DALBO Rollomaximum XL User manual

Rollomaximum XL
EN
930 and 1240 cm
Serial no.: 00100-XXXX

Rollomaximum XL
Types 930 and 1240 cm
Congratulations on the purchase of your new multifunctional agricultural implement.
For safety reasons and to achieve optimum performance from the product, please read
the User Guide before use.
©Copyright 2002. All rights reserved, DAL-BO A/S
Machine specifications:
Type no.:
Serial no.:
Month of manufac-
ture:
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
DAL-BO A/S
DK-7183 Randbøl
declares herewith that the above machine is manufactured in accordance with the pro-
visions of directive 2006/42 EC, which replaced directive 98/37/EC and change direc-
tives 91/368/EEC, 93/44/EEC and 93/68/EEC on harmonisation 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

Rollomaximum 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 .......................................................................................................................... 13
SETTING UP................................................................................................................................... 14
Adjusting drawbar height........................................................................................................ 14
DRIVING AND OPERATION............................................................................................................. 14
Extending and retracting......................................................................................................... 14
Extension.................................................................................................................................. 15
Retraction ................................................................................................................................ 16
Adjustment of hydraulic weight transfer system...................................................................... 18
Excess pressure........................................................................................................................ 19
Insufficient pressure................................................................................................................. 19
Adjustment of the hydraulic suspension on the middle cross-kill shaft................................... 19
Operating speed....................................................................................................................... 20
Adjusting crackerboard........................................................................................................... 20
Adjusting harrowing depth...................................................................................................... 21
..................................................................................................................................................... 21
Adjusting the rear levelling board........................................................................................... 22
Adjusting the rear cross-kill board.......................................................................................... 23
MAINTENANCE ............................................................................................................................. 23
Lubrication .............................................................................................................................. 23
Adjustment ............................................................................................................................... 26
Wheels...................................................................................................................................... 26
Hydraulics................................................................................................................................ 26
REPLACEMENT AND REPAIRS ........................................................................................................ 27
Hydraulics................................................................................................................................ 27
Replacing the extend/retract cylinder for the side sections (red)........................................... 27
Replacing the tilt cylinder (white valve block no. 4). .............................................................. 29
Replacement of wheel cylinder (yellow).................................................................................. 31
Replacing the harrow hoist cylinder (white valve block no. 3)............................................... 31
Replacing cylinder for the front centre cross-kill axle (black)................................................ 32
Replacing the track loosener cylinder (white valve block no. 2)............................................. 33

Rollomaximum XL
Page 5
Replacing the crackerboard cylinder (green) ..........................................................................34
Removal/fitting wheel...............................................................................................................36
Replacing rollers......................................................................................................................36
Replacing the roller in the front centre section........................................................................37
Replacing the front centre roller..............................................................................................37
HYDRAULIC DIAGRAM...................................................................................................................38
GUARANTEE..................................................................................................................................41
SCRAPPING ....................................................................................................................................42
SPARE PARTS.................................................................................................................................43

Rollomaximum 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 the safe operation 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 extension radius be-
fore operating the implement. Only operate machine from inside the trac-
tor.
When the implement is retracted, check that the side sections are locked.
Check all control levers are secured against accidental operation.
Before leaving the tractor or making adjustments, performing maintenance
or repairs on the implement, extend fully and lower it to the ground, or
maintain it in the transport position. Apply tractor handbrake, switch en-
gine off and remove ignition key to secure the machine against accidental
operation.
Never leave driver's seat while the machine is moving.
Always adjust speed to conditions.
Do not use machine unless all safety devices are in place. Defective safety
devices must be replaced immediately.

Rollomaximum XL
Page 7
Hydraulics
Fold out machine and set down on an underlay for any repair work on the
hydraulic system. Relieve hydraulic pressure, switch engine off and re-
move ignition key.
Clean hydraulic connections thoroughly before reconnecting. When con-
necting 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
removed 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 dis-
posal 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 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.

