Multiquip MDR-9DYE User Manual

OPERATION AND PARTS MANUAL

Vibratory

Walk-Behind Roller

Model

MDR-9DYE

(Yanmar Diesel)

© COPYRIGHT 2003, MULTIQUIP INC.

Revision #0 (12/19/03)

MULTIQUIP INC

18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: [phone]
310-537-3700
800-421-1244 800-478-1244
FAX: [phone] FAX: [phone]

E-mail:[e-mail] • www:multiquip.com

Atlanta • Boise • Dallas • Houston • Newark
Montreal, Canada • Manchester, UK
Rio De Janiero, Brazil • Guadalajara, Mexico

..

. PARTS DEPARTMENT:

..

SERVICE DEPARTMENT/TECHNICAL ASSISTANCE:

PAGE 2 — MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MULTIQUIP’S MAIN PHONE NUMBERS

800-421-1244 FAX: [phone]
310-537-3700

PARTS DEPARTMENT

800-427-1244 FAX: [phone]
310-537-3700 FAX: [phone]

MAYCO PARTS

800-306-2926 FAX: [phone]
310-537-3700 FAX: [phone]

SERVICE DEPARTMENT

800-478-1244 FAX: [phone]
310-537-3700

MQ POWER SERVICE DEPARTMENT

800-835-2551 FAX: [phone]

ON-HAND

WHEN CALLING

310-537-3700

TECHNICAL ASSISTANCE

800-478-1244 FAX: [phone]

WARRANTY DEPARTMENT

800-421-1244, EXT. 279 FAX: [phone]
310-537-3700, EXT. 279

MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03) — PAGE 3

TABLE OF CONTENTS

MIKASA MDR-9DYE­VIBRATORY ROLLER

Proposition 65 Warning ..............................................2

Here's How To Get Help .............................................3

Table Of Contents ......................................................4

Parts Ordering Procedures ........................................ 5

Safety Message Alert Symbols .............................. 6-7

Rules for Safe Operation ....................................... 8-9

Operation and Safety Decals ...................................10

Specifications ...........................................................11

Dimensions ..............................................................12

General Information ........................................... 14-15

Vibratory Roller Components ................................... 16

Yanmar Engine Components ...................................17

Inspection .......................................................... 18-19

Operation ........................................................... 21-23

Maintenance ...................................................... 24-29

Troubleshooting ................................................. 30-31

Explanation Of Code In Remarks Column ...............32

Suggested Spare Parts ............................................33

Yanmar L100EE­DEVMK2 Engine

Cylinder Block Assembly ....................................66-67

Cylinder Head and Cover Assembly ..................68-69

Muffler Assembly ............................................... 70-71

Air Cleaner Assembly .........................................72-73

Crankshaft, Piston and Camshaft Assembly .....74-75

Lub. Oil Pump and Governor Assembly .............76-77

Cooling and Starting Device Assembly .............. 78-79

Fuel Injection Pump Assembly ...........................80-81

Fuel Tank and Fuel Line Assembly ....................82-83

Starting Motor and Dynamo Assembly ..............84-85

Tool Label and Gasket Set Assembly ................86-87

Terms and Conditions Of Sale — Parts .................. 88

PARTS ILLUSTRATIONS

Decal Placement ................................................ 34-35

Body Assembly .................................................. 36-37

Front Cover Assembly ........................................ 38-41

Axle Assembly .................................................... 42-45

Transmission Assembly ...................................... 46-47

Hydraulic Oil Tank Assembly ............................. 48-49

Clutch Box Assembly ......................................... 50-53

Vibrator Assembly .............................................. 54-55

Upper Control Handle Assembly........................ 56-59

Lower Control Handle Assembly........................ 60-61

Battery Assembly ............................................... 62-63

Ignition Switch/Mounting Plate Assembly .......... 64-65

NOTE

Specification and part
number are subject to
change without notice.

PAGE 4 — MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03)

PARTS ORDERING PROCEDURES

When ordering parts,

please supply the following information:

❒❒

❒ Dealer account number

❒❒
❒❒

❒ Dealer name and address

❒❒
❒❒

❒ Shipping address (if different than billing address)

❒❒
❒❒

❒ Return fax number

❒❒
❒❒

❒ Applicable model number

❒❒
❒❒

❒ Quantity, part number and description of each part

❒❒
❒❒

❒ Specify preferred method of shipment:

❒❒

✓ FedEx or UPS Ground
✓ FedEx or UPS Second Day or Third Day
✓ FedEx or UPS Next Day
✓ Federal Express Priority One
✓ DHL
✓ Tr u c k

Note: Unless otherwise indicated by customer, all
orders are treated as “Standard Orders”, and will
ship within 24 hours. We will make every effort to
ship “Air Shipments” the same day that the order is
received, if prior to 2PM west coast time. “Stock
Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on
hand when calling.

