DALBO LEVELFLEX 150 User manual

LEVELFLEX
GB
150, 260, 300 and 400 cm solid frame
400, 450 and 600 cm hydraulic frame

LEVELFLEX
Thank you for purchasing a LEVELFLEX. For safety reasons and to attain optimal use of the
machine, please read the instructions before use.
Copyright© 2008. All rights reserved DALBO A/S
Instructions that are essential to safety are marked with


Tighten all screw joints after a few hours of use.

Operate only the machine while seated in the tractor and make sure that no one is on
or in immediate proximity of the machine.

Do not let children operate the machine.

When driving on public roads the LEVELFLEX hydraulic must be placed in transport
position.

The driver is responsible for proper use of lights and signs in accordance with the
Road Traffic Act.
Your LEVELFLEX has:
Manufacturing No.:
Type:
Month of manufacture:
Net weight in kilos:
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

Contents
USE IN FARMING ........................................................................................................................................................... 5
COUPLING AND UNCOUPLING........................................................................................................................................ 6
COUPLING ............................................................................................................................................................................6
The angle of the lift arms.......................................................................................................................................... 6
Hydraulics.................................................................................................................................................................. 6
UNCOUPLING ........................................................................................................................................................................7
HANDLING WITHOUT USE OF THE THREE-POINT LINKAGE ............................................................................................................... 7
OPERATION ................................................................................................................................................................... 8
TRANSPORT LOCK ..................................................................................................................................................................8
ADJUSTMENT ................................................................................................................................................................ 9
HYDRAULICS.........................................................................................................................................................................9
RUNNING .................................................................................................................................................................... 10
OPERATING SPEED...............................................................................................................................................................11
SCRAPERS ..........................................................................................................................................................................11
MAINTENANCE ............................................................................................................................................................ 12
IN GENERAL........................................................................................................................................................................12
BACKLASH IN THE RINGS .......................................................................................................................................................13
CLEANING AND MAINTENANCE................................................................................................................................................13
OPTIONAL EQUIPMENT................................................................................................................................................ 14
CRACKERBOARD ..................................................................................................................................................................14
Running ....................................................................................................................................................................14
Hydraulics................................................................................................................................................................14
Adjustment...............................................................................................................................................................15
Efficiency .................................................................................................................................................................15
Refitting....................................................................................................................................................................15
Maintenance............................................................................................................................................................16
INDICATION LIGHTS ..............................................................................................................................................................16
REPAIR........................................................................................................................................................................ 17
REPLACEMENT OF BEARINGS/SHAFTS/RINGS............................................................................................................................17
Solid model w. 80 and 90 cm rings........................................................................................................................18
Solid model m. Crosskillring ...................................................................................................................................18
Hyd. model w. 80 cm rings .....................................................................................................................................19
Hyd. model w. Crosskillring ....................................................................................................................................20
REPLACEMENT OF THE NYLON RAIL.........................................................................................................................................20
REPLACEMENT OF THE CYLINDERS FOR RAISING AND LOWERING THE SIDE SECTIONS........................................................................20
Replacement of the set of packings .....................................................................................................................21
Mounting ..................................................................................................................................................................22
REPLACEMENT OF THE CYLINDERS FOR THE CRACKERBOARD .......................................................................................................22
Replacement of the set of packings .....................................................................................................................23
Mounting ..................................................................................................................................................................23
SCRAPPING ................................................................................................................................................................. 25
SPAREPARTS............................................................................................................................................................... 26

LEVELFLEX
Side 5
Use in farming
LEVELFLEX is a multi-purpose implement depending on the equipment. when in-
stalled in the front lift, it is especially suitable to form part of a seeding combina-
tion. LEVELFLEX is a combined soil packer or a roller depending on the equipment
with a hydraulic operated crackerboard, which can be delivered as optional equip-
ment.
LEVELFLEX is equipped with soil packing rings (80 or 90 cm) or with roller rings
(normally 53-60 cm Crosskill rings).
The Crosskillrings are excellent for the preparation of seed-beds as they have a fri-
able effect on clods, leaving a seed-bed in a good crumb structure. In heavy and
fertile soils and where driving is relatively slow (under 6 km/h), it is recommended
to use the soil packer rings, because they will provide a better packing in depth.
LEVELFLEX is built so it is drawn across the subsoil, although it is front-mounted.
This is only possible, because the implement is specially mounted, which allows for
steering corrections during operation without raising the implement.

