DALBO SUPERMAX 250 User manual

SUPERMAX
EN
250/300
Serial no.: 100-XXX

SUPERMAX
Type 250/300
Congratulations on the purchase of your new SUPERMAX. For safety reasons and to achieve
optimum service from the product, please read the User Guide before use.
©Copyright 2011. 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
[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 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.......................................................................................................................................... 6
GENERAL ...........................................................................................................................................6
HYDRAULICS.......................................................................................................................................7
ASSEMBLY..........................................................................................................................................7
MAINTENANCE AND REPAIR ....................................................................................................................7
ROAD TRANSPORT ................................................................................................................................ 7
CORRECT USE......................................................................................................................................8
TECHNICAL DATA........................................................................................................................... 9
HOW TO USE THIS MANUAL .......................................................................................................... 10
DELIVERY.........................................................................................................................................10
DESCRIPTION .............................................................................................................................. 11
LIMITATIONS TO USE.................................................................................................................... 12
CONNECTING AND DISCONNECTING............................................................................................. 13
CONNECTING.....................................................................................................................................13
HYDRAULICS.....................................................................................................................................13
DISCONNECTION ................................................................................................................................14
SETTING UP ................................................................................................................................. 15
ADJUSTING MAIN FRAME......................................................................................................................15
ADJUSTING DEPTH..............................................................................................................................15
OPERATION ................................................................................................................................. 16
REPLACING SPRING BOLT.....................................................................................................................16
TROUBLESHOOTING .................................................................................................................... 17
MAINTENANCE ............................................................................................................................ 18
LUBRICATION ....................................................................................................................................18
REPLACEMENT AND REPAIRS ......................................................................................................19
HYDRAULICS.....................................................................................................................................19
Replacing depth adjustment cylinder..................................................................................19
Replacing gaskets on raise/lower cylinder..........................................................................20
Assembly.................................................................................................................................20
REPLACING TIPS ................................................................................................................................21
Replacing tips .........................................................................................................................21
Why replace tips?...................................................................................................................21
SCRAPPING ................................................................................................................................. 22
SPARE PARTS .............................................................................................................................. 23
GUARANTEE................................................................................................................................. 24

SUPERMAX
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.
•Before leaving the tractor or making adjustments, performing maintenance or
repairs on the machine, extend fully and lower to ground, or maintain in
transport position, apply tractor handbrake, switch engine off and remove igni-
tion key to secure the machine against accidental operation.
•Remember to secure support leg 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.

SUPERMAX
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.
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.
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
fitting the correct lighting and number plate required in accordance with appli-
cable legislation.

SUPERMAX
Page 8
•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 machine 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 machine.

SUPERMAX
Page 9
Technical data
The table below indicates how much oil
runs through the tractor when SUPERMAX is working at max. depth.
Model
Oil (litres)
300/250
1,2
SUPERMAX 250/300 incl.
800 mm bogie packer
Width (cm)
300
250
HP (recommended)
200
170
Weight in kg:
Incl. 800 mm bogie T-ring
3200
2625
Sections (pcs.)
1
1
Hydraulic requirements:
Double-acting
1
1
Single-acting
-
-
Transport:
Width (metres)
3,00
2,70
Height (metres)
2,00
2,00
Length (metres)
3,90
3,90

SUPERMAX
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 machine is delivered complete on a trailer.
If lifting the machine, we recommend the use of straps on the mid-section and
drawbar to maintain balance.

SUPERMAX
Page 11
Description
SUPERMAX is a heavy-duty combination cultivator, ideal for loosening and cultivat-
ing unploughed soil. The machine consists of a tine section, a plate section and a
packer section. The tines loosen the earth to a max. depth of 400 mm, whilst the
plates break soil down and smooth the surface to a max. depth of 150 mm. Finally,
the soil is packed by a bogie T-ring packer to maintain soil humidity.
The machine is supplied ready for use.
Fig. 1
SUPERMAX 300 (diagram)
SUPERMAX is intended for use after harvesting of crops such as wheat, maize, sun-
flower or rapeseed. Thanks to the machine's weight, soil can be loosened even un-
der very hard soil conditions.

SUPERMAX should only be used on soil which has previously been cultivated - i.e.
the machine should not be used on former woodland, gravel roads etc.
Working speed should be within the range of 6-8 kph. At slower speeds, the crum-
bling effect of the plate section will be degraded, whilst at higher speeds, the
spring bolts and tips of tines can be overloaded.

The machine is highly robust, to tolerate heavy loads. However, it will always be
necessary to match speed to conditions - e.g. reduce speed on hard ground.

SUPERMAX
Page 12
Limitations to use
Descriptions of what the machine can and cannot be used for:
•Can only be used for breaking down organic plant material on agricultural land under cultivation.
Areas worked must be in normal agricultural maintenance, i.e. with no significant unevenness or
holes. Any stones must be removed from the area to the normal extent. The area must be rea-
sonably well-drained.
•Plant material must not be stiffer than maize stalks.
•The machine can only be used towed behind an agricultural tractor, and must be connected to the
rear 3-point hitch.
•Maximum working speed is 10 kph. But always adapt speed to the nature of the soil to be worked.
Use of the machine which does not fulfil the conditions above will be regarded as non-authorised,
and will invalidate the factory guarantee.

