DALBO MINIMAX 830 2008 User manual

MINIMAX 830 2008
EN
830 cm
Serial no.: 100-xxx

MINIMAX 2008
Type 830 cm
Congratulations on the purchase of your new roller. For safety reasons and to achieve opti-
mum service from the product, please read the User Guide before use.
©Copyright 2002. All rights reserved, DALBO A/S
This product 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
declares herewith that the above machine is manufactured in accordance with the provisions
of directive 98/37/EC, which replaced directive 89/392/ECC and change directives
91/368/ECC, 93/44/ECC and 93/68/ECC on harmonisation 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

Table of Contents
SAFETY.......................................................................................................................................... 7
GENERAL ...........................................................................................................................................7
HYDRAULICS.......................................................................................................................................8
MOUNTING .........................................................................................................................................8
MAINTENANCE AND REPAIR ....................................................................................................................8
ROAD TRANSPORT ................................................................................................................................ 9
CORRECT USE......................................................................................................................................9
TECHNICAL DATA......................................................................................................................... 10
HOW TO USE THIS MANUAL .......................................................................................................... 11
DELIVERY.........................................................................................................................................11
USES ........................................................................................................................................... 12
CONNECTING AND DISCONNECTING............................................................................................. 13
CONNECTING.....................................................................................................................................13
HYDRAULICS.....................................................................................................................................13
DISCONNECTION ................................................................................................................................14
SETTING UP ................................................................................................................................. 15
ADJUSTING DRAWBAR HEIGHT...............................................................................................................15
OPERATION ................................................................................................................................. 16
EXTENDING AND FOLDING UP................................................................................................................16
Extending ................................................................................................................................16
Fold up.....................................................................................................................................17
WEIGHT EQUALISATION........................................................................................................................17
OPERATING SPEED .............................................................................................................................17
MAINTENANCE ............................................................................................................................ 18
LUBRICATION ....................................................................................................................................18
ADJUSTMENT ....................................................................................................................................19
Wheels.....................................................................................................................................19
HYDRAULICS.....................................................................................................................................19
REPLACEMENT ANDREPAIRS....................................................................................................... 20
HYDRAULICS.....................................................................................................................................20
Replacing extend cylinder for folding side sections ...........................................................20
Replacing raise/lower cylinder .............................................................................................22
Replacing gaskets on raise/lower cylinder..........................................................................23
REMOVAL/FITTING WHEEL ...................................................................................................................24
Replacing wheel bearings......................................................................................................24
REPLACING ROLLERS..........................................................................................................................25
Replacing side section rollers...............................................................................................25
Replacing middle roller ..........................................................................................................26
SCRAPPING ................................................................................................................................. 27

HYDRAULIC DIAGRAM...................................................................................................................28
SPARE PARTS...............................................................................................................................29

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 extension radius before
operating. Operate machine only from inside the tractor.
•When roller is folded together, check the side sections are locked. Check all op-
erating 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 lift arm (if relevant) 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.

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.
•It can be difficult to completely depressurise hydraulic systems with pilot-
controlled non-return valves. Hold a cloth around the fittings/part to be re-
moved to catch any oil.
•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.
•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.
•The roller 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.

Technical data
MINIMAX 2008
Size (cm)
830
HP (recommended)
140 –200
Gross weight kg:
4100
Sections (pcs.)
3
Axles (pcs.)
3
Wheels
10.0/75-15.3

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.
Always use a rig with straps attached to the mid section and ensure machine is
balanced when lifting.

Uses
This is a standard roller, designed for rolling and levelling ploughed and sown are-
as.
Fig. 1
The roller has three articulated
sections and integrated mechan-
ical weight equalisation, in which
the sections can move inde-
pendently of each other.
MINIMAX 2008 830

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, retract support leg and
place in working position (B)

•Remember to secure towbar pin with split pin or the like.
•Remember to secure the support leg with a split pin.

•If tractor towbar is too short, its lift arms can collide with the roller's sup-
port leg if cornering sharply to the left. Avoid by extending tractor towbar.
Hydraulics
The roller requires as standard a double-acting and single-acting hydraulic outlet,
where the double-acting is used for extending and single-acting for rais-
ing/lowering.
Table 1. Hose markings
Cylinder name
Colour
Outlet
Function
Raise/lower
cylinder
White
Single acting
Raises the drum 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 sec-
tions.

