DALBO FRONTFLEX User manual

FRONTFLEX
GB
150, 300 and 400 cm

DALBO FRONTFLEX
Type 150, 300 and 400 cm
Congratulations on the purchase of your new FRONTFLEX. To ensure safe operation and to
obtain optimal use of the machine, please read the rules and instructions of the following op-
erator’s manual carefully before operating the machine.
©Copyright 2000. DALBO. All rights reserved.
Your FRONTFLEX:
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
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/EC and change directives
91/368/ECC, 93/44/ECC and 93/68/ECC on harmonization 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.......................................................................................................................................................................... 5
APPLICATION ................................................................................................................................................................ 6
HITCHING AND UNHITCHING......................................................................................................................................... 7
HITCHING .......................................................................................................................................................................................7
Lift arm tilt angle ................................................................................................................................................................7
Mounting behind tractor ...................................................................................................................................................7
UNHITCHING ...................................................................................................................................................................................8
HANDLING WITHOUT USE OF THE THREE-POINT HITCH..........................................................................................................................9
ADJUSTMENTS AND SETTINGS..................................................................................................................................... 10
OPERATING AND DRIVING INSTRUCTIONS ................................................................................................................... 11
MAINTENANCE ............................................................................................................................................................ 12
BACKLASH IN THE RINGS ................................................................................................................................................................13
CLEANING AND MAINTENANCE ........................................................................................................................................................13
OPTIONS ..................................................................................................................................................................... 14
CRACKERBOARD............................................................................................................................................................................14
Operation............................................................................................................................................................................14
Angle and depth adjustment..........................................................................................................................................14
Power requirements ........................................................................................................................................................16
Refitting..............................................................................................................................................................................16
Maintenance .....................................................................................................................................................................17
INDICATOR LIGHTS.........................................................................................................................................................................17
REPAIRS...................................................................................................................................................................... 19
REPLACING BEARINGS/SHAFTS/RINGS .............................................................................................................................................19
Crosskill rings....................................................................................................................................................................19
Mounting ............................................................................................................................................................................19
REPLACING CRACKERBOARD TINE POINTS ........................................................................................................................................20
REPLACING TINES ON THE CRACKERBOARD ......................................................................................................................................20
REPLACING NYLON RAIL .................................................................................................................................................................20
REPLACING SPINDLES ON THE CRACKERBOARD ................................................................................................................................21
SCRAPPING ................................................................................................................................................................. 22

FRONTFLEX
Side 5
Safety
•Tighten all nuts, bolts or any other fastened assemblies after a few hours’ use.
•Operate the tractor and FRONTFLEX 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 compli-
ance with the present Traffic Act and Highway Code of the local traffic legisla-
tion.
•Remember to secure lift arms and top link connections with lynch pins.
•Before performing any adjustments, maintenance or repairs on the machinery,
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 hear-
ing 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


FRONTFLEX
Side 6
Application
The FRONTFLEX is a multi-purpose implement with a diverse range of applications to
accommodate various types of equipment. When mounted in the front lift, it is es-
pecially suited to form part of a combination for seedbed preparation.
FRONTFLEX is a roller of up to 400 cm, with a mechanically operated Crackerboard
up to 3 m available as optional equipment. FRONTFLEX is equipped with Crosskill
rings.
Crosskill rings are excellent for seedbed preparation, as they effectively crush clods
and achieve a good crumb structure.
FRONTFLEX is constructed to be drawn across the soil, even though it is mounted on
the front. This specially designed mounting system provides better manoeuvrability
and allows minor steering corrections during operation without having to raise the
implement.

FRONTFLEX
Side 7
Hitching and Unhitching
The FRONTFLEX is manufactured in compliance with DS/ISO 730-1 category 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 DALBO 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.

Remember 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 simulta-
neously maintained. (Steering can be made even easier if the top link is shortened,
so that the main frame points a few degrees upwards 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
Side 8
Fig. 2
Insert the bolts (A) with the FRONTFLEX resting on the ground. It is easiest to insert
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 po-
sition and the tines must be tilted in the passive setting (see page 13 ”Options”).

