DVH 550 Rand DVH 600 L vibration rollers. Read this manual prior to first start-up and familiarize yourself with all the detailsof your roller. Carefully follow all instructions and always execute the described activities in the specified sequence.
The general safety instructions are on the following page.
We reserve the right to make changes without notice.
In section 1 the roller is briefly described to provide you with a good overview of the position of the specific sub-assemblies and how they interact. In section 2 the activities for start-up and shutdown as well as working with theroller are described.
Section 3 provides an overview of the necessary maintenance activities and a description of the necessary specificmaintenance activities. Section 4 contains troubleshooting instructions for the operator. Measures for storing thevibration roller
Particular attention was paid to user-friendly design through instructive photos and text information. Referencesto photos are indicated by parentheses in the text. The first number indicates the photo number and the secondnumber separated by a forward slash indicates the position number on the respective photo.
Example 1: (2/1) means photo 2, position number 1
Example 2: (2/3,6) means photo 2, position number 3 and position number 6
Important information for operating and maintenance personnel is marked by pictograms.
indicates important information to which the operator or maintenance personnel must pay particularattention.
Indicates work procedures and operating procedures, execution of which additionally requires compliancewith applicable environmental protection provisions and disposal guidelines.
Indicates work procedures and operating procedures that must be precisely followed to avoid damage ordestruction to the roller.
indicates work procedures and operating procedures that must be precisely followed to exclude thepossibility of personal injury.
If needed you can obtain additional information from your authorized WEBER dealer, or you can obtain informationfrom one of the contact addresses listed on the last page.
4 DVH550/600
General safety guidelinesGeneral instructions
All safety instructions (see also the pictogram explanations in the introduction) must be read and complied with(if there are questions they must be resolved prior to first start-up), otherwise: * Danger to life and limb of the user
* Damage to the machine and other property exists.
In addition to the operating manual and the applicable binding regulations for accident prevention in the user’scountry and at the implementation site, the recognized specialized technical rules for safety* and professional workmust also be complied with.
Intended use
Rollers should only be operated properly, following the instructions in the operating and maintenance manual, incompliance with recognized safety rules and traffic regulations, and the country-specific regulations or higher leveldirectives (EU directives)*.
Intended use includes:
- Compaction of bituminous material (road coverings)
- Light compaction tasks for earth works (road foundations)
Any other use of the roller is considered to be non-intended use, for which the customer is exclusively responsible.
Permission to operate
Only suitable persons, at least 18 years of age should be assigned to operate vibration rollers. Such persons musthave been instructed by the customer or customer’s authorized representative beforehand relative to operatingand maintaining the roller.
Protective equipment
For the rollers described in this operating and maintenance manual it is possible that the permissible sound levelof 90 dB(A) may be exceeded. In accordance with the accident prevention guideline “Noise” (BGV-B3), personsworking with the roller must wear suitable hearing protection at evaluation sound levels of 90 dB(A), and greater.
Additional protective equipment includes hard hats and safety footwear.
*EU Equipment Directive, EN 500ff
DVH550/600 5
Par. Title page
3.3.9 Change V-belt for the .........................hydraulic pump ................................... 29
3.3.10 Lubricate the vibration shaft ............... 303.3.11 Adjust, clean the scraper .................... 30
3.4 Operating materials and fill levels .. 31
4 Faults in operation ........................... 32
4.1 General .............................................. 32
4.2 Troubleshooting ............................... 32
4.3 Hydraulic system diagram ............. . 33
5 Winter storage .................................. 34
5.1 Measures prior to storage ............... 34
5.2 Start-up afterstorage .............................................. 35
6 Contact addresses for .....................W E B E R ..........................................Maschinentechnik GmbH ................ 36
Para. Title Page
Introduction ...................................... 3
General safety guidelines ................ 4
Table of contents ............................. 5
1 Technical description ...................... 6
1.1 Graphic presentation ....................... 6
1.2 Device description ........................... 7
1.3 Technical data .................................. 8
2 Operation .......................................... 10
2.1 Safety guidelinesfor operation ..................................... 10
2.2 Transport .......................................... 112.2.1 Loading with crane ............................. 11
2.3 First start-up ..................................... 11
2.4 Activities prior to starting work ...... 112.4.1 Check the fuel level ............................ 122.4.2 Check the engine oil level ................... 122.4.3 Check the hydraulic fluid level ............ 13
2.5 Starting .............................................. 142.5.1 Normal start DVH 550 L/ 600 L .......... 142.5.2 Normal start DVH 550 R ..................... 15
2.6 Driving and compacting .................. 16
2.7 Shutdown .......................................... 17
3 Maintenance ..................................... 18
3.1 Safety guidelinesfor maintenance ............................... 18
3.2 Maintenance overview ..................... 193.2.1 Initial maintenance ............................. 193.2.2 Regular maintenance ......................... 20
3.3 Description ofmaintenance tasks ........................... 22
3.3.1 Change engine oil .............................. 223.3.2 Change engine oil filter ....................... 223.3.3 Clean/change air filter cartridge .......... 233.3.4 Clean/change fuel filter ....................... 243.3.5 Check & change the vibration V-belt .. 25/
........................................................... 263.3.6 Lubricate, tension, or replace the .......
drive chains ........................................ 273.3.7 Change hydraulic fluid ........................ 283.3.8 Change hydraulic fluid filter ................ 28
Table of contents
6 DVH550/600
1.1 Graphic presentation1. Technical description
Fig. 1 Overall view DVH 550 L / DVH 550 R / DVH 600 L
1 Hand guidance rod2 Hydraulic tank3 Lifting ring4 Water tank5 Fuel tank6 Engine7 Reversing starter8 Hydraulic fluid filter (illustration above)
9 Scraper10Drums11Chain guard12Parking brake13Gas lever14Vibration lever15Safety bar and drive lever16Crush guard
8
10
9
6
7
12
11
161 23
15
14
13
54
DVH550/600 7
1.2 Device description
Type DVH 550 L, DVH 550 R and DVH 600 L rollers are hand-guided devices and are used for compactionwork in road building applications.
