Instruction Manual

Vibratory Roller

Model VDR550DK

Model VDR650DK

Model VDR800DK

Table of Contents

1. PREFACE……….……………………………………………..1

2. APPEARANCE AND DESCRIPTIONS……….…………….1

3. TECHNICAL SPECIFICATIONS………………………….....2

4. SAFETY…………..……………………………………….…3-4

5. INTENDED USE……………………………………………….4

6. OPERATION CONTROL……………………………………..4

7. STARTING……………………………………………...……5-6

8. OPERATING INSTRUCTIONS………………………...…….6

9. CAUTION ON OPERATION……………………………..6-7

10. STOPPING AND PARKING………………………………...7

11. LIFTING AND TRANSPORTATION…………………………7

12. STORAGE……………………………………………...………7

13. MAINTENANCE AND INSPECTION…………………..7-10

1

1. PREFACE

This Instruction Manual contains important information on proper use and maintenance

of the machine. Read this manual very carefully, be acquainted with the contents

BEFORE attempting to operate and maintain this machine, and keep this manual with

the machine for quick reference.

The information with Mark is particularly important in terms of safety and for

prolonged life of the machine.

2. APPEARANCE AND DESCRIPTION

Note:

Handle drawings throughout this manual may differ from the actual handle style, the controls are still the

same though

2

3. TECHNICAL SPECIFICATIONS

Model VDR550DK VDR650DK VDR800DK

Dimension (L x W x H) mm 2295x630x1115 2385x700x1150 2465x754x1163

Operating Weight kg 565 675 830

Drum Size (D x W) mm 356 x 590 402 x 650 404 x 700

Centrifugal Force Kgf(KN) 900(8.8) 1100(10.8) 2243(22.0)

Vibration Frequency Hz(Rpm) 55(3300) 55(3300) 55(3300)

Max. Working Speed km/h 3.6 3.6 3.6

Gradeability ° 25 25 30

Fuel Tank Capacity ℓ 35 40 40

Hydraulic Tank Capacity ℓ 21 30 30

Engine - Model Kubota E75NB3 Kubota E75NB3 Kubota EA330E3

Kw(Hp) 4.8(6.5) 4.8(6.5) 5.2(6.9)

Type 4 Stroke 4 Stroke 4 Stroke

Diesel Diesel Diesel

Double Exciter

MEASUREMENT, MM A B C D E F G H I

VDR550DK 2295 1115 520 356 590 630 215 20 1740

VDR650DK 2385 1150 560 402 650 700 243 25 1780

VDR800DK 2465 1163 600 404 700 754 276 27 1780

G G

H H E

F

3

4. SAFETY

4-1 General Safety

This section deals with safety

instruction to prevent possible injury,

property damage, or possible death from

occurring arising from the use of this

machine. The operator is strongly

requested to read through this manual, and

be acquainted with the contents.

FAILURE TO OBSERVE THE

FOLLOWING SAFETY PRECAUTION MAY

CAUSE POSSIBLE INJURY, PROPERTY

DAMAGE, OR POSSIBLE DEATH!!

This machine must only be used for its

intended purpose.

The machine must be operated only by

well-trained personnel.

The machine must be operated on the

ground where stability is guaranteed.

When working near the rim of excavated

trenches, use the machine properly so that

the machine may not collapse or fall down.

When the machine needs to be operated

on slopes, avoid crossing the slope

diagonally. Always try to run the machine

along the slope.

The exhaust gas contains poisonous and

hazardous CARBON MONOXIDE. Use

the machine in well-ventilated area.

The exhaust pipe and muffler is subject to

extremely high temperature during and

after the operation. DO NOT touch it

during or immediately after the operation.

Never leave the inflammables such as fuel,

paper, matches, etc. near the exhaust port.

4-2 Labor Protection Regulations

The owner of this machine must

comply with the Safety Regulations of

Labor Protection in the country.

