DALBO Frontflex 2000 Series User manual

Frontflex 2000
GB
150, 300 and 400 cm

DAL-BO Frontflex 2000
Type 150, 300 and 400 cm
Congratulations on the purchase of your new Frontflex 2000. To ensure safe operation
and to obtain optimal use of the machine, please read the rules and instructions of the
following operator’s manual carefully before operating the machine.
©Copyright 2000. DAL-BO. All rights reserved.
Your Frontflex 2000:
Serial No.: Type:
Month of manufacture: Net weight (kg):
If you have any inquiries concerning spare parts or service, please do always inform us
of your manufacturing number. There is a list of spare parts at the back of the manual,
which provides you with an overview of the single parts.
EU-DECLARATION OF CONFORMITY
DAL-BO A/S
DK-7183 Randbøl
declares herewith that the above machine is manufactured in accordance with the provi-
sions of directive 2006/42/EC, which replaced directive 98/37/EC and change direc-
tives 91/368/ECC, 93/44/ECC and 93/68/ECC on harmonization 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

Table of Contents
SAFETY ..................................................................................................................................................... 4
APPLICATION......................................................................................................................................... 5
HITCHING AND UNHITCHING ...........................................................................................................6
HITCHING ................................................................................................................................................ 6
Lift arm tilt angle ............................................................................................................................... 6
Mounting behind tractor....................................................................................................................6
UNHITCHING............................................................................................................................................7
HANDLING WITHOUT USE OF THE THREE-POINT HITCH .............................................................................8
ADJUSTMENTS AND SETTINGS.........................................................................................................9
OPERATING AND DRIVINGINSTRUCTIONS ...............................................................................10
MAINTENANCE .................................................................................................................................... 11
BACKLASH IN THE RINGS .......................................................................................................................12
CLEANING AND MAINTENANCE.............................................................................................................. 12
OPTIONS................................................................................................................................................. 13
CRACKERBOARD ...................................................................................................................................13
Operation......................................................................................................................................... 13
Angle and depth adjustment ............................................................................................................13
Power requirements......................................................................................................................... 15
Refitting ........................................................................................................................................... 15
Maintenance .................................................................................................................................... 16
INDICATOR LIGHTS ................................................................................................................................ 17
REPAIRS .................................................................................................................................................18
REPLACING BEARINGS/SHAFTS/RINGS ....................................................................................................18
Crosskill rings.................................................................................................................................. 18
Mounting.......................................................................................................................................... 19
REPLACING CRACKERBOARD TINE POINTS............................................................................................. 19
REPLACING TINES ON THE CRACKERBOARD ..........................................................................................19
REPLACING NYLON RAIL........................................................................................................................20
REPLACING SPINDLES ON THE CRACKERBOARD.....................................................................................20
SCRAPPING ........................................................................................................................................... 21

Frontflex 2000
side 4
Safety
·Tighten all nuts, bolts or any other fastened assemblies after a few hours’
use.
·Operate the tractor and Frontflex 2000 only while seated in the driver’s
seat. Never allow anyone else to ride on or be in the immediate vicinity of
the equipment.
·Never allow children to operate the Frontflex.
·The driver is responsible for the correct use of lights and markings in
compliance with the present Traffic Act and Highway Code of the local
traffic legislation.
·Remember to secure lift arms and top link connections with lynch pins.
·Before performing any adjustments, maintenance or repairs on the ma-
chinery, always make sure the packer roller is resting securely on the
ground.
·It is strictly forbidden to allow anyone to be underneath Frontflex unless
the implement is securely blocked. Serious injury or death could result.
If the Frontflex is hitched to the tractor, it is important to set the tractor
brakes.
·When changing bearings, shafts and rings, the main frame must be
securely blocked by a solid support. Best results can be achieved by
mounting the Frontflex in the three-point hitch of the tractor, with the
Frontflex resting securely on the ground.
·Frontflex must not be used as a transport vehicle, a pile driver or anything
similar.
·A higher level of noise is produced when driving on rocky soil or with
worn roller rings. To protect against objectionable or uncomfortable loud
noises, wear hearing protection.
·Driving on extremely dry soil conditions can raise a large amount of dust.
It is recommended that the windows and doors of the tractor be closed or
that a dust mask be used.
Important safety information is preceded by a Ñ

