DALBO FRONTFLEX 450 User manual

FRONTFLEX
EN
450/600
Serial no.: 108422-xxxxxx

FRONTFLEX
FRONTFLEX
Type 450/600
Congratulations on your new FRONTFLEX. For safety reasons and to ensure the optimum utilisation of the
machine, you should read this instruction manual before commissioning.
© Copyright 2009. DALBO reserves all rights.
Your FRONTFLEX is equipped with:
Type no.:
Serial no.:
Month of manufacture:
Tare weight in kg:
When enquiring about spare parts or service, always state the type- and serial number. There is a spare
parts list on the back to make it easier to keep track of the individual parts.
EU DECLARATION OF CONFORMITY
DALBO A/S
DK-7183 Randbøl
[phone]
hereby declares that the above machines have been manufactured in accordance with the provisions of
Directive 2006/42/EC, which replaces Directive 98/37/EC and the amending Directives 91/368/EEC,
93/44/EEC and 93/68/EEC on the harmonisation of the laws of the Member States relating to the design and
manufacture of machinery.
This machine complies with the safety requirements of the European safety directives.
DALBO A/S
Date:
Alessio Riulini, CEO
CE

Table of Contents
SAFETY...............................................................................................................................6
GENERAL ..........................................................................................................................6
HYDRAULICS.......................................................................................................................6
ASSEMBLY .........................................................................................................................7
MAINTENANCE AND REPAIRS.....................................................................................................7
ROAD TRANSPORT .................................................................................................................7
CORRECT USE......................................................................................................................8
TECHNICAL DATA .................................................................................................................9
HOW TO READ THE MANUAL ................................................................................................10
DELIVERY........................................................................................................................10
DESCRIPTION OF THE MACHINE...........................................................................................11
COUPLING AND UNCOUPLING..............................................................................................12
COUPLING .......................................................................................................................12
HYDRAULICS.....................................................................................................................13
UNCOUPLING ....................................................................................................................13
LIFTING THE MACHINE..........................................................................................................13
MECHANICAL TRANSPORT LOCK ...............................................................................................15
ADJUSTMENT OF THE SIDE AND CENTRE SECTIONS ..........................................................................15
HYDRAULICS.....................................................................................................................16
DRIVING AND OPERATION ...................................................................................................17
FOLDING .........................................................................................................................18
TRAVELLING SPEED .............................................................................................................18
MAINTENANCE...................................................................................................................19
LUBRICATION ....................................................................................................................19
HYDRAULICS.....................................................................................................................21
REPLACEMENT AND REPAIRS..............................................................................................22
REMOVING THE ROLLER AXLES ................................................................................................22
INSTALLATION OF THE ROLLER AXLES .........................................................................................22
REPLACING THE AXLES,BEARINGS OR ROLLER RINGS.......................................................................22
REPLACING THE NYLON RAIL...................................................................................................23
HYDRAULICS.....................................................................................................................23
REPLACING THE CYLINDER FOR FOLDING.....................................................................................24
SCRAPPING .......................................................................................................................25
WARRANTY........................................................................................................................26
HYDRAULIC CIRCUIT DIAGRAM FOR THE FRONTFLEX..............................................................27

FRONTFLEX
Page 5

FRONTFLEX
Page 6
Safety
Before starting and using the machine on the tractor, the dealer must set the hydraulic
valves for the transport lock.
The indicative setting is shown on page 26 but it may vary for each tractor.
You will find this symbol throughout these operating instructions wherever you are being
advised on your safety, the safety of other users or the functional safety of the machine.
Pay attention to all safety instructions and make these available toall users of the machine.
General
•Before starting work, the user must be familiar with all arrangements and subassem-
blies of the machine.
•Safety signage has been attached to the machine containing important instructions for
your safety and that of others, as well as for the correct use of the machine.
•There must be no passengers present during work or transport.
•When operating the FRONTFLEX, ensure that there are no people within the operating
radius of the machine. Operate the machine from inside the tractor unit only.
•Before loading the tractor unit or if adjustments, maintenance or repair work is to be
carried out on the FRONTFLEX, unfold the machine and lower it to the ground. Alterna-
tively, if it is fixed in the transport position, apply the tractor unit brakes, switch off the
engine and remove the ignition terminals so that the machine is completely secured
against accidental activation.
•The driver must not leave the driver's seat while the machine is in motion.
•Always adapt the driving speed to the driving conditions.
•Only use the machine after all safety devices have been fitted. Replace defective safety
devices immediately.
Hydraulics
•Lower the machine to the ground before carrying out repair work on the hydraulic sys-
tem. Depressurise the system, switch off the engine and remove the ignition key.