A Lombardi diesel engine provides the motive power for rollers DVH 550 L and DVH 600 L; motive powerfor roller DVH 550 R is provided by a Robin gasoline engine.
Section 1.3 (Technical data) specifies which engine type (including performance data) is used inwhich roller.
The two drums (1/10) are hydrostatically powered via chains. The chain drive is executed individually oneach bandage. The chain drive also serves as a safety braking system for operating on slopes. The vibratorthat is positioned outside between the two drums is powered via a V-belt.
The hydraulic system consists of a closed circuit with hydraulic pump and hydraulic motor as well as ahydraulic tank (1/2).
The drums (1/10) are freed of adhering material by the adjustable scrapers (1/9).
A reversing starter (1/7) is used as the starting device for both versions (1/7).
The roller is steered with the hand guidance rod (1/1). All control levers are located on the hand guidancerod. The throttle (1/13) for engine speed control. Direction of travel and speed are controlled with the safetybar (1/16) (drive bar). The vibration adjustment lever (1/14) switches vibration on or off. The arrest lever (1/12) activates the parking brake that stops the rear drum.
For safety of the operator a crush protection fixture (1/16) is attached to the hand guidance rod (1/1). If theoperator bumps against the crush protection device (1/16) when moving in reverse, the machine comes toa stop.
Drive
Function
Operation
8 DVH550/600
* Depends on the ground
1.3 Technical data
DVH 550 L DVH 550 R DVH 600 L
Weight
Dead weight (in kg) 345 330 400
Operating weight CECE in kg 365 330 420
Average stat. line load (in N/cm)32,6 31,2 31,7
Dimensions
Overall length in (in mm) 1885 1885 1885
Overall width in (in mm) 655 655 755
Height (in mm) 1046 1046 1046
Drum width (in mm) 550 550 650
Drum diameter (in mm) 325 325 325
Axle base (in mm) 450 450 450
Lateral overhang L/R (in mm) 15/90 15/90 15/90
Drive
Engine manufacturer Lombardini Robin Lombardini
Type 15 LD 315 EH 25 D 15 LD 315
Max. power in accordance with DIN 70020 (in kW (PS)) 5 (6,8) 6,3 (8,5) 5 (6,8)
Combustion process 4-stroke diesel 4-stroke gasoline 4-stroke diesel
Operating rpm 3000 3000 3000
Traversing mechanism hydrostatic Both drums Both drums Both drums
Movement speed (In km/hours)*
- Working motion forward/reverse 0 - 1,5 / 0 - 1,5 0 - 1,5 / 0 - 1,5 0 - 1,5 / 0 - 1,5
- Drive motion forward/reverse 0 - 3,5 / 0 - 1,5 0 - 3,5 / 0 - 1,5 0 - 3,5 / 0 - 1,5
Climbing capacity (in %)* 40 / 30 40 / 30 40 / 30
Operating brake Hydrostatic Hydrostatic Hydrostatic
Parking brake Mechanical Mechanical Mechanical
Brake effective at friction µ = 0.25 (steel drum on firm rocky ground) to 20 % =̂ 11.3 slope
Vibratory
system Central exciter outside of the drums
Drive concept mechanical, connectable
DVH550/600 9
3 TYPE
.........................................
4 ENGINE/SERIAL NO
.........................................
1 MACH. NO.:
.........................................
2 YEAR OF MANUFACTURE
.........................................
4
3
MADE IN ITALY
3 4
DVH 550 L DVH 550 R DVH 600 L
Noise and vibration values*
Sound pressure level LAP
(at the operating station in accordance with 2000/14/EC, in dB(A))
85,5 85,5 85,5
Sound pressure level LWA
(in accordance with 2000/14/EC, in dB(A))
108 108 108
Hand/arm vibration (effective weighted value of the acceleration on the guide handle, determined in accordance with 2002/44/EC, Part 1, in m/s²)
5,3 5,3 5,3
*The noise values cited in this manual have been determined in accordance with Directive 2000/14/EC. In operational use, values that deviate from these values can occur depending on theprevailing operating conditions.
21
10 DVH550/600
Safety instructions and warnings
Behavior if there are defects
Machine operator behavior
Stability under load
Driving and compacting
2 Operation2.1 Safety guidelines for operation
Prior to starting each shift the machine operator must check the effectiveness of the operating and safety devices,and proper attachment of the protective devices. Only operate rollers if all protective devices are functioningproperly. The effectiveness of the control elements should not be impermissibly influenced or bypassed.
The machine operator must ensure that his personal noise protection measures are in place before starting theroller. Do not start the drive motor until after you have ensured that the roller cannot start moving on its own.
If you notice defects on the safety devices or other defects that impair safe operation of the device notify yoursupervisor immediately. If there are defects that impair operational safety then operation must be stoppedimmediately.
During operation rollers must be monitored constantly to ensure operationally safe condition. The machineoperator should not distance himself from the control devices when the device is in motion and must alwaysmaintain a sufficient view of the travel area of the roller. If view of the travel area is restricted by influences incidentalto deployment then a second person must be assigned to direct the operator.
