DALBO PowerRoll 1030 User manual

PowerRoll
GB –1030 & 1230

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3
DAL-BO PowerRoll 1030 & 1230 cm
Congratulations on your new PowerRoll. For safety reasons and to make the
best possible use of the machine, you should read the following instructions
before putting it into operation.
© Copyright 2002. All rights reserved, DAL-BO A/S
Points, which are of importance with regard to safety are marked

.

Using the roller with a non-original hydraulic circuit will invalidate the warranty.

Dal-Bo cannot be held liable for damage caused by a non-original hydraulic circuit.

Tighten all screw connections after a few hours' use.

The hydraulics must not be operated unless the roller is properly connected to a tractor.

The machine must only be operated from the tractor. There must be no-one in the
immediate vicinity of the roller.

The roller must not be operated by children.

The driver is responsible for ensuring that the roller is correctly marked in accordance with
the current Road Traffic Act.

The driver is responsible for the tractor used being large enough to handle the roller
properly. A minimum of 130 HP (97 kW) is recommended.
Your PowerRoll has:
Serial number: . Type designation: .
Month of manufacture: . Net weight kg: .
Please always quote the serial number when making inquiries about spare parts or service.
There is a list of spare parts at the back of the booklet which provides a summary of the roller's
individual parts.
EU COMPLIANCE DECLARATION
DAL-BO 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 concerning health and
safety requirements related to the construction and manufacture of machines.
This machine corresponds to the safety requirements in the European Safety Guidelines.
DAL-BO A/S
Date:
Managing Director Kaj Pedersen
CE

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Contents:
Application:........................................................................................................................................5
Noise:.............................................................................................................................................5
Dust: ..............................................................................................................................................5
Handling:............................................................................................................................................6
Assembly:...........................................................................................................................................6
Starting:..............................................................................................................................................9
Operation:...........................................................................................................................................9
Unfolding: .....................................................................................................................................9
Folding: .......................................................................................................................................10
Maintenance: ...............................................................................................................................11
REPAIRS:........................................................................................................................................12
Wheels:........................................................................................................................................12
Bearings, rings and shafts:...........................................................................................................13
Rams:...........................................................................................................................................16
Outer sections:.............................................................................................................................20
Intermediate sections:..................................................................................................................20
Drawbar:......................................................................................................................................21
Scrapping: ........................................................................................................................................21
OPTIONAL EXTRAS:....................................................................................................................22
Air brakes:...................................................................................................................................22
Air brake diagram:.......................................................................................................................22
SPARE PARTS:...............................................................................................................................25

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Application:
The PowerRoll is used before and after sowing to break up clods and press
down stones. It also creates good contact between seed and soil, ensuring
uniform crop germination.
The roller can also be used to advantage after stubble tilling to promote
conversion of plant residues and the germination of waste and weed seeds.
The PowerRoll can also be used for rolling pasture. Rolling presses stones
down and flattens out any molehills and irregularities so that they will not
hamper any future working in the field.
Rolling also breaks up the surface crust and increases the air supply to the
roots.

The PowerRoll must not be used as a transporter, pile driver, hydraulic press
or the like. If in doubt, ask your dealer or DAL-BO.

The PowerRoll must not be used for rolling roads or similar hard surfaces.

When operating the roller, the user must sit in the driver's seat of the tractor,
and there must be no-one on the roller or in its immediate vicinity.
Noise:
The roller may make a little noise during rolling, particularly if the Cambridge
rings are worn. It will be well below the danger level for the tractor driver,
however.
Dust:

Rolling in very dry conditions may generate a great deal of dust. It is
advisable to close the tractor's windows/doors and use the tractor's air-
conditioning system, or to use a dust mask.

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Handling:
The 12.3 m PowerRoll generally comes disassembled for transport. It should
be assembled by you DAL-BO dealer's qualified fitters at a professional
workshop which has an approved crane/lifting tackle.
It consists of the following main parts:
QTY
PARTS
WEIGHT
approx.
CROSSKILL
CAMBRIDGE
1
Drawbar
435
-
-
1
Central section without rings
625
720
875
2
Inner side section
330
720
875
2
Connecting link
60
-
-
2
Outer side section
100
615
745
2
Ram 110/50x700
41
2
Ram 80/40x350
21
2
Ram 63/30x400
20
2
Brake hub
70
2
Wheel 15.0/55-17
62
2
Wheel 19.0/45-17 (optional extra)
68
Assembly:
See fig. 1.
The machine should be assembled by your Dal-Bo dealer's qualified fitters at
an "approved" workshop:
A crane which can lift at least 1000 kg should be used.
1. Fit the central section pos. 1 with roller rings, and position it in the centre
of a flat area of floor so that it is resting on the roller rings and wheel
hubs. There must be approx. 7 m of space on either side of the centre.
2. Fit the drawbar pos. 2 with the two pins pos. 3. They must be inserted
from the outside so that the square end plate prevents rotation.

Remember the split pin.
3. Connect the two red hoses to a double-acting valve on a tractor or pump
station and run the two large rams pos. 4 out to their maximum length.
4. Mount the two large rams on the drawbar and central section. So that the
central section stands vertically.

Remember washers and split pins.
5. Mount the rams pos. 5 on the central section.

Remember the split pins.
6. Secure the hydraulic hoses in the clamps.

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7. Fit the inner side sections pos. 6 without the roller rings. This is done by
hooking onto the middle of the roller section itself so that the frame can
be turned to get the pin pos. 7 in.
This requires two people. It is important to guide the side sections so that
hole in the bushing is aligned with the hole in the pin. Lubricate the pins
before they are fitted, it is a tight fit. Do not strike the pin directly. Put a
wooden block in between so as not to damage the pin.

