Common Troubles, Causes and Remedies: Module 2 - Lesson 2

MODULE 2 - LESSON 2
COMMON
TROUBLES, CAUSES
AND REMEDIES
Causes of machinery breakdowns (and how to prevent them)
1. Not reading the operator's manual.

 Owner’s manuals cover everything from maintenance checklists to
calibration instructions. Most issues are addressed in the
troubleshooting section so farmers can fix the problems themselves
without having to wait for a technician.
2. Improper maintenance.
 Skipping daily maintenance is another mistake that can cause
downtime. Farmers should regularly replace fuel filters and
check chains, gearboxes and belts for wear and replace when
wear is excessive. On gravity wagons, wheels should be
checked for tightness and alignment before going to the field.
3. Poor electrical connections.
 This problem is hard to prevent and is becoming more
commonplace as more machinery is electronically controlled.
However, cleaning away dust and dirt around the connectors
can help. When cleaning, use compressed air instead of water to
keep moisture away from the wires.
4. Overrunning machines.
 Constantly pushing machines to run at maximum performance or at
the top of the engineering curve can strain joints and cause equipment
to die prematurely. Run machines just under their intended maximum
performance level at most times to avoid undue stress and prevent
premature wear.
5. Not replacing worn parts.
 When a part on a machine breaks, some customers will replace only
that part and not check or replace other parts that may have caused
the initial failure. Examples include replacing a drive chain when the
sprocket was shot or replacing a belt when the pulley was bad.
Replacing only the parts that are broken is a temporary fix that can cost
money in downtime.
6. Misaligned tighteners.
 Tighteners that are not tracking straight with the belt or chain in
relation to the main drives can put tension on the belt or chain,
causing it to break or wear excessively. It’s important to replace worn
bushings in the tightener pivot that may be pushing the belt or chain
sideways.
7. Improper storage.
 Combines and planters can build up dust and debris, which
attract rodents. Rodents gnaw on wires and the dust itself can
interfere with electrical connections. Store machinery inside and
clean around all electrical connections and other areas of buildup
before parking it inside. Compressed air is better and safer than
water for cleanup.
8. Weather-related issues.
 Operating in wet, muddy conditions can put strain on equipment. For
example, running wet, tough material through a combine can break
shafts or plug up the machine, which then puts strain on everything
from feeder house chains to shafts to bearings and pulleys. In tractors,
mud packed in between dual wheels can result in premature wear on the
tire sidewalls once the mud hardens.
While it’s difficult to avoid these conditions, understanding the weather-

