DALBO MaxiDisc User manual

MaxiDisc
GB
400/500/600 cm
Nr.
80005/80010/80020
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 obtain 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 DAL-BO 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
regarding 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 facili-
tate ordering.
EU DECLARATION OF CONFORMITY
DAL-BO A/S
DK-7183 Randbøl
Hereby declare that the above-mentioned machine has been manufactured in compli-
ance 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 Machin-
ery.
This machine complies with the safety requirements stipulated by the European safety
regulations.
DAL-BO A/S
Date:
Director Kaj Pedersen
CE

MaxiDisc
Side 5
Table of Contents
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..................................................................................................................................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................................................................................................................................20
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.................................................................................... 32
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
safety warning messages concerning your safety, the safety of other users or
the functional 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
operations of this equipment prior to using.
The safety signs on the MaxiDisc contain important instructions concern-
ing 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 driver’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 ma-
chinery, 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 de-
fective 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 prevent individuals from the danger of being
crushed.
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 pres-
sure 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 sys-
tem.
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
properly.
In case skin should come in contact with hydraulic oil or grease or in case cloth-
ing 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 se-
vere 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 re-
move 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 regula-
tions.

MaxiDisc
Side 9
Transport
All safety and warning signs and devices required by law must be dis-
played, mounted and tested for public road use. The driver is responsible
for the correct 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 order to ensure that the size, weight and load of the machinery may be
transported on public roads.
When towing the implement, the total weight of the tractor and the maxi-
mum allowed axle load must not be exceeded. The weight on the front ax-
le must not be less than 20 percent of the total mass of the tractor. If it is
less than 20 percent, 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
manufacturer 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 imple-
ment. 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 indi-
cate:

Points that are extremely important for the function and life of the machin-
ery.
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 residue management is concentrated. The MaxiDisc effectively per-
forms 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 microclimate for the organisms in the soil.
Fig. 1
MaxiDisc 600
MaxiDisc 600
The special construction of the MaxiDisc allows the two sections to move in-
dependently of each other.
The MaxiDisc is an effective stubble management tool for plough-free culti-
vation, 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 category 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 un-
folded and resting securely on the ground before unhitching.
Swing the hitch stand into place and secure with a pin. Disconnect the hydrau-
lic hoses, lower the MaxiDisc and remove the lift arms from the hitch.
Remember to relieve the pressure in the hydraulic system before discon-
necting the hoses.

Unhitching of the MaxiDisc must always be carried out on even ground. Se-
cure 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 MaxiDisc more versatile and allow you to obtain optimum performance
from the implement.
Fig. 3
A combination wrench is supplied
for turnbuckle and castle nut ad-
justment.
Adjustable Hitch
Fig. 4
The towing height of the MaxiDisc
drawbar hitch can be adjusted ac-
cording 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
adjustment, all discs are adjusted at the same time.
The angle of the front row and the back row of discs can be adjusted individu-
ally 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 aggres-
sively 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 being cast out by the disc in the
very front. Adjust the side disc ver-
tically by using the pin (A) accord-
ing 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
placement 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, al-
lowing 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 understand-
ing of all safety precautions.

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 to-
gether 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 distri-
bution of weight across all sections of the roller and an even field finish on all
types of terrain. The MaxiDisc is divided into two sections (3m or 2.5m)
which can move independently of each other.

It is very important to adjust the hydraulic weight transfer system correctly
and set the lever in the floating position.

MaxiDisc
Side 20
Adjustment
Fig. 11
1. Unfold the MaxiDisc and
continue 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 ma-
nometer is approx. 50 bar.
2Set the cylinders in the floating position. The floating position is nec-
essary 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
transfer. It might also be necessary to operate the machinery at a higher
or lower 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 uneven 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 authorized Dal-Bo 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 equip-
ment settings are necessary to ensure that the fields will be left even and with-
out any ridges.
Best results will be achieved by driving slightly diagonally to the sowing di-
rection. 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 necessary.
A