4-3 Residual Risks

This machine is designed to

eliminate the possible risks from the use of

it. However, the risks DO reside, and these

residual risks are not clearly recognizable,

and may cause personal injury or property

damage, and possible death. If such

unpredictable and unrecognizable risks

become apparent, the machine must be

stopped immediately, and operator or his

supervisor must take appropriate measure

to eliminate such risks. It is sometimes

necessary that the manufacturer must be

informed of such event for future counter

measuring.

4-3-1 Mechanical Hazards

Personal injury or property damage

may be caused by knocks, crushing,

slipping, tripping, falling, or by flying chips

due mainly to the improper or careless

handling of the machine, or working in a

confined area. To prevent such hazards,

wear proper working gloves, close-fitting

clothing, protective shoes, and face and

eye protector. Clear the obstacles around

the site to prevent unpredictable move of

the machine.

4

Vibration Lever

Forward/ Reverse Lever

Safety Lever for

Reverse Motion

Throttle Lever

4-3-2 Hazards caused by fuel and oil

Oil and fuel used in this machine

may cause following hazards;

Poisoning if the fuel or oil vapor is inhaled.

Allergies if the fuel or oil spills on the skin.

Fire and explosion if the fuel and oil is

handled near the smoking or open fires.

WHEN HANDLING THE FUEL OIL,

SMOKING OR USE OF OPEN FIRE IS

STRICTLY PROHIBITED.

Keep the fuel and oil in a suitable and

approved container, and keep the

container in a cool and dark place to

prevent any hazard arising from the

storage of these. Use extra caution when

handling fuel.

REMEMBER!! The diesel fuel is highly

flammable. When refueling, be sure to do

so after the engine is cooled off completely.

Use proper funnel when refueling, and

avoid spilling over the engine.

4-3-3 Hazards from Noise

Noise from the machine itself, as

well as noise from the ground being

compacted, may cause hearing difficulties

or physical disorder such as loss of

balance or consciousness disorder.

WEAR EAR PROTECTOR DURING THE

OPERATION.

5. INTENDED USE

These machines are intended to be used for

compaction of backfill and asphalt surface. It

may not be used for the compaction in

trenches when the trench is narrow or wall of

the trench is liable to be collapsed. It is not

recommended to apply vibration on any hard,

well-compacted ground or on concrete surface.

This will result in damages to the bearings, and

may affect the performance of the machine.

6. CONTROL LEVER

The Control Levers of these machines are

centralized at the operation handle.

Driving

Forward: Move the driving lever forward.

Reverse: Move the driving lever backward.

Vibration

Activate vibration:

Move the Vibration Lever to the right, and pull

backward.

Deactivate vibration:

Push the Vibration Lever forward, and move it

to the left.

5

7. STARTING

7-1 Before Starting

1) Please read Engine operation manual

BEFORE attempting to start the engine.

2) Check to see that the fuel and engine oil is

sufficient.

Be sure to confirm that the engine

is cooled off when refueling. Wipe off the

spilt fuel on the engine before starting. Use

clean fuel. Use of contaminated fuel may

damage the fuel injection system of the

engine.

Check the oil level in the engine

using the Oil level gauge. The oil should be

seen between the H and L position. Use

diesel engine oil with proper viscosity.

3) Check thoroughly around the engine to

confirm that there are no leaks of fuel or oil.

If any leak is apparent, DO NOT use the

machine, and have it repaired at the

authorized service facility.

7-2 Starting

Be sure to confirm that the Drive

Lever is set to Neutral, and Vibration Lever

to OFF, and the Parking Brake is at ON

(applied) position before attempting to start

the engine.

Before starting the engine, make

sure that there are no obstacles or

unauthorized person around the machine.

7-2-1 Starting the engine

(Crank Handle Starter)

1) Open the Fuel Cock.

2) Set the throttle lever to RUN position.

3) Insert the Starting Handle to the starter

bracket provided at the engine.

4) While pulling the Decompression lever with

your left hand, turn the start handle slowly.

5) When you hear the injection sound of the

fuel, turn the start handle rapidly, and

release the decompression lever until the

engine starts.

Never let your hands off from the

start handle during and after the engine

starts.

7-2-2 Starting the engine

(Electric Starter)

1) Open the Fuel Cock

2) Set the Throttle Lever to RUN position.