Do not use LEVELFLEX as a container, pile driver, hydraulic press or the like. If you
have any questions concerning the use of the implement, feel free to contact your
Dalbo distributor.

During operation in stony soil and with worn drum rings, noise might occur. Use a
hearing protector if necessary.

During operation in dry conditions dust generation might occur. It is recommended
to close the doors of the tractor and/or to use a dust mask.

LEVELFLEX
Side 6
Coupling and uncoupling
The front hanger is manufactured in accordance with the DS/ISO 730-1 category II.
If your tractor is not suitable for this type, please contact your distributor. The
arms of the front lift must be able to move sideways.
Coupling
First install the arms of the lift with the lift taps and hereafter install the top link.
The top link must be adjusted so the frame head is in a horizontal position and
thus, parallel with the base. Raise the implement, so the support legs are clear of
the ground and then place it in an operating position.
The angle of the lift arms
With the machine placed in a position of operation, aim at placing the tractor’s lift
arms in an angle preferably a couple of degrees above horizontal or at least hori-
zontal. In this way, the machine will more easily roll over any obstacles as the trac-
tor presses the implement tilted upwards and the steering will simultaneously be
maintained. (Steering can additionally be made easier if the top link is a bit short-
ened, so the frame head points a few degrees upwards at front).
Plate 1
Hydraulics
Depending on the type of LEVELFLEX 2000 there are different requirements for hy-
draulic tapping on the tractor.
LEVELFLEX
Number of double-acting hydraulic tappings
Solid frame
none
Solid frame w. crackeboard
1
Hyd. frame
1
Hyd. frame w. crackerboard
2
The hydraulic tubes are attached to a 1/2" female coupling, which is joined with
the front lift.

Remember to secure the lift arms and the top link joints with cotter pins.
A

LEVELFLEX
Side 7
Uncoupling
Uncoupling must be done in reverse order than that of coupling. Remember to de-
pressurise the cylinders before the hydraulic tubes are detached.
It is important that the LEVELFLEX is secured with rear (A) and front (B) support
legs, as this will prevent the machine from tipping over.
Plate. 2
Handling without use of the three-point linkage
If you need to move the LEVELFLEX in other ways than by use of the three-point
linkage, we recommend you to hook up the machine with slings in the frame head
or in the linkage, so the LEVELFLEX hangs in a state of balance.
(Look at plate. 2-C)
Weight in kg
Type
Crosskill
ring
800 mm
ring
900 mm
ring
Crackerboard
1,5 m solid
-
900
1140
-
1,5 m solid*
-
920
1160
250
3 m solid
1110/1445
1290
1520
175
3 m solid **
-
1290
-
175
4 m solid
1425
1550
-
200
4 m solid **
-
1575
-
200
4 m hyd.
1835
1850
-
250
4 m hydr. **
-
2125
-
250
4,5 m hyd.
1955
2125
-
275
6,0 m hyd.
2450
2470
-
380
*1,5 m solid model prepare for 4 m cracker board
**solid model whit 80/90/80 rings
B
A
C
C
C

LEVELFLEX
Side 8
Operation
There are no specific transport position for the solid types (A), whereas the hydrau-
lic types (B) must be secured with a lock during transport.
Plate 3
A
B
Transport lock

On the hydraulic types, where the side sections can be raised, the sections must
be secured during transport which will be done automatically when the side sec-
tions are raised to top position. The driver of the tractor must make sure that the
hook (plate 4) is in mesh and hereby keep the side sections in transport position.
Disengagement of the transport lock
Before the transport lock is disengaged, the loop (A) on the wire must be hooked
onto the ratchet (B).
Plate 4
Disengagement of the transport lock can be done safely from the tractor cab by
depressing the hydraulic actuating handle to the side sections and by pressing the
side sections in full top position. Hereby, the hook is disengaged and the side sec-
tions can be lowered. Simultaneously with the lowering of the side sections, the
loop (A) slips off the ratchet (B) and the hook (C) will again be ready for locking the
side sections in transport position.

