DALBO MAXICUT 920 User manual

MAXICUT
EN
920
Series no: 101163-XXXXXX

MAXICUT
Type 920
Congratulations on your new MAXICUT. For safety reasons and to achieve the best possible use
out of your machine, you should read through the user instructions carefully before taking the
machine into use.
©Copyright 2009. All rights reserved DALBO A/S.
Your MAXICUT has:
Type no.:
Serial no.:
Month of manufacture:
Tare weight in kg:
When enquiring about spare parts or servicing, we kindly ask 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 stip-
ulations in Directive 2006/42/EF, which replaces the Directive 98/37/EF and the amending Di-
rectives 91/368/EØF, 93/44/EØF and 93/68/EØF on a mutual approach for member state legis-
lation on machinery for health and safety requirements in connection with the construction and
manufacture of machinery.
This machine complies with the safety requirements of the European safety guidelines.
DALBO A/S
Date:
Carsten Jensen, CEO
CE

Table of Contents
SAFETY.......................................................................................................................................... 7
GENERAL ..................................................................................................................................................7
HYDRAULICS ..............................................................................................................................................8
INSTALLATION ............................................................................................................................................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...................................................................................................................................... 15
SETTINGS ...............................................................................................................................................16
TENSILE ADJUSTMENT .............................................................................................................................. 16
ADJUSTING THE SIDE FRAMES .................................................................................................................... 17
DRIVING AND OPERATING............................................................................................................ 19
UNFOLDING AND FOLDING......................................................................................................................... 19
Unfolding....................................................................................................................................... 19
Folding........................................................................................................................................... 20
TURNING IN THE FIELD OR HEADLAND ......................................................................................................... 21
DRIVING SPEED ....................................................................................................................................... 21
Power............................................................................................................................................. 21
TROUBLESHOOTING.................................................................................................................... 22
EXTRA EQUIPMENT...................................................................................................................... 23
WAVE PLATES.......................................................................................................................................... 23
Power............................................................................................................................................. 24
Hose markings ............................................................................................................................. 24
Driving and operating.................................................................................................................. 24
Retrofitting ................................................................................................................................... 25
GRASS DRUMS......................................................................................................................................... 26
Power............................................................................................................................................. 26
Driving and operating.................................................................................................................. 26
Installation.................................................................................................................................... 27
MOLE PLANKS......................................................................................................................................... 27
Power............................................................................................................................................. 28
Driving and operating.................................................................................................................. 28
Installation/Retrofitting.............................................................................................................. 28
SAW EQUIPMENT...................................................................................................................................... 28

Hose markings..............................................................................................................................29
Driving and operating ..................................................................................................................30
Retrofitting....................................................................................................................................30
MAINTENANCE.............................................................................................................................31
LUBRICATION ..........................................................................................................................................31
ADJUSTMENTS.........................................................................................................................................33
Wheels ...........................................................................................................................................33
Swivel stool ...................................................................................................................................33
WORN OUT PARTS.....................................................................................................................................34
KNIFE DRUMS..........................................................................................................................................34
HYDRAULICS ...........................................................................................................................................34
REPLACEMENTS AND REPAIRS.....................................................................................................35
HYDRAULICS ...........................................................................................................................................35
Changing out the cylinders for unfolding and folding the side sections.............................35
Changing out the cylinders for unfolding and folding the side sections.............................35
Installation....................................................................................................................................36
Changing the timing belt-cylinder.............................................................................................37
Change the gaskets on the timing belt-cylinder.....................................................................38
Installation....................................................................................................................................38
Changing the cylinder to raising and lowering the side sections.........................................39
Changing the cylinder gasket for raising and lowering the side sections ..........................40
Installation....................................................................................................................................40
Change cylinders for hydraulic pull...........................................................................................41
Replacement of the gaskets for hydraulic pull .......................................................................42
Installation....................................................................................................................................42
UNINSTALLING/INSTALLING OF WHEELS ......................................................................................................43
Replacing the bearings ...............................................................................................................43
DISASSEMBLY OF THE KNIFE DRUM .............................................................................................................44
Replacing the bearings on the knife drum ...............................................................................44
Installation of the bearings ........................................................................................................44
Replacement of the knife............................................................................................................45
Installation of the blades............................................................................................................45
DISPOSAL ....................................................................................................................................46
SPARE PARTS...............................................................................................................................47
WARRANTY...................................................................................................................................48
HYDRAULICS DIAGRAM FOR MAXICUT ..........................................................................................49

MAXICUT
Page 7
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 instruc-
tions 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, which contain important instructions
about your own and others' safety, and 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. The
machine may only be operated from inside the tractor.
•When the MAXICUT 920 is in transport position, it is important that the side sections are
lowered in the transport hooks 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.
•Never leave the driver's seat while the machine is driving.
•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.