SUPERMAX
Page 13
Connecting and disconnecting
Connecting
Fig.2
Attach to the tractor's lifting arms
and secure using balls and split pins
(A). The support leg (B) is raised and
secured by a pin.
Remember to secure drawbar with balls and split pins.
Hydraulics
SUPERMAX 300 requires a double-acting hydraulic outlet as standard, which is
linked to the hydraulic depth adjustment.
Hose markings
Cylinder name
Colour
Outlet
Function
Depth cylinder
black
Double acting
Set working depth on machine.
The hydraulic system is not fitted with pilot-controlled relief valves. If the tractor
hydraulic system leaks, please contact DALBO A/S.
A
B
A

SUPERMAX
Page 14
Disconnection
Always disconnect the machine on a flat surface to ensure maximum stability.
Set support leg vertically, disconnect hydraulic hoses and three point lift arms.

Remember to depressurise hoses before disconnecting them.

Check hydraulic hoses for crimping

SUPERMAX
Page 15
Setting up
SUPERMAX is very simple to work with. The machine's design makes it very easy to
set up.
Always check frame angle before use to ensure optimum use of the machine.
Adjusting main frame
To achieve uniform soil cultivation, the main frame must be horizontal longitudinal-
ly and latitudinally.
Fig. 3
SUPERMAX 300 at work. The main
frame is horizontal.
Adjusting depth
The working depth of the machine is hydraulically set using the packer (A fig. 3).
The depth of the tines in relation to the plates can also be set mechanically in a
row of holes on the tine (A fig. 4). To avoid throwing up a bank of earth at the side
of the machine, adjust the side plates (B fig. 3) until they do not throw soil beyond
the width of the machine.
HORIZONTAL
Fig. 4
A
A
B

SUPERMAX
Page 16
Operation
When working with SUPERMAX, the tines will hit stones which can cause the spring bolt to
break.
Replacing spring bolt
Fig. 5
If the spring bolt (A) breaks, extract
the split pin (B), lift the tine (C) up to
the required height and replace the
bolt in the tine. Remember to secure
the spring bolt with the split pin (B)
again. When all spring bolt positions
are used, replace it with a new one.
A
B
C

SUPERMAX
Page 17
Troubleshooting
Fault
Cause
Remedy
Uneven working
depth
•Frame is not hori-
zontal
•Adjust frame
•Tines not uni-
formly adjusted
•Adjust tines uniformly

SUPERMAX
Page 18
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. 6
A
B
C
D
Lubrication points
Number
of
nipples
Lubrication inter-
vals, hours
Illustration
Bearings in packer
4
50
A
Bearings on outer discs
2
50
B
Bearings on plates
22
50
C
Chassis
16
8
D

Lubricate all lubrication points at least once annually.

SUPERMAX
Page 19
Replacement and repairs

Safety is vital for all repair work on the machine. Always observe the following
points, plus those under Safety First in the instruction manual.
All maintenance and repair work on the machine can only be performed when the
machine 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 depth adjustment cylinder
Fig. 7
Lower machine to the ground, depres-
surise hydraulics (A), so that the
packer rests on the ground.
1. Disconnect hoses from cylinder
2. Support cylinder
3. Remove split pins in pins, remove pins
4. Remove cylinder
5. Fit new or repaired cylinder
Activate cylinders after assembly. Activate cylinders both ways, retract-
ing/extending fully in both outer positions. This is necessary to bleed the system
and cylinder.
A

SUPERMAX
Page 20
Ensure no personnel are within the extension radius of the side sections.
Replacing gaskets on raise/lower cylinder
Fig. 8
1. Drain oil from cylinder by moving ram carefully backwards and forwards.
2. Extend ram to centre position. Unscrew upper part (pos. 3) from cylinder tube
(pos. 1). Use special tool to remove upper part. If upper part is stuck, heat front
of upper part. When upper part is detached from cylinder tube, pull ram up to-
wards upper part and remove completely from cylinder tube (pos. 1).
3. Remove lock nut (pos. 10) retaining collar shoe (pos. 4).
4. Remove collar shoe (pos. 4) from ram, (pos. 2).
5. Remove upper part (pos. 3) from ram, (pos. 2).
6. Remove gaskets in upper part (pos. 5+6+7+8+9) along with collar shoe.
7. Clean all parts and check for particles etc. Check for rust around scraper ring
(pos. 5) in upper part. If detected, remove thoroughly.
Assembly
1. Fit new gaskets (pos. 5+6+7+8+9) in upper part, plus collar shoe.
2. Lubricate thread in upper part (pos. 3) and cylinder tube (pos. 1) with oil.
3. Fit upper part (pos. 3) on ram shaft.
4. Fit collar shoe (pos. 4) and screw on lock nut, secure with Loctite. Ensure that
thread is absolutely clean and free of oil or other impurities before applying
Loctite. Do not fill with oil for 12 hours after use of Loctite.
5. Lubricate outer collar shoe gasket in contact with cylinder tube and inside of
cylinder tube with oil, push ram into centre position.
6. Fit upper part onto cylinder tube and tighten.
7. For fitting cylinder see ”Replacing depth”.