When opening the side sections, no persons must be in the implement’s radius of
action.
Extra weight must not be mounted on the LEVELFLEX, as the implement is not di-
mensioned for that.
A
B
C

LEVELFLEX
Side 9
Adjustment
On the LEVELFLEX 2009 hydraulic type (plate 3,b), the side section must be ad-
justed with the bolts (A), so the frames on the side sections and the frame head
hang on a line (there is an adjustment bolt in each side of the frame head).
Plate 5
On the LEVELFLEX solid type there are no possibilities of adjustment except the ad-
justments, which must be made during regular maintenance.
Hydraulics
On the hydraulic model, solid variable flow control valves for the side sections have
been mounted, which gives the correct oil flow to the cylinders and there are no
further possibilities of adjustment.
A

LEVELFLEX
Side 10
Running
LEVELFLEX is constructed so that the implement’s centre of gravity is placed close
to the tractor. The result is that the implement’s weight on the tractor is reduced
and at the same time the implement will be easier to run.
The implement is drawn across the field, although it is mounted in the front lift,
which makes it easier to run over smaller hindrances. The frame head (A) is
mounted in three points (B,C) where the pulling from the tractor is transmitted
through point (B), which is the only point that is mounted rigidly. This means that
the steering properties are maintained which must be given a high priority if the
LEVELFLEX is to be part of a seed-bed combination.
Fig. 6
When arriving at the working place, disengage the transport lock (hydraulic mod-
els), so the side sections can be lowered (see plate 4). Pressure is put on the cyl-
inders for the side sections, so the unit is stiff. This causes a distribution of weight
on to all the rings and leaves a plane surface.
As the job begins, lower the LEVELFLEX and place the lift in a floating position so
the implement and the tractor can function independently of each other. If you are
working in very friable soil and want a larger control over the machine then the
linkage can be raised, so it does not rest on the frame head, but hangs from almost
tight chains. If the rings start sinking too deep into the ground, the frame head with
the packer module will quickly begin to hang from the chains.
As a point of departure it is recommended that the chains are loose and that the
linkage rests on the nylon rail. Thereby the packer module can move after the sur-
face of the ground.

Raise the LEVELFLEX when turning and driving backwards.

When using the double-acting front lift, weight must not be transmitted from the
tractor to the LEVELFLEX.
B
C
C
A

LEVELFLEX
Side 11
Operating Speed
The recommended operating speed depends on the packer rings, where the
Crosskillrings stand the maximum speed. To make the best possible use of the soil
packer rings, use them for intractable clayey soil or on newly ploughed soil, which
is not packed. Moreover, it must be recommended to drive according to the condi-
tions.
•80 and 90 cm packer rings: 5 to 8 km/h
•Crosskillrings (53/60 cm): 7 to 10 km/h
Scrapers
To secure cleaning of the rings, firm scrapers (A) are attached between each ring,
which is specially made of spring steel.
Plate 7
However, scrapers are not attached on the LEVELFLEX with Crosskillrings, because
the rings keep themselves clean.
A

LEVELFLEX
Side 12
Maintenance
A good maintenance secures a long life of the LEVELFLEX 2000 and thereby also a
full benefit of the machine. Therefore, lubricator nipples (A) have been placed on
the spots where hard wear takes place.
Plate 8
Grease points (amount of nipples)
A
B
C
Solid model
2
x
x
Hydraulic model
6
2
4
The ball bearings near the rings are to be lubricated every 50th working hour. Over-
greasing must be avoided, since it might destroy the sealings.
Tighten up all the screw joints after the first day of work. Split pins and screw bolts
must be checked up on to avoid damage on the machine.
In general
If the nylon rail is clean and free of oil, a smooth slide of the top piece can be
achieved. Therefore, the nylon rail must not be lubricated, as it would only increase
the wear and collect dust (see plate 21).

