DALBO Levelflex 2000 User manual

Levelflex 2000
GB
150, 300 and 400 cm solid frame

DAL-BO Levelflex 2000
Thank you for purchasing a Levelflex 2000. For safety reasons and to attain optimal
use of the machine, please read the instructions before use.
Copyright© DAL-BO 1995. All rights reserved.
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 trans-
port position.
∇The driver is responsible for proper use of lights and signs in accordance with
the Road Traffic Act.
Your Levelflex 2000 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
Machine factory DAL-BO A/S
DK-7183 Randbøl
hereby, declares that the above-mentioned machine is made in accordance with the
regulations of the directive 98/37/EC, which replaces the directive 89/392/EEC and the
directives of amendment 91/3681/EEC, 93/44/EEC and 93/68/EEC about the approxi-
mation of the laws concerning safety and health demands of Member States in connec-
tion with design and manufacturing of machines.
Machine factory DAL-BO A/S Date:
Managing director Kaj Pedersen

Contents
USE IN FARMING...................................................................................................................................4
COUPLING AND UNCOUPLING.........................................................................................................5
COUPLING ...............................................................................................................................................5
The angle of the lift arms...................................................................................................................5
Hydraulics .........................................................................................................................................5
UNCOUPLING...........................................................................................................................................6
HANDLING WITHOUT USE OF THE THREE-POINT LINKAGE........................................................................6
OPERATION ............................................................................................................................................7
TRANSPORT LOCK ...................................................................................................................................7
ADJUSTMENT.........................................................................................................................................8
HYDRAULICS...........................................................................................................................................8
RUNNING .................................................................................................................................................9
OPERATING SPEED ................................................................................................................................10
SCRAPERS .............................................................................................................................................10
MAINTENANCE....................................................................................................................................11
IN GENERAL...........................................................................................................................................11
BACKLASH IN THE RINGS.......................................................................................................................12
CLEANING AND MAINTENANCE .............................................................................................................12
OPTIONAL EQUIPMENT....................................................................................................................13
CRACKERBOARD ...................................................................................................................................13
Running ...........................................................................................................................................13
Hydraulics .......................................................................................................................................13
Adjustment.......................................................................................................................................14
Efficiency.........................................................................................................................................14
Refitting ...........................................................................................................................................14
Maintenance....................................................................................................................................15
INDICATION LIGHTS...............................................................................................................................15
REPAIR...................................................................................................................................................16
REPLACEMENT OF BEARINGS/SHAFTS/RINGS .........................................................................................16
Solid model w. 80 and 90 cm rings..................................................................................................16
Solid model w. 70 cm rings..............................................................................................................17
Solid model w. Crosskillring ...........................................................................................................18
Hyd. model w. 80 cm rings..............................................................................................................18
Hyd. model w. 70 cm rings..............................................................................................................19
Hyd. model w. Crosskillring............................................................................................................19
REPLACEMENT OF THE NYLON RAIL ......................................................................................................19
REPLACEMENT OF THE CYLINDERS FOR RAISING AND LOWERING THE SIDE SECTIONS ...........................20
Replacement of the set of packings..................................................................................................20
Mounting .........................................................................................................................................21
REPLACEMENT OF THE CYLINDERS FOR THE CRACKERBOARD ...............................................................21
Replacement of the set of packings..................................................................................................22
Mounting .........................................................................................................................................23
SCRAPPING...........................................................................................................................................24

Levelflex 2000
side 4
Use in farming
Levelflex 2000 is a multi-purpose implement depending on the equipment.
when installed in the front lift, it is especially suitable to form part of a seed-
ing combination.
Levelflex 2000 is a combined soil packer or a roller depending on the equip-
ment with a hydraulic operated crackerboard, which can be delivered as op-
tional equipment. Levelflex 2000 is equipped with soil packing rings (70, 80
or 90 cm) or with roller rings (normally 53 cm Crosskill rings).
The Crosskillrings are excellent for the preparation of seed-beds as they have
a friable 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 bet-
ter 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 im-
plement.
∇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 con-
tact 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 recom-
mended to close the doors of the tractor and/or to use a dust mask.

Levelflex 2000
side 5
Coupling and uncoupling
The front hanger is manufactured in accordance with the DS/ISO 730-1 cate-
gory II. If your tractor is not suitable for this type, please contact your distrib-
utor. 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 posi-
tion 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 trac-
tor’s lift arms in an angle preferably a couple of degrees above horizontal or
at least horizontal. In this way, the machine will more easily roll over any ob-
stacles as the tractor 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 shortened, so the frame head points a few degrees up-
wards at front).
Plate 1
Hydraulics
Depending on the type of Levelflex 2000 there are different requirements for
hydraulic tapping on the tractor.
Levelflex 2000 Number of double-actin
g
h
y
draulic ta
p
p
in
g
s
Solid frame none
Solid frame w. crackeboard 1
Hyd. frame 1
Hyd. frame w. cracker-
board 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 2000
side 6
Uncoupling Uncoupling must be done in reverse order than that of coupling. Remember
to depressurise the cylinders before the hydraulic tubes are detached.
It is important that the Levelflex is secured with rear (A) and front (B) sup-
port 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.
Weight in kg
Type Cross-
killring 700 mm ring 800 mm ring 900 mm ring Crackerboard
1,5 m solid - - 900 1140 -
3 m solid 1155 950 1290 1520 165
4 m solid 1425 1135 1550 - 225
4 m hyd. 1835 1560 1850 - 290
4,5 m hyd. 1955 1650 2125 - 310
6,0 m hyd. 2450 2000 2470 - 370
B
A