3) Turn the Key Switch clockwise. When the

engine has been started, release your hand

from the key. Leave the key to be at ON

position during the operation. Otherwise,

the battery will be fully discharged.

4) When the ambient temperature is low, turn

the Start Key to GL position. After 10

seconds, turn the key to start position to

start the engine. (KDS ONLY)

CAUTION

To avoid starter trouble, do not rotate

electric starter more than 5 seconds even

when the engine does not start.

If the engine does not start at the first

attempt, let the key return to the

“RUNNING” position and wait for about 10

seconds, and try again. Repeated turning

of the starter will deplete the battery.

Before turning the key to STARTING

position, be sure to return it once to “OFF”

6

position.

7-3 Warm Up

After engine has started, let the engine run at

idle without load for a few minutes for warm up.

8. OPERATING INSTRUCTIONS

These machines can only be

operated by qualified and well-trained

operator.

1) Always make sure before operation that

there are no unauthorized personnel

around the machine.

2) Disengage the Parking Brake by swinging

the Parking Brake Lever to the right.

Any attempt to drive the machine

without disengaging the Parking Brake may

cause serious damage to the machine.

3) Increase the engine speed to its prefixed

maximum by setting the Throttle Lever to

“RUN” or “HIGH” position.

4) Move the Drive Lever forward or reverse to

achieve the forward and reverse motion.

Always set the Throttle Lever to

MAX position during the operation. Do not

attempt to start or stop the drive or to

adjust the drive speed by altering the

setting of the Throttle Lever.

5) Set the Vibration Lever to “ON” position to

apply the vibration to the ground.

When you leave the machine

unattended, be sure to stop the engine, and

apply the parking brake.

9. CAUTION ON OPERATION

Avoid moving the drive lever suddenly or

irrationally. Be sure to set it to neutral once,

and move the lever slowly to change the

direction.

Do not ride on the machine during the

operation.

Always confirm that the machine stops

completely when the drive lever is set to

neutral. If the machine tends to creep even

when the drive lever is set to neutral, the

neutral setting needs to be re-adjusted.

(Please refer to the MAINTENANCE AND

INSPECTION section of this manual.)

Check to confirm that the SAFETY-BACK

LEVER moves smoothly, and works

properly before starting the engine.

Always operate the machine with all the

covers fitted on its position.

Never attempt to touch any of the moving

part of the machine.

Do not set the throttle lever halfway

between HIGH (RUN) and LOW position.

Otherwise, premature wear at the clutch

may result. Never try to adjust the drive

speed by altering the setting of throttle

lever.

Make sure that the Handle Stopper Pin is

securely in its position when the operation

handle is folded.

OFF

7

Avoid applying vibration on concrete or

well-compacted ground. Excessive

vibration may cause premature wear or

damages to the bearings.

Use extra caution when compacting on

steep slopes. Machine may roll over or

slide. Avoid crossing the slope.

10. STOPPING AND PARKING

1) Set the Vibration Lever to “OFF” position

2) Make sure that the driving lever is returned

to its NEUTRAL position.

3) Set the speed control lever to LOW position,

and let the engine run at idle for a few

minutes before stopping.

4) Move the speed control lever to “STOP”

position.

The machine should be kept at the

level surface at the time of stopping the

engine.

5) Pull the key out from the starter switch.

6) Close the fuel cock.

7) Apply Parking Brake by swinging the

Parking Brake Lever to the left.

For maximum safety, put suitable

shackles at the drum after applying the

parking brake.

Never attempt to park the machine

on the shoulder where it may be liable to be

collapsed.

11. LIFTING TRANSPORTATION

1) When lifting the machine with a hoist, be

sure to follow the safety regulation of the

hoist.

2) When loading on the vehicle, use proper

slopes with enough width and strength. Do

not stand aside the machine being loaded

using slopes.

3) After the machine is loaded on the truck, be

sure to apply the parking brake, and secure

the machine with rope and shackles. The

rope should go through the holes provided

at the side frame, and must be securely

anchored to the vehicle’s anchoring points.

12. STORAGE

1) Store the machinery at dry place.

