Weber mt DVH 550 L - 2 Operating instructions

DVH550/600 1
OPERATING AND
MAINTENANCE MANUAL
0408/englisch
DVH 550 L - 2
DVH 550 R - 2
Weber Maschinentechnik GmbH
Postfach 21 53, 57329 Bad Laasphe-Rückershausen
Telephone + 49 27 54 / 398-0
Fax + 49 27 54 3 98-101 (switchboard) & 3 98-102 (spare parts)
DVH 600 L - 2

2DVH550/600

DVH550/600 3
Introduction
This operating and maintenance manual provides instructions for safe handling of type DVH 550 L, DVH 550 R
and DVH 600 L vibration rollers. Read this manual prior to first start-up and familiarize yourself with all the details
of 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 the
roller are described.
Section 3 provides an overview of the necessary maintenance activities and a description of the necessary specific
maintenance activities. Section 4 contains troubleshooting instructions for the operator. Measures for storing the
vibration roller
Particular attention was paid to user-friendly design through instructive photos and text information. References
to photos are indicated by parentheses in the text. The first number indicates the photo number and the second
number 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 particular
attention.
Indicates work procedures and operating procedures, execution of which additionally requires compliance
with applicable environmental protection provisions and disposal guidelines.
Indicates work procedures and operating procedures that must be precisely followed to avoid damage or
destruction to the roller.
indicates work procedures and operating procedures that must be precisely followed to exclude the
possibility of personal injury.
If needed you can obtain additional information from your authorized WEBER dealer, or you can obtain information
from one of the contact addresses listed on the last page.

4DVH550/600
General safety guidelines
General 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’s
country and at the implementation site, the recognized specialized technical rules for safety* and professional work
must also be complied with.
Intended use
Rollers should only be operated properly, following the instructions in the operating and maintenance manual, in
compliance with recognized safety rules and traffic regulations, and the country-specific regulations or higher level
directives (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 must
have been instructed by the customer or customer’s authorized representative beforehand relative to operating
and maintaining the roller.
Protective equipment
For the rollers described in this operating and maintenance manual it is possible that the permissible sound level
of 90 dB(A) may be exceeded. In accordance with the accident prevention guideline “Noise” (BGV-B3), persons
working 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 ............... 30
3.3.11 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 after
storage .............................................. 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 guidelines
for operation ..................................... 10
2.2 Transport .......................................... 11
2.2.1 Loading with crane ............................. 11
2.3 First start-up ..................................... 11
2.4 Activities prior to starting work ...... 11
2.4.1 Check the fuel level ............................ 12
2.4.2 Check the engine oil level ................... 12
2.4.3 Check the hydraulic fluid level ............ 13
2.5 Starting.............................................. 14
2.5.1 Normal start DVH 550 L/ 600 L .......... 14
2.5.2 Normal start DVH 550 R ..................... 15
2.6 Driving and compacting .................. 16
2.7 Shutdown .......................................... 17
3 Maintenance ..................................... 18
3.1 Safety guidelines
for maintenance ............................... 18
3.2 Maintenance overview ..................... 19
3.2.1 Initial maintenance ............................. 19
3.2.2 Regular maintenance ......................... 20
3.3 Description of
maintenance tasks ........................... 22
3.3.1 Change engine oil .............................. 22
3.3.2 Change engine oil filter ....................... 22
3.3.3 Clean/change air filter cartridge .......... 23
3.3.4 Clean/change fuel filter ....................... 24
3.3.5 Check & change the vibration V-belt .. 25/
........................................................... 26
3.3.6 Lubricate, tension, or replace the .......
drive chains ........................................ 27
3.3.7 Change hydraulic fluid ........................ 28
3.3.8 Change hydraulic fluid filter ................ 28
Table of contents

6DVH550/600
1.1 Graphic presentation
1. Technical description
Fig. 1 Overall view DVH 550 L / DVH 550 R / DVH 600 L
1 Hand guidance rod
2 Hydraulic tank
3 Lifting ring
4 Water tank
5 Fuel tank
6 Engine
7 Reversing starter
8 Hydraulic fluid filter (illustration above)
9 Scraper
10Drums
11Chain guard
12Parking brake
13Gas lever
14Vibration lever
15Safety bar and drive lever
16Crush guard
8
10
9
6
7
12
11
16
12
3
15
14
13
5
4

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 compaction
work in road building applications.
A Lombardi diesel engine provides the motive power for rollers DVH 550 L and DVH 600 L; motive power
for 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 in
which roller.
The two drums (1/10) are hydrostatically powered via chains. The chain drive is executed individually on
each bandage. The chain drive also serves as a safety braking system for operating on slopes. The vibrator
that 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 a
hydraulic 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 guidance
rod. The throttle (1/13) for engine speed control. Direction of travel and speed are controlled with the safety
bar (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 the
operator bumps against the crush protection device (1/16) when moving in reverse, the machine comes to
a stop.
Drive
Function
Operation

8DVH550/600
* 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
34
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 the
prevailing operating conditions.
2
1

