DALBO MaxiDisc User manual

MaxiDisc
Hydraulic folding
rubber-suspension
GB
400 cm

MaxiDisc
Hydraulic folding with rubber-suspension
Type 400 cm
Congratulations on the purchase of your new MaxiDisc. To ensure safe operation and
to obtain optimal use of the machine, read the rules and instructions of the following
operator’s manual carefully before operating the machine.
©Copyright 2002, DAL-BO. All rights reserved.
Your MaxiDisc:
Type No.: Serial No.:
Month of manufacture: Net weight (kg):
For prompt service, always quote your machine serial number when making enquiries
regarding spare parts or service. A comprehensive index of spare parts can be found in
the back of this manual to give you an overview of MaxiDisc components and to facili-
tate ordering.
EU DECLARATION OF CONFORMITY
Maskinfabriken DAL-BO A/S
DK-7183 Randbøl
Hereby declare that the above-mentioned machine has been manufactured in compli-
ance with the provision of the Council Directive on the approximation of the laws of
the Member States relating to machinery 98/37/EC, which replaces Council Directive
89/392/EEC and amendments 91/368/EEC, 93/44/EEC and 93/68/ECC concerning the
Essential Health and Safety Requirements for the design and manufacture of Machin-
ery.
This machine complies with the safety requirements stipulated by the European safety
regulations.
Maskinfabriken DAL-BO A/S Date:
Carsten Jensen, CEO
CE

MaxiDisc
Side 5
Table of Contents
TABLE OF CONTENTS...............................................................................................5
SAFETY..........................................................................................................................7
GENERAL ......................................................................................................................7
HYDRAULIC SYSTEM.....................................................................................................8
HITCHING......................................................................................................................8
MAINTENANCE AND REPAIRS........................................................................................8
TRANSPORT...................................................................................................................9
CORRECT USE ...............................................................................................................9
TECHNICAL DATA...................................................................................................10
DELIVERY ...................................................................................................................10
HOW TO USE THIS MANUAL ................................................................................11
APPLICATION............................................................................................................12
HITCHING AND UNHITCHING..............................................................................13
HITCHING....................................................................................................................13
HYDRAULIC SYSTEM...................................................................................................13
UNHITCHING ...............................................................................................................14
ADJUSTMENTS AND SETTINGS ...........................................................................15
DEPTH.........................................................................................................................15
ANGLE ........................................................................................................................15
SIDE DISCS ..................................................................................................................16
OPERATING AND DRIVING INSTRUCTIONS....................................................17
FOLDING/UNFOLDING.................................................................................................17
ANGLE ........................................................................................................................17
TRAVEL SPEED............................................................................................................17
Power requirements...............................................................................................17
TROUBLESHOOTING ..............................................................................................18
OPTIONS......................................................................................................................19
DISC SCRAPERS...........................................................................................................19
MUDGUARD ................................................................................................................19
LIGHT..........................................................................................................................19
T-RING,70X70X8T-STEEL..........................................................................................19
MAINTENANCE.........................................................................................................20
LUBRICATION..............................................................................................................20
HYDRAULIC SYSTEM...................................................................................................21
DISC HUBS...................................................................................................................21
REPLACEMENTS AND REPAIRS ..........................................................................22
HYDRAULIC SYSTEM...................................................................................................22
Replacing angle adjustment cylinder.....................................................................22

Replacing angle adjustment seals..........................................................................23
Changing wing fold cylinders................................................................................23
Replacing wing fold cylinder seals........................................................................24
REPLACING SHAFT,BEARINGS AND T-RINGS ...............................................................25
REPLACING THE BEARING IN THE DISC HUB.................................................................26
SCRAPPING ................................................................................................................27
HYDRAULIC SYSTEM DIAGRAM.........................................................................28
SPARE PARTS ............................................................................................................29