All screw joints must be checked frequently and tightened up whenever it is neces-
sary.

Damaged hydraulic tubes must be replaced immediately. Leaks on tubes might
cause personal injury or damage on the machine.

Clean your hands thoroughly if your skin has had contact with oil and grease.
Change oil soaked clothing immediately, because it has a harmful effect on the
skin.
Avoid spillage of oil on the ground. Nevertheless, if spillage should happen it must
be picked up and sent to destruction.
A
B
C

LEVELFLEX
Side 13
After parking in moist conditions over a longer period, the piston rods should be lu-
bricated in oil to avoid rusting.
Backlash in the rings
In some cases due to normal tolerances of the castings washers might be placed
between the bearings and the rings and also between the lock washer (A) of the
shaft end and the outer ring. If unacceptable backlash occurs between the rings
during use, it can be reduced by mounting a washer of a suitable size to minimize
the backlash (see ‘Replacement of rings/bearings’).
Plate 9
Cleaning and maintenance
When the season is over, the machine should be cleaned of soil and moist collect-
ing materials. This will also ease future maintenance and repair of the machine.
Check that the rings easily turn and are intact coincident with no unnecessary
backlash in the bearings.
Check the wear of the linkage’s slide bar (nylon rail) and make sure that the Taptite
screws (self-tapping screws) do not stick out on the surface.
A

LEVELFLEX
Side 14
Optional equipment
Crackerboard
The crackerboard is mounted in front of the packer rings and is able to make a pro-
cessing of the soil in form of a leveling and compression dependent on how it is ad-
justed. The crackerboard makes an excellent processing both for rough plowing as
well as after a preceding cultivation of the soil, as the crackerboard both levels and
crushes clods.
Running
The crackerboard is a very flexible component with several possible applications
combined in one component. With a depth set approximately to 3 to 5 cm depend-
ing on the type of soil, the tines and their vibrating effect will result in a crushing of
the clods. If the crackerboard is set deeper, it will result in a larger leveling effect
as a small pile will be accumulated in front of the tines.
Fig. 10
The recommended direction of running, which can be used under most conditions,
is to adjust the crackerboard so that the tines’ angle with the surface of the ground
is at approx. 70. Working depth must be adjusted to the succeeding crop and the
condition of the field. It is not the purpose of the crackerboard to function as a
blade, but on the contrary to make a light cultivation of the soil. As each tine is able
to move individually and hereby give way to local resistances, this moreover re-
sults in a more regularly seed-bed than what can be obtained with a leveling plank.
Hydraulics
Hydraulic operation of the crackerboard’s depth regulation secures an easy ad-
justment, so that running with the optimal depth always can be achieved. Hereby,
variations in the condition of the soil within the same field are of minor importance,
as it can be secured that the crackerboard continuously during running, works with
the preferred amount of soil.
A double-acting extraction point for operation of the crackerboard is required.

LEVELFLEX
Side 15
Adjustment
The angle of the tines can be adjusted manually by use of spindles (A) plate 11.
The set angle will be retained independent of the depth as the tines are mounted in
a parallelogram.
Plate 11
Passively adjusted tine
Aggressively adjusted tine
The angle of the tine is important for whichever work one wants to have done. If the
tine is aggressively adjusted simultaneously with a working depth in the topsoil, it
will produce as many vibrations as possible for comminution of clods (plate 11).
If the tine is further lowered it will result in a compression of the soil and the tine
will also more easily be able to avoid any hindrances (plate11). This adjustment is
recommended if a leveling of the field is preferred. At the same time an effect will
be obtained, which is similar to the leveling plank with its crushing of the clods.
Efficiency
All in all the crackerboard does not require much efficiency, as the distance be-
tween the tines gives the soil the possibility to pass through. Each tine is concur-
rently able to move individually and hereby yield to local resistances. Hereby, a
great strength is in the crackerboard’s flexibility in opposition to a leveling plank,
as the entire leveling organ does not have to disconnect just because of an obsta-
cle.
If the crackerboard is adjusted to a large working depth a somewhat higher effi-
ciency is required as a larger load of material is processed.
Refitting
The crackerboard can be mounted from the factory, but if needed it can also be de-
livered later. The hose straps (A) and the hose carriers (B) are welded on where the
hydraulic tubes of the crackerboard are to be led through.
Plate 12
The hose carriers (B) make sure that the hose is secured and that it is not
squeezed.
A
A
B
A

