DALBO MAXIROLL 1030 User manual

MAXIROLL
EN
1030 –1230
Serial no.: 100-XXX

MAXIROLL
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, DALBO A/S
Your MAXIROLL has:
Type no.:
Serial no.:
Month of manufacture:
Net weight kg:
If contacting the manufacturer regarding spare parts or service, please state type and serial
number. A spare parts list is included at the back of this manual.
EU DECLARATION OF COMPLIANCE
DALBO A/S
DK-7183 Randbøl
[phone]
declares herewith that the above machine is manufactured in accordance with the provisions
of directive 2006/42/EC, which replaced directive 98/37/EC and change directives
91/368/ECC, 93/44/ECC and 93/68/ECC on harmonization of member state legislation con-
cerning health and safety requirements related to the construction and manufacture of ma-
chines.
This machine corresponds to the safety requirements in the European Safety Guidelines.
DALBO A/S
Date:
Carsten Jensen, CEO
CE

MAXIROLL
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
MAINTENANCE.............................................................................................................................24

MAXIROLL
Page 5
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
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 ma-
chine.
General
•Ensure you are familiar with all aspects of the machine before use
•There are safety stickers on the machine containing important instructions for
the safety of yourself and others, and correct use of the machine.
•Do not carry passengers during operation or transport.
•Ensure there are no personnel within the machine's working radius before op-
erating. Operate machine only from inside the tractor.
•When 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 de-
vices must be replaced immediately.

MAXIROLL
Page 7
Hydraulics
•Lower machine fully for any repair work on the hydraulic system. Relieve hy-
draulic pressure, switch engine off and remove ignition key.
•Clean hydraulic connections thoroughly before reconnecting. When connecting
hydraulic hoses to tractor hydraulics, ensure they are not under pressure.
•Bleed the hydraulic system thoroughly after any repairs.
•Check hydraulic hoses regularly for defects such as cracks, splits, crimps, wear
or breaks. Defective hoses must be replaced immediately.
•Avoid spilling oil on the ground. If oil is spilt, collect and deliver to a destruction
point.
•Clean hands thoroughly after contact with oil and grease. Change oil-stained
clothing immediately. Hydraulic oil can be harmful to the skin.
•Hydraulic oil released under high pressure can penetrate the skin and cause
severe injury. In the event of injury, seek medical help immediately.
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 connec-
tions regularly and tighten as required. Check all split pins and bolts to avoid
mechanical failure.
•Dispose of oil, grease and filters in accordance with local environmental pro-
tection rules.
Road transport
•All safety and warning precautions mandatory by law must be fitted and tested
before transporting the machine on public roads. The driver is responsible for
correct lighting and warning signs in accordance with traffic regulations.
•Check with local traffic authorities whether transport on public roads is allowed
given the machine's dimensions.

MAXIROLL
Page 8
•When transporting, ensure permitted total weight for tractor is not exceeded
and that loading on tractor front axle is not less than 20% of tractor net weight.
If this is the case, use weights on tractor front
Correct use
•Correct use of the machine includes observing the manufacturer's operating,
maintenance and repair instructions, and that original spare parts are always
used.
•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 modi-
fications made to the machine performed without prior permission from the
manufacturer. Neither can the manufacturer be held liable for injury or damage
arising from incorrect use. Such liability rests solely with the user.
•Do not add extra weight to the roller.

MAXIROLL
Page 9
Technical data
MAXIROLL
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 1230 has standard crackerboard fitted.
The table below indicates oil capacity.
Model
Oil (litres)
1030
Approx. 35 Litres
1230
Approx. 58 Litres

MAXIROLL
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
Page 11
Uses
MAXIROLL is an extra-heavy roller designed specifically for the mounting of extra
equipment for soil preparation.
Fig. 1
MAXIROLL 1030 and 1230 are 5-piece
rollers with independent sections. Hy-
draulic weight transfer and stone pro-
tection is standard for both models.
MAXIROLL, 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 purpose
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
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 other for rais-
ing/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 accumulators 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
Page 13
Setting up
MAXIROLL is supplied with factory settings, but fine adjustment will always be re-
quired before use. Numerous adjustment options make the roller more flexible and
ensure maximum use.
Adjusting drawbar height
To achieve uniform field compression, the machine's drawbar must be horizontal in
working position. Adjustment can be necessary, depending on tractor.
Incorrect drawbar height can cause uneven operation, as the roller will not apply
equal pressure for all sections.
Fig. 3
To achieve optimum drawbar height,
the drawbar can be turned or adjust-
ed up/down until the eye fits the
tractor towbar.
Stand MAXIROLL on support leg.
Slacken bolts (A) and adjust drawbar
to tractor.
A


MAXIROLL
Page 14
Operation
Correct operation is vital to get the best out of your MAXIROLL 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 col-
liding (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 im-
portant, 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 cylin-
der to flow setting last.

Before starting rolling, ensure weight transfer is correctly adjusted (see
”Adjustment of hydraulic weight transfer”).
A

MAXIROLL
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 low-
er roller into transport bar. (See fig. 5)

MAXIROLL
Page 16
Adjustment of hydraulic weight transfer
Hydraulic weight transfer distributes the weight evenly between all roller sections.
1. Once the roller is unfolded, relieve pressure in the extend/retract cylinders
(marked: Red), and activate cylinder control handle in the opposite direc-
tion.
Fig. 9
2 After short delay
the manometer will react.
Increase pressure to approx.
15 bar (A). This will trans-
fer some of the mid-
section weight to the side sec-
tions.
3Set control handle to flow setting. Flow setting is necessary to achieve hy-
draulic weight transfer, allowing the sections to move independently
4The pressure for hydraulic weight transfer may need adjustment. It can al-
so 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.

Failure to do so is incorrect use and can cause the frame to break in the
worst scenario.
A

MAXIROLL
Page 17
Operating speed
An operating speed of 6-10 km/h is recommended, but always operate according to
conditions.
Increased speed will increase wear, particularly in dry conditions. The rings can al-
so be damaged if operating at excessive speeds in unfavourable conditions.
Adjustment of hydraulic suspension of pendulum frames
Hydraulic weight transfer distributes the weight evenly between all roller sections.
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 ab-
sorb 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 hy-
draulics in flow setting. We rec-
ommend 70 bar. If additional
pressure is required, keep the
cock open and use the tractor
hydraulics to increase pres-
sure.
3The pressure for hydraulic suspension may need adjustment. It can also be
necessary to adjust pressure according to soil conditions.
A
B
C

MAXIROLL
Page 18
Excessive pressure
1If the cylinder does not move, pressure is too great. This can cause exces-
sive 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
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 pressure
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 pressure
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 MAXI-
ROLL standing for 30 mins. If pres-
sure drops, the driver-operated non-
return valve is defective, or there
may be dirt in the valve (disassem-
ble valve and clean parts)
Side sections not
following terrain
•Weight transfer
hydraulic system
not in flow setting
•Set hydraulic weight transfer in flow
setting (see ”Adjustment of hydrau-
lic weight transfer”)

MAXIROLL
Page 20
Accessories
MAXIROLL 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 level-
ling board, avoiding having to raise the entire arm in the event of it meeting an ob-
stacle.
Fig. 13
Power
Compared to a fixed levelling board, a crackerboard does not require so much pow-
er, although this can vary depending on how the board is used.
Table 3. Crackerboard power requirements in HP
1030
100+
*MAXIROLL 1230 is fitted as standard with a crackerboard.

By moving the minimum amount of soil, fuel consumption is reduced significantly
along with wear and tear.