MaxiDisc
Side 7
Safety
The safety alert symbol is used throughout this manual to identify important
safety warning messages concerning your safety, the safety of other users or
the functional safety of the implement. Observe all safety instructions and
make them readily accessible to all users of the equipment.
General
•The operator must be thoroughly familiar with all safety precautions and
operations of this equipment prior to using.
•The safety signs on the MaxiDisc contain important instructions concern-
ing your safety, the safety of those around you, and the correct operation
of the machinery.
•Never allow anyone to ride on the implement during operation or trans-
port.
•Never allow bystanders within the operating radius of the MaxiDisc when
the implement is in operation. Operate the MaxiDisc only while seated in
the driver’s seat of the tractor.
•Ensure that wing section locks are engaged when the MaxiDisc is in a
folded position. Secure control levers against unintentional operation.
•Before performing any adjustments, maintenance or repairs on the ma-
chinery, always unfold the MaxiDisc and lower the implement to the
ground or secure in transport position, set the tractor brakes, turn off the
engine and remove the ignition key.
•Remember to secure the drawbar stand and the lift arms (if applicable)
with lynch pins.
•Operate the tractor and MaxiDisc only while seated in the driver’s seat.
•Always drive according to conditions.
•Do not use the MaxiDisc unless all safety signs are installed. Replace de-
fective safety signs immediately.

MaxiDisc
Side 8
Hydraulic System
•Never allow bystanders within the operating radius of the MaxiDisc when
the hydraulic system is activated to avoid the danger of an individual be-
ing crushed or pinched between the equipment.
•Before performing maintenance or repairs on the hydraulic system, lower
the implement to the ground, relieve pressure in the system, turn off the
engine and remove the ignition key.
•Clean the hydraulic fittings thoroughly before connection. Ensure that the
pressure is relieved in the hydraulic system before connecting the hydrau-
lic hoses to the tractor’s hydraulic services.
•After making repairs to the hydraulic system, thoroughly bleed air out of
the system.
•Regularly check hydraulic hoses for defects such as cracks, bends, chafing
or leaks.
•Avoid spilling oil on the ground. In case of spills, collect the oil and dis-
pose of it properly.
•In case skin should come in contact with hydraulic oil or grease or in case
clothing should become stained with oil, remove the stained clothes im-
mediately and wash the affected skin areas thoroughly. Oil and grease are
harmful to the skin.
•Escaping hydraulic oil under high pressure can penetrate the skin and
cause severe injury. If an accident occurs, see a doctor immediately.
Hitching
•An individual is in danger of being crushed during the hitching process.
Never place yourself or anyone else between the tractor and the Maxi-
Disc, or between parts that must be attached or connected.
Maintenance and Repairs
•Before servicing or making adjustments to the machine, securely block or
unfold the machine, engage the tractor and machine brakes, stop the en-
gine and remove the keys.
•Tighten all nuts, bolts hydraulic fittings or any other fastened assemblies
after a few hours’ use. Check often to make sure that they remain thor-
oughly tightened. Inspect all pins, screws and bolts for wear or damage
and make sure that all are securely in place to avoid any possible damage
or breakdown of the machine.

MaxiDisc
Side 9
•Dispose of oil, grease and filters according to applicable environmental
regulations.
Transport
•All safety and warning signs and devices required by law must be dis-
played, mounted and tested for public road use. The driver is responsible
for the correct use of lights and markings in compliance with the present
Traffic Act and Highway Code of the local traffic legislation.
•It is the responsibility of the driver to consult with local traffic authorities
in order to ensure that the size, weight and load of the machinery may be
transported on public roads.
•When towing the implement, the total weight of the tractor and the maxi-
mum allowed axle load must not be exceeded. The weight on the front
axle must not be less than 20 percent of the total mass of the tractor. If it is
less than 20 percent, extra weight must be added to the front of the tractor.
Correct Use
•Correct use of the MaxiDisc includes adherence to the instructions of the
manufacturer concerning operation, maintenance and repair, as well as the
use of genuine factory replacement parts.
•Do not allow anyone to operate, maintain or repair the MaxiDisc unless
they are familiar with the implement and they are thoroughly aware of the
possible hazards.
•The manufacturer does not accept any liability for injury or warranty if the
equipment has been altered in any way without prior authorization from
the manufacturer or if the injury is a result of incorrect use of the imple-
ment. The user accepts complete responsibility in these cases.
•Never load extra weight onto the MaxiDisc.

MaxiDisc
Side 10
Technical Data
MaxiDisc
Size (cm) 400
HP (recommended) 140
Gross weight kg: 2780
T-rings Yes
Delivery MaxiDisc is delivered fully assembled on a flatbed lorry.
If the MaxiDisc needs to be lifted, it is recommended that you lift with straps
around the middle section, raising the machine so that it hangs in balance.