LEVELFLEX
Side 16
Plate 13
Stiff type
Hyd. type
Maintenance
Tighten up all screw joints after the first working day. It is important that the bolts
which the crackerboard is hinged around (A) plate 14 as well as the maintaining
hinges are adequately tightened, so the crackerboard can move freely (self-
tightening screw nuts are used). All screw joints must be checked regularly and
tightened according to necessity.
Plate 14
Indication lights
When driving on public roads, indication lights must be mounted. All models have a
particular constructed attachment for mounting of indication lights.
Plate 15
Although this requires that the tractor has a 7-pole female socket (a farm trailer
socket) connected with the front lift.
A
B
B
A
A

LEVELFLEX
Side 17
REPAIR

All repair and maintenance of the LEVELFLEX must be carried out while the packer
is securely placed on the ground and thus rests safely on the base.

It is extremely dangerous to stay underneath the LEVELFLEX before the implement
is supported properly. If the packer is attached to the tractor, it is important that
the tractor is braked properly.

When changing the bearings, shafts and rings, the frame head must be supported
by a solid support. However, it is recommended that the LEVELFLEX is mounted in
the tractor’s three-point linkage with the LEVELFLEX resting on the base. When re-
pairing the side sections (hydraulic models), the sections must be lowered and
rest on the base.
Replacement of bearings/shafts/rings
The procedure for replacing bearings and shafts depends on the model and the
type of ring. Due to normal tolerances on the casting, washers might in some cases
be placed between the bearings and the rings and also between the locking screw
of the shaft end and the outer ring. It depends on the new rings whether the wash-
ers can be used again or not, as the rings must be firmly fixed but only to the ex-
tent that the lock washer (plate 9) can be tightened as close as possible to the
shaft end. There must be no air between the lock washer and the shaft end since
the lock washer must press against the shaft end.
If the rings are difficult to pull off the shaft, try using a high pressure cleaner to
wash between the ring and shaft in order to remove fixed rust and soil. If the repair
is not an urgent matter, the shaft can be placed in an upright position and derust-
ing liquid can be applied, where after the shaft with the rings are left through the
night.
A ring can be so tight that it is necessary to cut through the shaft and thereafter
the ring can be pulled off in a hydraulic press. This requires a new shaft, as the old
shaft cannot be welded together again. If there is only one solid ring, then it will be
more economical to cut it through with an angle grinder and thereby spare the
shaft.
When the bearings are mounted on the shaft, it is important that the protruding
shaft ends are of equal length on both sides.

LEVELFLEX
Side 18
Solid model w. 80 and 90 cm rings
1. The packer frame is supported so the rings only just lean against the base.
Plate 16
2. Remove the locking bolts and the washer (A) so the rings outside the bearings
can be pulled off the shaft.
3. Loosen the pointed screws in the bearings and remove the bolts in the bear-
ings (two in each).
4. Pull the bearings off the shaft. If the shaft is to be replaced, then lift the frame
head off the rings so the shaft with the rings are free and now the shaft can be
pulled out of the rings (a 80 cm ring weighs about 45 kg).
5. New rings, bearings or shaft can be mounted. Notice that the shaft ends must
be of equal length on each side of the rings (after mounting the bearings, the
protruding shaft ends, which are to be of equal length, are measured).
6. Put together in reverse order. The locking bolts and the pointed screws must be
secured with Locktite (see also the introduction to the chapter on ‘Repair’).
Solid model m. Crosskillring
1. Follow point 1 and 2 as described in the instructions to the 80 and 90 rings.
Plate 17
2. Remove the bolts in the bearing plates (A).
3. Unscrew the pointed screws in the bearings and the bearing plates can be
pulled off the shaft. Then the bearings can be replaced individually on the
bearing plates
4. Put together in reverse order (see the introduction to the chapter on ‘Repair’).
A
A