Frontflex 2000
side 5
Application
The Frontflex 2000 is a multi-purpose implement with a diverse range of ap-
plications to accommodate various types of equipment. When mounted in the
front lift, it is especially suited to form part of a combination for seedbed
preparation.
Frontflex 2000 is a roller of up to 400 cm, with a mechanically operated
Crackerboard up to 3 m available as optional equipment. Frontflex 2000 is
equipped with Crosskill rings.
Crosskill rings are excellent for seedbed preparation, as they effectively crush
clods and achieve a good crumb structure.
Frontflex 2000 is constructed to be drawn across the soil, even though it is
mounted on the front. This specially designed mounting system provides bet-
ter manoeuvrability and allows minor steering corrections during operation
without having to raise the implement.

Frontflex 2000
side 6
Hitching and Unhitching
The Frontflex 2000 is manufactured in compliance with DS/ISO 730-1 cate-
gory II. The arms of the front lift must be rigid, preventing them from moving
sideways. If the front lift of your tractor is not suitable, please contact your
Dal-bo distributor.
Hitching
Mount the lift arms into the hitch points (A, Fig. 1). Next, install the top link.
Adjust the top link so that the main frame of the Frontflex is in a horizontal
position and parallel to the ground. Raise the implement, allowing the parking
stands (front and rear) to clear the ground and placing the implement in an
operating position.
ÑRemember to secure the lift arms and top link with lynch pins.
Fig. 1
Lift arm tilt angle
With the Frontflex in an operating position, the lift arms (B) should be tilted
at an angle preferably a couple of degrees above horizontal of the direction of
travel or at least horizontal. This angle will enable the Frontflex to roll over
any obstacles, as the tractor presses the implement tilted upwards and the
steering will be simultaneously maintained. (Steering can be made even easier
if the top link is shortened, so that the main frame points a few degrees up-
wards in the front.)
Mounting behind tractor
The Frontflex can be mounted in the three-point hitch on the rear of the tractor
if needed.
A
B

Frontflex 2000
side 7
Fig. 2
Insert the bolts (A) with the Frontflex resting on the ground. It is easiest to i n-
sert the bolts with the front linkage raised slightly upwards and the tubes (B)
parallel. Tighten the bolts until there is no space between the main frame and
the linkage.
Be extremely careful when mounting the Frontflex onto the rear of the tractor
while it is equipped with the Crackerboard. The Crackerboard must be in a
raised position and the tines must be tilted in the passive setting (see page 13
”Options”).
ÑRemember to secure the lift arms and top link with lynch pins.
Unhitching
To unhitch, the procedure for hitching should be followed in reverse order.
ÑIt is important to secure the Frontflex with the rear (A) and front (B) parking
stands to prevent the implement from tipping over.
Fig. 3
B
A
A
B

Frontflex 2000
side 8
Handling without use of the three-point hitch
If you need to move the Frontflex other than by use of the three-point hitch,
we recommend lifting it with straps in the main frame or in the linkage so that
the Frontflex hangs in balance.
Weight (kg)
Type Crosskill Ring
150 cm 715
300 cm 1075
400 cm 1215

Frontflex 2000
side 9
Adjustments and Settings
There are no adjustments to be made on the Frontflex 2000 except for any ad-
justments necessary during regular maintenance.
Operation of Frontflex requires no hydraulic outlets on the tractor.
The Frontflex does not have any special transport position.
Fig. 4