MaxiDisc
Side 11
How to Use This Manual
If the order of points described under the main subject areas of the manual
seems confusing or illogical, refer to the Table of Contents where all subject
headings can be found.
The main points of the operator’s manual are placed into five main categories:
•Safety
•Set-up and Operation
•Options
•Maintenance
•Repairs
The following safety alert symbols are used throughout this manual to indi-
cate:
L
Points that are extremely important for the function and life of the machin-
ery.
Points that involve safety.

MaxiDisc
Side 12
Application
MaxiDisc represents a whole new generation of lift-mounted disc harrows
providing the ultimate in compactness.
The MaxiDisc is specially designed for work in the uppermost soil layer
where residue management is concentrated. The MaxiDisc effectively per-
forms full cutting penetration of the field and uniform mixing and blending of
plant residue and soil microorganisms in just one pass. The final element of
the soil management system is a packer roller, ensuring moisture conservation
and promoting an optimal microclimate for the organisms in the soil.
Fig. 1

MaxiDisc
Side 13
Hitching and Unhitching
Hitching Fig. 2
Attach the lift arms first and then
the top link. Adjust the top link so
that the frame is horizontal.
L
•Remember to secure with lynch pins.
•Remember to put the hitch jack in transport position and secure with
lynch pins, if MaxiDisc is folded when hitching.
Hydraulic System
The MaxiDisc requires two double-acting hydraulic outlet.
Hose markings
Cylinder Colour Outlet Function
Angling Green Double-acting Angling discs
Folding Red Double-acting Folding of the frame
L
•Check the hydraulic hoses for kinks or pinches.

MaxiDisc
Side 14
Unhitching Fig. 3
MaxiDisc can be unhitched folded
or unfolded.
If the MaxiDisc is unhitched
folded, remember to pull out all of
the 4 hitch jacks (A) and secure
with lynch pins
Position the MaxiDisc on solid, even ground. Disconnect the top link and then
lift arms.
Remember to relieve the pressure in the hydraulic system before discon-
necting the hoses.
A

MaxiDisc
Side 15
Adjustments and Settings
The MaxiDisc is preset in the factory, but it will always be necessary to make
some fine adjustments before use. Numerous adjustment possibilities make
your MaxiDisc more versatile and allow you to obtain optimum performance
from the implement.
Depth The operating depth is controlled by the rear T-ring roller.
Fig. 4
To increase the working depth,
shorten the turnbuckles (A) by turn-
ing the turnbuckle with the supplied
combination spanner. To decrease
the working depth, lengthen the
turnbuckles. The depth indicators
show the depth reading, which must
be equal on both packer roller sec-
tions.
L
It is important that the turnbuckles have the same length on both of the packer
roller modules to ensure even depth penetration.
It might be necessary to readjust the top link after changing the depth. The
frame must always be horizontal.
Angle The discs can be hydraulically adjusted from 0 to 20 degrees. With hydraulic
adjustment, all discs are adjusted at the same time.
Fig. 5
The angle of the front row and the
back row of discs can be adjusted
individually with the turnbuckle
(A). It is generally recommended
that you set the row in the back
slightly more aggressive than the
row in the front to prevent the ma-
chine from pulling unevenly.
A
A

MaxiDisc
Side 16
Turnbuckle length (A)
Side discs Fig. 6
A disc mounted on the outside edge
of the MaxiDisc limits the amount
of soil being cast out by the disc in
the very front. Adjust the side disc
vertically by using the pin (A) ac-
cording to the working depth of the
MaxiDisc. The disc can also be
moved in a horizontal direction by
loosening the mounting bolt.
The outer harrow (B) can as well be
adjusted.
Type Turnbuckle length abt. [mm] Specification [degree rear/front]
Maxidisc 300 (80150) 444 20/20 ; 0/0
Maxidisc 300 (80150) 431 23/20 ; 3/0
Maxidisc 400 (80160) 444 20/20 ; 0/0
Maxidisc 400 (80160) 431 23/20 ; 3/0
Maxidisc 300 Ü (80151) 538 20/20 ; 0/0
Maxidisc 300 Ü (80151) 524 23/20 ; 3/0
Maxidisc 400 Ü (80161) 415 20/20 ; 0/0
Maxidisc 400 Ü (80161) 401 23/20 ; 3/0
Maxidisc 400 ÜH (80171) 442 20/20 ; 0/0
Maxidisc 400 ÜH (80171) 457 23/20 ; 3/0
Maxidisc 400 (80005) 442 20/20 ; 0/0
Maxidisc 400 (80005) 457 23/20 ; 3/0
Maxidisc 500 (80010) 442 20/20 ; 0/0
Maxidisc 500 (80010) 457 23/20 ; 3/0
Maxidisc 600 (80020) 398 20/20 ; 0/0
Maxidisc 600 (80020) 383 23/20 ; 3/0
A
B

