DALBO Maxiroll 1030 2008 User manual

Maxiroll 2008
EN
1030 –1230
Serial no.: 100-XXX

Maxiroll 2008
Type 1030 - 1230
Congratulations on the purchase of your new Maxiroll. For safety reasons and to
achieve optimum service from the product, please read the User Guide before use.
©Copyright 2002. All rights reserved, DAL-BO A/S
Your Maxiroll 2008 has:
Type no.:
Serial no.:
Month of manufactu-
re:
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
DAL-BO A/S
DK-7183 Randbøl
[phone]
declares herewith that the above machine is manufactured in accordance with the provi-
sions of directive 2006/42/EC, which replaced directive 98/37/EC and change direc-
tives 91/368/ECC, 93/44/ECC and 93/68/ECC on harmonization of member state legis-
lation concerning health and safety requirements related to the construction and manu-
facture of machines.
This machine corresponds to the safety requirements in the European Safety Guide-
lines.
DAL-BO A/S
Date:
Managing Director Kaj Pedersen
CE

Maxiroll 2008
Page 4
Table of Contents
SAFETY..........................................................................................................................6
GENERAL ......................................................................................................................6
HYDRAULICS.................................................................................................................7
MOUNTING....................................................................................................................7
MAINTENANCE AND REPAIR ..........................................................................................7
ROAD TRANSPORT.........................................................................................................7
CORRECT USE................................................................................................................8
TECHNICAL DATA.....................................................................................................9
HOW TO USE THIS MANUAL ................................................................................10
DELIVERY ...................................................................................................................10
USES..............................................................................................................................11
CONNECTING AND DISCONNECTING...............................................................12
CONNECTING...............................................................................................................12
HYDRAULICS...............................................................................................................12
DISCONNECTION..........................................................................................................12
SETTING UP................................................................................................................13
ADJUSTING DRAWBAR HEIGHT ....................................................................................13
OPERATION ...............................................................................................................14
EXTENDING AND FOLDING UP ......................................................................................14
Extending ...............................................................................................................14
Fold up...................................................................................................................15
ADJUSTMENT OF HYDRAULIC WEIGHT TRANSFER ........................................................16
Excessive pressure .................................................................................................16
Insufficient pressure...............................................................................................16
OPERATING SPEED.......................................................................................................17
ADJUSTMENT OF HYDRAULIC SUSPENSION OF PENDULUM FRAMES ..............................17
Excessive pressure .................................................................................................18
Insufficient pressure...............................................................................................18
TROUBLESHOOTING ..............................................................................................19
ACCESSORIES ...........................................................................................................20
CRACKERBOARD .........................................................................................................20
Power.....................................................................................................................20
Hose markings........................................................................................................21
Adjusting angle of teeth..........................................................................................21
Operation...............................................................................................................22
Retrofitting.............................................................................................................22
Locking set .............................................................................................................23

Maxiroll 2008
Page 5
MAINTENANCE.........................................................................................................24
LUBRICATION..............................................................................................................24
ADJUSTMENT...............................................................................................................25
Adjustment of rollers..............................................................................................25
Wheels ....................................................................................................................25
Wear parts..............................................................................................................25
HYDRAULICS...............................................................................................................26
REPLACEMENT ANDREPAIRS .............................................................................27
HYDRAULICS...............................................................................................................27
Replacing extend cylinder for folding side sections...............................................27
Replacing gaskets for side section fold/unfold.......................................................28
Mounting................................................................................................................29
Replacing raise/lower cylinder on main frame......................................................29
Replacing gaskets on raise/lower cylinder ............................................................30
Mounting................................................................................................................30
Replacing pendulum frame suspension cylinder....................................................31
Replacing gasket set for suspension.......................................................................31
Replacing crackerboard depth-adjustment cylinder..............................................32
Replacing gasket set for depth adjustment.............................................................32
REMOVAL/FITTING WHEEL...........................................................................................33
Replacing wheel bearings......................................................................................33
REMOVING ROLLER AXLES ..........................................................................................34
Replacing axles ......................................................................................................34
Fitting axles with roller rings ................................................................................35
REPLACING AXLES,BEARINGS OR ROLLER RINGS.........................................................35
Crosskill ring..........................................................................................................35
SCRAPPING.................................................................................................................37
HYDRAULIC DIAGRAM..........................................................................................38
SPARE PARTS.............................................................................................................42