Parts Department

800-427-1244 Fax: [phone]

310-537-3700 Fax: [phone]

Mayco Parts

800-306-2926 Fax: [phone]

310-537-3700 Fax: [phone]

Service Department

800-478-1244 Fax: [phone]

310-537-3700

MQ Power Service Department

800-835-2551 Fax: [phone]

310-537-3700

Technical Assistance

800-478-1244 Fax: [phone]

Warranty Department

800-421-1244, Ext. 279 Fax: [phone]

310-537-3700, Ext. 279

Multiquip’s Main Phone Numbers

800-421-1244 Fax: [phone]

310-537-3700

Place Your Parts Order Via Web or Fax

For Even More Savings!

Extra Discounts!

All parts orders which include complete part numbers
and are received by our automated web parts order
system, or by fax qualify for the following extra
discounts:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances
when you order 10 or more
line items via Web or Fax!**

FedEx Ground Service

No other allowances on freight shipped by any other
carrier.

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

at no charge for freight

MULTIQUIP INC.

18910 WILMINGTON AVENUE
POST OFFICE BOX 6254
CARSON, CALIFORNIA 90749
310-537-3700 • 800-421-1244
FAX: [phone]
E-MAIL: [e-mail]
WWW: multiquip.com

MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

MDR-9DYE — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when
operating this equipment. Failure to read and understand the
Safety Messages and Operating Instructions could result in
injury to yourself and others.

This Owner's Manual has
been developed to provide
complete instructions for the

NOTE

Before using this vibratory roller, ensure that the operating
individual has read and understands all instructions in this
manual.

safe and efficient operation
of the Multiquip Model
MDR-9DYE Vibration Roller.
Refer to the engine
manufacturer’s instructions for
data relative to its safe
operation.

HAZARD SYMBOLS

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure to
the operator, and are preceded by one of three words: DANGER,

WARNING, or CAUTION.

L

Lethal Exhaust Gases

Engine exhaust gases contain poisonous
carbon monoxide. This gas is colorless and

odorless, and can cause death if inhaled.
NEVER operate this equipment in a confined

area or enclosed structure that does not
provide ample free flow air.

Explosive Fuel

Diesel fuel

vapors can cause an explosion if ignited. DO
NOT start the engine near spilled fuel or

combustible fluids. DO NOT fill the fuel tank
while the engine is running or hot. DO NOT
overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or

sparks from the ignition system. Store fuel in
approved containers, in well-ventilated areas
and away from sparks and flames. NEVER
use fuel as a cleaning agent.

is extremely flammable, and its

DANGER: You WILL be KILLED or

SERIOUSLY injured if you do not follow
directions.

WARNING: You CAN be KILLED or

SERIOUSLY injured if you do not follow
directions.

CAUTION: You CAN be injured if you

do not follow directions.

Potential hazards associated with this vibratory roller operation
will be referenced with Hazard Symbols which appear
throughout this manual, and will be referenced in conjunction
with Safety Message Alert Symbols.

Burn Hazards

Engine components can generate extreme heat.
To prevent burns, DO NOT touch these areas
while the engine is running or immediately after
operations. Never operate the engine with heat
shields or heat guards removed.

Rotating Parts

NEVER operate equipment with covers, or

guards removed. Keep fingers, hands, hair and
clothing away from all moving parts to prevent
injury.

PAGE 6 — MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03)

MDR-9DYE — SAFETY MESSAGE ALERT SYMBOLS

Accidental Starting

ALWAYS place the engine ON/OFF switch in

the OFF position, when the vibration roller is
not in use.

Sight and Hearing hazard

ALWAYS wear approved eye and

hearing protection.

Respiratory Hazard

ALWAYS wear approved respiratory

protection.

Equipment Damage Messages

Other important messages are provided throughout this manual
to help prevent damage to your vibration roller, other property,
or the surrounding environment.

NOTE

This vibratory roller, other
property, or the surrounding
environment could be
damaged if you do not follow
instructions.

MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03) — PAGE 7

CAUTION:

MDR-9DYE — RULES FOR SAFE OPERATION

Failure to follow instructions in this manual
may lead to serious injury or even death! This
equipment is to be operated by trained and
qualified personnel only! This equipment is
for industrial use only.

The following safety guidelines should always be used when
operating the MIKASA MDR-9DYE Vibratory Roller.

GENERAL SAFETY

■

DO NOT operate or service this equipment before
reading this entire manual.

■

This equipment should not be operated by
persons under 18 years of age.

■

NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steel­toed boots and other protective devices required
by the job. ALWAYS wear slip resistant safety
shoes or boots.

■

NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the
influence or drugs or alcohol.

■

NEVER touch the hot exhaust manifold,
muffler or cylinder. Allow these parts to
cool before servicing engine or vibratory
roller.

■

High Temperatures – Allow the engine to cool before adding
fuel or performing service and maintenance functions. Contact

hot

with

■

The engine of this vibratory roller requires an adequate free
flow of cooling air. NEVER operate the vibratory roller in any
enclosed or narrow area where free flow of the air is restricted.
If the air flow is restricted it will
cause serious damage to the
vibratory roller or engine and
may cause injury to people and
property. Remember the roller’s
engine gives off DEADLY gases.

