DALBO MAXICUT 260 Series User manual

MAXICUT
EN
400
Series no: 260-XXX

MAXICUT
Type 400
Congratulations on your new MAXICUT. For safety reasons and for optimal use from your
machine, you should read through the user manual thoroughly before using the machine.
©Copyright 2009. All rights reserved DALBO.
Your MAXICUT has:
Type no.:
Serial no.:
Month of manufacture:
Tare weight in kg:
When enquiring about spare parts or servicing, we kindly asks that you always provide the
type number and serial number. At the back you will find a list of spare parts, which helps give
an overview of the individual parts.
EU DECLARATION OF CONFORMITY
DALBO A/S
DK-7183 Randbøl
[phone]
hereby declares that the aforementioned machine is manufactured in accordance with the
stipulations in Directive 2006/42/EF, which replaces the Directive 98/37/EF and the
amending Directives 91/368/EØF, 93/44/EØF and 93/68/EØF on a mutual approach for
member state legislation on machinery for health and safety requirements in connection with
the construction and manufacture of machinery.
CE
This machine complies with the safety requirements of the European safety guidelines.
DALBO A/S
Date:
Carsten Jensen, CEO

Table of Contents
SAFETY ........................................................................................................................................... 7
GENERAL............................................................................................................................................ 7
HYDRAULICS........................................................................................................................................ 8
MOUNTING .......................................................................................................................................... 8
MAINTENANCE AND REPAIR..................................................................................................................... 8
DRIVING ON ROADS ............................................................................................................................... 8
CORRECT USE ...................................................................................................................................... 9
TECHNICAL DATA ..........................................................................................................................10
HOW TO READ THE INSTRUCTION MANUAL ....................................................................................11
DELIVERY ......................................................................................................................................... 11
DESCRIPTION OF THE MACHINE....................................................................................................12
LIMITATIONS IN THE USE OF THE MACHINE...................................................................................13
CONNECTING AND DISCONNECTING..............................................................................................14
CONNECTING ..................................................................................................................................... 14
HYDRAULICS...................................................................................................................................... 14
DISCONNECTING.................................................................................................................................14
SETTINGS......................................................................................................................................16
TENSILE ADJUSTMENT .........................................................................................................................16
DRIVING AND OPERATING .............................................................................................................18
UNFOLDING AND FOLDING .................................................................................................................... 18
Unfolding..................................................................................................................................18
Folding...................................................................................................................................... 19
DRIVING SPEED .................................................................................................................................. 20
Power........................................................................................................................................ 20
TROUBLESHOOTING......................................................................................................................21
MAINTENANCE..............................................................................................................................22
LUBRICATION..................................................................................................................................... 22
ADJUSTMENTS ...................................................................................................................................23
Wheels......................................................................................................................................23
Worn out parts.........................................................................................................................23
BLADE DRUMS ...................................................................................................................................23
HYDRAULICS...................................................................................................................................... 23
REPLACEMENTS AND REPAIRS .....................................................................................................24
HYDRAULICS...................................................................................................................................... 24
Changing the tilt cylinder .......................................................................................................24
Change the gaskets on the tilt cylinder................................................................................25

Mounting.................................................................................................................................. 25
REMOVING/FITTING OF WHEELS.............................................................................................................25
Replacing the bearings...........................................................................................................26
REMOVAL OF THE CUTTER DRUM.............................................................................................................27
Replacing the bearings on the cutter drum..........................................................................27
Mounting the bearings............................................................................................................27
Replacement of the cotter ..................................................................................................... 28
Mounting the blades ...............................................................................................................28
DISPOSAL .....................................................................................................................................29
SPARE PARTS ..................................................................................................................................... 30
WARRANTY........................................................................................................................................31
HYDRAULICS DIAGRAM FOR MAXICUT 400 ............................................................................................ 32

MAXICUT
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Safety
You will see this symbol in the instruction manual each time advice is given about your
safety, the safety of other users, or the functional safety of the machine. All safety
instructions must be observed and made available to all users of the machine.
General
Before starting work, the user must be familiar with all parts of the machine.
Safety markings have been placed on the machine that contain important
instructions about your own safety and of others, as well as on the correct use of
the machine.
There must be no passengers on the machine, either during work
or transportation.
When operating MAXICUT, ensure that there are no people within the machine's
reach.
When MAXICUT is in transport mode, the seat sections are locked by turning the
handle in the drop-down boxes in the bottom before driving on public roads.
Likewise, this secures the control levers against accidental operation.
Before leaving the tractor, performing any adjustments, maintenance or repairs
to MAXICUT, unfold the machine and lower it to the ground or, secure it in
transport mode, put the brakes on the tractor, turn off the engine and remove the
ignition key so that the machine is secured against accidental starting.
Remember to secure nails with linchpins, and secure blade drums with regards to
transport and working mode by using the handle of the roller boxes.
Never leave the driver's seat while the machine is running.
The driving speed must always be adjusted to the conditions.
Only use the machine if all safety devices have been mounted. Defective safety
devices must be replaced immediately.