Maxiroll 2008
Page 6
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 machine.
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
operating. Operate machine only from inside the tractor.
When roller is folded together, check the side sections are locked. Check
all control handles are secured against accidental operation.
Before leaving the tractor or making adjustments, performing maintenance
or repairs on the roller, extend fully and lower to ground, or maintain in
transport position, apply tractor handbrake, switch engine off and remove
ignition key to secure the machine against accidental operation.
Remember to secure support legs 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
devices must be replaced immediately.

Maxiroll 2008
Page 7
Hydraulics
Lower machine fully for any repair work on the hydraulic system. Relieve
hydraulic pressure, switch engine off and remove ignition key.
Clean hydraulic connections thoroughly before reconnecting. When con-
necting 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 de-
struction 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.
Mounting
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 con-
nections 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
protection 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 re-
sponsible for correct lighting and warning signs in accordance with traffic
regulations.

Maxiroll 2008
Page 8
Check with local traffic authorities whether transport on public roads is al-
lowed given the machine's dimensions.
When transporting, ensure permitted total weight for tractor is not exceed-
ed 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 operat-
ing, maintenance and repair instructions, and that original spare parts are
always used.
Maxiroll 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
modifications made to the machine performed without prior permission
from the manufacturer. Neither can the manufacturer be held liable for in-
jury or damage arising from incorrect use. Such liability rests solely with
the user.
Do not add extra weight to the roller.

Maxiroll 2008
Page 9
Technical data
Maxiroll 2008
Size (cm)
1030
1230
HP (recommended)
200+
350+*
Gross weight kg:
Cambridge 50
7590
*
Cambridge 55
8415
*
Cambridge 60
9550
-
Crosskill 53
6320
*
Crosskill 60
7750
*
Sections (pcs.)
5
Wheels
520/50-17
710/40-22,5
Hydraulic requirements:
DV
3
EV
0
Accessories
Wheels
600/50-22.5
-
Crackerboard (kg)
1200
1300*
Requires DV hydr.
1
*Maxiroll 2008 1230 has standard crackerboard fitted.
The table below indicates oil capacity.
Model
Oil (litres)
1030
Approx. 35 Litres
1230
Approx. 58 Litres

Maxiroll 2008
Page 10
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 roller is delivered complete on a trailer.
If lifting the roller, we recommend the use of straps on the mid-section and
drawbar to maintain balance. Lifting points are marked on the machine.

Maxiroll 2008
Page 11
Uses
Maxiroll 2008 is an extra-heavy roller designed specifically for the mounting
of extra equipment for soil preparation.
Fig. 1
Maxiroll 2008 1030 and 1230 are 5-
piece rollers with independent sec-
tions. Hydraulic weight transfer and
stone protection is standard for both
models.
Maxiroll 2008, 1030
Maxiroll is used prior to sowing to crush lumps and afterwards to prepare for
shooting and to break down stones. Maxiroll can also be used for breaking up
a compressed soil surface in wheat fields or grassed areas.
Can be fitted with accessories, such as hydraulic crackerboard. The main pur-
pose of the crackerboard is preparation for sowing. The vibrating effect of the
teeth breaks up lumps, preparing and levelling ploughed and pre-prepared
fields. If the crackerboard is not required, it can be raised and Maxiroll used
exclusively as a roller.

Maxiroll 2008
Page 12
Connecting and disconnecting
Connecting
Fig.2
Connect roller to the tractor's fixed
towbar, where drawbar (A) must fit
between the towbar forks.
Insert pin and remove leg.
Remember to secure towbar pin with split pin or the like.
Hydraulics Maxiroll requires a standard double-acting hydraulic outlet with flow setting.
One of the double-acting outlets is for unfolding the side sections and the oth-
er for raising/lowering the roller.
Table 1. Hose markings
Cylinder name
Colour
Outlet
Function
Raise/lower cylinder
White
Double acting
Raises Maxiroll up onto its wheels
and down into working position.
Fold/
weight equalisation
Red
Double acting
Folds side sections up/out and acts
as weight equalisation from mid-
section to side sections.
Suspension
Blue
Single acting
For suspension of pendulum frames
in conjunction with the accumula-
tors to absorb shock on the frames.