■

ALWAYS refuel in a well-ventilated area, away from sparks
and open flames.

■

ALWAYS use extreme caution when working with flammable
liquids. When refueling, stop the engine and allow it to cool.

DO NOT

explosion could result from fuel vapors, or if fuel is spilled on
a hot engine.

components can cause serious burns.

smoke around or near the machine. Fire or

■

NEVER operate the vibratory roller in an explosive

■

NEVER use accessories or attachments, which are not
recommended by Multiquip for this equipment. Damage to
the equipment and/or injury to user may result.

atmosphere or near combustible
materials. An explosion or fire could
result causing severe

bodily harm or

even death.

■

Manufacturer does not assume responsibility for any accident
due to equipment modifications.

■

Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.

■

ALWAYS wear proper respiratory (mask), hearing and eye
protection equipment when operating the vibratory roller.

PAGE 8 — MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03)

■

Topping-off to filler port is dangerous, as
it tends to spill fuel.

■

ALWAYS store the vibratory roller in a clean, dry location out
of the reach of children.

■

NEVER run engine without air cleaner. Severe engine

damage may occur.

■

NEVER leave the vibratory roller unattended, turn off engine.

■

CAUTION must always be observed while servicing this

vibratory roller. Rotating parts can cause injury if contacted.

■

DO NOT leave vibratory roller with engine running. Use
chock blocks if parking

vibratory roller on a grade.

MDR-9DYE — RULES FOR SAFE OPERATION

■

NEVER disconnect any

These devices are intended for operator safety. Disconnection
of these devices can cause severe injury, bodily harm or even
death! Disconnection of any of these devices will void all
warranties.

Loading and Unloading (Crane)

■

Before lifting, make sure that machine parts (hook and
vibration insulator) are not damaged and screws are not
loosened or lost.

■

Always make sure crane or lifting device has been properly
secured to the hook of guard frame on vibratory roller.

■

NEVER lift the machine while the engine is running.

■

Use adequate lifting cable (wire or rope) of sufficient strength.

■

Use one point suspension hook and lift straight upwards.

■

NEVER allow any person or animal to stand underneath the
machine while lifting.

■

Try not to lift machine to unnecessary heights.

Transporting

"emergency or safety devices"

.

■

■

In emergencies

nearest phone or
Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an
emergency.

ALWAYS know the location of the nearest and

always

know the location of the

keep a phone on the job site

and

fire department

. This

first aid kit

.

.

■

Always shutdown engine before transporting.

■

Tighten fuel tank cap securely and close fuel cock to prevent
fuel from spilling.

■

Drain fuel when transporting vibratory roller over long
distances or bad roads.

■

Always tie-down the vibratory roller during transportation by
securing the roller's guard frame with rope.

Emergencies

■

ALWAYS know the location of the nearest

fire extinguisher

Maintenance Safety

.

■

■

■

■

■

NEVER lubricate components or attempt service on a
running machine.

ALWAYS allow the machine a proper amount of time to

cool before servicing.
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always replace

broken parts.
Dispose of hazardous waste properly. Examples of

potentially hazardous waste are used motor oil, fuel and
fuel filters.

■

DO NOT use food or plastic containers to dispose of
hazardous waste.

■

DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.

MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03) — PAGE 9

MDR-9DYE — OPERATION AND SAFETY DECALS

Figure 1 displays the operation and safety decals as they appear on the vibratory roller. Should any of these decals become
damaged or unreadable, contact the Multiquip Parts Department for a replacement set.

Figure 1. Operation and Safety Decals

PAGE 10 — MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03)

MDR-9DYE — SPECIFICATIONS

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MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03) — PAGE 11

MDR-9DYE — DIMENSIONS

Figure 2. MDR-9DYE Vibratory Roller Dimensions

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PAGE 12 — MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03)

NOTE PAGE

MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03) — PAGE 13

MDR-9DYE — GENERAL INFORMATION

The Mikasa Model MDR-9DYE is a powerful compacting tool
capable of applying a tremendous force in consecutive impacts
to a soil surface. With 28-inch drums and 32 inches overall width,
virtually any asphalt or mixed granular soil compaction job is
quickly cut down to size.

The impact force of the MDR-9DYE levels and uniformly
compacts voids between soil particles to increase dry density.

Features include:



Hydraulic variable speed transmission assures easy
handling.



Deadman device which when pressed or hit will
cause the travel lever to return to neutral position
bringing the machine to a stop.



Non-corrosive water tank for the sprinkler system with a
capacity of 6 gallons.



Simple dual-lever controls assure operator safety and
convenience.



Sight gauge for hydraulic oil tank.



Front -mounted auxiliary travel lever.



Four large rubber shock mounts minimize vibrations to the
engine and hydraulics.

FREQUENCY/SPEED

The vibrating roller maximum frequency is 3000 vpm (vibrations
per minute). The forward and reverse travel speed of the vibratory
roller is approximately 1.8 mph (3 km/hour).