MaxiDisc
Side 17
Operating and Driving Instructions
Proper operation is essential for optimum performance of your MaxiDisc.
Proper operation concerns both the carrying out of tillage operations in the
field as well as the following of safety precautions. Make sure that you have a
thorough understanding of all safety precautions.
Best results will be achieved by driving slightly diagonally to the sowing di-
rection. Also, you should drive as closely as possible to the previous pass to
minimise the distance between the rows.
Folding/ unfolding
Fig. 7
1. Before unfolding the trans-
port locks must be released.
2. Activate the handle for the
folding/unfolding of the side
sections and make sure that
the wing sections are fully
raised.
3. Release the transport lock by
pulling in the wire.
4 The wings can be un folded.
Angle The angle of the discs can be continuously adjusted hydraulically during op-
eration, enabling the operator to obtain the optimal setting according to field
conditions. If there are many patches of plant residue on the field, the angle
can quickly be reduced to avoid blockage. The angle can also be reduced if
the need for pulling force becomes too great.
Travel Speed A working speed between 8-12 km/hour is recommended, but always drive
according to conditions.
When the travel speed is increased, wear on the implement is increased, espe-
cially under dry soil conditions. Damage to the discs and T-rings may also re-
sult from driving too fast under unfavourable conditions.
Power requirements
Power requirements change according to soil type, terrain and travel speed.
Working width 300 cm 400 cm
Power requirements hp 90 - 100 120 - 140
A

MaxiDisc
Side 18
Troubleshooting
Problem Cause Action
•MaxiDisc is not
horizontal.
•Adjust the top link until the main
frame is horizontal.
•The travel speed
is too fast.
•Drive slower.
•The angle is too
aggressive.
•Adjust the angle.
Soil is thrown too
far out to the sides,
creating a ridge.
•Driving too
closely or too far
away from the
previous pass.
•Driving too closely or too far
away from the last pass.
•Driving too
closely or too far
away from the
previous pass.
•Driving too closely or too far
away from the last pass.
A depression in
the soil or furrow
develops between
passes.
•The rear row of
discs is too ag-
gressive or too
passive.
•Set the rear row of discs less or
more aggressively.

MaxiDisc
Side 19
Options
Disc Scrapers Fig. 8
Disc scrapers can be mounted if
necessary. The scrapers are fastened
by two bolts and ensure clean discs
under all field conditions.
Adjust the disc scrapers to allow
only 3 to 5 mm of space between
each disc and scraper.
Mudguard Fig. 9
Mudguard can be mounted to pre-
vent soil to be frown form the front
row of discs to the rear row
The mudguard is mounted in mount-
ings under the frame.
Light Fig. 10
Marking lights can be mounted and
easy connected to the socket outlet
of the tractor.
The marking lights must be folded
up before the MaxiDisc is unfolded
and secure with the lynch pin.
T-ring, 70x70x8 T-steel
To give MaxiDisc a better support from the ground, MaxiDisc can be
equipped with a wider T-ring, special aiming for the lighter soil.
A

MaxiDisc
Side 20
Maintenance
Proper maintenance ensures a long life for the MaxiDisc and optimum per-
formance from the implement. To facilitate maintenance, grease fittings have
been mounted on those locations where wear on the equipment is the greatest.
L
Tighten all nuts, bolts, hydraulic fittings or any other fastened assemblies
after the first workday. Inspect all pins and bolts for wear or damage and
make sure that all are securely in place to avoid any possible damage or
breakdown of the machine. Check for leaks in the hydraulic system.
Before servicing the machine, always lower the implement, engage the trac-
tor brakes, stop the engine and remove the ignition key to avoid uninten-
tional operation and personal injury.
Lubrication Fig. 11
A A B
C D E
F G H
Lubrication points Number of
fittings Lubrication inter- val (hours) Photo
T-ring bearings 3/4 50 A
Hub 24/34 50 B
Disc pipe 24/34 8 C
Side discs 1 50 D
Angle adjustment cylinder 2 25 E
Wing section 4 50 F
Wing section ram 8 50 G
T-ring packer roller 4 50 H