Frontflex 2000
side 10
Operating and Driving Instructions
The Frontflex 2000 is constructed so that the implement’s centre of gravity is
close to the tractor, reducing the weight of the implement on the tractor as
much as possible and easing operation.
Even when the Frontflex is mounted in the front lift, the implement is drawn
across the field, making it easier to pass over minor obstacles. The frame (A)
is mounted in three points (B and C). The pulling force of the tractor is trans-
mitted through point (C) which is the only rigidly mounted point. This feature
enables the operator to retain the steering capabilities of the tractor, which
must be given high priority if the Frontflex is to be part of a combination for
seedbed preparation.
Fig. 5
When starting operation, lower the Frontflex and place the lift in a starting po-
sition so the implement and the tractor can function independently of one an-
other. If you are working in loose and friable soil and would like greater con-
trol over the machine, raise the linkage to reduce the slack in the chains. The
implement will then be hanging from the chains (almost tight) instead of rest-
ing on the main frame. If the rings start sinking too deeply into the ground, the
main frame and the packer module will quickly begin to hang from the chains.
Initially, start with the chains loose and the linkage resting on the nylon rail,
enabling the packer module to follow the contours of the field surface.
A working speed between 7 and 10 km/hour is recommended, but always
drive according to conditions.
Never load extra weight onto the Frontflex 2000, as the implement was
not designed to carry additional weight.
When using the double-acting front lift, weight must not be transferred
from the tractor to the Frontflex.
Raise the Frontflex before backing up or turning.
C
B
A

Frontflex 2000
side 11
Maintenance
Proper maintenance ensures a long lifetime for the Frontflex 2000 and also
optimum performance from the implement. To facilitate maintenance, grease
fittings (A) have been mounted on those locations where wear on the equip-
ment is the greatest.
Fig. 6
Lubrication Points Number of Fittings
Bearings 2
Lubricate the bearings near the rings every 50 hours of operation. Do not over
lubricate since this will destroy the seals.
The top piece will slide best if the nylon rail is clean and free of oil. There-
fore, do not lubricate the nylon rail. Lubricants can collect dirt and grit which
may cause excessive wear.
ÑTighten all nuts, bolts or any other fastened assemblies after a few hours’ use.
Check often to make sure that they remain thoroughly tightened. Inspect all
pins, screws and bolts for wear or damage and make sure that all are securely
in place to avoid any possible damage or breakdown of the machine.
Avoid spilling oil on the ground. In case of spills, collect the oil and dispose
of it properly.
ÑIn case skin should come in contact with oil or grease or in case clothing
should become stained with oil, remove the stained clothes immediately and
wash the affected skin areas thoroughly. Oil and grease are harmful to the
skin.
A

Frontflex 2000
side 12
Backlash in the rings
Due to normal tolerances of the castings, washers may have been added be-
tween the bearings and the roller rings and also between the lock washer (A)
at the end of the shaft and the outermost ring (Fig. 7). To reduce and minimize
backlash, insert a washer of suitable size between the ring and the lock washer
(see page 18 ”Replacing bearings/shafts/rings”).
Fig. 7
Cleaning and maintenance
When preparing for storage at the end of the season, clean the machinery
thoroughly to prevent corrosion and facilitate future maintenance and repairs.
Check that the rings are intact and can turn freely without unnecessary play in
the bearings.
Check the linkage slide bar (nylon rail) for wear and make sure that the self-
tapping screws do not stick up above the surface.
A

Frontflex 2000
side 13
Options
Crackerboard
The Crackerboard is mounted in front of the packer roller rings and can be set
to perform tillage actions of crumbling, levelling and packing as needed. Only
the 150 and 300 cm models can be equipped with a Crackerboard.
Operation
The Crackerboard is a versatile piece of equipment, with several application
possibilities in one unit. At a depth setting of approximately 3 to 5 cm, de-
pending on the soil, the vibrating power of the tines will crush clods. A deeper
setting of the Crackerboard provides a greater levelling effect than that of a
levelling board, as a small amount of soil builds up in front of the tines.
Fig. 8
Under most conditions, best results will be achieved by setting the tines of the
Crackerboard at a 70˚ angle to the surface of the ground. The working depth
must be adjusted according to subsequent crops and the condition of the field.
The Crackerboard is not intended for use as a bulldozer blade but rather for
light tillage operations. Each tine moves and flexes individually in response to
counter pressure from land contours, resulting in a more uniform field surface
than that obtained from use of a levelling bar.
Angle and depth adjustment
The angle of the tines of the Crackerboard can be adjusted manually if neces-
sary.
The angle of the tines influences the action of the tines in the soil. If the tines
are set to work aggressively and the working depth is set in the uppermost soil
layer, the tines will produce the greatest amount of vibrations possible to
crush clods, resulting in a finely crumbled surface (Fig. 9).