Vibration rollers must be used and operated in such a manner that their stability is ensured. Stability is particularlyin jeopardy on the edges of embankments and shoulders. Consequently maintain a safe distance from the edgesof embankments and brinks.
When moving backward rollers must be operated from the side to exclude the possibility of crushing injury to themachine operator between the hand guidance rod and obstacles.
For compaction work on inclines or slopes the machine operator must always walk on the uphill side. Compactionwork on slopes that exceed the maximum climbing capacity of the roller, is prohibited. Inclines and slopes mustbe worked/traversed with extreme caution and always with the device moving directly up or directly down. In thisregard the roller should not be abruptly accelerated or braked.
Wet and loose substrates on inclines and slopes significantly reduce roller traction. Increased accidentdanger!
Movements over unlevel areas and curbs should only be executed at reduced speed. In addition the roller mustbe guided in such a manner that the possibility of injury due to sudden swing-out of the hand guidance rod isexcluded.
EmissionsNever inhale exhaust gas, it contains carbon monoxide, a colorless and odorless gas that is extremely dangerousand that can result in unconsciousness and death within a short time. Never operate the engine in enclosedareas or in poorly ventilated locations (tunnels, caverns, etc.). Particular caution is required, if the engine is
operated in the vicinity of people or livestock. Ensure that there are no foreign objects in the exhaust pipe.
DVH550/600 11
2.3 First start-upFor first start-up only the activities prior to starting work (see section 2.4) must be executed.
The initial maintenance intervals (see section 3.2.1) must be maintained.
2.2.1 Loading with crane- Shut off the roller as described in section 2.7.
- Hook the crane hook into the transport ring (2/1)
Do not lift from the engine ring!
- Lift the roller onto the means of transport
Do not step under suspended loads!
2.2 TransportFor transport over short distances within the construction sitethe roller can be moved as specified in section 2.6.
For transport over greater distances the roller can be crane liftedonto suitable means of transport (truck, trailer).
Fig. 2
Only use lifting tackle and crane with sufficient bearingcapacity.
- Carefully lash the roller on the transport trailer as prescribed(see the operating manual provided by the manufacturer ofthe trailer.
2.4 Activities prior to starting work
- Visually inspect the complete roller for visible damage.
- Check all threaded unions for firm seat, retighten if necessary
- Check the fuel level, top-up with fuel if necessary (see section 2.4.1)
- Check the engine oil level, top-up with engine oil if necessary (see section 2.4.2)
- Check the hydraulic fluid level (see section 2.4.3)
- Open the water tank cap (2/2) and check the water level, if necessary top up with clean water
1
12 DVH550/600
Do not let fuel get on hot motor components. Smokingand open flame are prohibited when fueling.
Carefully wipe up spilled fuel. Dispose of cloths that aresoaked with fuel in an environmentally responsiblemanner.
2.4.1 Check fuel level- Shut off the roller as described in section 2.7.
- Open the fuel tank with the tank cap (3/2 or 4/2).
See section 3.4 for fill quantity and specification
- Fill to the lower edge of the filler neck
- Firmly close the fuel tank with the tank cap (3/2 or 4/2).
Fig. 3
Fig. 4
1
2
1
Fig. 5
Fig. 6
Fig. 7
Never top up with fuel when the engine is running
Fill DVH 550 L/ DVH 600 L (Lombardini engine) withclean diesel fuel
Fill DVH 550 R (Robin engine) with clean, lead-freenormal gasoline
2.4.2 Check the engine oil levelThe roller must be positioned on a horizontal surface tocheck the engine oil!
- Pull out (5/1) or unscrew (7/1) the oil dip stick
- Wipe off the oil dip stick with a clean cloth
- Insert the oil dip stick and pull it out again
- The oil level must extend to the upper mark (6/max.) of thedip stick (6/-)
- Top up the engine oil if necessary (see section 3.4 for fillquantity and specification)
21
Min.
Max.Min.
1
DVH550/600 13
The roller must be positioned on a horizontal surfacewhen checking the hydraulic fluid level!
- Check the hydraulic oil level in the view glass (8/1)
- Top up the hydraulic fluid if necessary (see section 3.4 forfill quantity and specification)
No hydraulic fluid is consumed during operation. If thefluid level drops, you must check the hydraulic systemfor leaks
2.4.3 Check the hydraulic fluid level
The hydraulic fluid level must be between the middleand the upper edge (marking) of the view glass.
1
Fig. 8
14 DVH550/600
- Slowly pull the handle of the reversing starter (10/1) untilresistance is noticeable.
- Allow the handle (10/2) to slide back into the initial position,and then forcefully and completely pull it through with bothhands.
If the engine does not start, repeat the start process.
- As soon as the engine starts running, guide the starter ropeback into the reversing starter.
2.5 StartingPrior to starting always ensure, that no one is in theroller’s danger zone and that all protective devices areproperly attached.
Never use start-aid sprays.
When starting in enclosed spaces ensure adequateventilation - Danger of suffocation!
Fig. 10
Fig. 9
1
2
2.5.1 Normal start DVH 550 L / DVH 600 LTo start, push the vibration lever (9/1) into the offposition ( ).
- Pull the gas lever (9/2) back to the stop.
2
1
DVH550/600 15
- Position the fuel shut-off valve vertically (12/1) to open
- Open or close the choke depending on the engine and/orambient temperature.
a) If the engine is cold and/or at a lower ambient temperatureclose the choke (13/2) entirely (move it to the right).
b) If the engine is hot and/or at higher ambient temperatureopen the choke (13/2) between half way and the fully openposition (move it to the left).