MAXICUT
Page 8
Hydraulics
•Prior to any repair work on the hydraulics unit, the machine's undercarriage must be low-
ered, 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 re-
moved 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. Change out of oil-soaked
clothing immediately, as this can be 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.
Installation
•There is a risk of crushing when carrying out installation. 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 environmen-
tal legislation.
Driving on roads
•When driving on public roads, all safety arrangements andwarnings required by law must
be installed and tested. The driver is responsible for the correct use of lights and traffic
signs in accordance with the applicable traffic laws.
•With regard to the dimensions of the machinery, the driver must enquire with the traffic
authorities to ensure that it may be transported on public roads.

MAXICUT
Page 9
•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 per cent of
the tractor's overall weight. In that case, use the front weight of 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 car-
ried 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 installed on the MAXICUT.

MAXICUT
Page 10
Technical data
MAXICUT 920
Ground
machine
The plate
equipment
Saw equipment
500L tank
Working width (cm)
920
920
920
HP (recommended
min)
300
50–100
-
Sections (pieces)
3
3
3
Wheels
700/40-22.5
700/40-22.5
700/40-22.5
Weight in kg:
Without water approx.
10,000
1380
565
With water approx.
12,300
-
-
Hydraulic require-
ments:
Double-acting
3
1
-
Single-acting
-
-
1
Unpressurised return
-
-
1
Transport:
Width (meters)
3
3
3
Height (meters)
2.51
2.51
3.51
Length (meters)
8.5
8.5
8.5

MAXICUT
Page 11
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
•Extra equipment
•Maintenance
•Repairs
The following symbols are used in the instruction manual for:

Points that are 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 straps with the main frame so that
the machine is balanced.

MAXICUT
Page 12
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 designed 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 inde-
pendently of each other, while being sus-
pended like a pendulum.
Hydraulic weight distribution is installed
on the machine so the pressure will be
the same over the entire working width.
By default, there are strong bearings.
MAXICUT 920 in work mode
MAXICUT's intended purpose is harvesting, for example, corn, sunflower or rape seed. The ma-
chine's total weight and the nature of the soil play a large part here. 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, prefer-
ably 15–20 km/hour where one will find the knife-drums at their best across the stubble and
plant remains. Run over the field twice if you wish to do any further work on the field.

The machine is constructed so sturdily that it can tolerate high loads. Neverthe-
less, it is always necessary to adjust the driving speed to the conditions, i.e. re-
duce driving speed, for example, when the ground is uneven.

MAXICUT
Page 13
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 culti-
vated. Those areas to be tilled must have been subject to normal agricultural maintenance, i.e. without sig-
nificant 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 must not be any stiffer 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 20 km/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
Page 14
Connecting and disconnecting
Connecting
The MAXICUT 920 can be fitted with 2 different types of features.
One feature designed for installing in the tractor's three-point suspension; the height adjust-
ing via the suspension.
The machine can also be fitted with a hydraulic feature that adjusts the height via hydraulics,
as well as hydro-clips. This feature is installed in the drawbar
Fig.2
MAXICUT with lift feature. The machine is
connected to the tractor's lift arms and
is secured with ball joints and splitters
(A)
MAXICUT with hydraulic pull. The ma-
chine is installed in the tractor's drawbar
and the plinth is secured with a split (B)
or lock device if there is a ball hitch.
Remember to secure the connection with ball joints and linchpins.
Hydraulics
By default, the MAXICUT 920 requires three double-acting hydraulic jacks.
Hose markings
Cylinder name
Colour
Outlet
Function
Timing belt cylinder
and hydraulic pull if
installed
Yel-
low
Double-acting
Lift the MAXICUT up on the
wheels and down into working
mode.
Hydraulics
Weight distribution,
as well as lift to
transport position
Red
Double-acting
Raises the side frames up/down.
Unfolding and fold-
ing, as well as sup-
port legs
Blue
Double-acting
Folds the side frames in and out.
With the help of ball valves, the
support leg can be raised and
lowered.
The yellow and red hydraulic system is equipped with pilot-operated check valves. This re-
sults in a supply of pressure in one of the hoses to enable the cylinders to move. The cylin-
ders, therefore, do not move if the tractor's lever is shifted to the on position.
A
B

MAXICUT
Page 15
Furthermore, the timing belt cannot be lowered if the tractor's motor is switched off.
If the plate equipment is installed on the machine, 1 extra double-acting hydraulic outlet is
required to adjust this.
Hose markings
Cylinder name
Colour
Outlet
Function
the plate equipment
Green
Double-acting
For lifting and adjusting the
plate equipment
If saw equipment is installed on the machine, 1 extra single-acting hydraulic outlet and 1
pressure-free return are required. For hydraulic fan.
Hose markings
Cylinder name
Colour
Outlet
Function
Saw equipment
White
(Green
)
Single-acting
For the hydraulic fan
Unpressurised re-
turn
Disconnecting
Fig.3
The machine must be collapsed and low-
ered on solid ground when disconnected
from the tractor.
Remove the hydraulic hoses and
the machine is released from the tractor.
Always disconnect the machine on a flat surface to ensure maximum stability.