LEVELFLEX
Side 19
Notice the rotational direction of the drum rings. Alternation occurs between the
small and the large rings, where a washer closest to the bearings is followed by a
small ring. Remember the bushings underneath the large rings (see also the intro-
duction to the chapter on ‘Repair’).
Hyd. model w. 80 cm rings
Plate 19
1. Remove the bolts in the bearings, where after the frame head and the side
section can be lifted off the rings and the shaft by use of the three-point link-
age or a crane.
2. Remove the locking bolts and the lock washer, and then the rings outside the
bearings can be pulled off the shaft.
3. Unscrew the pointed screw in the bearings so the bearings can be pulled off
the shaft.
4. Put together in reverse order. The locking bolts and the pointed screws must
be secured with Locktite (see also the introduction to the chapter on ‘Repair’).
If it is only the middle section in which the bearings, the shaft or the rings are to be
replaced, then it is done with the side sections in upright position. Remember that
the transport lock must be in mesh. Hereafter, the same procedure as in ‘Replace-
ment of bearings on the solid model’ with 70 rings is adopted. In order to replace
the bearings, the shaft or the rings on the side sections, the side sections must be
removed.
1. Remove the hose carriers of the linkage for the crackerboard, so the tubes can
be disengaged.
2. Remove split pins and spikes on the cylinder heads for the side sections.
3. Remove the locking bolts and the shaft for the side section’s centre of rota-
tion. Remember that the side sections must rest on the base. Use a crane or
front loader to disengage the side sections from the frame head. Mount the
slings so the section hangs in balance. Let the side section only just rest on
the base with the rings, but still hanging in the slings.
4. Remove the locking bolts and the inmost ring can be pulled off the shaft.
5. The pointed screws of the bearings can now be unscrewed and the bolts of the
bearing plates can be removed.

LEVELFLEX
Side 20
6. The bearing plates with bearings can be pulled off the shaft and new bearings,
shaft or rings can be mounted.
7. Put together in reverse order. The locking bolts and the pointed screws must
be secured with Locktite.
8. Mount the cylinder spikes of the side sections in the correct direction, which
means that the rivet head should be in mesh with the rivet stop. Remember
the split pins.
9. Check the hydraulic tubes for squeezing.
Hyd. model w. Crosskillring
1. Follow the instructions in points 1 to 3 as in ‘Replacement of bearings, shafts
and rings’ to 80 cm rings.
2. Loosen the bolts in the bearings of the bearing plates and remove them. In this
way the shaft can be rolled away from the bearing plates. Thereafter, loosen
the pointed screws in the bearings and the bearings can be pulled off the
shaft.
3. Hereafter, follow the instructions in points 8 to 9 as in ‘Replacement of bear-
ings, shafts and rings’ for 80 cm rings. Notice the rotational direction of the
rings. Alternation occurs between small and large rings, where a large ring is
placed innermost to the side section with a Ø300 washer (A) uttermost to the
bearing. Remember the bushings underneath the large rings.
Plate 20
Replacement of the nylon rail
1. Lift the top piece by using the tractor’s three-point linkage or by using a jack
until the chains (A) are tight. Support the top piece to avoid the possibility of
squeezing.
2. Remove the self-tapping screws in the nylon rail.
3. Remove the nylon rail and mount a new rail in reverse order.
Plate 21
Replacement of the cylinders for raising and lowering the side sections
Repair must be done with the LEVELFLEX lowered and with the side sections in a
downward position, so the implement rests on the ground. Remember to depres-
surise the cylinder before loosening the hydraulic tubes.
A
A