DALBO MEGAROLL 2130 User manual

MEGAROLL
EN
2130 and 2430
Series no.: 100000-XXXXXX

2

MEGAROLL
1
MEGAROLL
Type 2130 and 2430 cm
Congratulations on your new MEGAROLL. For safety reasons and to achieve the best possible use
out of your machine, you should read through these user instructions carefully before using the
machine.
©Copyright 2010. All rights reserved DALBO A/S.
Your MEGAROLL information:
Type no.:
Serial no.:
Month of manufacture:
Tare weight in kg:
When enquiring about spare parts or servicing, we kindly ask that you always provide us with the
type number and serial number. At the back of this manual you will find a list of spare parts, which
will help give you an overview of the individual parts.
EU DECLARATION OF CONFORMITY
DALBO A/S
DK-7183 Randbøl
[phone]
Hereby declares that the aforementioned machine is manufactured in accordance with the stipulations
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 a mutual approach for member state legislation on machinery for health
and safety requirements in connection with the construction and manufacture of machinery.
This machine complies with the safety requirements of the European safety guidelines.
DALBO A/S
Date:
Carsten Jensen, CEO
CE

MEGAROLL
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Table of Contents
Safety.............................................................................................................................................................................. 4
General........................................................................................................................................................................ 4
Hydraulics ..................................................................................................................................................................5
Installation................................................................................................................................................................. 5
Maintenance and repair ............................................................................................................................................ 5
Driving on roads ......................................................................................................................................................... 6
Correct use ................................................................................................................................................................. 6
Technical Data................................................................................................................................................................ 7
How to Read this Instruction Manual ........................................................................................................................... 8
Delivery....................................................................................................................................................................... 8
Use................................................................................................................................................................................... 9
Connecting and Disconnecting...................................................................................................................................10
Connecting ...............................................................................................................................................................10
Hydraulics ................................................................................................................................................................10
Hose markings.....................................................................................................................................................11
Disconnecting ..........................................................................................................................................................11
Settings.........................................................................................................................................................................12
Towing height adjustment ......................................................................................................................................12
Adjustment of the central section..........................................................................................................................13
Driving and Operating..................................................................................................................................................14
Unfolding and folding ..............................................................................................................................................14
Unfolding ..............................................................................................................................................................14
Folding ..................................................................................................................................................................16
Adjustment of the hydraulic suspension of the pendle frames ..........................................................................18
Too much pressure ..............................................................................................................................................18
Too little pressure................................................................................................................................................18
Adjustment of the hydraulic weight transfer ........................................................................................................19
Too much pressure ..............................................................................................................................................19
Too little pressure................................................................................................................................................19
Driving speed............................................................................................................................................................20
Troubleshooting ...........................................................................................................................................................21
Maintenance.................................................................................................................................................................22
Lubrication ...............................................................................................................................................................22
Adjustments.............................................................................................................................................................25
Adjustment of the rings.......................................................................................................................................25
Wheels ..................................................................................................................................................................26

MEGAROLL
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Hydraulics ................................................................................................................................................................26
Replacements and Repairs.........................................................................................................................................27
Hydraulics ................................................................................................................................................................27
Replacement of cylinders...................................................................................................................................27
Replacement of the gaskets...............................................................................................................................29
Uninstalling/installing of wheels ...........................................................................................................................30
Replacing the bearings .......................................................................................................................................30
Dismantling the roller shafts..................................................................................................................................31
Replacement of the shafts on the three outermost side sections on either side .........................................31
Replacement of shafts on the three middle sections ......................................................................................31
Replacement of shaft, bearing or roller rings .......................................................................................................31
Three outermost side sections on either side ..................................................................................................31
Three middle sections.........................................................................................................................................32
Disposal ........................................................................................................................................................................33
Hydraulics Diagram .....................................................................................................................................................34
Spare Parts ...................................................................................................................................................................35