- Slowly pull the handle (14/2) of the reversing starter (14/1)until resistance is noticeable.
- Allow the handle (14/2) to glide back into the initial position,and then forcefully and completely pull it through with bothhands.
If the engine does not start, repeat the start process.
- As soon as the engine starts running, guide the starter ropeback into the reversing starter (14/1)
- Move the choke (13/2) slowly into the completely openposition (to the left) allow the engine to warm up at idle speedfor approximately 5 min.
2.5.2Normal start DVH 550 R
Fig. 11
Fig. 12
Fig. 13
2
1Fig. 14
2
1
Open
To start the push the vibration lever (11/1) into the offposition ( ).
- Pull the gas lever (11/2) back to the stop.
2
1
16 DVH550/600
Forward
= Press the drive bar forward
Reverse
=Pull the drive bar back/down
Standstill
= Allow the drive bar to slide into 0 position
- Move the vibration adjustment lever (15/3 to the stop
( )
- Push the safety bar (15/1) into the desired direction of travel
2.6 Driving and compacting- Start the roller (see section 2.5).
As soon as the engine has reached its operating temperature:
- Pull the gas lever (15/2) all the way back until the stop in fullthrottle position
- Push the parking brake (16/1) into vertical position(disengage)
- Open the water shut-off valve (17/1) if necessary
Fig. 15
Fig. 16
Fig. 17
Fig. 18
1
2.6.1 Movement
- Press the drive bar (15/1) forward
The roller will come to an immediate stop as soon as thedrive bar (15/1) is released.
2.6.2 Compacting
Always move the vibration adjustment level to the stop,otherwise increased abrasion occurs on the V-belt.
At obstructions (walls, pits, etc.) ensure that no one canbe caught between the machine and the obstruction; orensure that the machine does not slip into the pit.
- Use the hand guidance rod (18/1) to steer the machine in thedesired direction.
1
The engine accelerates to full rpm
4
31
2
If the operator bumps against the crush guard (15/4) whenmoving in reverse, the machine comes to a stop.
Through swinging out the drive lever (15/1) forward in thedirection of travel, the crush protection fixture is again lifted up.
5
1
DVH550/600 17
2.7 ShutdownPrior to breaks and when concluding work the roller mustbe placed on stable and horizontal terrain (to the extentpossible).
- Push the vibration lever (19/1) to position ( )
- Push the gas lever (19/2) forward
- close the water shut-off valve if necessary
Parked devices that represent an obstacle must besafeguarded against through conspicuous measures. Ifrollers are parked the route of traffic, then in addition thesafety measures specified in road traffic regulations mustalso be employed.
Do not switch off the engine under full load
- Pull the parking brake all the way back (horizontal) until it locksin place on slopes the roller must additionally be secured againstrolling off via wedges!
2.7.1 Switch off the engine DVH 550 L / 600 L
Fig. 23
Fig. 19
Fig. 20
1
Fig. 21
Fig. 22
1
- Turn the stop switch (23/1) to the „OFF“ position.
- Close the fuel shut-off valve (12/1)
2.7.2 Switch off the engine DVH 550 R
1
- Move stop lever (22/1) to the left until the engine comes to astandstill
1
1
2
18 DVH550/600
3 Maintenance3.1 Safety guidelines for maintenance
Hand-guided vibration rollers must be inspected by an expert to ensure safe operational status in accordancewith use conditions and operating conditions, as needed; this inspection however is required at least once ayear. Inspection results must be recorded in writing and must be kept at least until the next inspection.
Maintenance tasks should only be performed when the drives are at a standstill. The only exceptions are thosetasks that cannot be executed without drive. In addition the roller must be safeguarded from rolling off.
Discharged operating fluids must be collected and stored in suitable containers. Discharged fluidsmust be appropriately disposed of in accordance with environmental protection regulations.
Prior to performing work on parts that are not protected, the combustion engines must be safeguarded againststarting unintentionally.
After maintenance work the protective devices must be properly reattached.
Unauthorized changes or conversions to rollers are prohibited for safety reasons. The manufacturer expresslyexcludes any liability for damage that occurs due to changes or conversions to the roller. To ensure safe andreliable operation, only use original WEBER spare parts.
Maintenance
Safety instructions of the engine manufacturer
The maintenance tasks for the engines are described in the operating manual provided by the enginemanufacturer, either Lombardini or Robin.
Changes and conversions
Tests
DVH550/600 19
3.2 Maintenance overviewAll maintenance tasks that must be executed on the roller are listed in two tables. The maintenance tasks in thefirst table (section 3.2.1) must be executed at certain times and once after first start up. The maintenance activitiesin the second table (section 3.2.2) must be repeated regularly.
The tables are structured identically. In the „Maintenance interval“ column the time or the number of hours isspecified at which/after which the maintenance task must be executed.
In the „Maintenance point“ column the component of the roller is specified on which the task specified in the„Maintenance task“ column must be performed.
The „Comment“ column contains cross references to sections of this operating and maintenance manual or toother documents where the execution of the maintenance task is described in more detail.
3.2.1 Initial maintenance
Maintenance interval Maintenance point Maintenance activity Comment/instructions
After the first 20 operating hours Hydraulic system - Change hydraulic fluid filter # 3.3.8
Robin - engine - Change engine oil # 3.3.1
Total machine - Check all threaded unions for firm seat, retighten if necessary
After the first 50 operating hours Lombardini - engine - Change engine oil # 3.3.1
- Change oil filter # 3.3.2
20 DVH550/600
3.2.2 Regular maintenance
Maintenance interval Maintenance point Maintenance activity Comment/instructions
Every 8 operating hours Total machine -Check for visible damage, leaks, etc.