10 DVH550/600
Safety instructions and warnings
Behavior if there are defects
Machine operator behavior
Stability under load
Driving and compacting
2 Operation
2.1 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 functioning
properly. 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 the
roller. 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 your
supervisor immediately. If there are defects that impair operational safety then operation must be stopped
immediately.
During operation rollers must be monitored constantly to ensure operationally safe condition. The machine
operator should not distance himself from the control devices when the device is in motion and must always
maintain a sufficient view of the travel area of the roller. If view of the travel area is restricted by influences incidental
to 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 particularly
in jeopardy on the edges of embankments and shoulders. Consequently maintain a safe distance from the edges
of embankments and brinks.
When moving backward rollers must be operated from the side to exclude the possibility of crushing injury to the
machine 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. Compaction
work on slopes that exceed the maximum climbing capacity of the roller, is prohibited. Inclines and slopes must
be worked/traversed with extreme caution and always with the device moving directly up or directly down. In this
regard the roller should not be abruptly accelerated or braked.
Wet and loose substrates on inclines and slopes significantly reduce roller traction. Increased accident
danger!
Movements over unlevel areas and curbs should only be executed at reduced speed. In addition the roller must
be guided in such a manner that the possibility of injury due to sudden swing-out of the hand guidance rod is
excluded.
Emissions
Never inhale exhaust gas, it contains carbon monoxide, a colorless and odorless gas that is extremely dangerous
and that can result in unconsciousness and death within a short time. Never operate the engine in enclosed
areas 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-up
For 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 Transport
For transport over short distances within the construction site
the roller can be moved as specified in section 2.6.
For transport over greater distances the roller can be crane lifted
onto suitable means of transport (truck, trailer).
Fig. 2
Only use lifting tackle and crane with sufficient bearing
capacity.
- Carefully lash the roller on the transport trailer as prescribed
(see the operating manual provided by the manufacturer of
the 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. Smoking
and open flame are prohibited when fueling.
Carefully wipe up spilled fuel. Dispose of cloths that are
soaked with fuel in an environmentally responsible
manner.
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) with
clean diesel fuel
Fill DVH 550 R (Robin engine) with clean, lead-free
normal gasoline
2.4.2 Check the engine oil level
The roller must be positioned on a horizontal surface to
check 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 the
dip stick (6/-)
- Top up the engine oil if necessary (see section 3.4 for fill
quantity and specification)
2
1
Min.
Max.
Min.
1

DVH550/600 13
The roller must be positioned on a horizontal surface
when 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 for
fill quantity and specification)
No hydraulic fluid is consumed during operation. If the
fluid level drops, you must check the hydraulic system
for leaks
2.4.3 Check the hydraulic fluid level
The hydraulic fluid level must be between the middle
and the upper edge (marking) of the view glass.
1
Fig. 8

14 DVH550/600
-Slowly pull the handle of the reversing starter (10/1) until
resistance is noticeable.
- Allow the handle (10/2) to slide back into the initial position,
and then forcefully and completely pull it through with both
hands.
If the engine does not start, repeat the start process.
- As soon as the engine starts running, guide the starter rope
back into the reversing starter.
2.5 Starting
Prior to starting always ensure, that no one is in the
roller’s danger zone and that all protective devices are
properly attached.
Never use start-aid sprays.
When starting in enclosed spaces ensure adequate
ventilation - Danger of suffocation!
Fig. 10
Fig. 9
1
2
2.5.1 Normal start DVH 550 L / DVH 600 L
To start, push the vibration lever (9/1) into the off
position ( ).
- 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/or
ambient temperature.
a) If the engine is cold and/or at a lower ambient temperature
close the choke (13/2) entirely (move it to the right).
b) If the engine is hot and/or at higher ambient temperature
open the choke (13/2) between half way and the fully open
position (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 both
hands.
If the engine does not start, repeat the start process.
- As soon as the engine starts running, guide the starter rope
back into the reversing starter (14/1)
- Move the choke (13/2) slowly into the completely open
position (to the left) allow the engine to warm up at idle speed
for approximately 5 min.
2.5.2 Normal start DVH 550 R
Fig. 11
Fig. 12
Fig. 13
2
1
Fig. 14
2
1
Open
To start the push the vibration lever (11/1) into the off
position ( ).
- 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 full
throttle 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 the
drive 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 can
be caught between the machine and the obstruction; or
ensure that the machine does not slip into the pit.
- Use the hand guidance rod (18/1) to steer the machine in the
desired direction.
1
The engine accelerates to full rpm
4
3
1
2
If the operator bumps against the crush guard (15/4) when
moving in reverse, the machine comes to a stop.
Through swinging out the drive lever (15/1) forward in the
direction of travel, the crush protection fixture is again lifted up.
5
1

DVH550/600 17
2.7 Shutdown
Prior to breaks and when concluding work the roller must
be placed on stable and horizontal terrain (to the extent
possible).
- 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 be
safeguarded against through conspicuous measures. If
rollers are parked the route of traffic, then in addition the
safety measures specified in road traffic regulations must
also be employed.
Do not switch off the engine under full load
- Pull the parking brake all the way back (horizontal) until it locks
in place on slopes the roller must additionally be secured against
rolling 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 a
standstill
1
1
2

18 DVH550/600
3 Maintenance
3.1 Safety guidelines for maintenance
Hand-guided vibration rollers must be inspected by an expert to ensure safe operational status in accordance
with use conditions and operating conditions, as needed; this inspection however is required at least once a
year. 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 those
tasks 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 fluids
must 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 against
starting unintentionally.
After maintenance work the protective devices must be properly reattached.
Unauthorized changes or conversions to rollers are prohibited for safety reasons. The manufacturer expressly
excludes any liability for damage that occurs due to changes or conversions to the roller. To ensure safe and
reliable 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 engine
manufacturer, either Lombardini or Robin.
Changes and conversions
Tests

DVH550/600 19
3.2 Maintenance overview
All maintenance tasks that must be executed on the roller are listed in two tables. The maintenance tasks in the
first table (section 3.2.1) must be executed at certain times and once after first start up. The maintenance activities
in 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 is
specified 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 to
other 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/inst
ructions
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 mac hine - 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 plug
Manual 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 # 3.3.6
Scraper - Visually inspect or readjust # 3.3.11