ENGINE

The Mikasa MDR-9DYE Vibratory Roller is equipped with a
YANMAR L100EE-DEVMK2.

CONTROLS

Before starting the MDR-9DYE Vibratory Roller, identify and
understand the function of the controls and components as
indicated in Figure 6.

TRANSPORTATION

Adjustable transport hooks allow an operator to place the roller
on the tailgate of a dump truck without any assistance. The
control handle of the MDR-9DYE Vibratory Roller can be folded
vertically for ease of transport and storage.

LIFTING THE ROLLER

When lifting of the roller is required (Figure 3), attach a suitable
hook or shackle to the
lifting device is capable of lifting 1,940 lbs (880 kg).

lifting hooks

of the roller. Make sure the



Convenient tie-downs, front and rear.



Scraper Bar.



Drum sprinkler system.



Handle folds to 90 degrees for storage and transport..

Figure 3. Lifting The Roller

PAGE 14 — MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03)

MDR-9DYE — GENERAL INFORMATION

CAUTION :

NEVER! stand under, or get onto the roller

while it is being lifted or moved.

CAUTION :

CAUTION :

NEVER! use any other part of the roller for

lifting purposes. Use the lifting eye. Using other
parts of the roller for lifting will cause severe
damage to the roller,

Tipping (Rollovers)

NEVER! operate the roller on side slopes (Figure 5). The

possibility exist that the roller could tip over (roll over), thus
causing bodily harm even death and serious damage to the
equipment.

ONLY! use steel ropes or chains that are
capable of lifting at least 1,940 lbs. (880 kg ).

Figure 5. Recommended Slope

OPERATING ON SLOPES

Special care must be taken when operating the roller on hills or
slopes. There exist the possibility of serious injury to the operator
and severe damage to the roller in the event of a roll over.
ALWAYS operate the roller up and down hills rater than from
side to side. For safe operation hillside slopes should not exceed
12 degree (21 % grade). See Figure 4 below.

In the event the roller does tip over, extreme care must be taken
to prevent damage to the engine. When the roller has been
tipped over, oil from the engine crankcase can flow into the
combustion chamber, which can severely damage the engine
the next time it is started.

IMMEDIATELY after a unit has tipped over upright the unit as
soon as possible to prevent oil from leaking into the combustion
chamber.

CAUTION :

NOTE

Figure 4. Recommended Slope

To prevent damage to the engine after a
rollover, the unit must NOT be started.
NEVER start a unit after a rollover. CONTACT
your nearest authorized Multiquip dealer for
instructions or servicing.

NEVER! operate the roller on

slopes

causing injury to personnel and
severe damage to the equipment

. The roller may tip over

side

MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03) — PAGE 15

MDR-9DYE — VIBRATORY ROLLER COMPONENTS

Figure 6. MDR-9DYE Vibratory Roller

Components

Figure 6 illustrates the location of the major components
for the MDR-9D Vibratory Roller. The function of each
component is described below:

1. Handle Bar – When operating the roller, this handle is to
be in the downward position. When the roller is to be

stored

, move the handle bar to the upright position.

2. Hand Grip – When operating the roller, use this hand grip
to maneuver the roller. Also has dead man device, when
pressed or hit while traveling in reverse, causes the travel
lever to return to neutral position to stop the machine.

Push

3. Travel Lever –
in a forward direction,
will move in backwards direction. Placing the lever in the
middle (midway) will cause the roller not to move (neutral).

4. Vibrator Lever – Turns the vibration on and off.

5. Hydraulic Oil Tank/Cap – Stores hydraulic fluid. Open cap
to fill with recommended hydraulic oil (Shell Tellus #46).

6. V-Belt Cover – Remove this cover to gain access to the
v-belts. NEVER run the vibratory roller without the v-belt
cover. If the v-belt cover is not installed, the possibility exist
that your hand may get caught between the v-belt and clutch,
thus causing serious injury and bodily harm.

the lever forward, the roller will move

pull

the lever backwards, the roller

7. Engine – This vibratory roller uses a YANMAR L100EE-
DEVMK2 diesel engine. Refer to the owner’s manual for
engine information and related topics.

8. Vibrator Lever (on the body of machine) – Turns the
vibration on and off.

9. Water Tank – Holds 6 gallons (23 liters) of water for the
sprinkler system.

10. Shock Absorber -

11. Scraper Bar – This bar helps prevent buildup of material
between the drum and the frame.

12. Vibration Rollers – 18-inch diameter steel drums that
provide the compaction force in the compaction and
patching of asphalt-type surfaces.

13. Checking Cover for Chains – Take off the cover to check
and lubricate chains.

14. Water Valves– Turn on the water sprinkling system.

15. Hydraulic Oil Gauge – Indicates the hydraulic oil level.

PAGE 16 — MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03)

MDR-9DYE — YANMAR L100EE-DEVMK2 ENGINE COMPONENTS

Figure 7. YANMAR L100EE-DEVMK2 Engine Components

ENGINE COMPONENTS

Figure 7 illustrates the location of the major engine
components of the Yanmar engine. Each component is
described below:

1. Fuel Filler Cap – Remove this cap to add unleaded
gasoline to the fuel tank. Make sure cap is tighten securely.
DO NOT over fill.

