DALBO MINIMAX User manual

MINIMAX
EN
630 and 830 cm
Serial no.: 00100-XXXX

MINIMAX
Types 630 and 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 CONFORMITY
DALBO A/S
DK-7183 Randbøl
declares herewith that the above machine is manufactured in accordance with the provisions
of directive 2006/42 EC, which replaced directive 98/37/CC 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

MINIMAX XL
Page 4
Table of Contents
SAFETY...................................................................................................................................................................6
General...........................................................................................................................................................6
Hydraulics......................................................................................................................................................7
Assembly........................................................................................................................................................7
Maintenance and repair ...............................................................................................................................7
Road transport ..............................................................................................................................................8
Correct use.....................................................................................................................................................8
Technical data ...............................................................................................................................................8
HOW TO USE THIS MANUAL ..........................................................................................................................................9
Delivery ..........................................................................................................................................................9
LIMITATIONS TO USE ............................................................................................................................................... 10
DESCRIPTION OF THE MACHINE ................................................................................................................................. 11
Construction ............................................................................................................................................... 11
CONNECTING AND DISCONNECTING ............................................................................................................................ 12
Connecting.................................................................................................................................................. 12
Hydraulics................................................................................................................................................... 12
Disconnection............................................................................................................................................. 12
SETTING UP .......................................................................................................................................................... 13
Adjusting drawbar height .......................................................................................................................... 13
OPERATION .......................................................................................................................................................... 14
Extending and retracting........................................................................................................................... 14
Extending.................................................................................................................................................... 14
Retract......................................................................................................................................................... 15
Weight equalisation ................................................................................................................................... 16
Operating speed ......................................................................................................................................... 16
MAINTENANCE ...................................................................................................................................................... 17
Lubrication.................................................................................................................................................. 17
Adjustment ................................................................................................................................................. 18
Wheels......................................................................................................................................................... 18
Hydraulics................................................................................................................................................... 18
REPLACEMENT AND REPAIRS.................................................................................................................................... 19
Hydraulics................................................................................................................................................... 19
Replacing extend cylinder for extending and retracting side sections ................................................ 19
Replacing raise/lower cylinder ................................................................................................................. 21
Replacing gaskets on raise/lower cylinder ............................................................................................. 22
Removal/fitting wheel ............................................................................................................................... 23
Replacing wheel bearings ......................................................................................................................... 23
Replacing rollers......................................................................................................................................... 24
Replacing side section rollers................................................................................................................... 24
Replacing centre section rollers............................................................................................................... 24
Replacing middle roller.............................................................................................................................. 25

MINIMAX XL
Page 5
HYDRAULIC DIAGRAM.............................................................................................................................................. 26
ACCESSORIES........................................................................................................................................................ 27
Greenline roller for grass ........................................................................................................................... 27
Frost safety ................................................................................................................................................ 27
Levelling board ........................................................................................................................................... 27
Board hydraulic system ............................................................................................................................ 28
Bleeding the system .................................................................................................................................. 28
Crackerboard .............................................................................................................................................. 28
Seed drill...................................................................................................................................................... 29
Filling seed.................................................................................................................................................. 29
GUARANTEE.......................................................................................................................................................... 30
SCRAPPING........................................................................................................................................................... 31
SPARE PARTS ........................................................................................................................................................ 32

MINIMAX XL
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 extension 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 leg 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.

MINIMAX XL
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.
•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.
Assembly
•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.

MINIMAX XL
Page 8
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 XL
Width (cm)
630
830
HP (recommended)
80
100
* Gross weight kg:
4440
5775
Transport width
2.55 m
2.55m
Sections (pcs.)
3
3
Axles (pcs.)
3
3
Wheels
11.5/80-15.3
400/60-15.5
* Depends on roller type (weighed with a 60 cm Cambridge)
All MINIMAX are available with 480/45-17 wheels. If fitted, the transport width will
exceed 2.55 m.

MINIMAX XL
Page 9
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 main sections:
•Safety
•Description of the machine, including settings
•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.

MINIMAX XL
Page 10
Limitations to use
The following describes what the machine can and cannot be used for:
•Can only be used for rolling and levelling ploughed or sown fields under cultivation.
The roller can also be used for rolling grass Fields on which the machine is used must be in a good
state of agricultural maintenance, i.e. without major unevenness or potholes.
•The machine can only be used when drawn by a tractor, attached to the tractor towbar.
•Max. speed when in use is 10 km/h. Speed must always be adapted to suit the terrain.
Any other use of the machine which does not meet the above conditions will be considered as
unauthorised use, and invalidate the guarantee.

MINIMAX XL
Page 11
Description of the machine
Construction
The MINIMAX is a robust roller, featuring the following construction:
•There are 3 sections. A centre section which is identical on the 630 and 830 versions.
Two side sections, which can be hydraulically retracted into their transport position, re-
sulting in a transport width of 2.55 metres. The side sections are 1 metre longer in the
830 version than the 630, to provide a wider working width.
•The side sections are fitted with tension springs designed to transfer some of the
weight of the centre frame and drawbar to the side sections in order to achieve uniform
rolling across the full width of the machine.
•The drawbar on the 830 version is extended to make room for the longer side sections
when in transport position.
•MINIMAX is designed to take rollers up to 61 cm in diameter (but not 60 cm "Crosskill"
rollers, due to the construction of the rings which require more room in the frame than is
available).
MINIMAX is designed to be take the following optional extras:
•Heavy-duty crackerboard with hydraulic depth adjustment.
•"Greenline" 61cm diameter steel rollers for grass. These rollers can be filled with water
to add weight.
•A hydraulically-adjustable levelling board can be fitted to Greenline rollers.
•All versions of MINIMAX can be fitted with Einböck Pneumatic box or P-Box Speed Seed
Boxes and brackets.