Air filter - Clean air filter insert for damage, replace if necessary # 3.3.3
Hydraulic system - Check threaded unions, hoses for leaks, tighten threaded unions or change hoses as needed
- Only perform work if the hydraulic system is de-pressurized!!
Engine - Check the engine oil level # 2.4.2
Every 50 operating hours Vibration shaft -Check V-belt for damage, replace if necessary # 3.3.5
Robin - engine - Change engine oil # 3.3.1
- Clean spark plugManual provided by
engine manufacturer
Every 200 operating hours Robin - engine - Clean fuel filter # 3.3.4.2
- Clean spark plug and adjust electrode gap
Total machine - Check all threaded unions for firm seat, retighten if necessary
All bare parts - Lightly oil
Drive activation cable - Exterior cleaning
Every 250 operating hours Lombardini - engine - Change oil filter and engine oil# 3.3.1 # 3.3.2
- Change the fuel filter # 3.3.4.1- Clean the cooling fins
Drive chains - Lubricate, retighten if necessary # 3.3.6Scraper - Visually inspect or readjust # 3.3.11
DVH550/600 21
Maintenance interval Maintenance point Maintenance activity Comment/instructions
Every 500 operating hours Robin - engine - Clean, adjust carburetor as needed Manual provided by engine manufacturer
- Clean cylinder head "- Adjust valve play "
Lombardini - engine - Check the injection nozzle adjust if necessary
Manual provided by engine manufacturer
- Check injection pump "- Adjust valve play "- Clean cylinder head "
Every 1000 operating hours Complete roller -
Check all modules for visible damage and wear
- Remove fouling, old grease and rust
Hydraulic system - Change hydraulic fluid filter # 3.3.8
- Change hydraulic fluid # 3.3.7
Water tank & sprinkling system
- Clean, remove lime scale
Drive - Check V-belt for tension and wear, replace / retighten as needed # 3.3.9
- Check drive chains & drive pinion for wear, replace if necessary # 3.3.6
22 DVH550/600
- Remove the oil filter cover (25a/1) by loosening the two Allenscrews (25a/4)
- Pull the oil filter out of the engine block
Dispose of old oil filters in an environmentally responsiblemanner
Always use new original oil filters
- Insert new oil filter in the engine block
- Re-attach the oil filter cover (25a/1)
- Check the Allen screws (25a/4) for firm seat
- Top-up engine oil (for quantity and specification see section3.4.2)
- Check engine oil level (25a/3) as specified in section 2.4.2.
3.3 Description of maintenance tasks3.3.1 Change engine oil
- Shut off the roller as described in section 2.7.
Only drain engine oil when the engine is warmed up andthe roller is at a standstill.
- Unscrew the protective cap (25a/2)
- Place a collecting container under the discharge pipe.
Select a vessel that is large enough to prevent oil fromspilling on the ground.
- Screw on the oil discharge hose (included with the on-boardtools)
Screwing on the discharge hose opens the drain valve -the oil flows out
Danger of scalding due to hot oil.
- Unscrew the oil discharge hose
- Screw on the protective cap (25a/2)
Dispose of collected oil in an environmentally responsiblemanner
- Fill engine oil as specified in the fill quantity table (3.4) into theoil fill opening (25b/1 or 26/1).
3.3.2 Change engine oil filter (only DVH 550 L/ 600 L)
2
3
4
1
1
Fig 25b
Fig. 25a
Fig. 26
1
DVH550/600 23
If adequate cleaning is not possible with this procedure(e.g. due to wet or oily fouling) then a new pre-filter ormain filter must be used.
At the latest after ten cleanings the pre-filter or mainfilter must be replaced with a new filter
3.3.3 Clean/change air filter cartridge
3.3.3.1 DVH 550 L / DVH 600 L (Lombardini 15LD 315)
Fig. 27
- Loosen the fastening screw (27/2) and take the lid (27/1) offof the air filter housing
- Take the air filter insert (28/2) out of the air filter housing
- Take the pre-filter (28/1) off of the main filter (28/2)
- Clean the pre-filter (28/1) with water and soap
- Clean the main filter (28/2) with compressed air.
- Loosen the three clips (29/1 + 2) and take the cover off of theair filter housing
- Take the pre-filter (30/1) off of the main filter (30/2)
- Wash out the pre-filter in gasoline
- Knock out or blow out the main filter
Fig. 28
Fig. 29
2
1
1
2
1
2
Fig. 30
1
2
3.3.3.2 DVH 550 R Robin - engine EH 25
If adequate cleaning is not possible with this procedure(e.g. due to wet or oily fouling) then a new filter insertmust be used.
- Re-assemble the filter system
- Re-insert filter
- Place the cover (27/1) back on the air filter housing and sealtightly with the fastening screw (27/2)
Dispose of washing liquid in an environmentallyresponsible manner.