Remember to secure the lift arms and top link with lynch pins.
Unhitching
To unhitch, the procedure for hitching should be followed in reverse order.

It 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
Side 9
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
Side 10
Adjustments and Settings
There are no adjustments to be made on the FRONTFLEX except for any adjustments
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
Side 11
Operating and Driving Instructions
The FRONTFLEX 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 transmitted
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 posi-
tion so the implement and the tractor can function independently of one another. If
you are working in loose and friable soil and would like greater control over the ma-
chine, raise the linkage to reduce the slack in the chains. The implement will then be
hanging from the chains (almost tight) instead of resting on the main frame. If the
rings start sinking too deeply into the ground, the main frame and the packer mod-
ule will quickly begin to hang from the chains.
Initially, start with the chains loose and the linkage resting on the nylon rail, ena-
bling 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, 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
Side 12
Maintenance
Proper maintenance ensures a long lifetime for the FRONTFLEX and also optimum
performance from the implement. To facilitate maintenance, grease fittings (A)
have been mounted on those locations where wear on the equipment is the great-
est.
Fig. 6
Lubrication Points
Number of Fittings
Bearings
2
Lubricate the bearings near the rings every 50 hours of operation. Do not over lubri-
cate since this will destroy the seals.
The top piece will slide best if the nylon rail is clean and free of oil. Therefore, do not
lubricate the nylon rail. Lubricants can collect dirt and grit which may cause exces-
sive wear.

Tighten 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.

In case skin should come in contact with oil or grease or in case clothing should be-
come stained with oil, remove the stained clothes immediately and wash the affect-
ed skin areas thoroughly. Oil and grease are harmful to the skin.
A

FRONTFLEX
Side 13
Backlash in the rings
Due to normal tolerances of the castings, washers may have been added between
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 ”Replac-
ing bearings/shafts/rings”).
Fig. 7
Cleaning and maintenance
When preparing for storage at the end of the season, clean the machinery thorough-
ly 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
Side 14
Options
Crackerboard
The Crackerboard is mounted in front of the packer roller rings and can be set to per-
form 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 possibil-
ities in one unit. At a depth setting of approximately 3 to 5 cm, depending on the
soil, the vibrating power of the tines will crush clods. A deeper setting of the Crack-
erboard 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 necessary.
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, result-
ing in a finely crumbled surface (Fig. 9).
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 setting is rec-
ommended for levelling the field. At the same time, an effect similar to the clod
crushing action of a levelling bar will be achieved.

FRONTFLEX
Side 15
Fig. 9
Aggressive setting
Passive setting
Adjust the depth manually by using the spindles (B, fig. 10). The sides of the spin-
dles 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
Side 16
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 response 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 assembled and
ready to be mounted on the FRONTFLEX.
B
A

FRONTFLEX
Side 17
Fig. 12
1. Mount the telescoping brackets (A) behind the front tube of the main frame.
Mount the middle telescoping piece halfway between the spacing 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 tel-
escoping 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 workday. It is
important that the bolts on which the Crackerboard is hinged (Fig. 13, A) are proper-
ly 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
Lubricate the grease fittings on the spindles (B) every 6 months or as necessary.
There are no other points on the Crackerboard that require lubrication.
Indicator Lights
A
B
A
B
C

FRONTFLEX
Side 18
When driving on public roads, indicator lights must be mounted. All Crackerboard
models are equipped with a specially designed bracket for mounting indicator 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
Side 19
Repairs

Before performing any adjustments, maintenance or repairs on the machinery, al-
ways make sure the packer roller is resting firmly on the ground.

It is strictly forbidden to allow anyone to be underneath FRONTFLEX unless the im-
plement 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 se-
curely on the ground.
Replacing bearings/shafts/rings
Due to normal tolerances of the castings, washers may have been added between
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 defective, re-
move 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.
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.).

FRONTFLEX
Side 20
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 alternate.
Closest to the bearing there is a washer followed by a small ring. Remember the
bushings underneath the large rings (see also introduction to section ”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 posi-
tion the tine and insert the bolt.
Fig. 19
•Tine distance 140 mm
Replacing nylon rail
1. Lift the top piece (A) by using the three-point hitch of the tractor or by using 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.
A