Rollomaximum XL
Page 8
Road transport
All statutorily required safety and warning features 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.
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 ensuring that original spare
parts are always used.
The implement may only be used, maintained or repaired by persons who
are familiar with it and who are aware of the risks that may be involved.
The manufacturer cannot be held liable for injury or damage arising from
modifications made to the machine performed without its prior agreement.
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 implement.
Technical data
Rollomaximum XL
Width (cm)
930
1240
HP (recommended)
Min. 275
Min. 350
Weight in kg (cross-kill):
10,470
12,970
Transport width
3.00 m
3.00 m
Sections back (pcs.)
6
8
Axles front (pcs.)
5
3
Wheels
600/50-22.5
710/40-22.5
Brakes
Yes
Yes
Light
Yes
Yes

Rollomaximum XL
Page 9
How to use this manual
The sequence of topics in this manual may at first glance not always appear to
be logical. Please refer to the table of contents for page numbers for individu-
al items.
The manual is divided into main sections:
Safety
Description of the machine, including settings
Starting routine and running
Maintenance
Repairs
The following symbols represent:

Points which are important to functionality and service life.
Points relevant to safety.
Delivery Rollomaximum is delivered complete on a trailer or separated into sections.
If the sections are to be hoisted, attach straps to the respective sections so that
they are balanced.

Rollomaximum XL
Page 10
Limitations to use
The following describes what the machine can and cannot be used for:
The machine may only be used for levelling, compacting and harrowing cultivated land.
Fields on which the machine is used must be well tilled, i.e. without major unevenness or
potholes.
The machine can only be used when drawn by a tractor, attached to the tractor drawbar.
Max. speed when in use is 10 km/h. Speed must always be adapted to suit the terrain.
When turning at headlands raise machine off the ground, preventing effects of unnecessary
wear and tear, especially on machines fitted with Crosskill rings ahead of the harrow.
Any other use of the machine which does not meet the above conditions will be considered
as unauthorised use, and will invalidate the guarantee.

Rollomaximum XL
Page 11
Description of the machine
Construction
The Rollomaximum XL is a robust, multifunctional agricultural implement with the fol-
lowing features:
The machine consists of 5 different working implements. At the front there is a
parallel-mounted hydraulically adjustable crackerboard, followed by a Ø53/Ø48
cm cross-kill roller. This in turn is followed by a harrow with four rows of hydrau-
lically adjustable tines. The maximum harrow depth is adjusted mechanically by a
"hydro-clip" on the hydraulic lift, but the entire harrow section is hydraulically
raised off the ground, for example when turning at headlands. The surface is lev-
elled again by a spring-mounted mechanically adjustable levelling board. Finally
the ground is compacted with a row of Ø50/Ø45 cm cross-kill rings.
The side sections are fitted with a hydraulic weight transfer system, which is de-
signed to transfer some of the weight from the machine centre section to the side
wings, in order to ensure uniform tilling of the ground across the full width of the
machine.
For optimum protection of the machine's core components, all assemblies are
mounted on spring mechanisms.
Rollomaximum XL is designed to receive the following optional extras:
The machine can be optionally fitted with track looseners for tractor rear wheel
widths of up to 4.5 metres. In addition, the cross-kill rings can be replaced with a
Ø50 cm front roller cage and a Ø45 cm back roller cage.

Rollomaximum XL
Page 12
Connecting and disconnecting
Connecting
Rollomaximum may only be cou-
pled to the tractor's fixed drawbar,
where the towing eye (A) must fit
between the drawbar forks.
The towing pin (C) is inserted and
the support leg is hydraulically
raised to the maximum height off
the ground. (B)
The towing pin can be secured with a split pin or similar.
Note that hydraulic hoses and the support leg are mounted so that they
are not damaged by the tractor's lift arms and tyres when the tractor /
machine train is turned.
Rollomaximum XL 930 / 1240 should never be hitched to a tractor
with a dead weight of less than 5 tonnes on the rear axle. This is
because the machine presses down on the tractor drawbar when
retracting and extending.
Rollomaximum XL 930 / 1240 may only be hitched to a tractor via
a pick-up hitch as shown in the photo on this page. Never use a
ball hitch or the tractor lift arms. This is because the machine
presses down on the tractor drawbar when retracting and extend-
ing.
Hydraulics Rollomaximum XL 930/1240 requires the standard four double-acting and
single-acting hydraulic couplings, whereby the assignment and colour-coding
are as described in the table on the next page. One of the four double-acting
couplings is connected to an electrical valve block on the machine, which
supports a total of four double-acting functions on the machine. This valve
block is electrically controlled from the tractor's cab via a contact box (A) and
requires a 12 V supply (B). When the green lamp (C) lights up, it means that
the valve with the corresponding number is activated on the machine, when
the valve connected to the white hoses is activated in the tractor's cab. Only
one function can be actuated at a time.
A
B
C
A
B
C