Flow setting is required for both double-acting outlets.
Check hydraulic hoses for crimping
Disconnection Fit leg, remove towing pin and disconnect hydraulic hoses.

Remember to depressurise hoses before disconnecting them.
Maxiroll must be in transport or working position when disconnecting.
A

Maxiroll 2008
Page 13
Setting up
Maxiroll is supplied with factory settings, but fine adjustment will always be
required before use. Numerous adjustment options make the roller more flexi-
ble and ensure maximum use.
Adjusting drawbar height
To achieve uniform field compression, the machine's drawbar must be hori-
zontal in working position. Adjustment can be necessary, depending on trac-
tor.
Incorrect drawbar height can cause uneven operation, as the roller will not ap-
ply equal pressure for all sections.
Fig. 3
To achieve optimum drawbar
height, the drawbar can be turned
or adjusted up/down until the eye
fits the tractor towbar.
Stand Maxiroll 2008 on support
leg. Slacken bolts (A) and adjust
drawbar to tractor.
A


Maxiroll 2008
Page 14
Operation
Correct operation is vital to get the best out of your Maxiroll 2008 1030 or
1230. This applies to field use and safety. Always ensure you are fully familiar
with all safety aspects of the machine.
Extending and folding up
Extending and folding the machine up must always be performed with tractor
parked.

Before extension and folding, check crackerboard is fully raised to avoid teeth
colliding (see "Accessories, Crackerboard")
Extending
Fig. 4
1Side sections are lifted from the
transport bar (A) using
raise/lower cylinder (marked:
White).
Fig. 5
2Activate extend/retract cylinders
(marked: Red) to fully extend
side sections.
3Activate raise/lower cylinders to
lower roller to ground. While the
roller is getting lower is it very
important, that the two outer
shafts and the middle shaft are
hitting the ground exactly at
the same time, so the middle
section won´t get overloaded.
Set raise/lower cylinder to flow
setting last.

Before starting rolling, ensure weight transfer is correctly adjusted (see
”Adjustment of hydraulic weight transfer”).
A

Maxiroll 2008
Page 15
Fold up

If there is a crackerboard fitted, check it is fully raised before starting folding
(see "Accessories, Crackerboard, Operation")
Fig. 6
1. Activate extend/retract cylinders
(marked: Red) to lift end of side
sections (A) a little.
Fig. 7
2 Activate raise/lower cylinder
(marked: White) to full length. Roller
will lift from ground.
Fig. 8
3. Activate extend/retract cylinders
to fold side sections in.
4. Activate raise/lower cylinder to
lower roller into transport bar. (See
fig. 5)

Maxiroll 2008
Page 16
Adjustment of hydraulic weight transfer
Hydraulic weight transfer distributes the weight evenly between all roller sec-
tions.
1. Once the roller is unfolded, relieve pressure in the extend/retract cyl-
inders (marked: Red), and activate cylinder control handle in the oppo-
site direction.
Fig. 9
2 After short delay
the manometer will react.
Increase pressure to approx.
15 bar (A). This will
transfer some of the mid-
section weight to the
side sections.
3Set control handle to flow setting. Flow setting is necessary to achieve
hydraulic weight transfer, allowing the sections to move independently
4The pressure for hydraulic weight transfer may need adjustment. It can
also be necessary to adjust pressure according to soil conditions.
Excessive pressure
1Pressure on the side sections will be too great, leaving clear tracks in
the soil.
2The mid-sections will not apply sufficient pressure, leaving the soil
higher and not as compressed as the sides.
Insufficient pressure
1The pressure on the extremities of the side sections will be insufficient
to give uniform compression.
2The mid-sections will compress too much, leaving the soil lower than
the sides.