2. Fuel Tank – Diesel engine holds 5.8 quarts of diesel fuel.

3. Air Cleaner – Prevents dirt and other debris from entering
the fuel system. Remove wing-nut on top of air filter
cannister to gain access to filter element.

4. Muffler – Used to reduce noise and emissions.

5. Recoil Starter (pull rope) – Type of engine starting method.
Alternate type would be electric start (ignition key).

6. Recoil Starter – Housing for pull rope and starter.

7. Oil Filler Cap/Dipstick – Remove this cap to add oil to the
oil tank. Use dipstick to check oil level.

8. Oil Drain Plug – Unscrew plug to drain oil from engine
crankcase. Dispose of oil in a safe manner.

9. Decompression Lever – Press down before starting
engine. To prevent damage to the engine, DO NOT use for
any other purpose.

10. Fuel Cock – Controls the flow of diesel fuel to the engine.
Must be in the ON position when starting and running the
engine.

MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03) — PAGE 17

MDR-9DYE — INSPECTION

CAUTION :

Never operate the vibratory
roller in a confined area or
enclosed structure that
does not provide ample

free flow of air.

ALWAYS wear approved eye and hearing

protection before operating the vibratory roller.

BEFORE STARTING

1. Read safety instructions at the beginning
of manual.

2. Familiarize yourself with the operating
and control elements of the machine and
the working environment. This includes obstacles in the
working area, bearing capacity of the ground and the
necessary safety provisions.

3. Check the air filter for dirt and dust. If the air filter is dirty, replace

air filter with a new one as required.

4. Check fastening nuts and bolts for tightness. Loose threads
may cause damage to the machine when vibrating.

3. If the oil level is low, fill to the edge of the oil filler
hole with the recommended oil type (Table 4).
Maximum oil capacity is 1.6 quarts (1.1 liters).

Explosive Fuel

Explosive Fuel

DANGER

CHECKING FUEL

EPYTLIO.4ELBAT

nosaeS erutarepmeT epyTliO

remmuS rehgiHroC°52 03-W01EAS

llaF/gnirpS C°01~C°52 02/03-W01EAS

retniW rewoLroC°0 01-W01EAS

Diesel fuel is highly flammable and can be
dangerous if mishandled. DO NOT smoke while
refueling. DO NOT attempt to refuel the vibra-

hot!

or

tory roller if the engine is

running.

5. Understand the geographical features and regulations of
the job site.

6. Clean the vibratory roller, removing dirt and dust, particularly,
the bottom of the plate, engine cooling air inlet.

CHECKING ENGINE OIL LEVEL

1. Make sure that the machine is situated in a flat
surface so that level measurements will be accurate.

2. Pull out the dipstick from the oil tank (Figure 8).

1. Remove the fuel cap located on top of fuel tank.

2. Visually inspect to see if fuel level is low. If fuel is low, replenish
with diesel fuel (Figure 9).

3. When refueling, be sure to use a strainer for filtration. DO NOT
top-off fuel. Wipe up any spilled fuel.

CAUTION :

DO NOT overfill oil tank. This could cause oil

leaks and sluggish operation. Clean cap and
surrounding area before opening to prevent dirt
from entering tank.

DANGER

Figure 9. Refueling

Fuel spillage on a hot engine can case a

explosion

spilled fuel completely to prevent fire hazards.

NEVER!

. If fuel spillage occurs, wipe up the

smoke around or near the roller.

fire

or

Figure 8. Oil Dipstick

PAGE 18 — MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03)

MDR-9DYE — INSPECTION

CHECKING HYDRAULIC SYSTEM

1. Check the oil tank level gauge (Figure 10). Oil level
should be at the middle indication of the gauge or
higher. Fill as required

2. Check the surroundings of the oil tank, hydraulic
pump and motor for oil leakage.

Figure 10. Hydraulic System Oil Level Gauge

DANGER

ALWAYS keep hands and fingers away from

pinch points. DO NOT allow anyone to reach in
on dangerous sections of the machine to avoid
any accidents.

CHECKING THE CLUTCH BOX OIL LEVEL

1. Check clutch box for any oil leakage.

2. Remove the level plug and check oil level (Figure 12).

3. Add oil if necessary.

CHECKING THE VIBRATOR OIL LEVEL

1. Remove the red filler plug and the oil level inspection hole
plug from the vibrator case (Figure 13).

2. Fill with oil until oil overflows from inspection hole.

Figure 12. Clutch Box Oil Level Check

CHECKING THE V-BELT

1. Check all bolts and screws and make sure all are
securely tightened.

2. Check V-belt for proper tension. The normal slack
should be approximately 1/8 inch (3 to 5 mm) when
the belts are forcibly depressed between the two
sheaves (Figure 11). Insufficient tension causes
weak vibration and machine damage.