MEGAROLL
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Safety
This symbol is used throughout the instruction manual each time advice is given
concerning your safety, the safety of other users or the safe use of the machine. All
safety instructions must be observed and made available to all users of the
machine.
This symbol is used throughout the instruction manual when there are points
that are especially important for the functionality as well as the lifetime of the
machine.
These symbols indicate that protective equipment is required
during the operation, maintenance and repairs of the machine.
- Different types of gloves may be required to be used, depending on task.
- Approved safety footwear must be worn at all times, when working at and around the machine.
General
- Before commencing work, the user must be familiar with all parts of the machine.
- Safety markings have been placed on the machine, which contain important instructions
about your own and the safety of others and the correct use of the machine.
- There must be no passengers on the machine, when in use or while being transported.
- When operating the MEGAROLL, ensure that there is no one within the machine’s operating
radius. The machine may only be operated from inside the tractor.
- When the MEGAROLL is folded up, ensure that the side sections are in the transport locks.
Likewise, secure the control levers to prevent accidental operation.
- Before leaving the tractor, performing any adjustments, or carrying out any maintenance or
repairs to the MEGAROLL, unfold the machine and lower it to the ground, or, secure it in transport
mode, activate the tractor's parking break, turn off the engine and remove the ignition key so that
the machine is secured against accidental starting.
- Remember to secure the supporting legs with the hydraulic ball valve as well as the bolts with
linchpins.
- Never leave the driver’s seat while the machine is operating.
- The driving speed must always be adjusted according to the prevailing conditions.
- Only use the machine if all safety devices have been installed. Defective
safety devices must be replaced immediately.
- All work with and around the machine must be performed wearing approved safety footwear.
- Any work involving the use of oil and grease must be performed wearing gloves approved for the
specific task.

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Hydraulics
- Prior to any repair work on the hydraulics unit, the machine must be lowered to the ground, the
pressure must be removed from the unit, the engine must be switched off and the ignition key
must be removed.
- Hydraulic connections must be cleaned thoroughly before connecting. When connecting
the hydraulic hoses to the tractor’s hydraulic system, ensure that the pressure has been
removed from the hydraulic system.
- After repairs on the hydraulic system have been completed, all air must be completely removed from
the system.
- Check the hydraulic hoses regularly for defects such as tears, cracks, wear or damage.
Defective hoses must be replaced immediately.
- Avoid spilling oil on the ground. If this happens, it should be collected and sent for proper disposal.
- During repairs on the hydraulic system, where there is a risk of coming into contact with oil or
grease. Suitably-approved gloves should be worn in order to reduce any potential allergic reaction
to the hydraulic oil.
- If oil or grease comes into contact with the skin, the affected area should be cleaned
thoroughly. Oil-soaked clothing should be changed immediately, as such contact can be
harmful to the skin.
- Hydraulic oil that gushes out under high pressure can penetrate through the skin and cause
serious injuries. Seek professional medical assistance immediately in the event of any injury,
as oil entering the blood stream may lead to a serious case of blood poisoning.
Installation
- There is a risk of crushing when carrying out installation. Anyone present must not be positioned
between the machinery and the tractor or between the parts that are being connected.
- All bolts must be secured with linchpins, or by other means of securing, before further work can be
performed.
Maintenance and repair
- When undertaking any repair or maintenance work, the machine must be properly supported and
unfolded, resting on the ground, the tractor and machine must have their brakes properly
activated, the engine must be turned off and the ignition key removed.
- Tighten all screw fittings after a few hours of use. All screw fittings must be checked at regular
intervals and tightened when necessary. Check cotter pins and bolts to avoid mechanical failure.
- Oil, grease and other material or objects that have been contaminated with oil should be
disposed of in accordance with the applicable environmental legislation.