- Pull the pre-filter over the main filter
- Insert filter
- Place the cover on the air filter housing and seal tightly
with the three clips (29/1 + 2)
24 DVH550/600
- Unscrew the view glass (33/3) below the fuel shut-off valve (33/2)
Wash off escaping fuel immediately, dispose of cleaningcloths that are saturated with fuel in an environmentallyresponsible manner
- Remove the sieve from the view glass (33/3) and clean
- Install the view glass in the reverse sequence
Check for leaks
3.3.4Clean/change fuel filter
- Loosen the clips (31/2), pull the diesel line (31/3) off of the fueltank (31/1), and completely empty the tank
- Re-connect the fuel line (31/3) and fasten the clips
ensure that the line is firmly seated on the tank
Immediately wipe up/wipe off escaping fuel; dispose offuel-soaked cleaning cloths in an environmentallyresponsible manner
- Loosen the two clips (32/1) and pull the fuel line off of both sidesof the fuel filter (32/2)
- Unscrew and take off the screw of the retaining clips (32/3) ofthe fuel filterdispose of the old fuel filter in an environmentallyresponsible manner
- Fasten the new fuel filter (32/2) by attaching the clips (32/3 andscrewing in the screw
- Re-connect the two fuel lines to the filter and fasten with the twoclips (32/1)
Ensure that the clips are firmly seated and check for leaks
Fig. 31
Fig. 32
1234
5
2
1
Fig. 33
32
3
Select a collecting container that is large enough to preventoil from spilling on the ground.
- Take the tank cap (33/1) off of the tank
- Remove the sieve from the tank and clean sieve
- Install the sieve in the reverse sequence
3.3.4.2 Robin - engine EH 25
Shut off roller as described under section 2.7
3.3.4.1 Lombardini - engine 15 LD 315
1
DVH550/600 25
- Shut off the roller as described in section 2.7,
- Unscrew the water hose (34b/2) from the water valve (34b/1)
- Take off water tank (34c/2) after loosening the four capnuts (34c/1)
- Place the vibration adjustment lever (34a/1)
in position ( )
- The V-belt (34e/1) is tensioned by the clamping force ofthe clamp element (34e/2) above the V-belt
pulley (34e/3)
- The V-belt tension meets specification, if it can be pressedin approximately 10 mm with a force of 100 N.
If the V-belt tension is insufficient, tighten as describedbelow:
- Loosen screw (34d/1) and pull the tension element (34d/2) to the rear, towards the hand guidance rod.
- When the desired tension is reached, fasten the tensionelement (34d/2) with the screw (34d/1).
Fasten the tension element so that the holder (34d/3) and clamping element (34d/2) are horizontalrelative to each other (see Fig. 34d)
- Check the tension again, as described above.
3.3.5.1 Check and tension the vibration V-belt
3.3.5 Check, tension and change the vibration v-belt
Fig. 34e
Fig. 34c
Fig. 34b
1
2
2
1
Fig. 34d
1
23
21
3
Ensure that the V-belt (34e/1) is properly aligned onthe belt pulley.
- Replace the water tank (34c/2) and fasten with the 4 capnuts (34c/1)
- Screw the water hose (34b/1) onto the water shut-offvalve (34b/2)
Fig. 34a
1
26 DVH550/600
3.3.5.2 Change the vibration V-belt- Shut off the roller as described in section 2.7
- Unscrew the water hose (35b/2) from the water valve (35b/1)
- Take off water tank (35c/2) after loosening the four cap nuts(35c/1)
- Place the vibration adjustment lever (35a/1) in position () (the V-belt tension is reduced)
- Take off the V-belt (35d/1) from the drive pulley (35d/2) onthe engine
- Loosen the two Allen screws (35e/1) on the underside of theroller frame (35e/2)
This must be done on the left side (from the operator’sperspective - below the reversing starter)!
This allows the vibration shaft to be raised slightly.
- Slightly raise the vibration shaft and pull the V-belt (35d/1)over the vibration shaft
- Slide the new V-belt over the vibration shaft and onto thedrive pulley
- Refasten the vibration shaft via the two Allen screws (35e/1) on the underside of the roller frame (35e/2)
Ensure that the screws are firmly seated!!
Apply Loctite 270 to the screws!!
- Place the V-belt on the drive V-belt pulley (35d/2) on theengine block
- Check the V-belt tension as specified in section 3.3.5.1 andtension as described, if necessary
Fig. 35a
Fig. 35b
2
1
1
2
Fig. 35e
Fig. 35d
Fig. 35c
1 1
2
Ensure that the V-belt (35d/1) is properly aligned onthe belt pulley (drive pulley, idler pulley, vibrationshaft)!
- Replace the water tank (34c/2) and fasten with the 4 capnuts (34c/1)
- Screw the water hose (35b/1) onto the water shut-off valve(35b/2)
Fig. 36 to 38 free
2
3
1
1
DVH550/600 27
- Remove the chain guard (38/2) by loosening the 6 screws(38/1)
- Check the tension of the chains (39/2)
- If chain tension is insufficient loosen the 3 fastening screws(39/1 or 39a/1) of the hydraulic motor
- Use a round steel bar (large screw driver) to raise the
hydraulic motor through the opening (39/3) until thechains (39/2) have reached the desired tension
The chains are tightened by lifting the pinion
- Retighten the screws (39/1 or 39a/1)
- Remove the chain guard (38/2) by loosening the 6 screws 38/1)
3.3.6.3 Change the drive chain- Loosen the tension 3.3.6.2
- Take the chains off of the pinion
Operation of the roller with one chain is prohibited!Danger of injury!!
- Re-tension the chains (39/2) as described under section3.3.6.2.
