DALBO MAXIDISC 300 User manual

MAXIDISC
GB
300, 400 cm

MAXIDISC
Type 300, 400 cm
Congratulations on the purchase of your new MAXIDISC. To ensure safe operation and to ob-
tain optimal use of the machine, read the rules and instructions of the following operator’s
manual carefully before operating the machine.
©Copyright 2002, DALBO. 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 regard-
ing 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 facilitate ordering.
EU DECLARATION OF CONFORMITY
DALBO A/S
DK-7183 Randbøl
Hereby declare that the above-mentioned machine has been manufactured in compliance
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 Machinery.
This machine complies with the safety requirements stipulated by the European safety regu-
lations.
DALBO 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
HOW TO USE THIS MANUAL ..........................................................................................................11
DELIVERY.........................................................................................................................................11
APPLICATION............................................................................................................................... 12
HITCHING AND UNHITCHING........................................................................................................ 13
HITCHING.........................................................................................................................................13
HYDRAULIC SYSTEM ...........................................................................................................................13
UNHITCHING .....................................................................................................................................13
ADJUSTMENTS AND SETTINGS .....................................................................................................14
DEPTH.............................................................................................................................................14
Deeper soil penetration .........................................................................................................14
ANGLE.............................................................................................................................................15
DISC SCRAPERS .................................................................................................................................16
SIDE DISCS .......................................................................................................................................16
OPERATING AND DRIVING INSTRUCTIONS ....................................................................................17
ANGLE.............................................................................................................................................17
TRAVEL SPEED ..................................................................................................................................17
Power requirements...............................................................................................................17
TROUBLESHOOTING ....................................................................................................................18
MAINTENANCE ............................................................................................................................19
LUBRICATION ....................................................................................................................................19
HYDRAULIC SYSTEM ...........................................................................................................................20
DISC HUBS........................................................................................................................................20
REPLACEMENTS AND REPAIRS ....................................................................................................21
HYDRAULIC SYSTEM ...........................................................................................................................21
Replacing angle adjustment cylinder...................................................................................21
Replacing angle adjustment seals .......................................................................................22
REPLACING SHAFT,BEARINGS AND T-RINGS.............................................................................................23
REPLACING THE BEARING IN THE DISC HUB ..............................................................................................23
SCRAPPING ................................................................................................................................. 25
HYDRAULIC SYSTEM DIAGRAM..................................................................................................... 26

SPARE PARTS ............................................................................................................................. 27

MAXIDISC
Side 7
Safety
The safety alert symbol is used throughout this manual to identify important safe-
ty warning messages concerning your safety, the safety of other users or the func-
tional 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 oper-
ations of this equipment prior to using.
•The safety signs on the MAXIDISC contain important instructions concerning
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 transport.
•Never allow bystanders within the operating radius of the MAXIDISC when the
implement is in operation. Operate the MAXIDISC only while seated in the driv-
er’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 machinery,
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 defective
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 being
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 hydraulic
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 dispose 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 immedi-
ately 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 MAXIDISC, or be-
tween parts that must be attached or connected.
Maintenance and Repairs
•Before servicing or making adjustments to the machine, securely block or un-
fold the machine, engage the tractor and machine brakes, stop the engine 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 thoroughly tight-
ened. 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 ma-
chine.

MAXIDISC
Side 9
•Dispose of oil, grease and filters according to applicable environmental regula-
tions.
Transport
•All safety and warning signs and devices required by law must be displayed,
mounted and tested for public road use. The driver is responsible for the cor-
rect 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 or-
der to ensure that the size, weight and load of the machinery may be trans-
ported on public roads.
•When towing the implement, the total weight of the tractor and the maximum
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 per-
cent, 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 man-
ufacturer 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 implement. The
user accepts complete responsibility in these cases.
•Never load extra weight onto the MAXIDISC.

MAXIDISC
Side 10
Technical Data
MAXIDISC
Size (cm)
300
400
HP (recommended)
100
140
Gross weight kg:
1720
2290
T-rings
Yes
Yes

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 indicate:

Points that are extremely important for the function and life
of the machinery.
Points that involve safety.
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 12
Application
MAXIDISC represents a whole new generation of lift-mounted disc harrows provid-
ing the ultimate in compactness.
The MAXIDISC is specially designed for work in the uppermost soil layer where resi-
due management is concentrated. The MAXIDISC effectively performs 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 micro-
climate 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.