related issues can alert you to problems to look for.
9.Ignoring warning signals.
 Warning lights on screens are there for a reason, often
signaling issues that need to be addressed, such as low
hydraulic pressure, high engine temperature or a shaft
that isn’t turning. However, too often those signals are
ignored, resulting in machinery failure.
10. Untrained operators.
 As farms get larger, farm owners are having to hire outside help
that may not be trained to operate machinery. Lack of training can
result in abused machinery and costly breakdowns. Time invested
in training can make your machinery last longer.
PRE-OPERATIVE AND POST-OPERATIVE CHECKS OF FARM MACHINERY
The equipment operator can prevent downtime, extend service life and
ensure more efficient operation with just a few minutes of preventive
inspection both pre- and post-operation.
Check tires, rims or undercarriage for damage or abnormal wear and clear
away debris. Much like you or I don’t operate at full capacity on a broken foot
or while wearing shoes that are broken or don’t fit, a machine can be hobbled
by the inefficiencies of the tires or tracks it sits on. Identify and report any
damage or potential damage.
 Check fluid levels - engine and hydraulic oil, diesel and diesel
exhaust fluid (DEF), and coolant. Fluids are the lifeblood of each
machine and require specified levels to operate properly. A sudden
drop in fluid levels may point to any number of problems with the
machine that require immediate attention (blown hoses, leaking
filter, etc.).
 Clear any accumulated debris from around the radiator and
other engine components. The engine is made of moving parts
and belts that generate heat and friction – and systems designed
to cool the engine compartment require room to breathe. It’s
important to check and remove any clutter or material from the
jobsite that may have found its way into the engine compartment.
 Check the fuel, oil, air and other filters for signs of damage or
leaking. Filters are often a quick and easy item to replace – and
operating with properly working filters can prevent any number of
problems with the machine.
 Check belts (alternator, fan, etc.). A worn and frayed belt is
another wear item that is relatively easy to replace. If noticed
before it fails, then the operator can communicate with the
maintenance team to replace during scheduled downtime or the
next PM to ensure it doesn’t create unplanned downtime during
the course of the work day.
 Identify greasing points and frequency. Every machine is
different – and keeping the machine properly greased is critical
considering the power and friction created by these giant pieces of
steel working together. It can also help keep out moisture and
abrasive materials from the jobsite that can work into joints and
friction points if not properly greased.
 Check for leaking or pooled fluid around and under the
machine. This is an easy indicator that something isn’t right,
and the source of that fluid should be identified and
addressed/fixed before operation, and those fluids should be
replaced.
 Check auxiliary hydraulic connections and pressure.
Simply check the integrity of the coupling structure and that
it hasn’t been damaged. Newer equipment often includes
pressure relieving quick disconnects – take the time to relieve
the pressure when disconnecting attachments.
 Check for new signs of structural damage, scratches or dents on the
machine. This is almost more important post-operation than it is pre-
operation. Once done for the day, noticing and identifying any damage to the
machine ensures that needed repairs are made before the next shift starts, and
also allows the operator to identify how that damage occurred. Is there
another structure on site that the machine came into contact with? Is there
damage elsewhere on site that needs to be addressed? Similarly, if damage is
noticed before a shift starts, and it was not there when the operator inspected
it the day before, that pinpoints that something happened overnight or that
there was possible unauthorized use of the machine.
 Check for damage on ground engaging tools (buckets, teeth, etc.).
A machine’s performance is affected greatly by the efficiency of how
its working tools engage with the material it is digging into and
moving. Worn or broken buckets and teeth lead to inefficient
operation, greater fuel use, and greater wear and tear to the
machine as a whole. Identifying and addressing these elements of
the machine before they become problematic will make the operator
more productive and efficient.
 Inspect the attachment mount-up to ensure proper connection.
This includes checking that the coupler is flush and fully engaged
(either via manual or automatic/hydraulic means), and that the
hydraulic hoses (and electrical connections, if applicable) are
properly connected.
 Inspect the operator compartment and clear away any
debris or obstructions. Clutter can be distracting – and
anything in the cab that ultimately prevents the full range of
controls from being engaged is a hazard to operation.
 Check and set mirrors. This might seem obvious, but
visibility is critical to jobsite awareness, safety and
productivity. Having mirrors set to the operator’s preference
will make them a better operator.
 Familiarize yourself with the control style and change as
needed. Most of today’s machine’s come with rather simple
pattern selectors that allow the operator to use the control
pattern that they are most familiar with. This will lead to greater
productivity and greater operator satisfaction.
 Identify auxiliary/attachment controls. Each type and style of
machine controls attachments differently – operators should
identify how to properly work their attachment prior to
attempting to use it.
 Start the engine and review console indicators and warnings.
Today’s machines are built to give the operator more feedback on the
workings of internal systems than ever previously available. Take note
of any flashing symbols or warning lights, check the owner’s manual
and consult with maintenance staff prior to operation.
 If equipped, check the rearview camera. Again – jobsite
awareness and safety is paramount. If that rearview camera
is otherwise obstructed or disabled, it handicaps the
operator’s ability to have full awareness of the worksite
around him/her.
 Review all external surroundings from the cab.
Know your work site, and the people and structures that exist
inside your working envelope. This will ensure optimal jobsite
safety and productivity.
THANK YOU FOR
LISTENING!

Common Troubles, Causes and Remedies: Module 2 - Lesson 2

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MODULE 2 - LESSON 2

1. Not reading the operator's manual.

While it’s difficult to avoid these conditions, understanding the weather-

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