Take care that the section does not swing round!
Secure the pin with the loose bushing and M12 bolt pos. 8
Fig. 1:
8. Run the rams (pos.5) out slightly (blue hoses) and connect the inner
sections with the pins pos. 9.

When both sections have been fitted, swing them out carefully with the
rams. The rams ensure that they do not swing back and tip over
backwards.

Remember washers and split pins.
9. Fit the outer sections pos. 10 with the pin pos. 11. Secure with the
washer and screw the bolt, to which Loctite 270 has been applied, firmly
into the end of the pin.

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10. Mount the connecting links on the inner sections with the pin pos. 12.
Secure with the washer and screw the bolt, to which Loctite 270 has been
applied, firmly into the end of the pin.
11. Secure the rams for the outer sections to the inner sections.
12. Fit the rocker arms as shown in fig. 1 pos. 13 + 14 (pos. 13 being the
wide top part) and join the outer section to the inner section with them.
Secure all pins with split pins.
13. Mount all hydraulic hoses, components and fittings as shown in the
hydraulic diagram at the back of the book.

It is very important that the hydraulic circuit is fitted according to
the diagram, as the system contains several safety components.
Operating the roller without these components can result in personal
injury and mechanical damage.

Using the roller with a non-original hydraulic circuit will invalidate the warranty.

Dal-Bo cannot be held liable for damage caused by a non-original hydraulic circuit.
14. Operate the large rams so that the roller tips into working position. This
allows the wheels to be fitted without using a jack.
15. Fit the wheels.

Remember to tighten them properly.
16. Lift the drawbar and fit the jack. Unscrew it until the drawplate is
approx. 45 cm above the ground.
17. Tip the roller up with the large rams.

Not too quickly or the roller will tip over backwards.
If the hydraulics have been connected correctly, the restricted flow
will ensure that these operations cannot be carried out too quickly.
18. Fit the roller rings on all side sections. Use an
approved crane which can lift min. 1000 kg.
roller rings with an approved strap/chain. As shown
in fig. 2.

Guide the rings into place on the roller and tighten
up properly.
Figure 2:

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19. Using the rams (pos. 5), swing the side sections in until they hit the stop/
transport bearing. Keep an eye on the hydraulic hoses.

Take care not to get trapped.
20. Using the large rams (red hoses), lower the side sections into the transport
bearing.
Starting:
Connect the roller to the drawbar of the tractor . This should be approx. 45
cm above the ground so that the drawbar is horizontal in working position. If
the tractor's drawbar is lower, the drawplate on the roller can be fitted
underneath the drawbar.

Remember to secure the drawbar pin.
Connect each of the two sets of hydraulic hoses to its own double-acting
hydraulic tap. All the hoses have a ½" male connector. If your tractor is not
equipped for this, your dealer will be able to help.
A maximum pump pressure of 160 bar is required.

Defective hoses must be repaired or replaced immediately.
A broken hose can in bad cases cause personal injury or mechanical damage
to the roller in adverse circumstances.
Operation:
The roller must always be operated from the driver's seat and there must be
no-one else in the vicinity of the roller.
The changeover from transport position to working position should take place
while stationary on approximately level ground with the tractor almost idling.

It is extremely dangerous to modify the hydraulic system, as the circuit
contains several safety components.
Unfolding:
First raise the side sections clear of their transport bearing
with the large rams (red hoses). Swing the side sections
out jointly, with the swing rams (blue hoses pos. 5), and
then push the outer sections out into working position.
Hydraulic valves on the central section ensure that this is
done in the correct sequence through operation of the
valve connected to the blue hoses.
Figure 3

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Tip the roller down with the large rams (red hoses) until
the adjusting bolt on the central section is touching the
leaf spring mounted on the drawbar. It may be necessary
to adjust the bolt, depending on the height of the tractor's
draw bar.
Put the operating valve, connected to the red hoses, into
the neutral position.
If the adjustment is correct, the large rams should move in neutral position,
the adjustment bolt should be touching the leaf spring, and all the roller
sections should exert the same pressure across the full working width.
Before rolling is started, activate the swing rams (blue hoses ) for folding until
the pressure gauge mounted above the accumulator reads 60-120 bar. After
this it is very important that the handle for the swing rams are put in floating
position. The floating position is necessary to achieve hydraulic weight
transfer, in which the sections are free to move individually. The accumulator
will then work as an hydraulic "spring" that is preset. The presetting means
that the roller transfers weight from the central section out to the side sections,
ensuring uniform pressure across the full working width and giving the roller
great freedom to follow uneven ground.
Check all the accumulators on the machine at least once a year for leaks and
to ensure that the precharge pressure is set correctly. Contact an
authorized Dal-Bo dealer for more information.
Folding:
First release the pressure from the side sections (blue hoses) by unfolding
them (pressure on the gauge drops).
Then tilt the roller up on to the wheels with the large rams (red hoses). Fold
the side sections in using the swing rams (blue hoses), pulling the outer
sections in first and then bringing the side sections in together until they hit
the transport bearing.
Finally lower the side sections into the transport bearing using the large rams
(red hoses).

It must not be possible for the valves to apply pressure to the roller by
themselves during transport. It is advisable to put them in neutral position if
possible.
The roller should only be folded for transport. It does not have to be folded
for turning in the field.
It is also possible to reverse in working position.
Recommended driving speed: 6-8 kph. Slower on stony ground.
Figure 4