To prolong service life and the final result in the field, Maxiroll
must be set in flow setting when working in the field.
A

Maxiroll 2008
Page 17

Failure to do so is incorrect use and can cause the frame to break
in the worst scenario.
Operating speed
An operating speed of 6-10 km/h is recommended, but always operate accord-
ing to conditions.
Increased speed will increase wear, particularly in dry conditions. The rings
can also be damaged if operating at excessive speeds in unfavourable condi-
tions.
Adjustment of hydraulic suspension of pendulum frames
Hydraulic weight transfer distributes the weight evenly between all roller sec-
tions. Pressure on the pendulum frames must therefore also be uniform!
1Once the roller is unfolded and adjusted for the correct pressure and
flow setting, adjust the suspension pressure.
Fig. 11
2 Cylinder (A) is fitted
on all 5 pendulum frames, to
absorb impact from large
stones.
Fig. 12
3 Manometer (B) is fitted
on top of the machine for the
operator to monitor pressure.
Cock (C) is fitted for easy ad-
justment of pressure. Adjust
cock until the correct pressure
is achieved with the tractor
hydraulics in flow setting. We
recommend 70 bar. If addi-
tional pressure is required,
keep the cock open and use
the tractor hydraulics to in-
crease pressure.
A
B
C

Maxiroll 2008
Page 18
3The pressure for hydraulic suspension may need adjustment. It can al-
so be necessary to adjust pressure according to soil conditions.
Excessive pressure
1If the cylinder does not move, pressure is too great. This can cause ex-
cessive strain on the frames.
2Reduce pressure until the cylinder moves again.
Insufficient pressure
1 Pressure is too low if the cylinder cannot extend fully.
2Adjust (increase) pressure until all 5 suspension cylinders extend.

We recommend running at a pressure of 70 bar!
But always operate according to conditions!

Maxiroll 2008
Page 19
Troubleshooting
Fault
Cause
Remedy
Mid-section apply-
ing too much pres-
sure
Insufficient pres-
sure transferred
to side sections
Activate hydraulic control handle
for extend/retract to increase pres-
sure to side sections (see
”Operation”).
Drawbar too high
Adjust drawbar and mid-section
(see ”Adjusting drawbar height”
page 13.
Mid-section not
horizontal
Adjust drawbar and mid-section
(see ”Adjusting drawbar height”
page 13.
Side section ex-
tremities applying
too much pressure
Insufficient pres-
sure in mid-
section
Activate hydraulic control handle
for extend/retract to increase pres-
sure to mid-section (see
”Operation”).
Drawbar too low
Adjust drawbar and mid-section
(see ”Adjusting drawbar height”
page 13.
Mid-section not
horizontal
Adjust drawbar and mid-section
(see ”Adjusting drawbar height”
page 13.
Pressure on ma-
nometer dropping
Handle not in
flow setting
Adjust pressure on weight transfer
and set handle to flow setting (see
”Adjustment of hydraulic weight
transfer”)
Driver-operated
non-return valve
defective
Cylinder (gasket
set) leaking
Set weight transfer to 15 bar, set
handle to flow setting. Leave
Maxiroll standing for 30 mins. If
pressure drops, the driver-operated
non-return valve is defective, or
there may be dirt in the valve (dis-
assemble valve and clean parts)
Side sections not
following terrain
Weight transfer
hydraulic system
not in flow set-
ting
Set hydraulic weight transfer in
flow setting (see ”Adjustment of
hydraulic weight transfer”)

Maxiroll 2008
Page 20
Accessories
Maxiroll 2008 can be fitted with a range of accessories to suit requirements.
Crackerboard with curved wear parts.
Crackerboard with crust-breakers.
Rake.
Large wheels.
Crackerboard The major benefit of the board is that the teeth can move individually, and
flex when meeting local resistance. This provides a big advantage compared
to a levelling board, avoiding having to raise the entire arm in the event of it
meeting an obstacle.
Fig. 13
Power
Compared to a fixed levelling board, a crackerboard does not require so much
power, although this can vary depending on how the board is used.
Table 3. Crackerboard power requirements in HP
1030
100+
*Maxiroll 2008 1230 is fitted as standard with a crackerboard.

By moving the minimum amount of soil, fuel consumption is reduced signif-
icantly along with wear and tear.