DALBO MAXICUT User manual

MAXICUT
EN
200/300/600
Serial no.: 100-XXX

MAXICUT
Type 200/300/600
Congratulations on the purchase of your new MAXICUT. For safety reasons and to achieve
optimum service from the product, please read the User Guide before use.
© Copyright 2009. All rights reserved DALBO A/S
This product has:
Type no.:
Serial no.:
Month of manufacture:
Net weight kg:
If contacting the manufacturer regarding spare parts or service, please state type and serial
number. A spare parts list is included at the back of this manual.
EU DECLARATION OF COMPLIANCE
DALBO A/S
DK-7183 Randbøl
[phone]
declares herewith that the above machine is manufactured in accordance with the provisions
of directive 2006/42/EC, which replaced directive 98/37/EC and change directives
91/368/ECC, 93/44/ECC and 93/68/ECC on harmonization of member state legislation con-
cerning health and safety requirements related to the construction and manufacture of ma-
chines.
This machine corresponds to the safety requirements in the European Safety Guidelines.
DALBO A/S
Date:
Carsten Jensen, CEO
CE

Table of Contents
SAFETY.......................................................................................................................................... 7
GENERAL ...........................................................................................................................................7
HYDRAULICS.......................................................................................................................................8
ASSEMBLY..........................................................................................................................................8
MAINTENANCE AND REPAIR ....................................................................................................................8
ROAD TRANSPORT ................................................................................................................................ 8
CORRECT USE......................................................................................................................................9
TECHNICAL DATA......................................................................................................................... 10
HOW TO USE THIS MANUAL .......................................................................................................... 11
DELIVERY.........................................................................................................................................11
USES ........................................................................................................................................... 12
CONNECTING AND DISCONNECTING............................................................................................. 13
CONNECTING.....................................................................................................................................13
HYDRAULICS.....................................................................................................................................13
DISCONNECTION ................................................................................................................................13
SETTING UP ................................................................................................................................. 15
ADJUSTING DRAWBAR .........................................................................................................................15
OPERATION ................................................................................................................................. 16
EXTENDING AND RETRACTING ...............................................................................................................16
Extending ................................................................................................................................16
Retract.....................................................................................................................................17
OPERATING SPEED .............................................................................................................................17
Power.......................................................................................................................................17
TROUBLESHOOTING .................................................................................................................... 18
MAINTENANCE ............................................................................................................................ 19
LUBRICATION ....................................................................................................................................19
ADJUSTMENT ....................................................................................................................................20
Wheels.....................................................................................................................................20
Wear parts...............................................................................................................................20
HYDRAULICS.....................................................................................................................................20
REPLACEMENT ANDREPAIRS....................................................................................................... 21
HYDRAULICS.....................................................................................................................................21
Replacing extend cylinder for retracting side sections......................................................21
Replacing gasket set for extend/retract cylinder ...............................................................22
Mounting .................................................................................................................................23
Replacing raise/lower cylinder .............................................................................................23
Replacing gaskets on raise/lower cylinder..........................................................................24

Mounting................................................................................................................................. 24
REMOVAL/FITTING WHEEL................................................................................................................... 25
Replacing wheel bearings..................................................................................................... 25
REMOVING BLADE ROLLER .................................................................................................................. 26
Replacing blade roller bearings............................................................................................ 26
Fitting bearings...................................................................................................................... 26
Replacing blades.................................................................................................................... 27
Fitting blades ......................................................................................................................... 27
SCRAPPING..................................................................................................................................28
HYDRAULIC DIAGRAM...................................................................................................................29
SPARE PARTS...............................................................................................................................30

MAXICUT
Side 7
Safety
This symbol appears in the instruction manual each time there is a safety warning
concerning your safety, the safety of others or functionality of the machine. All
safety instructions must be observed and made available to all users of the ma-
chine.
General
•Ensure you are familiar with all aspects of the machine before use
•There are safety stickers on the machine containing important instructions for
the safety of yourself and others, and correct use of the machine.
•Do not carry passengers during operation or transport.
•Ensure there are no personnel within the machine's working radius before op-
erating. Operate machine only from inside the tractor.
•When retracting MAXICUT, ensure that the side sections are locked using the
chain provided before leaving the field. Check all control handles are secured
against accidental operation.
•Before leaving the tractor or making adjustments, performing maintenance or
repairs on the machine, extend fully and lower to ground, or maintain in
transport position, apply tractor handbrake, switch engine off and remove igni-
tion key to secure the machine against accidental operation.
•Remember to secure support leg and pins with split rings.
•Never leave driver's seat whilst machine is moving.
•Always adapt speed to conditions.
•Do not use machine unless all safety devices are in place. Defective safety de-
vices must be replaced immediately.