•Check hydraulic hoses for crimping
A
A
B
B

Disconnection
The roller must be folded up (transport position) or extended before disconnection.
Lower support leg to lift roller drawbar from tractor towbar. Remove pin and dis-
connect hydraulic hoses.
Remember to depressurise hoses before disconnecting them.

Setting up
The roller 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.
To achieve uniform pressure applied on the ground, the drawbar must be correctly set up for the tractor
used. Towbar height on tractor must be approx. 54 cm.
Adjusting drawbar height
Fig. 3
To achieve uniform
pressure applied on
the ground, the draw-
bar must be correctly
set up for the tractor
used.
Height under drawbar
must be approx. 54
cm.
Fig. 4
Always ensure machine mid-section
(A) is horizontal during adjustment.

Always ensure machine is on a level surface to ensure correct setting.
A
t
B
Height un-
der
drawbar:
54 cm
B
A
B
Heig

Operation
Correct operation is vital for optimum use of the roller. This applies to working in
the field and for 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.
Extending
Fig. 5
1Lift side sections from
transport hook (A) using
raise/lower cylinder (marked:
White).
Fig. 6
2Activate extend cylinder
(marked: Red) to fully extend
side sections.
3Activate raise/lower cylinder to
lower roller to ground.
4Set extend cylinder (marked:
Red) into flow position.
A

Fold up
Fig. 7
1. Activate extend cylinder
(marked: Red) to lift end of
side sections (A) as much as
possible.
Fig. 8
2. Activate raise/lower cylinder
(marked: White) to full length.
Roller will lift from ground
Fig. 9
3. Activate extend cylinder to fold
side sections in.
4. Activate raise/lower cylinder to
lower roller into transport hooks.
Weight equalisation
Spring-loaded weight equalisation spreads weight equally across roller sections.
Weight equalisation is factory set, and must not be changed by user.
Operating speed
An operating speed of 6-10 km/h is recommended, but always operate according to
conditions.
Power requirement will depend on soil type, terrain and speed.
Table 2, Guide to power requirement in HP
Working width
830
Power
140
A
r

Maintenance
Good maintenance ensures long service life and optimum use. Grease nipples are
fitted where wear is heaviest.

Tighten all screw connections after first working day. Check all split pins and bolts
to avoid mechanical failure. Check hydraulic system for leaks.
Lubrication
Fig. 10
A
B
C
D
E
F
Lubrication points
Number
of nipples
Lubrication
intervals,
hours
Illustra-
tion
Flange bearings
6
50
A
Rotation pin for extending side sections
2
25
C
Extend cylinder
2
50
B/D
Rotation pin for raise/lower
2
50
E

Lubricate all lubrication points at least once annually.
d
r
a
w
b
a
r
:
5

Adjustment
Wheels
Lubricate and adjust wheel bearings at least once annually. Check tyre pressures
at least once annually (see recommended pressure on tyre).
Adjustment and lubrication of wheel bearings
1. Remove hub caps.
2. Remove split pin.
3. Tighten castle nut 1/6th of a turn until hole is aligned with axle. Turn wheel,
check for resistance. A little play should be detected in the hub housing when
rocking wheel from side to side. If play is excessive, repeat process.
4. Replace split pin
5. Fill hub cap ¾ full with grease. Replace.
Hydraulics
Check all hydraulic hoses for wear or cracks. Check all hoses for crimping.

Lubricate exposed rams with oil or pressure-resistant grease to avoid rust forming
when storing for long periods. Remember to remove before use.

Replacement and repairs

Safety is vital for all repair work on the roller. Always observe the following points,
plus those under Safety First in the instruction manual.

When replacing cylinders, always fill new cylinder with oil before pressurising sys-
tem. We recommend fitting cylinder to frame first, fill with oil, before completing
fitting at top.
All maintenance and repair work on the roller can only be performed when the ma-
chine is lowered to the ground or locked in transport position, tractor is braked,
engine stopped and ignition key removed to prevent accidental start.
Particular attention must be paid to safety when repairing hydraulics. Before
commencing work, depressurise hydraulic system and support part being worked
on.
Always ensure hydraulic system is bled after repairs and before use to prevent
mechanical breakdown and injury to person.
Hydraulics
Replacing extend cylinder for folding side sections
Roller must be fully extended and standing on ground for repairs.
Fig. 17
1. Depressurise cylinder.
2. Disconnect hoses
3. Remove split pins and pins. Cylinder will
now be free.
4. Fit new or repaired cylinder. Check pin
locks into place, secure pins with split
pins.
5. Connect hoses. Check there is no dan-
ger of hoses being ripped or crimped af-
ter fitting.