Remember to release the pressure from the connecting hoses to the hydraulic sys-
tem before disconnecting the hoses.

Make sure the hydraulic hoses have not been crushed.

MAXICUT
Page 16
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 incline of the frame before use to ensure optimum use of
the machine.
Tensile adjustment
To achieve uniform cutting of crops and unnecessary load of the machine, the main frame
should be horizontal or slightly tilted over the ground surface. The main frame and knife
drums will then also be horizontal in relation to each other.
Fig. 4
Here you can see the MAXICUT 920 at
work. The main frame is horizontal
while the individual knife sections
have the opportunity to move.
Properly adjusted feature results in a uniform packing/cultivation of the field, as the drum
will pack evenly on each of the 3 sections. The 3 knife sections are pendulum suspended and
can move in relation to the slope of the ground.
Fig. 5

An incorrectly installed feature can cause unnecessary load to the machine and
lead to a breakdown. In particular, a pull installed too high (the main frame is tilted
backwards), as this places a lot of weight on the middle knife section.

It is important to make sure that the main frame is horizontal or slanting a little
forward.
If the pull leans backwards, the tractor's lift arm is too far up. If the pull leans forwards, the
tractor's lift arm should be raised.
HORIZONTAL

MAXICUT
Page 17
If the machine is installed with hydraulic pull, there are various adjustment options. It is pos-
sible to adjust the cylinders (A) as there are different thicknesses of hydroclips with the ma-
chine. It is also possible to move the feature up and down in 2 different flange plates (B and
C).
Fig. 6
Adjusting the side frames
The side frames must run perpendicular to the direction of travel (A). This can be adjusted via
spacer discs that are bolted onto (B) where the top rods fit (C). It is important that the angle
is 90 degrees or slightly under so as not to damage the machine or fold the cylinders.
B
C
A
A

MAXICUT
Page 18
Fig. 7

It is important to make sure that the top rods are set against the spacers and that
the angle is 90 degrees or slightly under so as not to damage the machine or un-
fold the cylinders.
B
C
A

MAXICUT
Page 19
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 near the machine.
Unfolding
Fig. 8
1The machine is raised as high as possible
with the timing belt and pull (hose marked
with: yellow), after which the side frames
are lifted free of the transport latches with
the lifting cylinders (hose marked with:
red) and are folded out with the folding cyl-
inders (hoses marked with: blue).

If additional equipment is fitted on the machine, it is important that this is com-
pletely lowered before the machine is started or unfolded.
Fig. 9
2The machine is lowered and the timing
belt is tilted up in the air (hose marked
with: yellow)
Timing belt and hydraulic pull are fol-
lowed by automatic lifting and lowering.
Fig. 10
3Press the large cylinders on the side
frames (the hoses are marked with:
Red), so a pressure of approx. 45 bars is
achieved. This can be read on the ma-
nometer. Once the desired pressure has
been reached, the hydraulic lever in
question is set to float position.
The hydraulic weight distribution is now
activated and work can be started.

MAXICUT
Page 20

It is extremely important that the hydraulic lever that goes to the hydraulic weight
distribution of the machine is in float position during work in the ground so as not
to damage the hydraulic system (the large cylinder lifting the side frames. The
hose marked with: Red)

Before the rolling is initiated, the pull must be horizontal.
When turning the machine on the headland, the machine must be lifted up onto
the timing belt to avoid unnecessary twisting in the machine's frame construc-
tion. An easier curve speed can be used with the machine in the ground.
Folding
The timing belt is lowered down to the ground and the knife roller is lifted off the
ground.
From here, the side sections can be raised to the maximum height and folded to-
gether.
When the side sections are fully folded down, they are lowered into the transport
locking device.

If additional equipment is fitted on the machine, it is IMPORTANT that this is com-
pletely lowered before the machine is folded. Otherwise the machine could be
damaged.
When driving the machine in transport position, it is important to ensure the side
sections are located in the transport hooks. Otherwise, this may cause personal
injury or damage to the machine.