Rollomaximum XL
Page 13
Hose markings
No. in valve
block
Cylinder name
Colour
Outlet
Function
4
Tilt cylinder
White
Double-acting
Raises side frames off the transport locks at the
front of the drawbar and tilts the whole ma-
chine middle frame with side frames back-
wards / forwards.
-
Retract/
weight equalisa-
tion
Red
Double-acting
Retracts/extends side sections and distributes
weight from mid-section to side sections, when
the machine is in the working position. Con-
nected with manometer and requires float posi-
tion when working in the field.
-
Crackerboard
front
Green
Double-acting
Adjusts the working intensity at the front
crackerboard.
-
Transport wheel
Yel-
low
Double-acting
Adjusts the position of the transport wheels.
3
Harrow section
White
Double-acting
Adjusts the working depth of the harrow sec-
tion.
1
Support leg
White
Double-acting
Adjusts the position of the support leg.
2
Track loosener
White
Double-acting
Moves the track loosener tines between work-
ing and transport positions
-
Pressure on the
centre front
cross-kill roller
Black
Single-acting
Adjusts the weight equalisation from the frame
to the centre front cross-kill axle. Connected
with manometer and is blocked with ball cock
when working in the field.

Check hydraulic hoses for crimping before coupling.
Disconnection Rollomaximum should be folded up (into the transport position) or folded out
into the working position with the transport wheels lifted off the ground be-
fore disconnection.
The support leg is adjusted so that the drawbar is free in the drawbar forks
both above and below. Remove towing pin and disconnect hydraulic hoses.
Remember to depressurise hoses before disconnecting them.When the
machine is disconnected in transport position, the machine should remain
stationary on the transport wheels and on the hydraulic support leg. Do
not use the centre cross-kill axle as a support.
Rollomaximum may only be disconnected on a level surface.

Rollomaximum XL
Page 14
Setting up
Rollomaximum is supplied with factory settings, but fine adjustment will al-
ways be required before use. Numerous adjustment options make the machine
more flexible and optimise its use.
To ensure that the ground is uniformly worked, the drawbar must be correctly
aligned to the tractor used.
Adjusting drawbar height
Supported on a level concrete floor
or similar, the machine is folded out
to working position and the
transport wheels (A) raised free.
The crackerboard (B) and harrow
section (C) are also raised, so that
the machine is now only supported
by the two compaction sections. In
this position, the entire drawbar
shaft (D) should be level. If it is not
so, the assembly should be adjusted
by the drawbar eye (E) and flange
plate (F) until the drawbar shaft is
horizontal.
Driving and operation
Correct operation is vital to get the most out of the Rollomaximum. This ap-
plies to working in the field and to safety. Always ensure you are fully famil-
iar with all safety features of the machine.
Extending and retracting
Extending and retracting the machine must always be performed with
the tractor parked, and on a level surface.
A
B
C
D
E
F
Horizontal

Rollomaximum XL
Page 15
Ensure there are no personnel within the machine's working radius when
extending or retracting.
Extension
Lift side sections off the
transport cradle (A) with the
tilt cylinder (marked: white
valve block no. 4).
Extend/retract cylinder
(marked: Red) is activated
and the side sections are
completely folded out.
The tilt cylinder (marked:
white valve block no. 4) is
activated and the machine is
lowered back to the ground.
The wheel frame (marked:
yellow) is activated and the
wheels are lifted off the
ground. Extend/retract cylin-
der (marked: red) is actuated
until the desired operating
pressure is indicated on the
manometer and is set to the
float position.
A

Rollomaximum XL
Page 16
Retraction
The wheel frame (marked:
yellow) is activated and the
machine is lifted off the
ground.
The tilt cylinder (marked:
white valve block no. 4) is
retracted and the machine is
tilted forward to the side
frames and the centre frame
is in the upright position.
The extend/retract cylinder
(marked: red) is activated
again and the side sections
are retracted in over the
transport cradles (A).
The tilt cylinder (marked:
white valve block no. 4) is
activated and the side arms
are lowered into the transport
cradles (A). Finally the tilt
cylinders are depressurised
by briefly setting the outlet
(marked: white valve block
no. 4) to the float position.
A
A