MAXICUT
Side 8
Hydraulics
•Lower machine fully for any repair work on the hydraulic system. Relieve hy-
draulic pressure, switch engine off and remove ignition key.
•Clean hydraulic connections thoroughly before reconnecting. When connecting
hydraulic hoses to tractor hydraulics, ensure they are not under pressure.
•Bleed the hydraulic system thoroughly after any repairs.
•Check hydraulic hoses regularly for defects such as cracks, splits, crimps, wear
or breaks. Defective hoses must be replaced immediately.
•Avoid spilling oil on the ground. If oil is spilt, collect and deliver to a destruction
point.
•Clean hands thoroughly after contact with oil and grease. Change oil-stained
clothing immediately. Hydraulic oil can be harmful to the skin.
•Hydraulic oil released under high pressure can penetrate the skin and cause
severe injury. In the event of injury, seek medical help immediately.
Assembly
•Danger of crushing! Ensure no personnel are between implement and tractor,
or between the parts to be connected.
Maintenance and repair
•Ensure machine is adequately supported or fully extended for all repair and
maintenance work. Ensure tractor and machine are properly braked, engine
stopped and ignition key removed.
•Tighten all screw connections after a few hours use. Check all screw connec-
tions regularly and tighten as required. Check all split pins and bolts to avoid
mechanical failure.
•Dispose of oil, grease and filters in accordance with local environmental pro-
tection rules.
Road transport
•All safety and warning precautions mandatory by law must be fitted and tested
before transporting the machine on public roads. The driver is responsible for
fitting the correct lighting and number plate required in accordance with appli-
cable legislation.

MAXICUT
Side 9
•Check with local traffic authorities whether transport on public roads is allowed
given the machine's dimensions.
•When transporting, ensure permitted total weight for tractor is not exceeded
and that loading on tractor front axle is not less than 20% of tractor net weight.
If this is the case, use weights on tractor front
Correct use
•Correct use of the machine includes observing the manufacturer's operating,
maintenance and repair instructions, and that original spare parts are always
used.
•MAXICUT may only be used, maintained or repaired by personnel familiar with it
and who are aware of the risks that can be involved.
•The manufacturer cannot be held liable for injury or damage arising from modi-
fications made to the machine performed without prior permission from the
manufacturer. Neither can the manufacturer be held liable for injury or damage
arising from incorrect use. Such liability rests solely with the user.
•Do not add extra weight to the machine.

MAXICUT
Side 10
Technical data
The table below indicates how much oil
will return to the tractor when MAXICUT is extended.
Model
Oil (litres)
600
2
MAXICUT 600
Width (cm)
200
275
580
HP (recommended)
70
90
150
Weight in kg:
Without water approx.
1450
1750
4300
With water approx.
2025
2450
6100
Sections (pcs.)
1
1
3
Wheels
-
-
400/60-15.5
Hydraulic requirements:
Double-acting
-
-
2
Single-acting
-
-
-
Transport:
Width (metres)
2,42
3
3
Height (metres)
1,8
1,8
3,6
Length (metres)
1,35
1,35
5

MAXICUT
Side 11
How to use this manual
The sequence of subject matter in this manual can seem illogical. Please refer to
the table of contents for page numbers for individual items.
The manual is divided into 5 main sections:
•Safety
•Starting routine and running
•Accessories
•Maintenance
•Repairs
The following symbols represent:

Points which are important to functionality and service life.
Points relevant to safety.
Delivery
The machine is delivered complete on a trailer.
If lifting the machine, we recommend the use of straps on the mid-section and
drawbar to maintain balance.

MAXICUT
Side 12
Uses
MAXICUT is a newly-developed heavy blade roller, designed for use on crops with
long, thick stems. By cutting the remaining organic materials, decomposition is
accelerated.
Fig. 1
MAXICUT is a blade roller, on which the
sections are independent of each other.
Heavy-duty bearings are standard.
MAXICUT 600 at work
MAXICUT is used after harvesting on crops such as maize, sunflower or rape, when
the total weight of the machine and ground conditions are optimum. When the roll-
ers are filled with water and the ground is as dry as possible, the machine is at its
most effective.
The machine has to be operated at relatively high speeds of over 15 km per hour,
preferably 18-25 km per hour at which the rollers will perform best on stubble and
plant residue. For an extra thorough result, another run can be made over the field.
The rollers are designed to be filled with water if required. The machine comes from
the factory without water to simplify transport.

The steel tubes may only be filled with water or liquid with a density less than
1.15 g / cm³. This avoids overloading the machine's hydraulics and welded
frames.

MAXICUT
Side 13
Connecting and disconnecting
Connecting
Fig.2
MAXICUT is attached to the tractor's
lifting arms and secured using balls
and split pins (A). The support leg (B)
is raised and secured by a pin (C).
MAXICUT 200/300 coupled so that
the drum section, always preferred to
in paragraph (D).
Remember to secure drawbar with balls and split pins.
Hydraulics
MAXICUT requires a double-acting hydraulic outlet, in which one line is used for
lowering the side sections and other for towing the frame to transport the roller
from field to field.
Table 1. Hose markings
Cylinder name
Colour
Outlet
Function
Wheel
frame cylinder
Yellow
Double acting
Raises MAXICUT up onto its
wheels and down into working
position.
Extend/retract
Red
Double acting
Retracts the sides up-
wards/downwards.