•Remember to secure with lynch pins.
Hydraulic System
The MAXIDISC requires one double-acting hydraulic outlet.
Table 1. Hose markings
Cylinder
Colour
Outlet
Function
Angling
Green
Double-acting
Angling discs

•Check the hydraulic hoses for kinks or pinches.
Unhitching
Position the MAXIDISC on solid, even ground. Disconnect the lift arms and the top
link.
Remember to relieve the pressure in the hydraulic system
before disconnecting the hoses.

MAXIDISC
Side 14
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 MAXI-
DISC more versatile and allow you to obtain optimum performance from the imple-
ment.
Depth
The operating depth is controlled by the rear T-ring roller.
Fig. 3
Adjust the depth of the discs by mov-
ing the pins in the brackets. The top-
most pin (A) determines the depth,
while the pin at the bottom (B) is the
supporting pin that bears the roller
when the implement is raised.
It might be necessary to readjust the top link after changing the depth. The frame
must always be horizontal.
Deeper soil penetration
To increase the penetration depth, raise the implement. Next, remove the pin (A)
from the bracket and insert it one hole higher. Lower the MAXIDISC and move the
pin on the bottom (B) correspondingly up, so that the support is as close to the arm
as possible.
If the MAXIDISC has been operating at a deep setting, it might be necessary to run
the discs slightly in the soil (or to support the roller) to put pressure on the roller.
The pin (B) can then easily be inserted into the hole that is closest to the arm.
A
B

MAXIDISC
Side 15
Angle
The discs can be hydraulically adjusted from 0 to 20 degrees. With hydraulic ad-
justment, all discs are adjusted at the same time.
Fig. 4
The angle of the front row and the back
row of discs can be adjusted individu-
ally with the turnbuckle (A). It is gen-
erally recommended that you set the
row in the back slightly more aggres-
sive than the row in the front to pre-
vent the machine from pulling uneven-
ly.
Turnbuckle length (A)
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

MAXIDISC
Side 16
Disc scrapers
Fig. 5
Adjust the disc scrapers, allowing only
3 to 5 mm of space between each disc
and scraper.
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) according to the
working depth of the MAXIDISC. The
disc can also be moved in a horizontal
direction by loosening the mounting
bolt.
A

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 under-
standing of all safety precautions.
Best results will be achieved by driving slightly diagonally to the sowing direction.
Also, you should drive as closely as possible to the previous pass to minimise the
distance between the rows.
Angle
The angle of the discs can be continuously adjusted hydraulically during operation,
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 re-
duced 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 accord-
ing to conditions.
When the travel speed is increased, wear on the implement is increased, especially
under dry soil conditions. Damage to the discs and T-rings may also result from
driving too fast under unfavourable conditions.
Power requirements
Power requirements change according to soil type, terrain and travel speed.
Table 2, Guidelines for power requirements in HP
Working width
300 cm
400 cm
Power requirements
hp
90 - 100
120 - 140

MAXIDISC
Side 18
Troubleshooting
Problem
Cause
Action
Soil is thrown too far
out to the sides,
creating a ridge.
•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.
•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 devel-
ops between pass-
es.
•Driving too closely
or too far away
from the previous
pass.
•Driving too closely or too far away
from the last pass.
•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
Maintenance
Proper maintenance ensures a long life for the MAXIDISC and also optimum perfor-
mance from the implement. To facilitate maintenance, grease fittings have been
mounted on those locations where wear on the equipment is the greatest.

Tighten all nuts, bolts, hydraulic fittings or any other fastened as-
semblies 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 tractor brakes, stop the engine and remove the
ignition key to avoid unintentional operation and personal inju-
ry.
Lubrication
Fig. 7
A
A
B
C
D
E
Lubrication points
Num-
ber of
fit-
tings
Lubrica-
tion in-
terval
(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

Lubricate all lubrication points at least once a year.

MAXIDISC
Side 20
Hydraulic System
Inspect all hydraulic hoses for chafing or leaks. Check hoses for
pinching.

To avoid rust, any projecting piston rods should be coated with oil
or grease if the MAXIDISC is to be parked for a long period of time.
Remember to remove the oil or grease prior to operation.
Disc hubs
Tighten the disc hubs once a year or as needed.
Fig. 8
1. Screw off the cap.
2. Remove the split cotter pin
from the nut.
3. Tighten the nut ¼ turn or until
there is no play in the hub.