2) The operation handle may be folded up by

pulling the Eye bolt, and push up the

operation handle.

13. MAINTENANCE & INSPECTION

13-1 Inspection Before Daily

Operation

1) Inspect all the control levers for the

smoothness and function.

2) Inspect all the fastenings, (Bolts and Nuts)

for tightness.

3) Inspect any leaks of water, oil, or fuel.

4) Inspect the sufficiency of fuel, oil, and

coolant.

5) Inspect the sufficiency of hydraulic oil.

13-2 Maintenance of the Machine

1) Belt Tension Adjustment (DRIVE BELT)

ON

8

The belt should deflect approximately 5mm

when pushed with thumb at the center

between centrifugal clutch and pump pulley. To

adjust the tension, loosen four bolts, which fix

the Pump Bracket, and screw the Adjust Bolt

until proper tension is achieved. Then,

retighten the bolts.

Replace the belt if it has been worn out or

damaged.

2) Vibration Unit

Confirm that the Vibration Lever works

properly to switch the vibration. Apply light coat

of grease at the moving parts for every 100

hours of operation.

If the belt is worn or damaged, replace with

new one.

Belt Size: A-33 (VDR550DK, VDR650DK)

A-37 (VDR800DK)

13-3 Drive Lever: Neutral Setting

Perform this setting on the level

surface.

1) Stop the engine

2) Remove the nut at the Rod End of the Drive

Lever.

Never start the engine while this nut is

removed. Any attempt to run the engine

may cause serious injury when the drive

wire is moved either intentionally or

unintentionally. Remember: You

cannot control the machine with the

Drive Lever if this nut is removed.

3) Loosen the Lock Nut at the Rod End.

4) Turn the Rod End clockwise or

counterclockwise depending upon how the

neutral has been shifted.

5) Refit the Rod End to the Drive Lever with

nut, and start the engine.

6) Increase the engine speed, and move the

Driver Lever to see if the neutral position is

properly adjusted.

7) Repeat the procedure until the neutral

position has been properly adjusted.

8) Apply LOCTITE to the nut at the Rod End,

and tighten it.

9) Tighten the Lock Nut.

9

13-4 Scrapers

Remove the scrapers occasionally, and wipe

off any dust, dirt, or asphalt adjust the gap

between the drum and the scraper as

necessary by shifting the scrapers after

loosening the bolts.

13-5 Water Tank

Clean the inside of the water tank occasionally.

Small particles in the water tank may cause

sprinkler nozzle to be clogged.

13-6 Sprinkler Nozzle

Remove the cap at the sprinkler nozzle, and

clean the inside of the nozzle occasionally.

13-7 Drive Lever

1) Adjust the operation force of the Drive

Lever using the adjust nuts. Operation

force should be 2 to 3 Kgf.

2) Apply grease to the moving portion at every

100 hours of operation.

13-8 Hydraulic System

Check the Hydraulic System daily to see if

there is any leakage of hydraulic oil from the

pipe and connectors.

10

1) Oil Filter Element

New machine initial change of Oil Filter

Element should be after 50 hours of operation.

After that every 500 to 600 hours of operation.

Use genuine oil filter.

2) Hydraulic Oil

New machine initial change of Hydraulic Oil

should be after 50 hours of operation. After

that every 500 to 600 hours of operation. Flush

the inside of the Hydraulic tank with suitable

solvent when the old hydraulic oil is drained.

After new hydraulic oil is resupplied, leave the

filler cap unclosed, and run the engine for 10

minutes at its maximum speed for vent the aid

from the hydraulic system.

Negligence of periodical replacement of

hydraulic oil may cause trouble to the entire

hydraulic system including the pump and

motors.

Recommended Hydraulic Oil

Shell: Tellus T37

Mobile: Mobile DTE15

13-9 Electric System

1) Battery

Hydrometer is provided to check the condition

of the battery.

2) Wires and Connectors

Never flush the pressurized water directly to

the electric wire, connectors, or components.

When the machine has been left outside for a

long time, remove the electric connectors and

dry thoroughly from machine, and cover the

terminal with caps of suitable material, and

store it in cool, dry area.