MINIMAX XL
Page 12
Connecting and disconnecting
Connecting
Fig. 1
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)

•The pin can be secured using a split pin or the like.
•Secure 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 cylin-
der
White
Single-acting
Raises the roller 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
Disconnection
The roller must be retracted (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.
A
B

MINIMAX XL
Page 13
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. 45cm. on the 630 and approx. 55 cm. on the 830.
Adjusting drawbar height
Fig. 2
To achieve uniform
pressure applied on
the ground, the draw-
bar must be correctly
set up for the tractor
used.
Fig. 3
B
Height under
drawbar:
45cm on 630
55cm on 830

MINIMAX XL
Page 14
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 retracting
Extending and retracting the machine must always be performed with tractor
parked, and on a reasonably level surface.
Ensure there are no personnel within the machine's working radius when extending
or retracting.
Extending
Fig. 4
1Lift side sections from
transport hook (A) using
raise/lower cylinder (marked:
White).
Fig. 5
2Set extend cylinder (marked:
Red) to fully extend side sec-
tions.
3Activate raise/lower cylinder to
lower roller to ground.
4Set extend cylinder (marked:
Red) into flow position.
A

MINIMAX XL
Page 15
Retract
Fig. 6
1. Activate extend cylinder
(marked: Red) to lift end of
side sections as much as pos-
sible.
Fig. 7
2. Activate raise/lower cylinder
(marked: White) to full length.
Roller will lift from ground
Fig. 8
3. Activate extend cylinder to fold
side sections in.
4. Activate raise/lower cylinder to
lower roller into transport hooks.
Fig. 10
Always observe the correct sequence when retracting. I.e.: operate the side
section extend cylinders to maximum extension first, and then take them out
of flow position. Activate raise/lower cylinder, lift rollers from wheels If the ex-
tend cylinders are not taken out of flow position before the raise/lower cylin-
der is activated, the side sections will move forward during retraction, placing
unnecessary strain on the frame of the machine.

MINIMAX XL
Page 16
Weight equalisation
To achieve uniform rolling across the
full width of the machine, a weight
equalisation system is fitted. The
need for weight equalisation arises
because the weight of the centre
frame and drawbar alone will affect
the central part of the roller. The sys-
tem consists of 2 tension springs
which tighten when the side sections
are extended. The system is correctly
set when the springs are just hanging
loosely with the side sections in
transport position.
Important!: The machine must always be fully retracted in transport position when
setting up the weight equalisation system.
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. But the most im-
portant factor is whether the machine is fitted with a crackerboard, and if so, how
hard it is applied to the ground.
Table 2, Guide to power requirement in HP
Working width
630
830
Power requirement, approx.
80 (140)
100 (180)
The figure in brackets states power requirement if the crackerboard is fitted and
used at maximum depth.

MINIMAX XL
Page 17
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. 9
Lubrication points
Number of
nipples
Lubrication in-
tervals, hours
Balloon
Flange bearings
6
50
A
Rotation pin for extending side sections
2
25
D
Extend cylinder
2
50
B
Rotation pin for raise/lower
2
50
C
Wheel hub
2
50
E

Lubricate all lubrication points at least once annually.
A
B
C
D
B
E

MINIMAX XL
Page 18
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 aligns 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.

MINIMAX XL
Page 19
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 extending and retracting 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.

MINIMAX XL
Page 20
Activate extend cylinder after fitting until cylinder shows movement. Reverse cyl-
inder until it returns to start position. Move cylinder backwards and forward sever-
al times. Raise roller fully onto wheels, extend side sections fully to bleed system.
If a cylinder is not bled correctly as described above, there is a risk that part of the
machine can suddenly move much quicker than normal, and before the tractor
driver can prevent it. This is because air (in contrast to oil) can be compressed. A
side section can therefore swing out very quickly if bleeding is not performed cor-
rectly. This represents a major risk of injury and personnel and damage to the ma-
chine.
Ensure no personnel are within the extension radius of the side sections.
Replacing gaskets
REMOVAL:
1. Drain oil from cylinder, use compressed air to move ram backwards and
forwards (if required) to force oil out.
2. Extend ram to centre position. Screw upper part (pos. 3) 30 mm outwards.
If upper part is stuck, heat front of sleeve to approx. 300

C, and allow to
cool.
When upper part has been unscrewed, extend ram towards upper part.
Unscrew and remove upper part, extract ram.
3. Remove lock nut (pos. 10).
4. Remove collar shoe (pos. 4).
5. Remove upper part from ram, (pos. 2).
6. Remove gaskets in upper part and collar shoe, (pos. 5+6+7+8+9) using an
awl or screwdriver if necessary.
7. Clean all parts, check for particles etc. Check for
rust around scraper ring (pos. 5) on the upper part. If any is
detected, remove thoroughly.