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Hydraulics
Prior to any repair work on the hydraulics unit, the machine's undercarriage must
be lowered, the pressure must be removed from the unit, the engine must be
switched off and the ignition key must be removed.
Hydraulic connections must be cleaned thoroughly before connecting. When
connecting the hydraulic hoses to the tractor's hydraulics, ensure that the
pressure has been removed from the hydraulic system.
After repairs on the hydraulic system have been completed, all air must be
thoroughly removed from the system.
Check the hydraulic hoses regularly for defects such as tears, cracks, wear or
damage. Defective hoses must be replaced immediately.
Avoid spilling oil on the ground. If this should happen anyway, it should be
collected and sent for destruction.
Clean hands thoroughly after skin contact with oil and grease. Oiled clothing
should be removed immediately as it is harmful to the skin.
Hydraulic oil that flies out under high pressure can penetrate through the skin
and cause serious injuries. Seek professional medical assistance immediately in
the event of any injury.
Mounting
There is a risk of crushing when mounting. People must not be positioned
between the machinery and the tractor or between the parts that are being
connected.
Maintenance and repair
The machine must be properly supported while undertaking all repair and
maintenance work, the tractor and machine must have brakes properly
activated, the engine must have been turned off and the ignition key removed.
Tighten all screw fittings after a few hours of use. All screw fittings must be
checked at regular intervals and tightened when necessary. Check cotter pins
and bolts to avoid breakdowns.
Oil, grease and filters shall be disposed of in accordance with the applicable
environmental legislation.
Driving on roads
When driving on public roads, all safety arrangements and warnings required by
law must be mounted and tested. The driver is responsible for the correct use of
lights and traffic signs in accordance with traffic laws.

MAXICUT
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Out of a regard for the dimensions of the machinery, the driver must enquire with
the traffic authorities to ensure that it may be transported on public roads.
When transporting the machine, care must be taken not to exceed the total
weight and axle load of the tractor and that the load on the front axle is not less
than 20 percent of the tractor's overall weight. In that case, use the front weight
on the tractor.
Correct use
Correct use of the machine also includes compliance with the manufacturer's
operating, maintenance and repair instructions, as well as the exclusive use of
original spare parts.
MAXICUT may only be used, maintained and repaired by people who are familiar
with the machine and who are aware of the dangers that can arise.
The manufacturer is not liable for damage that results from changes to the
machine carried out without the manufacturer's prior permission. Furthermore,
the manufacturer is not liable for any damage that results from incorrect use.
Responsibility for this rests solely with the user.
No extra weight may be mounted on the MAXICUT.

MAXICUT
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Technical data
MAXICUT 400
Working width (cm)
390
HK (my
recommendation)
100
Weight in kg:
Without water
approx.
3340
With water approx.
4540
Sections (pieces)
2
Wheels
300/80-15.3
Hydraulic
requirements
Double-acting
1
Single direction
-
Transport:
Width (meters)
2.3
Height (meters)
2.1
Length (meters)
6

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How to read the instruction manual
It is possible that the order in which the topics are listed does not appear as logical.
Please refer to the table of contents, where the titles for the relevant topics can be
found.
The main points in the instruction manual are divided into 5 key sections:
Safety
Getting Started and Driving
Additional Equipment
Maintenance
Repairs
The following symbols are used in the instruction manual for:
Points that is especially important for the functionality as well as the lifetime of the
machine.
Points that are relevant to safety.
Delivery
MAXICUT is delivered completely assembled via platform truck.
If MAXICUT needs to be lifted, it is recommended to use the straps to pull so that the
machine is balanced.

MAXICUT
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Description of the machine
MAXICUT is a powerful knife-drum, designed specifically to drive through crops with
long, strong stems. Here the remaining organic residue is cut so that the decay starts
faster. The drums are formed as watertight containers, which can be filled with water as
needed to increase the machine's weight.
The machine is delivered from the factory without water in the containers.
Fig. 1
The knife-drums are constructed so that
the individual sections can move
independently of each other. By default,
there are strong bearings.
MAXICUT 400 in work mode
MAXICUT's intended purpose is harvesting, for example, corn, sunflower or rapeseed,
which is greatly influenced by the machine's total weight and the soil. The machine is
most effective when the knife-drum is completely filled with water and the soil is
completely dry.
The containers must not be filled with water or a liquid with a density less than
1.15 g/cm3. This avoids overloading the machine's hydraulic and welded frames.
The speed of the machine must be high to be effective, with speeds over 15 km/hour,
preferably 18-25 km/hour where one will find the knife-drums at their best across the
stubble and plant remains. For further processing of the field, run over the field twice.
The machine is constructed so sturdily that it can tolerate high loads. Nevertheless, it
is always necessary to adjust the driving speed to the conditions, i.e. reduce travel
speed, for example, when the ground is uneven.