FRONTFLEX
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•Hydraulic connections must be carefully cleaned before connecting. When connecting
the hydraulic hoses to the tractor unit's hydraulic system, ensure that the hydraulic
pressure is released.
•After repair work, bleed the hydraulic system thoroughly.
•Check hydraulic hoses regularly for defects such as cracks, slits, wear and tear or break-
age. Replace defective hoses immediately.
•Avoid oil splashes and oil spillages on the ground. If this happens, clean up the
splash/spillage and dispose of it.
•Clean your hands thoroughly after the skin has come into contact with any oil or grease.
Changed any oil-soaked clothing immediately as it is harmful to the skin.
•Hydraulic oil escaping under high pressure can penetrate the skin and cause serious
injuries. Consult a doctor immediately in the event of injuries.
Assembly
•There is a risk of crushing during installation. No persons must stand between the ap-
paratus and the tractor unit or between components that are coupled together.
Maintenance and repairs
•Support the machine must well or fold the machine out for all repair and maintenance
work. Apply the tractor unit and machine brakes safely, switch off the engine and re-
move the key.
•Tighten all screw connections after the machine has been in operation for a few hours.
Check all screw connections regularly and tighten them as required. Check split pin
rings and bolts to prevent accidents.
•Dispose of any oil and grease in accordance with the applicable environmental regula-
tions.
Road transport
•When driving on public roads, all legally prescribed safety and warning devices must be
installed and approved. The driver is responsible for proper lighting and labelling in ac-
cordance with the applicable road traffic law.
•With regard to the destination of the machine, the driver must check with the transport
authorities that it may be transported on public roads.
•When transporting the machine, you must ensure that you do not exceed the maximum
weight and axle load of the tractor unit and that the load on the front axle of the tractor
unit is not less than 20% of the unladen weight of the tractor unit.

FRONTFLEX
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Correct use
•Correct use of the machine includes compliance with the manufacturer's operating-,
maintenance- and repair instructions, as well as the exclusive use of original spare
parts.
•The FRONTFLEX may only be used, maintained and repaired by people who are familiar
with the machine and who are aware of the potential hazards.
•The manufacturer is not liable for damage caused by modifications made to the ma-
chine without the manufacturer's prior authorisation. Furthermore, the manufacturer is
not liable for damage caused by improper use. The user bears sole responsibility for
this.
•No additional weight is to be attached to the FRONTFLEX.

FRONTFLEX
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Technical Data
FRONTFLEX
450
600
Working width (cm)
450
600
HP (min. recom-
mended)
50–100
50–100
Parts (sections, pcs.)
3
3
Weight in kg:
2,000
2,300
Requirements for the
hydraulics:
Double-acting
2
2
Single-acting
Unpressurised return
line
Transport:
Width (metres)
2.85
2.85
Height (metres)
2.4
3.1
Length (metres)
1.25
1.25

FRONTFLEX
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How to Read the Manual
It may be the case that the order of the elements described does not appear to be logical.
Please, therefore, refer to the Table of Contents, in which headings for the relevant topics
can be found.
The manual is divided into five main sections:
•Safety
•Commissioning and operation
•Additional equipment
•Maintenance
•Repairs
The following symbols are used in the manual for the following:

Points that are particularly important for the functionality and durability of the
machine.
Points that have an impact on safety.
Delivery
The FRONTFLEX is supplied complete on a block trailer.
If the FRONTFLEX is to be lifted, it is recommended that the straps are attached to the main
frame and the front suspension so that the machine is balanced.

FRONTFLEX
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Description of the Machine
The FRONTFLEX 450/600 is a machine that is mounted on the front lifting unit and is partic-
ularly suitable for use in combination with a seed set.
The FRONTFLEX is a roller up to 600 cm, equipped with Cross Combi Light rings.
It can be extended hydraulically and has a valve lock.
Fig. 1
The Cross Combi Light rings are ideal for
seed preparation, as they have a ‘crum-
bling’ effect on tubers and are well suited
for compacting the soil.
FRONTFLEX 600
The FRONTFLEX is designed to be pulled over the surface despite front mounting. This is only
possible if the apparatus is specially suspended, which also allows minor steering correc-
tions to be made during work without having to lift the apparatus.
The recommended driving speed depends on the conditions but speeds of 7 to 10 km/h are
recommended.

The machine has an extremely robust design to withstand high loads. However, it
is always necessary to adapt the travelling speed to the conditions, namely, to
reduce the travel speed if the area is uneven or contains a lot of large stones, for
example.

FRONTFLEX
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Coupling and Uncoupling
The front suspension is manufactured in accordance with ISO 730-1 category II/III. If the
front lift of the tractor unit is not prepared accordingly, contact your dealer. The arms of the
front lifter must not be able to move sideways.
Coupling
First of all, fit the lifting arms with the lifting pins, then, fit the top rod. Adjust the upper bar
so that the main frame is horizontal and, hence, parallel to the base. Raise the machine so
that the support legs (B) Fig. 2-3 no longer touch the ground. Then, bring the machine into
the working position.
Angle of the lifting arms
The lifting arms of the tractor unit (A), Fig. 2, with the machine lowered into the working po-
sition, preferably should have an angle that is a few degrees above the horizontal in the
direction of travel or at least equal to the horizontal. With the front lift arms pointing a few
degrees into the air, the machine can be rolled over a potential obstacle more easily, as the
tractor unit pushes the machine upwards at an angle while maintaining the steering. (It can
make steering even easier if the upper bar is shortened slightly so that the main frame
points upwards a few degrees at the front)
Always secure the pull lever with balls and a split pin ring.
Fig. 2
Fig. 3
A
B
B