Check hydraulic hoses for crimping
Disconnection
Fit support leg vertically, release drawbar from tractor and disconnect hydraulic
hoses.
A
B
C
D

MAXICUT
Side 14

Remember to depressurise hoses before disconnecting them.
MAXICUT must be in transport or working position when disconnecting.

MAXICUT
Side 15
Setting up
MAXICUT is very simple to work with. The design makes it very simple to set up, alt-
hough the main frame must be horizontal.
Always check frame angle before use to ensure optimum use of the machine.
Adjusting drawbar
To ensure uniform cutting, the drums must be horizontal on the drawbar. The side
frames can swing in relation to the lie of the field.
Fig. 3
MAXICUT 600 at work. The main frame
is horizontal whilst the side frames
are free to swing.
Incorrect drawbar height can cause uneven compression of the soil, as the roller
will not apply equal pressure for all sections. If the drawbar is low at the back, the
tractor lift arm is too high. If the drawbar is low at the front, raise the tractor lift
arm.
HORIZONTAL

MAXICUT
Side 16
Operation
Correct operation is vital for optimum use.
This applies to working in the field and for safety. Always ensure you are fully famil-
iar with all safety aspects of the machine.
Extending and retracting
Extending and retracting the machine must always be performed with tractor
parked.
Extending
Fig. 4
1Remove transport chain, extend
side sections to horizontal using
the extend cylinder (hose marked:
red).
Fig. 5
2Activate extend/retract cylinder
(marked: Red) to fully extend side
sections.
3Raise wheel frame (marked: yel-
low)

Before commencing rolling, drawbar must be horizontal. When driving with MAXICUT
200/300 lift must always be in a floating position when the machine is in working
position.
By turning with the machine on the headland, the machine has to be lifted up on
the wheel frame to make sure, that the frames will not be overloaded. Slight curve
speed can be made with the machine in the ground.

MAXICUT
Side 17
Retract
Lower wheel frame and raise roller clear of ground.
Retract side sections, fit transport chain.
Operating speed
An operating speed of 18-25 km/h is recommended, but always operate according
to conditions.
Increased speed will increase wear, particularly in dry conditions. There will also be
a risk of the roller throwing up soil and stones.
Power
Power requirement will depend on soil type, terrain and speed.
Table 2, Guide to power requirement in HP
Model (cm)
200
300
600
HP min.
70
90
150

MAXICUT
Side 18
Troubleshooting
Fault
Cause
Remedy
Mid-section apply-
ing too much pres-
sure
•Drawbar too high
•Adjust drawbar to horizontal
(see "Adjusting drawbar")
•Too much water
•Adjust volume of water to the same
in all three rollers
•Too much water
•Adjust volume of water to the same
in all three rollers
Side sections press-
ing too much
•Drawbar too low
•Adjust drawbar and mid-section (see
"Adjusting drawbar")
•Wheel frame tou-
ching ground
•Lift wheel frame higher
•Blades worn
•Replace with new blades
Blades not cutting
sufficiently
•Drum not heavy
enough.
•Fill rollers with water
•Field/surface too
soft
•Wait until field is dry

MAXICUT
Side 19
Maintenance
Good maintenance ensures long service life and optimum use. Grease nipples are
fitted where wear is heaviest.

Tighten all screw connections after first working day. Check all split pins and bolts
to avoid mechanical failure. Check hydraulic system for leaks.
Lubrication
Fig. 6
A
B
C
D
E
F
Lubrication points
Number
of
nipples
Lubrication intervals,
hours
Illustration
Drawbar
2
8
A
Wheel frame and cylinder
6
8
B
Turn plates and cylinder
10
8
C
Swinging frames
2
8
D
Bearings
6
50
E
Wheel bearings
2
200
F
Rolls
2
8
G

Lubricate all lubrication points at least once annually.
G

MAXICUT
Side 20
Adjustment
Wheels
Lubricate and adjust wheel bearings at least once annually. Check tyre pressures
(see recommended pressure on tyre).
Adjustment and lubrication of wheel bearings
1. Remove hub caps.
2. Remove split pin.
3. Tighten castle nut 1/6th of a turn until hole aligns with axle. Turn wheel, check
for resistance. A little play should be detected in the hub housing when rocking
wheel from side to side. If play is excessive, repeat process.
4. Replace split pin
5. Fill hub cap ¾ full with grease. Replace.
Wear parts
Fig. 7
Blades are fitted with a protective
plate at factory (A) between each one
to protect bolts and holders. Blades
can be replaced as required. There are
2 blades per row on each roller.
Hydraulics
Check all hydraulic hoses for wear or cracks. Check all hoses for crimping.

Lubricate exposed rams with oil or pressure-resistant grease to avoid rust forming
when storing for long periods. Remember to remove before use.
A