MAXICUT
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Limitations in the use of the machine
The following describes what the machine may/must not be used for:
The machine may only be used for tilling organic plant material in agricultural areas that have
been cultivated. Those areas to be tilled must have been subject to normal agricultural
maintenance, i.e. without significant bumps or holes. Any rocks in the field must be collected
from the normal scope of the area. The area must be reasonably drained.
The plant material cannot be more stiff than corn stalks
The machine may only be used after first being attached to an agricultural tractor, by way of
connection to the rear 3-point hitch. The machine can work at a maximum speed of 25km/h.
The speed shall however always be adjusted to the nature of the area. This means, for example,
that transverse crops must be driven over at a much lower speed to avoid extreme pressure on
the machine.
Any other use of the machine, which does not fulfil the aforementioned conditions, will be
considered as unauthorised use, and will therefore be in breach of the manufacturer's
warranty.

MAXICUT
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Connecting and disconnecting
Connecting
Fig.2
MAXICUT is connected to the tractor's
lift arms and is secured with ball
joints and splitters (A)
Remember to secure the connection with ball joints and linchpins.
Hydraulics
As a standard, MAXICUT 400 requires a double-acting hydraulic cylinder, which is then
put on a forklift, to transport the machine form one field to another.
Table 1. Hose markings
Cylinder name
Colour
Outlet
Function
Wheel frame cylinder
Yellow
Double-acting
Lift the MAXICUT up on the wheels
while in working mode.
The hydraulic system is equipped with pilot-operated check valves. This results in a
supply of pressure in one of the hoses to enable the cylinders to move. The cylinders,
therefore, do not move if the tractor's lever is shifted to the on position.
Furthermore, it is not possible to lower the wheel frame if the tractor's motor is
switched off.
Disconnecting
Make sure the hydraulic hoses have not been crushed.
Always disconnect the machine on a flat surface to ensure maximum stability.
A

MAXICUT
Page 15
The drawbar is released from the tractor and the hydraulic hoses are mounted.
Remember to release the pressure from the connecting hoses to the hydraulic system
before disconnecting the hoses.
MAXICUT can be in transport mode or unfolded when disconnected.

MAXICUT
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Settings
MAXICUT is incredibly easy to work with. The machine's design makes it very easy to
set.
It is always necessary to check the ramp slope before use to ensure optimum
utilization of the machine.
Tensile adjustment
To obtain a uniform cut across the crops, the knife drums move horizontally, while the
side frames move with respect to the ground slope.
Fig. 3
Here you can see the MAXICUT 600 at
work. The main frame is horizontal
while the side frame is moving. The
same goes for the MAXICUT 400.
HORIZONTAL
Properly adjusted tensile results in a uniform cultivation of the field, as the drum will
put equal pressure on each of the 2 sections. With a backwards pull, the tractor's lift
arm is too far up and in the future, the tractor's lift arm should be raised.

MAXICUT
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MAXICUT
Page 18
Driving and operating
Proper operation is important in order to get optimal performance from your MAXICUT.
This applies not only to working in the field but also in terms of safety. It is therefore
crucial that you have thoroughly read the safety precautions that cover the machine.
Unfolding and folding
Unfolding and folding are conducted with the tractor in park.
Before unfolding, ensure that no person is positioned between the side sections and
the main frame of the machine.
Unfolding
Fig. 4
1. Always start with the left side
section.
2. Turn the drop-down box handle up so
the side sections can be moved.
3. The drawbar is pulled out and the
side section is pushed into the
working position.
4. The side section is locked by turning
the handle in the drop-down box
down.

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Fig. 5
Fig. 6
5. The wheel frame is tilted up in the air.
Fig. 7
Before the tumbling is initiated, the pull must be horizontal.
When turning the machine on the headland, the machine must be lifted up onto the
wheel frame to avoid unnecessary twisting in the machine's frame construction. An
easier curve speed can be used with the machine in the ground.
Folding
The wheel frame is lowered down to the ground and the knife drum is lifted off the
ground.
Turn the drop-down box handle up so the side sections can be moved.
The drawbar is pulled out and the side section is pushed into the transporting position.
The side section is locked by turning the handle in the drop-down box down.

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Driving speed
It is recommended that the machine be driven at 18-25 km/h, but driving should always
be done according to conditions.
If the speed is increased, wear will also increase, especially under dry conditions. At the
same time, there is a danger that the knife drum will start throwing soil material and
rocks.
Power
The power requirement is very dependent on the type of soil and terrain as well as the
speed.
Table 2, Guide for power requirements in HP
Model (cm)
400
HP min.
100