Figure 11. V-Belt Tension

Figure 13. Vibrator Oil Level Check

MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03) — PAGE 19

MDR-9DYE — INSPECTION

CHECKING WATER TANK

1. Check the water tank to see if filled. Add water if necessary.
The water tank has a capacity of approximately 6 gallons
(23 liters) (Figure 14).

Figure 14. Water Tank Check

CAUTION :

Be careful not to confuse the water tank with the
oil tank.

POSITIONING THE HANDLE BAR

1. Release the handle bar release pin (Figure 15) and position
the handle bar to the lowered position before starting
operation.

2. When machine is not in use, release the handle bar release
pin and position the handle bar to the upright position.

Handle Bar

Release Pin

Figure 15. Handle Bar Positioning

INITIAL STARTUP (ENGINE)

CHECKING LEVERS

1. Check travel and vibrator levers to make sure they are
functioning properly (Figure 6).

2. With travel lever placed in reverse, push the deadman
device and verify that the travel lever returns to neutral
position. The travel lever stays in neutral position once the
deadman device is released.

CHECKING SCRAPER BAR

1. Check scraper bar and make sure that they are not clogged
with mud, bent or damaged (Figure 6).

2. Adjust clearance between drums and scrapers as
necessary.

CHECKING BOLTS, NUTS, AND SCREWS

1. Check bolts, nuts, and screws on various parts of the
machine, including the engine, for proper tightness.

Electric Start

1. On the handle bar:
A. Move the
B. Move the

2. Open the fuel cock by turning it clockwise to the
down position (Figure 16).

travel lever

vibrator lever

to the NEUTRAL position.

to the OFF position.

Figure 16. Open Fuel Cock

PAGE 20 — MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03)

3. Insert the starter key into the key switch and turn it to
the RUN position (Figure 17).

Figure 17. Starter Key

4. Turn the starter key further to the right to the START
position to start the engine.

5. If the engine fails to start, DO NOT continue to rotate
the starter key for more than 5 seconds. Return the
key to the RUN position and wait 20 to 30 seconds
before starting again.

6. After starting the engine, continue to warm up the
engine for about 3 to 10 seconds especially in cold
weather.

Recoil Start

NOTE

MDR-9DYE — OPERATION

Figure 19. Decompression Lever

When starting with a motor
starter, a decompressor is
not normally required.
However, when ambient
temperature or battery
charger level is low, use of
a decompressor will help
make the start-up easier.

1. Open the fuel cock by turning it clockwise to the down
position (Figure 16).

2. Pull the starting handle slowly until you feel some
resistance (Figure 18). Return handle to original
position.

Figure 18. Engine Start Handle

3. Push down the decompression lever (Figure 19).

4. Pull the starting handle hard and fast to start engine.

5. If the engine does not start, repeat steps
2 through 4.

MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03) — PAGE 21

MDR-9DYE — OPERATION

TRAVELING

CAUTION :

Make sure to follow all safety rules referenced in
the safety section of this manual before operating
roller. Keep work area clear of debris and other
objects that could cause damage to the roller or
bodily injury.

1. To make the roller move in the forward direction push the
travel lever ( Figure 20) forward. This roller has a hydraulic
variable speed transmission. By moving the travel lever
varioys increments, you can vary the speed from 0 to 1.8 mph
(0 to 3 km/hr).

VIBRATING

1. Shift the two vibrator levers (Figures 21 and 22) to the
vibrate position to start vibrations.

Figure 21. Vibrator Lever

Figure 20. Travel Lever

2. To make the roller move in the reverse direction pull the travel
lever ( Figure 20) backwards.

CAUTION :

3. Firmly gasp the roller's hand grip, the roller will begin moving
in the desired position when the direction lever has been
placed in the desired position.

CAUTION :

DO NOT reduce speed during work. When

shifting travel lever from forward to reverse,
be sure to stop the lever at the neutral
position first before moving the lever to the
opposite direction. DO NOT shift the lever
from forward to reverse (or reverse to
forward) in one motion.

WATERING

1. To operate water sprinkling system, turn on the front and
rear water valves on the side of the roller. (Figure 23).

CAUTION :

After test travel, shut down engine and
check for any problems including oil
leakage. If any trouble is found, correct the
problem before attempting to operate the
roller again.

Figure 22. Vibrator Lever (Body)

Using vibration with clutch slipping causes
the clutch to burn. Also, vibration should
NOT be used over completely compacted
area, paved road surface, or with stationary
roller.

Figure 23. Water Valves

PAGE 22 — MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03)

MDR-9DYE — OPERATION

STOPPING

1. Place the vibrator and travel levers to the neutral position.

2. Slow down the engine and allow to cool for at least 2
minutes. In an electric start, return the key switch to
the STOP position as soon as the engine stops.