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Driving on roads
- When driving on public roads, all safety arrangements and warnings required by law must be
installed and tested. The driver is responsible for the correct use of lights and compliance with
traffic signs in accordance with the relevant country’s applicable traffic laws.
- With regards to the dimensions of the machinery, the driver must enquire with the relevant
traffic authorities to ensure that the MEGAROLL may be transported on public roads.
- When transporting the machine, care must be taken not to exceed the total weight and axle load
of the tractor and that the load on the front axle is not less than 20 per cent of the complete road
train’s total weight. If such is the case, then a ballast weight at the front of the tractor must be
used.
Correct use
- Correct use of the machine also includes compliance with the manufacturer’s operating,
maintenance and repair instructions, as well as the exclusive use of original spare parts.
- The MEGAROLL may only be used, maintained and repaired by those who are familiar with
the machine and who are aware of the dangers that can arise.
- The manufacturer is not liable for damage resulting from changes to the machine carried out
without the manufacturer’s prior permission. Furthermore, the manufacturer is not liable for any
damage resulting from incorrect use. Responsibility for this rests solely with the user.
- No extra weight may be installed on the MEGAROLL.

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Technical Data
MEGAROLL
Size (cm)
2130
2430
HP (recommended)
Min. 250–350
Min. 300–400
Gross weight in kg:
Cambridge Snowflake
20750
21690
Sections (pieces)
9
9
Hydraulic requirements:
3 DV
X
X
Extra equipment
Air brakes
X
X
It is possible for a smaller tractor to pull the roller, if it is able to make firm contact with the ground and
complies with the weight requirements for the steering wheels.
Wheels
- All models are equipped with: 600/50 x 22.5 wheels
Oil consumption
The table below indicates how much oil flows back to the tractor when the MEGAROLL is unfolded.
Model
Oil in litres
2130 / 2430
51

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How to Read this Instruction Manual
It is possible that the order in which the topics are listed may not appear as logical. Please refer to the table
of contents, where the headings for the relevant topics can be found.
The main points contained in this instruction manual are divided into 13 key sections:
- Safety
- Technical Data
- How to Read this Instruction Manual
- Use
- Connecting and Disconnecting
- Settings
- Driving and Operating
- Troubleshooting
- Maintenance
- Replacements and Repairs
- Disposal
- Hydraulics Diagram
- Spare parts
The following symbols are used throughout this instruction manual for:
This symbol is used throughout the instruction manual each time advice is given
concerning your safety, the safety of other users or the safe use of the machine. All
safety instructions must be observed and made available to all users of the machine.
This symbol is used throughout the instruction manual when there are points that are
especially important for the functionality as well as the lifetime of the machine.
These symbols indicate that protective equipment is required during the
operation, maintenance and repairs of the machine.
Delivery
The MEGAROLL is delivered completely assembled via platform truck.
If the MEGAROLL needs to be lifted, the use of straps on the middle section and the tow bar is
recommended, so that the machine is balanced.

MEGAROLL
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Use
The MEGAROLL is a heavy roller, specifically designed to follow the surface of the ground, in the best
possible way, across the entire working width.
Fig. 1
The MEGAROLL is a nine-piece roller, whereby the
sections move independently of each other. The
machine is equipped with hydraulic weight
distribution, which ensures even distribution across
all the sections, even over slightly uneven terrain.
As a roller, the MEGAROLL is used after sowing to improve sprouting and to push down stones. In addition,
the MEGAROLL can be used to break up a compacted surface both in fields of grain and grass.

MEGAROLL
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Connecting and Disconnecting
Connecting
Fig. 2
1. The MEGAROLL is connected to the tractor’s
fixed drawbar, whereby the towing eye (A) must
be between the drawbar’s forks.
2. The tow bar pin must be inserted and secured
with a linchpin
3. The support leg must be raised by activating
button 1 (B) and activating the hydraulic hose
marked with white
Remember to secure the pin with linchpins or similar.
Hydraulics
By default, the MEGAROLL requires three double-acting hydraulic outlets, an air outlet for the air
brakes, and a 3-pole power outlet.
The machine is equipped with electronic controls, making it possible to use the same hydraulic
outlet for several things (hydraulic hose marked in white).
To utilise the electronic control, it must be connected to the power and then the relevant toggle switch
(A) for the operation desired should be activated so that the relevant LED (B) is on. Only one switch must
be activated at one time. This hydraulic outlet is also used to pressurise the inner stone protectors by
opening the ball valve (C) and not activating any switches.
Fig. 3
The switches control the following:
None: Stone protector 5 innermost sections.
•(No switches activated).
1. Hydraulic support leg.
2. Tilt cylinders on the main frame.
3. The raising and lowering of the middle roller.
4. Folding the outermost side sections in and out.
A
B
B
A
C