Fig. 38
Fig. 39
3.3.6 Lubricate, tension, or replace the drive chain- Shut off roller as described under section 2.7
3.3.6.1 Lubricate the drive chains- Remove the chain guard (38/2) by loosening the 6 screws (38/
1)
- Lubricate the chains (39/2) as needed
- For lubricant and specification, see the table in section 3.4
2
- Replace the chain guard (38/2) with the 6 screws 38/1)
3.3.6.2 Tension the drive chains
2
1
1
Fig. 39a
1
2
3
28 DVH550/600
3.3.7 Change hydraulic fluid- Shut off roller as described under section 2.7
Always drain the hydraulic fluid when the roller is at astandstill
- Open the hydraulic tank cap (40/1) on the tank
- Unscrew the protective cap (41/1) from the drain connection (41/4)
- Have a suitable collection container ready
- Screw the drain hose (included in the tool set) onto the drainconnection (41/4)
As soon as the drain hose is screwed on, the drain valvewill open
Danger of scalding due to hot oil
- Allow the old oil to drain out completely
Dispose of old oil in an environmentally responsiblemanner
- Unscrew the discharge hose
- Clean oil discharge duct (41/4) and drain valve
- Replace the protective cap (41/1)
- Fill hydraulic fluid in the hydraulic fluid filler neck (40/1), seesection 3.4 for oil quantity and specification
- Check the hydraulic fluid level in the view glass (42/1)3.3.8 Change hydraulic fluid filter- Shut off roller as described under section 2.7
- Drain hydraulic oil as described under section 3.3.7
- Remove the protective grating (41/3) by loosening the threescrews
- Unscrew the hydraulic oil filter (41/2)
- Wipe off/wipe up escaping residual fluid
Dispose of cleaning cloths, filter, and residual fluid in anenvironmentally responsible manner
- Lightly oil the rubber seal of the hydraulic oil filter
- Screw on new hydraulic oil filter
Only hand tighten the hydraulic fluid filter
- Top up hydraulic liquid (see section 3.3.7)
Fig. 41
1
Fig. 40
3
2
4
1
1
Fig. 42
DVH550/600 29
Only tighten the screws (46/4) tight enough that the pumpholder (46/5) can still slide in the slotted holes
- With a tire lever (flat bar steel) push the hydraulic pump holder(46/5) forward (away from the roller operator)
- After the V-belt (46/2) has reached the required tension, pressthe pump holder against the eccentric (46/3) and tighten the twoscrews (46/4)
- Replace the hydraulic tank (45/2), fasten with the four screws (45/1) on the side, and with one screw (46/1) on the pump holder
- Place the water tank (44/2) on the roller frame and fasten with thefour cap nuts (44/1)
- Screw the water hose (43/2) onto the water shut-off valve (43/1).
- Shut off roller as described under section 2.7
- Unscrew the water hose (43/2) from the water shut-off valve (43/1)
- Take off water tank (44/2) after loosening the four cap nuts (44/1)
- Unscrew the hydraulic tank (45/2). To do this loosen screw (46/1) on the pump holder (46/5) and the four screws (45/1) on theside of the hydraulic tank
- Lift off the hydraulic tank (45/2) and place it down to the rear
Ensure that hydraulic lines are not kinked or damaged!
- Loosen the pump holder by removing the two screws (46/4) fromthe roller frame
This reduces the tension of the V-belt (46/2).
Do not loosen the two eccentrics (46/3) (!) (factory beltalignment setting)!
- Replace the old V-belt with a new V-belt
- Fasten the pump holder (46/5) with the screws (46/4) on theroller console
The two nuts are welded onto a steel sheet, this must bepressed against the engine console from below
3.3.9 Change V-belt for the hydraulic pump
Fig. 43
Fig. 44
Fig. 45
Fig. 46
1
1
1
1
24
3
2
2
5
2
30 DVH550/600
3.3.10 Lubricate the vibration shaft
1
3.3.11 Adjust, clean the scraper- Shut off the roller as described in section 2.7
- Loosen each of the three screws (48/1) front or rear on the roller
- Slide the scraper (48/2) closer to the respective drum
The scrapers should not touch the drums!
- Tighten the three screws2 1
Fig. 48
Fig. 47
- Shut off roller as described under section 2.7
- Clean the lubricating nipple (47/1) on both sides of the vibrationshaft
- Place the grease gun on the lubricating nipple (47/1) of thevibration shaft
- See section 3.4 for fill quantity and specification
- Press grease into the bearing housing until fresh grease escapesat the edges
DVH550/600 31
3.4 Operating fluids and fill levels
Subassembly Operating material QuantitySummer Winter DVH
Quality 550 L 550 R 600 LEngineEngine oil SAE 10 W 40 1.0 l 1.0 l 1.0 l
(-10 ~ + 50 °C)API - CD CE
or SHPDor CCMC - D2 - D3 - PD1
Fuel tankGasoline Normal, unleaded gasoline 6.0 lDiesel Diesel Winter diesel fuel
(from approximately -12 °C) *
4.3 l 4.3 l
Diesel in accordance with DIN 51601-DKor BS2869-A1/A2
or ASTM D975-1D/2D
Hydraulic system Hydraulic fluid (ISO) H-LP 68 6.0 l 6.0 l 6.0 lKinem. viscosity 68mm²/s (cSt) at +40°C
First filling:Fuchs Renolin MR 68MC
Multigrade oil
Water tank Clean water 35.0 l 35.0 l 35.0 l
Lubricating pointsHigh pressure grease (lithium saponified), in accordance with DIN 51502 and 51825
KP2N-30, to 150°C As necessary
First filling: DEA Paragon EP2, Fuchs Renolit Duraplex
EP2 KKP2P-30
32 DVH550/600
4 Faults in operation4.1 GeneralIf a defect fault occurs on the roller then the following procedure must be executed:
- Shut off the roller as described in section 2.7.