Frontflex 2000
side 14
If the tines are set deeper into the soil, pressure on the soil will be created and
the tines will more easily be able to overcome obstructions (Fig. 9). This set-
ting is recommended for levelling the field. At the same time, an effect similar
to the clod crushing action of a levelling bar will be achieved.
Fig. 9
Aggressive setting Passive setting
Adjust the depth manually by using the spindles (B, fig. 10). The sides of the
spindles are marked with numbers to facilitate uniform angle adjustment.
Never set the Crackerboard too deep when first starting the machine since this
will put a greater strain on the Crackerboard than necessary.
Fig. 10
If a ridge suddenly builds up in front of the Crackerboard while the implement
is in operation, raise the lift slightly, but only until the chains (fig. 5, B) are
tight. The Frontflex will tilt as the rigidly mounted point in the front is raised.
You will still be able to achieve the same packing action after carrying out this
adjustment, as no significant weight will be removed from the Frontflex.
B

Frontflex 2000
side 15
Adjust the angle of the tines by loosening the plates (A).
Fig. 11
1. Lower the Frontflex to the ground or block it securely.
2. Loosen the bolts (B, Fig. 11). Check that the lower bolt on which the
plates rotate is loose.
3. Adjust the angle of the entire Crackerboard unit by taking hold of a
tine and either pulling or pushing the tine until the desired setting is
obtained.
4. Tighten the bolts.
Power requirements
Overall, the Crackerboard does not require much power, as soil is able to pass
freely between the tines. The greatest advantage of the Crackerboard lies in
the fact that the tines can move independently and thus flex individually in re-
sponse to counter pressure from land contours. This provides the user with
greater flexibility than a levelling board since the entire levelling unit does not
have to be disturbed because of a single obstacle.
Increasing the penetrating depth of the Crackerboard will result in greater
power consumption, as a greater amount of field material will need to be
processed.
Refitting
The Crackerboard can be mounted at the factory prior to delivery, but it can
also be delivered later if necessary. The Crackerboard is delivered fully as-
sembled and ready to be mounted on the Frontflex.
B
A

Frontflex 2000
side 16
Fig. 12
1. Mount the telescoping brackets (A) behind the front tube of the main
frame. Mount the middle telescoping piece halfway between the spac-
ing piece and the towing eye (B).
2. Attach the mounting plates (C) to the threaded spindle shafts. Fasten
the nuts. Only the two spindles on the outside adjust the depth. The
middle telescoping piece is mounted without a spindle and a different
mounting plate is used.
Crackerboard
Model Weight Number of
Tines
150 115 18
300 175 22
Maintenance
Tighten all nuts, bolts, or any other fastened assemblies after the first work-
day. It is important that the bolts on which the Crackerboard is hinged (Fig.
13, A) are properly tightened so the Crackerboard can move freely when
changing the angle. (The nuts are self-tightening). Check all nuts, bolts and
fastened assemblies regularly and tighten when necessary.
Fig. 13
A
B
A
B
C

Frontflex 2000
side 17
Lubricate the grease fittings on the spindles (B) every 6 months or as neces-
sary. There are no other points on the Crackerboard that require lubrication.
Indicator Lights
When driving on public roads, indicator lights must be mounted. All Cracker-
board models are equipped with a specially designed bracket for mounting in-
dicator lights (Fig. 15, A).
Fig. 15
The use of indicator lights requires a 7-pole female socket (farm trailer socket)
on the tractor in connection with the front lift.
A