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Hose markings
Cylinder name
Colour
Outlet
Function
El. control box, no switches
activated - Hydraulic stone
protector 5 innermost
sections
White
none
Single-acting
Together with the accumulator, they are
to dampen the pendle frames in order to
prevent impact and breakage to the
frames.
El. control box switch 1 -
Hydraulic support leg
White 1
Double-acting
Raising/lowering of the tow bar on the
roller upon connection.
El. control box switch 2 - Tilt
cylinder
White 2
Double-acting
Tilts the middle frame to and from the
working position
El. control box switch 3 -
Middle roller section
White 3
Double-acting
Raising and lowering of the middle roller
section
El. control box switch 4 -
Outside sections
White 4
Double-acting
Folding the outside sections in/out
Folding/ weight distribution
of the innermost side
frames
Red
Double-acting
Folding the innermost side sections in/out
to transfer the weight from the mid-
section to the innermost side sections.
Weight distribution of
outermost side frames
Yellow
Double-acting
Acting as weight distribution from the
middle section to the outermost side
sections.
Flow position for the outlets is required for the folding/weight distribution, marked with
red and yellow.
Ensure the hydraulic hoses have not been crushed.
It is EXTREMELY IMPORTANT that the hydraulic outlets for the hydraulic weight
distribution for the innermost and outermost side sections are set to the flow position
during work in fields (hoses marked with yellow and red)
Disconnecting
Lower the support leg, remove the tow bar pin and disconnect the hydraulic hoses.
Remember to release the pressure from the connecting hoses to the hydraulic system
before disconnecting the hoses.
The MEGAROLL can either be in transport mode or unfolded in the working position
when disconnected.

MEGAROLL
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Settings
The MEGAROLL is factory-set upon delivery, but fine tuning will always be necessary before usage.
Different adjustment options make your MEGAROLL more versatile and allow for optimal use of the
machine.
Towing height adjustment
Fig. 4
In order to achieve a unified compression of the field, the main frame/tow bar and the middle section
must be horizontal to the surface in the working position. Individual setting from tractor to tractor may be
necessary.
It is important to check the towing height each time a new tractor is hooked up to the
roller.
Fig. 5
To achieve an optimal towing height, it is possible to
adjust the tow bar up or down, so that the towing eye
is placed correctly for your specific tractor.
One must pay attention to the tractor's wheel spring
compression when mounting/dismounting the
machine or when readjusting the height of the draw
bar.
With the MEGAROLL resting on the support leg, the
bolts (A) should be loosened and the tow bar should
be adjusted to suit your tractor.
An incorrect towing height will result in an uneven compression of the field, as the
roller will not put equal pressure on all sections.
A

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Adjustment of the central section
Fig. 6
With the MEGAROLL unfolded on an even surface (see "Driving and operating"), you must check that the
middle frame (A) is horizontally aligned with the tow bar and the surface, in the direction of driving.
This must be performed after the tow bar has been adjusted and with the MEGAROLL connected to the
tractor.
A

MEGAROLL
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Driving and Operating
Proper operation is important in order to get optimal performance from your MEGAROLL. This applies not
only to working in the field but also in terms of safety. It is therefore crucial that you are thoroughly
familiar with the safety precautions relating to the machine.
Unfolding and folding
Unfolding and folding are conducted with the tractor parked.
It is EXTREMELY IMPORTANT to ensure that there is no one within or close to the
machine's working radius before unfolding or folding is performed, in order to prevent
personal injury.
It is important that the roller is unfolded on a horizontal surface, or with little incline, to
prevent tilting, unnecessary strain on the machine or damage to the machine during
the unfolding and folding process.
Unfolding
Fig. 7
1. Lift the side sections up from the transport
locks (A) with the tilt cylinder (hose marked with
white →activated by switch 2).
Fig. 8
2. Activate the cylinders for unfolding and
folding of the innermost side frames and unfold
the side sections (hose marked with red).
A