Rollomaximum XL
Page 17
To reduce the height of the ma-
chine's centre of gravity and
lower the transport height to a
maximum of 4 metres, the ma-
chine can be lowered via the
wheel frame (A) (marked: yel-
low). The machine is lowered
until there is approx. 9 cm of
clearance under the centre cross-
kill axle (B)
To reduce the machine's
transport width to a maximum of
3 metres, the harrow section is
activated (A) (marked: white
valve bock no. 3), so that they
are pulled as far in to the ma-
chine's centre as possible. The
same is done with the machine's
crackerboard (B) (marked:
green)
Always observe the correct sequence when retracting. i.e., the wheel
frame (marked: yellow) is first activated and the machine is lifted off
the ground. The tilt cylinder (marked: white valve block no. 4) is then
activated and the machine is tilted forward until the side frames and
the centre frame are in the upright position. The side frames can then
be retracted via the extend/retract cylinders (marked: red) and are set
down on the transport cradles via the tilt cylinder (marked: white valve
block no. 4).
This is very important for the machine's durability and safety that
the side arms remain in the transport cradles, when the machine is
transport in the retracted state.
A
B
9 cm
400 cm
A
B
300 cm

Rollomaximum XL
Page 18
Adjustment of hydraulic weight transfer system
The hydraulic weight transfer system distributes the weight evenly between
all the machine's sections.
Once the roller is fully extended and the transport wheels are off the ground,
the extend/retract cylinders are depressurised (marked: red), the cylinder con-
trol lever is then moved in the opposite direction.
This is indicated after
a short delay
by a deflection of the
manometer. The pres-
sure is increased to
approx. 15 bar (B).
Some of the weight
from the machine's
centre is thus trans-
ferred to the side sec-
tions.

The control lever connected to the outlet (marked: red) is then set to
the float position. The floating setting is required to achieve hydrau-
lic weight transfer, allowing the sections to move independently and
protecting the machine's key components. The pressure will remain
indicated on the manometer after float position has been adopted.
The pressure for hydraulic weight transfer may need adjustment. It may also
be necessary to adjust pressure according to soil conditions.
The accumulator precharge pressure (air pressure) is pre-set ex works, but
must be adjusted according to the actual type and character of the soil. This
must be done in consultation with a licensed Dal-Bo dealer.
Check all the accumulators on the machine at least once a year for leaks
and to ensure that the precharge pressure is set correctly. Contact an
authorized Dal-Bo dealer for more information.
A
B

Rollomaximum XL
Page 19
Excess pressure
1Pressure on the side sections will be too great, leaving clear tracks in
the soil after the side sections have passed.
2The centre section will not compact the soil enough, as the soil after
the centre section has passed is higher and not as compacted as that
worked by the side sections.
Insufficient pressure
1The pressure on the extremities of the side sections will be insufficient
to give uniform compaction.
2The mid-sections will compact the soil too much, leaving the soil after
the mid-section has passed more compacted than that worked by the
side sections.

To prolong the Rollomaximum's service life and the optimise the
tilled field finish, it is very important that the extend/retract outlet
(marked: Red) is set to the float position for field work.

If the outlet (marked: red) is not set to float position, this consti-
tutes incorrect use and in the worst case may cause the frame to
break.
Adjustment of the hydraulic suspension on the middle cross-kill shaft
The hydraulic suspension on the front centre cross-kill shaft (A), transfers part of
the machine's total weight to the axle, but also has the task of helping the axle to
vertically avoid collisions with rocks or when driving on undulating terrain.
The pressure of this
suspension is set ex
works to 50 bar (B),
which is the optimum
setting under most
conditions. The ma-
nometer for this func-
tion is the first (C) of
the two manometers
mounted on the ma-
chine. If it is wished to
change the pressure,
the stop cock (D) on
the single-acting outlet
is opened (marked:
black), the pressure ad-
justed and the cock is
closed again.
A
B
C
D

Rollomaximum XL
Page 20

If the pressure on the centre axle are not identical with that on the
side arm axles, the pressure in the hydraulic system may be dissipat-
ed and the system should be refilled with oil. If, however, the earth
piles up in front of the centre axle or the it only clears rocks with
difficulty, the pressure is too high and should be lowered.

Never set the pressure higher than 70 bar, as this may damage the
centre axle and result in very uneven working of the field.
Operating speed
An operating speed of 6-10 km/h is recommended, but always operate accord-
ing to conditions.
Power requirement will depend on soil type, terrain and speed. This is a cru-
cial factor as it determines the working depth with crackerboards and the har-
row section.
Table 2, Guide to power requirement in HP
Working width
930
1240
Power requirement
Min. 275
Min. 350
Adjusting crackerboard
Crackerboard depth is hydraulically
adjustable. The angle of attack of
the tines is manually adjusted via
the spindles (A). To ensure uniform
crackerboard angle setting, there are
numbers on the side of the spindles.
The angle set will be retained re-
gardless of depth, as the tines are
mounted in a parallelogram array.
For an aggressive tine setting (vertical) make the spindles shorter.
For a passive tine setting (horizontal) make the spindles longer.
A