CAUTION :

Neglecting to return the key switch to the
STOP position will cause the battery to
discharge, making start-up impossible the

LIFTING

1. Use a crane or lift to load and unload the machine. A
skilled crane operator is required to perform the job.

2. When lifting the machine, check for any damaged or
loose bolts, lifting hooks, and shock mounts.

3. Check any damaged or loose bolts in the guard frame to
avoid machine sliding off.

4. Make sure that the machine is shut off before machine is
lifted.

5. Use reliable cable for lifting.

next time.

6. Always lift the machine vertically and keep the

3. After the engine stops, close the fuel cock.

4. The hydraulic brake is automatically engaged when the
travel lever is in neutral position. When parked on a slope
with the engine turned off, place a block against the
roller drum to prevent the roller from moving.

UNLOADING

1. If you need to move the roller by pushing it manually
once engine is stopped, push in the upper and lower
knobs of the transmission check valve. This will
cause the hydraulic break to disengage and allow
the roller to be moved without causing damage
(Figure 24).

machine away from workers and animals.

7. Do not lift the machine higher than the required
height.

TRANSPORTING

1. Always make sure that the machine is shut off while
being transported.

2. Check that the fuel cap is properly closed and
tightened.

3. When traveling long distances or on rugged terrain,
drain the fuel of the machine before transporting.

4. Tie down the machine securely on the
transportation so that it will not move or topple over.

Figure 24. Disengaging Hydraulic Brake

2. After moving, reset upper and lower knobs.

CAUTION :

NEVER tow roller with any type of vehicle.

Doing so will damage the hydraulic system.
NEVER perform unloading procedure on a

slope. This may cause roller to roll down if
parking brake or blocking is deficient.

MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03) — PAGE 23

MDR-9DYE — MAINTENANCE

CAUTION:

Inspection and other services should
be carried out on hard and level ground with
the engine shutdown.

INSPECTION AND MAINTENANCE SERVICE TABLES

1. To make sure your plate vibratory roller is always in good
working condition before using, carry out the maintenance
inspection in accordance with Tables 5 through 7.

EYD9-RDM.5ELBATNOITCEPSNIENIHCAM

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traPmetsyS

FOSRUOH

NOITAREPO

sruoh8yrevE

)yadyreve(

sruoh8yrevE

)yadyreve(

sruoh8yrevE

)yadyreve(

always

SKRAMER

CAUTION:

Fuel piping and connections should be
replaced every 2 years.

METINOITAREPOFOSRUOH

kaeLleuFroliO)yadyreve(sruoh8yrevE

sdaerhT

tnemhsinelpeR

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)level

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noisneTniahC

tnemtsujdA

tnemecalpeR

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tnemecalpeR

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

sruoh05yrevE62egapeeS

52retfayllaitinI

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82egapeeS

72egapeeS

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These inspection intervals are for operation
under normal conditions. Adjust your inspection
intervals based on the number hours vibratory
roller is in use, and particular working conditions.

DAILY SERVICE

z

Check for leakage of fuel or oil.

z

Check for loose screws including tightness. See Table 6
below (tightening torque ), for retightening:

T4 07 051 003 005 057 001,1 004,1 000,2

T8-6 001 052 005 008 003,1 000,2 007,2 008,3

T11 051 004 008 002,1 000,2 009,2 002,4 006,5

* 001

z

Remove soil and clean the bottom of roller.

z

Check the levers, cables and linkage.

z

Check engine oil.

mm6 mm8 mm01 mm21 mm41 mm61 mm81 mm02

lairetaM

~003

~056

053

007

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)dednahthgirllaeraenihcamsihthtiwesunisdaerhT(

.kcehcenignenosliatedroflaunamenigneetarapeseeS

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PAGE 24 — MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03)

ENGINE OIL REPLACEMENT

1. Replace engine oil in the first 25 hours of operation and
every 50 to 100 hours afterwards.

2. Oil may be drained more easily when it is warm after
operation (For more details, see separate engine Owner's
Manual).

AIR FILTER

1. The air filter element should be cleaned because a clogged
air cleaner can cause poor engine starting, lack of power
and shorten engine life substantially.

CAUTION:

Figure 25. Engine Air Filter and Element

MDR-9DYE — MAINTENANCE

Figure 27. Chain Tightener

NEVER attempt to check the V-belt with the engine

running. Severe injury can occur if your hand gets
caught between the V-belt and the clutch (Figure

28). Always use safety gloves.

CLUTCH
PULLEY

2. To clean or replace air filter loosen the wing nut on the air
filter housing (Figure 25) remove the cover and take out air
filter cartridge. If only cleaning of the air filter is desired blow
through the air filter cartridge from the inside, moving a jet of
dry compressed air up and down until all dust is removed.

CHECKING THE CHAINS

1. Take off the checking cover on roller and coat grease on the
chain if necessary (Figure 26. The chain should be lightly
lubricated with motor oil.

Figure 26. Chain Cover

VIBRATOR
PULLEY

Figure 28. V-Belt Hazard

VIBRATION CLUTCH ADJUSTMENT

1. Remove the protective cover from the clutch by removing
the 4 allen screws.

2. Pull out the stop key and turn to the release position (Figure

29).