Frontflex 2000
side 18
Repairs
ÑBefore performing any adjustments, maintenance or repairs on the machinery,
always make sure the packer roller is resting firmly on the ground.
ÑIt is strictly forbidden to allow anyone to be underneath Frontflex unless the
implement is securely blocked. Serious injury or death could result. If the
Frontflex is hitched to the tractor, it is important to set the tractor brakes.
ÑWhen changing bearings, shafts and rings, the main frame must be se-
curely blocked by a solid support. Best results can be achieved by mounting
the Frontflex in the three-point hitch of the tractor, with the Frontflex resting
securely on the ground.
Replacing bearings/shafts/rings
Due to normal tolerances of the castings, washers may have been added be-
tween the bearings and the roller rings and also between the lock washer at the
end of the shaft and the outermost ring. It depends on the new rings whether
the washers can be used again or not, as the rings must be tightly adjusted but
only to the extent that the lock washer (see Fig. 7) can be tightened as close
as possible to the shaft end. There must be no air between the lock washer and
the end of the shaft since the lock washer must press against the end of the
shaft.
If the rings are difficult to pull off the shaft, try using a high pressure cleaner
to flush out rust and soil from out between the rings and the shaft. If there is
time, place the shaft upright in a vertical position, apply a rust releasing agent
and let the shaft and rings stand overnight.
Rings can be so tight that it is necessary to cut through the shaft and then press
the ring off with a hydraulic press. This requires getting a new shaft, as the old
shaft cannot be welded together again. If only one ring is stuck, it will be more
economical to cut through it with an angle grinder and save the shaft.
Crosskill rings
1. Support the packer frame so the rings are just barely touching the ground.
2. Remove the locking bolts and the washer (A, Fig. 18) and pull the rings
located outside the bearing off the shaft.
3. Loosen the set screws in the bearings.
4. Remove the bolts fastening the bearing plates to the main frame and pull
the bearings and the bearing plates off the shaft. If the bearings are defec-
tive, remove the bearing plates and install new bearings. If the shaft needs
replacing, raise the main frame off the rings so the shaft and the rings are
free. Pull the shaft out of the rings.

Frontflex 2000
side 19
Mounting
1. Mount new rings, bearings or shaft. Make sure the shaft ends are of equal
length on each side of the rings. (After installing the bearings, measure the
protruding shaft ends to ensure that they have an equal length.).
2. Assemble in reverse order. Secure the locking bolts and the set screws
with (see also introduction to section ”Repairs”).
Fig. 18
Check the rotational direction of the roller rings. The small and large rings al-
ternate. Closest to the bearing there is a washer followed by a small ring. Re-
member the bushings underneath the large rings (see also introduction to sec-
tion ”Repairs”).
Replacing Crackerboard tine points
Replace tine points before the tines themselves become worn.
1. The Frontflex must be in a lowered position, resting securely on the
ground.
2. Remove the bolts fastening the points to the tines and mount new
points. The bolts may be used again if they are in good condition, but
changing the bolts makes replacing points easier the next time.
Replacing tines on the Crackerboard
It may be necessary to replace the tines if they become bent or broken.
1. Remove the bolt in the mounting plate (A), freeing the tine.
2. To mount a new tine, first place the plate onto the square tube, then
position the tine and insert the bolt.
Fig. 19
·Tine distance 140 mm
A

Frontflex 2000
side 20
Replacing nylon rail
1. Lift the top piece (A) by using the three-point hitch of the tractor or by us-
ing a jack until the chains (A) are tight. Support the top piece to prevent
the risk of getting pinched or crushed.
2. Remove the Taptite screws (self-tapping screws) from the nylon rail.
3. Remove the nylon rail and install a new rail.
Fig. 20
Replacing spindles on the Crackerboard
Lower the Frontflex to the ground and make sure that there is no danger of
personal injury.
1. Securely block the Crackerboard.
2. Remove the bolts (A).
3. Install a new spindle.
Fig. 21
A
A