DALBO MAXIDISC User manual

MAXIDISC
GB
400/500/600 cm
Serial no.: 580-xxx

MAXIDISC
Side 3
MAXIDISC
Type 400/500/600 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. All rights reserved DALBO A/S.
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 2006/42/EC, which replaces Council Directive 98/37/EC 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
SAFETY ............................................................................................................................................................. 7
GENERAL ............................................................................................................................................................... 7
HYDRAULIC SYSTEM ................................................................................................................................................. 7
HITCHING............................................................................................................................................................... 8
MAINTENANCE AND REPAIRS...................................................................................................................................... 8
TRANSPORT ............................................................................................................................................................ 8
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 ......................................................................................................................................................... 14
ADJUSTMENTS AND SETTINGS......................................................................................................................... 15
ADJUSTABLE HITCH................................................................................................................................................ 15
SIDE WING WHEELS............................................................................................................................................... 15
ANGLE................................................................................................................................................................. 16
DEPTH................................................................................................................................................................. 17
HYDRAULIC WEIGHT TRANSFER ................................................................................................................................ 17
SIDE DISC ............................................................................................................................................................ 18
TRANSPORT LOCKS................................................................................................................................................. 18
Transport locks........................................................................................................................................... 18
OPERATING AND DRIVING INSTRUCTIONS........................................................................................................ 19
UNFOLDING AND FOLDING ....................................................................................................................................... 19
Folding......................................................................................................................................................... 19
HYDRAULIC WEIGHT TRANSFER ................................................................................................................................ 19
Adjustment.................................................................................................................................................. 19
Too much pressure..................................................................................................................................... 20
Too little pressure....................................................................................................................................... 20
DRIVING INSTRUCTIONS........................................................................................................................................... 20
Hydraulic depth adjustment ..................................................................................................................... 21
ANGLE................................................................................................................................................................. 21
TRAVEL SPEED ...................................................................................................................................................... 21
Power requirements................................................................................................................................... 21
TROUBLESHOOTING........................................................................................................................................ 22
OPTIONS ......................................................................................................................................................... 23
BOGIE T-RING ....................................................................................................................................................... 23

ELECTRO-HYDRAULIC OPERATION............................................................................................................................. 23
MAINTENANCE ................................................................................................................................................24
LUBRICATION........................................................................................................................................................ 24
HYDRAULIC SYSTEM ............................................................................................................................................... 25
DISC HUBS........................................................................................................................................................... 25
Disc hubs..................................................................................................................................................... 25
Wheels......................................................................................................................................................... 26
REPLACEMENTS AND REPAIRS........................................................................................................................27
HYDRAULIC SYSTEM ............................................................................................................................................... 27
CHANGING ANGLE ADJUSTMENT CYLINDER .................................................................................................................. 27
Replacing angle adjustment seals........................................................................................................... 28
CHANGING WING FOLD CYLINDERS ........................................................................................................................... 29
Replacing fold/unfold cylinder seals........................................................................................................ 29
CHANGING WHEEL FRAME CYLINDER ........................................................................................................................ 30
Replacing wheel frame cylinder seals ..................................................................................................... 30
CHANGING PACKER ROLLER FOLD CYLINDERS ............................................................................................................ 31
Replacing packer roller cylinder seals..................................................................................................... 31
REPLACING DISC HUB BEARING................................................................................................................................ 33
DISMOUNTING/MOUNTING OF WHEELS ...................................................................................................................... 34
Changing wheel bearings .......................................................................................................................... 34
LIGHTS ................................................................................................................................................................ 35
SCRAPPING .....................................................................................................................................................36
HYDRAULIC SYSTEM DIAGRAM ........................................................................................................................37
SPARE PARTS ..................................................................................................................................................38

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 hitch 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.
Hydraulic System

MAXIDISC
Side 8
•Never allow bystanders within the operating radius of the MAXIDISC when the hydrau-
lic system is activated to prevent individuals from the danger of being crushed.
•Before performing maintenance or repairs on the hydraulic system, lower the imple-
ment 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.
Replace defective hoses immediately.
•Avoid spilling oil on the ground. In case of spills, collect the oil and dispose of it proper-
ly.
•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 immediately 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 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, turn off the engine and remove the
ignition key.
•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 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.
•Dispose of oil, grease and filters according to applicable environmental regulations.
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.