3. Viewing the clutch from the shifter-pulley side: if the clutch
nut is turned to the right, the clearance between the adjusting
and pressure plate decreases as the amount of torque
increases. Normal adjustment is from 1 to 2 notches.

4. Make sure that the shifting lever is not too stiff. Lever should
engage with moderate pressure.

5. After adjustment, return the stop key to the locked position.

2. Check the chain tension and if loose, adjust the chain tension
with the tightener (Figure 27). Chain tension should be
adjusted every 50 hours of operation.

Figure 29. Clutch Adjustment

MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03) — PAGE 25

MDR-9DYE — MAINTENANCE

HYDRAULIC OIL CHECK

1. Check for any oil leakage from the hoses and joints daily.

2. Check hydraulic oil level every 4 to 5 hours after starting
operation.

3. After one week of operation, check hydraulic level twice a
day .

4. After two weeks of operation, check hydraulic level once a
day .

5. Replace hydraulic oil after first 200 hours and in every 1,000
hours of operation.

HYDRAULIC OIL FILTER CHECK

1. The hydraulic oil filter should be replaced after first 25 hours
of operation.

2. After first replacement, it should be replaced after 250 hours
operation (2 months), every 500 hours of operation (4
months), and every 1,000 hours of operation thereafter.

3. When the suction resistance exceeds 254 mmHg (oil
temperature in operation is 140 degrees F), replace filter.

4. To remove the oil filter, wind a cloth around the filter to prevent
slipping (Figure 31).

5. Tie a rope securely around the filter (Figure 31).

CAUTION:

Make sure hydraulic oil is at a normal safe
operating level. DO NOT over fill.

REPLACING HYDRAULIC OIL

1. Change the hydraulic oil every 1,000 to 1,500 hours of
operation. Change the hydraulic oil more often in high
ambient temperature operation.

2. Remove the drain plug and hose tank and drain the hydraulic
oil.

3. Reinstall the drain plug to the oil tank.

4. Open the tank cap (Figure 30) and fill tank with hydraulic oil.
(Capacity: About 4.5 gallons). Use
equivalent.

Figure 30. Hydraulic Oil Change

5. After filling tank, tighten the tank cap firmly with a wrench.

Shell Tellus Oil #46

or

6. Forcibly pull the rope to remove the filter (Figure 32).

7. Immediately replace with new filter, screwing it on by hand
to avoid hydraulic oil leak.

CAUTION:

Make sure that dust , water, and other foreign
objects do not enter tank. It is recommended to
filter the oil through a cloth.

Figure 31. Cloth and Rope Around Filter

Figure 32. Filter Removal

NOTE

Use only genuine Mikasa
replacement oil filters (10
micron filter paper. Do not use
automobile-type oil filters.

PAGE 26 — MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03)

HYDRAULIC AIR EXTRACTION

1. After filling hydraulic oil tank with oil, loosen the oil hose
joint and check that oil is enough to reach the oil suction
and outlet ports in the hydraulic transmission. Tighten the
hose joint securely after checking.

2. Loosen the charge relief valve located on the front side of
the hydraulic transmission (Figure 33).

Figure 33. Loosening Charge Relief Valve

MDR-9DYE—MAINTENANCE

Figure 34. Unscrewing Right Lock Nut

3. Check that oil flows out from the valve hole.

4. Replace the charge relief valve tightly.

5. With the travel and vibrator levers in neutral position, start
the engine and idle at low speed for 3 to 5 minutes.

6. Check the forward and reverse rotation of the output shaft
by moving the travel lever slowly to its forward and reverse
positions.

7. Check the oil level gauge and make sure that there are no
air bubbles mixed in the oil. After checking, operate the roller
slowly at first then at full speed.

8. When oil level in the tank is low, replenish oil up to the
specified level, and screw the cap securely with a wrench.

9. If bubbles remain in the oil or foam is found, air is being
sucked through the suction side and should be checked.

NEUTRAL POSITION ADJUSTMENT

Once the travel lever has been set to neutral position with the
engine running, the hydraulic brake is operating and the roller
should not move. If the roller inches forward or backwards with
the lever in the neutral position, turn-buckle of the cable should
be adjusted as follows:

3. If the machine moves forward, screw the turn-buckle
clockwise. If the machine moves backwards, screw the turn­buckle counterclockwise (Figure 36).

4. Screw back the lock nuts on the turn-buckle.

5. Start the engine and make sure that the roller does not inch
forward or backward at the neutral position of the travel
lever.

Figure 35. Unscrewing Left Lock Nut

1. Stop the engine and set the travel lever in the neutral
position.

2. Unscrew the two lock nuts on the sides of the cable (Figures
34 and 35).

MQ-MIKASA MDR-9DYE VIBRATORY ROLLER — PARTS & OPERATION MANUAL — REV. #0 (12/19/03) — PAGE 27

Figure 36. Adjusting the Turn-Buckle