Levelflex 2000
side 7
Operation
There are no specific transport position for the solid types (A), whereas the
hydraulic 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 sections 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 press-
ing the side sections in full top position. Hereby, the hook is disengaged and
the side sections 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 ra-
dius of action.
Extra weight must not be mounted on the Levelflex 2000, as the implement is
not dimensioned for that.
A
B
C

Levelflex 2000
side 8
Adjustment
On the Levelflex 2000 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 2000 solid type there are no possibilities of adjustment ex-
cept the adjustments, which must be made during regular maintenance.
Hydraulics On the hydraulic model, solid variable flow control valves for the side sec-
tions have been mounted, which gives the correct oil flow to the cylinders and
there are no further possibilities of adjustment.
A

Levelflex 2000
side 9
Running
Levelflex 2000 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 trans-
mitted 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.
Plate 6
When arriving at the working place, disengage the transport lock (hydraulic
models), so the side sections can be lowered (see plate 4). Pressure is put on
the cylinders for the side sections, so the unit is stiff. This causes a distribu-
tion 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 ma-
chine 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 surface 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 2000
side 10
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 accord-
ing to the conditions.
•70, 80 and 90 cm packer rings: 5 to 8 km/h
•Crosskillrings (48/53 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, be-
cause the rings keep themselves clean.
A

Levelflex 2000
side 11
Maintenance
A good maintenance secures a long life of the Levelflex 2000 and thereby al-
so 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.
Overgreasing 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
necessary.
∇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 2000
side 12
After parking in moist conditions over a longer period, the piston rods should
be lubricated 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 be-
tween the rings during use, it can be reduced by mounting a washer of a suita-
ble 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 col-
lecting materials. This will also ease future maintenance and repair of the ma-
chine.
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 2000
side 13
Optional equipment
Crackerboard The crackerboard is mounted in front of the packer rings and is able to make a
processing of the soil in form of a leveling and compression dependent on
how it is adjusted. 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 applica-
tions combined in one component. With a depth set approximately to 3 to 5
cm depending on the type of soil, the tines and their vibrating effect will re-
sult 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.
Plate 10
The recommended direction of running, which can be used under most condi-
tions, 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 succeed-
ing crop and the condition of the field. It is not the purpose of the cracker-
board 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 lo-
cal resistances, this moreover results 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
adjustment, 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 mi-
nor 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 2000
side 14
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 ad-
justment 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
between the tines gives the soil the possibility to pass through. Each tine is
concurrently 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 obstacle.
If the crackerboard is adjusted to a large working depth a somewhat higher ef-
ficiency 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 delivered 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
A
A B
A

Levelflex 2000
side 15
The hose carriers (B) make sure that the hose is secured and that it is not
squeezed.
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 lightsWhen 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 trai-
ler socket) connected with the front lift.
A
B
B
A
A

Levelflex 2000
side 16
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 imple-
ment is supported properly. If the packer is attached to the tractor, it is impor-
tant 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 Levelf-
lex is mounted in the tractor’s three-point linkage with the Levelflex resting
on the base. When repairing 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 lock-
ing screw of the shaft end and the outer ring. It depends on the new rings
whether the washers can be used again or not, as the rings must be firmly
fixed but only to the extent 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 posi-
tion and derusting 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 thereaf-
ter 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 pro-
truding shaft ends are of equal length on both sides.
Solid model w. 80 and 90 cm rings
1. The packer frame is supported so the rings only just lean against the base.

Levelflex 2000
side 17
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
bearings (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 bear-
ings, the protruding shaft ends, which are to be of equal length, are meas-
ured).
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 w. 70 cm rings
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 (a 70 cm ring weighs about 28 kg).
4. Put together in reverse order (see the introduction to the chapter on ‘Re-
pair’).
A
A

Levelflex 2000
side 18
Solid model w. Crosskillring
Follow the points as described in the instructions to the 70 rings.
Plate 18
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 fol-
lowed by a small ring. Remember the bushings underneath the large rings (see
also the introduction 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
linkage 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’).

Levelflex 2000
side 19
Hyd. model w. 70 cm rings
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. Re-
member that the transport lock must be in mesh. Hereafter, the same pro-
cedure as in ‘Replacement 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 sec-
tions, 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 ro-
tation. 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.
6. The bearing plates with bearings can be pulled off the shaft and new bear-
ings, 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 70 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. Thereaf-
ter, 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
bearings, shafts and rings’ for 70 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
A

Levelflex 2000
side 20
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 pos-
sibility 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 de-
pressurise the cylinder before loosening the hydraulic tubes.
Plate 22
1. Remove the tubes. (To avoid pollution of the ground during repair, it is
recommended to pick up the oil in a tray).
2. Remove split pins and rivets, so the cylinder is free.
3. Mounting of a new cylinder must be done in reverse order. Remember to
make sure that the spike is in mesh with the spike stop and secure the
spikes with the split pins.
∇4. Carefully raise and lower the side sections a few times after the mounting
in order to air the system. No persons must be in the implement’s radius
of action.
Replacement of the set of packings
Repair must be done with the Levelflex resting on the base and with the side
sections lowered. Repair can be done either with the Levelflex mounted in the
lift on the tractor or unfastened while standing on both support legs. Remem-
ber to depressurise the cylinders before loosening the hydraulic tubes.
1. Remove the tubes (to avoid pollution of the ground during repair, it is
recommended to pick up the oil in a tray).
A