MAXIDISC
Side 9
•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)
400
500
600
HP (recommended)
120-140
140-160
180-220
Gross weight kg:
4950
5540
Packer Roller (suspended)
T-rings 70x70x8 mm (pc)
32
36
40
Sections (pc.)
2
2
2
Axles (pc.)
2
2
2
Options
Disc scrapers
Electro-hydraulic operation
F-iron cage roller

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. The implement may be
partially disassembled for export.
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 towed disc harrows providing 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 600
MAXIDISC 600
The special construction of the MAXIDISC allows the two sections to move inde-
pendently of each other.
The MAXIDISC is an effective stubble management tool for plough-free cultivation,
and at the same time it conditions the soil for an ideal seedbed.

MAXIDISC
Side 13
Hitching and Unhitching
The linkage of the MAXIDISC is manufactured in compliance with DS/ISO 730-1 cat-
egory II and III.
Hitching
First mount the lift arms into the ball sockets (A). Elevate the lift and move the
hitch stand up into the transport/working position (B).
Fig. 2

•Remember to secure the lift arms and the hitch stand with lynch pins.
•Remember to raise the hitch stand.

•Adjust the sway chains tightly until there is no slack in the lift arms.
Hydraulic System
The MAXIDISC requires four double-acting hydraulic outlets.
Table 1. Hose markings
Cylinder
Colour
Outlet
Function
Wing fold
Red
Double-acting
Fold wing sections
Wheel frame
Yellow
Double-acting
Raise and lower MAXIDISC
Angle
Blue
Double-acting
Adjust working angle of discs
Depth
Green
Double-acting
Adjust working depth of discs

•Wing fold cylinder requires a hydraulic outlet with a floating position.
•Check the hydraulic hoses for kinks or pinches.
A
B

MAXIDISC
Side 14
Unhitching
The MAXIDISC must be completely folded up (in the transport position) or unfolded
and resting securely on the ground before unhitching.
Swing the hitch stand into place and secure with a pin. Disconnect the hydraulic
hoses, lower the MAXIDISC and remove the lift arms from the hitch.
Remember to relieve the pressure in the hydraulic system before disconnecting
the hoses.

Unhitching of the MAXIDISC must always be carried out on even ground. Secure the
MAXIDISC against unintentional operation.

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 MAXI-
DISC more versatile and allow you to obtain optimum performance from the imple-
ment.
Fig. 3
A combination wrench is supplied for
turnbuckle and castle nut adjust-
ment.
Adjustable Hitch
Fig. 4
The towing height of the MAXIDISC
drawbar hitch can be adjusted accord-
ing to needs. This provides you with
several possibilities to obtain proper
adjustment to fit your tractor. Adjust
by turning the hitch around.
Side Wing Wheels
Fig. 5
If the working depth of the MAXIDISC is
changed, the support wheels of the
side wing sections must also be ad-
justed. Adjust the depth using the
turnbuckle (A). The depth must be the
same on both sides. Use the depth
indicator mounted with the turnbuckle
as a guide.
A

MAXIDISC
Side 16
Angle
The discs can be hydraulically adjusted from 0 to 20 degrees. With hydraulic ad-
justment, all discs are adjusted at the same time.
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 machine
from pulling unevenly.
Fig. 6
Lengthen or shorten the turnbuckle (A)
according to needs.
If the soil is very dry and hard, set the
front row of discs more aggressively
than the row in the rear to increase
power and effect.
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
MAXIDISC 400 (80006)
407
20/20 ; 0/0
MAXIDISC 400 (80006)
421
23/20 ; 3/0
MAXIDISC 500 (80016)
407
20/20 ; 0/0
MAXIDISC 500 (80016)
421
23/20 ; 3/0
MAXIDISC 600 (80026)
433
20/20 ; 0/0
MAXIDISC 600 (80026)
419
23/20 ; 3/0
A

MAXIDISC
Side 17
Depth
The working depth can be adjusted using the lift and the rear T-ring packer roller.
Depth adjustment is fully hydraulic.