- Determine the source of the fault (see section 4.2 Troubleshooting).
- Correct the fault, see section 3 (maintenance tasks) and section 2 (description of the different fasteningelements)
Correction of faults that affect the engine are described in the manual of the engine manufacturer.
The detailed descriptions of the various control elements, localization via the instructions in the maintenanceoverview (section 3), and troubleshooting (section 4.2) enable fast fault correction. The prerequisite is precisecompliance with the specified sequence for execution of the repair work.
The repair work must be executed with proper tools and the safety instructions specified in this operatingand maintenance manual must be complied with for all tasks.
If a fault is not eliminated after replacing a component, or a subassembly, the repair must be continued withexecution of the next described activity.
If a fault could not be eliminated even after execution of all specified repair activities, or if the repair is not describedin this operating and maintenance manual, then this fault must be eliminated by authorized service personnel.
4.2 TroubleshootingFault Possible cause Remedy Note
Roller does not start Operating error Execute start process as prescribed # 2.5
Lack of fuel Check the fuel level # 2.4.1Fuel filter fouled Change the fuel filter
# 3.3.4
Air filter fouled Clean/change air filter cartridge# 3.3.3
Roller does not move Operating error Repeat movement attempt # 2.6
Hydraulic pump is no longer working
Check the V-belt for the hydraulic pump, replace if necessary
# 3.3.9
No vibration V-belt for the vibration shaft is defective
Change V-belt # 3.3.5
Roller surface fouled Drums are fouled Adjust the scraper # 3.3.11
DVH550/600 33
4.3 Hydraulic circuit diagram
Fig. 47
Hydraulic circuit diagram
1 Diesel/gasoline engine2 Axial piston adjustment pump3 Filter change cartridge4 Hydraulic motor5 Hydraulic liquid tank
34 DVH550/600
5 Winter storage
5.1 Measures prior to storage
If the roller will not be used for a longer period (approximately 1 to 6 months) (e.g. during winter), it must be storedin a frost-free and dry location. The measures listed in section 5.1 must be executed prior to storage. After storagethe roller must be started up as described in section 5.2.
If the roller will be stored for longer than 6 months then contact the WEBER service organization to discussadditional measures.
Subassembly Measure NoteComplete roller - Clean thoroughly
- Check, status, fastenings, leakage
- Have the identified defects repaired
- Check oil level and top off as needed # 2.4.2
Engine -Startup at the storage location and run until operation temperature is achieved
- Shutdown# 2.7
- Seal all opening points
DVH 550/600 L -Remove the injection nozzle and spray engine oil into the seat, slowly activate the reversing starter
DVH 550/600 L - Top up with winter diesel to the lower edge of the filler neck
# 2.4.1
DVH 550 R
Fuel tank - Top up with normal gasoline to the lower edge of the filler neck
# 2.4.1
Hydraulic tank - Top up with hydraulic fluid to the upper edge of the view glass marking # 2.4.3
All bare parts - Coat with a thin application of grease or oil
Accelerator cable, drive activation cable
- Exterior cleaning
Water tank - Completely empty water tank and hose system
DVH550/600 35
5.2 Start-up after storage
Subassembly Measure Note
Complete roller - Clean thoroughly
- Execute same activities as those described before starting work
# 2.4.
36 DVH550/600
DVH550/600 37
38 DVH550/600
6 Weber Maschinentechnik GmbH
For problems, questions and further information refer to one of the following addresses:
in Germany
WEBER Maschinentechnik GmbH Postfach 2153
57329 Bad Laasphe - Rückershausen
Telefon Telefax E-Mail
+ 49 (0) 2754 - 398-0 + 49 (0) 2754 - 398101-switchboard + 49 (0) 2754 - 398102- spare parts- directlinie [email protected]
in Netherlands
WEBER Machinetechniek B.V.
Graafschap Hornelaan 159 6001 AC Weert
Telefon Telefax E-Mail
+ 31 (0) 495 - 530215 + 31 (0) 495 – 541839 [email protected]
in France
WEBER Technologie SARL
26’ rue d’ Arsonval 69680 Chassieu
Telefon Telefax E-Mail
+ 33 (0) 472 -791020 + 33 (0) 472 – 791021 [email protected]
in Poland
WEBER Maschinentechnik
Sp. zo.o. Ul. Grodziska 7
05-830 Stara Wies
Telefon Telefax E-Mail
+ 48 (0) 22 - 739 70 - 80 + 48 (0) 22 - 739 70 - 81 + 48 (0) 22 - 739 70 – 82 [email protected]
in
USA and Canada
WEBER Machine (USA), Inc.
45 D Dowd Road Bangor, ME 04401
Telefon Telefax E-Mail
+ 1(207) - 947 - 4990 + 1(207) - 947 - 5452 [email protected]
in South - America
WEBER Maschinentechnik do Brasil
Máquinas Para Construção Ltda. Rua Curt Wacker, n° 45
93332 – 200 Novo Hamburgo, RS Brasil
Telefon Telefax E-Mail
+ 55 (0) 51- 587 3044 + 55 (0) 51- 587 2271 [email protected]
DVH550/600 39
40 DVH550/600
> Vibration plates
> Vibrating tampers
> Vibration rollers
> Joint cutters
> Internal vibrators and converters
> Rollers
Weber MASCHINENTECHNIK GmbHIm Boden
57334 Bad Laasphe - RückershausenPostfach 2153
57329 Bad LaaspheTelephone + 49 27 54 / 398 0 - fax +49 27 54 / 398 101