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Hydraulics
The FRONTFLEX 450/600 requires a double-acting hydraulic outlet as standard
Labelling the hoses
Cylinder designation
Col-
our
Outlet
Function
Folding and lifting
into the transport
position
Red
Double-acting
Lifts the side frames up/down.
Uncoupling
Carry out uncoupling using the coupling sequence in reverse. Remember to depressurise
the cylinders before disconnecting the hydraulic hoses.
It is important to connect the FRONTFLEX with rear (A), Fig. 4 and front (B) Fig. 4 support
legs, as these prevent the machine from tipping over.
Lifting the machine
If the machine is moved other than in the
three-point suspension, it is recom-
mended that it is secured to the main
frame with straps and suspended in such
a way that it hangs in a balanced man-
ner.
Fig. 4
When uncoupling the tractor unit, you
must fold up the machine and lower it
onto a firm surface.
Then, remove the hydraulic hoses and
uncouple the machine from the tractor
unit.

Check the hydraulic hoses for possible crushing

Remember to depressurise the connection hoses of the hydraulic system before
disconnecting the hoses.
B
B
A

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Always uncouple the machine must on a level and firm surface to ensure the best
possible stability.

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Mechanical transport lock
The hydraulic models must be secured with a transport lock during transport.
This prevents the centre section and the side sections from swaying from side to side.
The transport lock must be secured with a split pin (A), Fig. 5 and a split pin ring (B), Fig. 5.
Fig. 5
Actuating the transport lock
Remove the transport lock before use on site. This is done by following the assembly se-
quence in reverse. Then, position it as shown (A) in Fig. 6.
Fig. 6
Adjustment of the side and centre sections
A
B
A

FRONTFLEX
Page 16
On the FRONTFLEX, adjust the side sections with the screws (A), Fig. 7 so that the side sec-
tions and the centre section correspond/are parallel to each other (there is an adjustment
screw on each side of the centre section).
This ensures a standardised work approach on site.
Fig. 7

It is important to ensure that the side section and centre section are horizon-
tal/parallel.
The distance between the end panels of the centre section and the side section is approx.
65 cm.
Hydraulics
Mount the pressure relief valve and the changeover valve in such a way that they exert op-
timum pressure on the sides of the centre section and do not stress the bearing.
A
Approx. 65
mm

FRONTFLEX
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Driving and Operation
The FRONTFLEX 450/600 is designed so that the centre of gravity of the apparatus is close
to the tractor unit. This reduces the load on the tractor unit and makes driving with the ma-
chine easier.
The machine is pulled across the field even though it is suspended from the front lift and,
therefore, runs easily over smaller obstacles. Fix the centre section at three points (A, B),
Fig. 8-9, whereby the traction is transmitted from the tractor unit via point (B) –the only
fixed point. This ensures that the steering characteristics of the tractor unit are maintained.
This is extremely important if the FRONTFLEX is to be integrated into a seedbed combina-
tion.
Fig. 8 Fig. 9
On arrival at the workplace, release the mechanical transport lock; see page 16, Fig. 5-6.
Then, activate the hydraulic system.
At the start of the work task, lower the FRONTFLEX and lift it into the suspended position so
that the machine and the tractor unit can work independently of each other.
The FRONTFLEX must be lifted off the ground when turning and reversing.
Before folding and unfolding, make sure that no persons are in the vicinity of the
machine.

The lifting device must be placed in the floating position so that the machine and
tractor unit can work independently of each other.
B
A
A

FRONTFLEX
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Folding
After the work task is complete, fold up the side panels.
Engage the mechanical transport lock; see page 16, Fig. 5-6. The machine may now be lifted
off the ground and is ready for transport.
Travelling speed
The recommended driving speed depends on the conditions but speeds of 7 to 10 km/h are
recommended.
When travelling with the machine in the transport position, it is important that
both the hydraulic and mechanical transport locks are activated.

FRONTFLEX
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Maintenance
Good maintenance ensures a long service life for the FRONTFLEX 450/600 and, hence, opti-
mum utilisation of the machine. Grease nipples are thus fitted at points where wear and tear
is greatest.
Lubrication
It is important to lubricate the machine at the specified intervals to prevent unnecessary
wear and tear on moving parts.
The lubrication points are shown on the following page.
A B
C D
E

FRONTFLEX
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Lubrication points
Num-
ber of
grease
nipples
Lubrica-
tion in-
terval in
hours
Illustra-
tion
Cylinder –Mounting on side panel
2
8
A
Cylinder –Mounting on the centre section
2
8
B
Roller axle –Lubrication of the roller tube
2
8
D
Bushing –Lubrication of side and centre sections
2
8
C
Bearings
6
50
E
Lubricate the bearings on the rings for every 50 hours of operation. Avoid lubricating too
frequently, as this can destroy the seals.
The front suspension slides best on the nylon rail if it is clean and oil-free.
Therefore, do not lubricate the nylon rail (A), as per Fig. 10. This will only increase wear and
tear, as well as the accumulation of dust.
Fig. 10

Lubricate all lubrication points at least once a year.
A