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Fig. 9
3. Activate the tilt cylinder and lower the roller to
the ground (hose marked with white →
activated by switch 2).
Fig. 10
4. Activate the cylinders for unfolding and
folding of the outermost side frames and unfold
the side sections completely (hose marked with
white →activated by switch 4).
Fig. 11
5. Activate the cylinder for lowering the
rear/middle roller section and lower the section
to the ground (hose marked with white →
activated by switch 3).
Fig. 12
6. Activate the cylinders for the hydraulic weight
distribution and bring the pressure up to the
prescribed pressure for the relevant section,
after which set the hydraulic handle for the
relevant section to the flow position (hoses
marked with red and yellow (see "Adjustment of
hydraulic weight distribution")). At the same
time, you will need to check that the pressure for
the hydraulic stone protection, for the five
middle sections, is correctly adjusted (see
"Adjustment of the hydraulic weight distribution
on pendle frames").
Before rolling begins, the weight distribution must be adjusted correctly (see
"Adjustment of the hydraulic weight distribution").

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Folding
It is important to raise the rear/middle section before folding of side frames is started,
in order not to overload the section and its cylinder.
Fig. 13
1. Activate the cylinders for the hydraulic weight
distribution and release the pressure so the
manometers (A and B) show 0, or close to it
(hoses marked with red and yellow).
Fig. 14
2. Activate the cylinder for the rear/middle roller
section and raise the section from the ground
(hose marked with white →activated by switch
3).
Fig. 15
3. Activate the cylinders for unfolding and folding of
the outermost side frames and fold the side
sections in (hose marked with white →
activated by switch 4). Check that the sections
are fully inserted into the transport lock (A).
A
A
B
A

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17
Fig. 16
4. Activate the tilt cylinder and raise the roller from
the ground (hose marked with white →activated
by switch 2).
Fig. 17
5. Activate the cylinders for unfolding and folding of
the innermost side frames and fold the side
sections in (hose marked with red).
Fig. 18
6. Lower the side sections into the transport lock (A)
with the tilt cylinder (hose marked with white →
activated by switch 2)
Check that the side sections are fully inserted
into the transport lock.
A

MEGAROLL
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Adjustment of the hydraulic suspension of the pendle frames
The hydraulic suspension of the five middle pendle frames is designed to relieve rings and frames from
hard impacts and loads, which might occur during driving in fields from stones and undulations.
It may be necessary to readjust the pressure for the hydraulic weight distribution. Likewise, it may be
necessary to drive with more or less pressure, depending upon the soil conditions.
It is important to close the ball valve again when the desired pressure is achieved in
order not to unintentionally adjust the pressure while using other functions and
thereby risk damaging the machine.
Too much pressure
1. The pressure is too high if the cylinder will not move. The frames may be overloaded.
2. Reduce the pressure until the cylinder starts moving again.
Too little pressure
1. The pressure is too low if the cylinder is unable to extend to its full stroke.
2. Adjust the pressure until all five cylinders for the suspension are, at least, extended again.
It is recommended to operate with a working pressure of 90 bar!
But, driving should always be done according to conditions!
Fig. 20
1. Adjustment of the hydraulic suspension must
be performed with the roller unfolded and
resting on the surface, and before the
hydraulic weight distribution is pressurised
(this can also be performed with the machine
in the transport position).
2. Cylinder (A) is mounted on the five middle pendle
frames and acts as a shock absorber to counter
impacts from rocks and other heavy impacts
during work.
Fig. 21
3. Connect the manometer (B) to the hydraulic
stone protection and this must be set to a
pressure of approx. 90 bar (the pressure may
need to be adjusted depending on driving
conditions).
4. This is done by opening the ball valve (C) and
activating the hose marked with white, without
any switch being activated (white hose →no
buttons activated).
5. The ball valve must be closed again
when the desired pressure is achieved.
A
C
B