It is important that the cylinders on the packer has the same length.
Hydraulic Weight Transfer
( See ”Operating and driving instruction, Hydraulic Weight Transfer ”).

MAXIDISC
Side 18
Side Disc
Fig. 8
A disc mounted on the left edge of the
MAXIDISC limits the amount of soil be-
ing 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.
Transport Locks
An adjustment bolt (A) on the wheel frame transport lock ensures correct place-
ment of the transport lock.
Fig. 9
Transport locks
To ensure the correct setting of the transport locks (hooks), a wire tightener has
been mounted on the wire attached to the wings and to the packer roller. The wire
must be long enough that the transport locks can be disengaged, allowing the side
wings and the packer roller to be free, but also long enough that the transport locks
can fall down, catch and become completely engaged on the side sections and the
packer roller.
Fig. 10
Transport lock on the packer roller
Transport lock on the main frame
A
A

MAXIDISC
Side 19
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 pre-
cautions.

•Every day before operating the MAXIDISC, inspect all pins, nuts, bolts and
connections to be sure that all are tightened and securely in place.
•The MAXIDISC must be in the fully raised position on both liftarms and
wheel frame when moving in reverseor turning around.
Unfolding and Folding

Always fold and unfold the wings of the MAXIDISC while the equipment is stationary
and the tractor is parked.
The mechanical transport locks become engaged and disengaged when the side wings are
folded and unfolded between the transport and the working position. Upon arrival to the
working area, activate the lever for the folding/unfolding of the side wings. Make sure that
the side sections are fully raised. Release the transport lock by activating the lever to the
wheel cylinder so that the cylinder is pressed out to the fully extended position. The
transport locks will be released, and the side wings together with the packer roller can
then be unfolded.
Folding
Move the wheel cylinders to the fully extended position before folding up the side sections
into the transport position. This ensures that the mechanical transport lock of the wheel
frame is able to fall down and lock the wheel frame into place.
After the side wings and the packer roller have been folded up, lower the MAXIDISC so that
the transport lock of the wheel suspension locks firmly and securely.

Make sure that all transport locks are securely fastened before transporting the
implement on public roads.
Hydraulic Weight Transfer
The hydraulic weight transfer system of the MAXIDISC ensures an even distribution
of weight across all sections of the roller and an even field finish on all types of ter-
rain. The MAXIDISC is divided into two sections (3m or 2.5m) which can move inde-
pendently of each other.

It is very important to adjust the hydraulic weight transfer system correctly and
set the lever in the floating position.
Adjustment

MAXIDISC
Side 20
Fig. 11
1. Unfold the MAXIDISC and con-
tinue to hold the wing
fold/unfold cylinder lever in
the same position until the
pressure reading of the
fold/unfold cylinder (red out-
let) displayed on the manome-
ter is approx. 50 bar.
2Set the cylinders in the floating position. The floating position is necessary
to achieve hydraulic weight transfer, in which the sections are free to move
individually.
3It may be necessary to readjust the pressure of the hydraulic weight trans-
fer. It might also be necessary to operate the machinery at a higher or low-
er pressure, depending on soil conditions.
Too much pressure
1The pressure on the outermost rings of the wing sections will be too great.
The rings and the support wheels will be pressed too far down and they will
leave clearly visible ridges in the soil.
2The middle/inside section of the side wings will not penetrate deep enough
into the soil and the field finishing will be uneven.
Too little pressure
1There is not enough pressure on the outer rings of the wing sections and
the support wheels to press the T-rings sufficiently into the soil.
2The middle of the MAXIDISC will pack the soil too heavily, resulting in an un-
even field finishing.
Check all the accumulators on the machine at least once a year for leaks
and to ensure that the precharge pressure is set correctly. Contact an au-
thorized DALBO dealer for more information.
Driving Instructions
The MAXIDISC is an effective soil management tool that is capable of mixing a large
quantity of soil and plant residue. Proper driving practices and equipment settings
are necessary to ensure that the fields will be left even and without any ridges.
Best results will be achieved by driving slightly diagonally to the sowing direction.
When the correct working depth has been found, set a fixed depth stop position on
the tractor lift. The depth can also be continually adjusted during operation if nec-
essary.
A