Heavy equipment machinery

All hydraulic breakers, regardless of design or manufacturer, have the task of shattering, cracking or splitting material. The assignment isn’t exactly gentle on the equipment. Wear and tear is an outright certainty, but the life cycle and performance of a given unit can be greatly enhanced through proper maintenance, which can be viewed from three separate perspectives: routine maintenance by the contractor, periodic rebuilds by the manufacturer and preventative maintenance features within the breaker itself.
The Routine Stuff

When talking about routine breaker maintenance, it would be irresponsible to do so without mentioning lubrication. Without lubrication, metal-to-metal contact between the breaker’s tool and bushing would cause the bushing to wear out quickly, subsequently exposing the breaker’s major components to serious damage.

The lubrication process begins by applying down pressure on the tool to ensure that it is pushed all the way into the breaker, eliminating the possibility of grease filling into a chamber between the piston and the top of the tool. Lubricant should be applied until it comes out of the lower bushing area, which indicates that the breaker cavity is full and ready to go to work. A paste or grease film should always appear on the tool at the lower bushing while the breaker is operational. The absence of grease is a good visual indication that it’s time to apply more lubricant.

Several breaker manufacturers offer their own chisel paste or other lubricant designed specifically for breakers. Standard grease is inferior to specially designed chisel pastes because the heat and pressure from the working tool will cause the grease to melt and run, which increases the frequency of lubrication applications. Although the cost for a tube of chisel paste or special shank grease is higher than the price of regular grease, manual lubrication with paste is only required once every two hours on average, compared with one hour or less intervals using standard grease. Having the operator stop work to apply grease twice as often can cost a contractor far more in downtime than can be saved using the cheaper lubricant.

Even with the very best lubrication techniques, the bushing will wear out and need to be replaced at some point. Measuring the bushing diameter to see how much it has worn often requires that the tool be removed. A simple measurement trick that can be performed without disassembly is to take a 3/16-inch drill bit and try to slide it between the tool and bushing. Typically, at most about 1/4-inch of space is the allowed wear limit, so if the drill bit fits between the tool and the bushing, the tool should be taken out so the bushing can be properly measured to see if it has reached the designated wear specification.

While most understand the importance of lubrication and wear items, not all contractors may be aware that many hydraulic breakers feature a nitrogen gas assist that should also be maintained in the field as necessary. Expansion and contraction due to heating and cooling will lower the gas pressure in the breaker’s piston accumulator, much like the way that car tires will gradually lose air.

Gas pressure checks do not need to be performed on a daily basis. And unlike car tires, there’s nothing visual to suggest when the pressure should be checked. Instead, if there is a noticeable drop in the breaker’s power output, it could be an indication of low gas pressure. Manufacturers recommend using a special kit and following the operator’s manual while performing this check.

The hydraulic flow going from a carrier to the breaker is just as critical as lubrication to the physical condition of the breaker. Although machine specifications may indicate a good match, a carrier should be tested at least once a year — more often in heavy-duty applications.

Unfortunately, many contractors fail to have their carriers tested, either due to a lack of awareness or to avoid the expense. It’s important to realize that flow problems can pose just as much risk of damage to an excavator or other carrier as they would to the breaker. Improper machine setup is a problem from which no breaker can hide.
Just Like New

Although often classified as an attachment, a hydraulic breaker is a specialized piece of machinery. Even with proper care, a hydraulic breaker will require a periodic overhaul to replace all of its wear components.

The terminology for such a job varies. Rebuild, refurbishment and recondition are a few of the phrases out there. There is no set timetable for a breaker rebuild, as it largely depends on the application and size of the breaker. The type of repair that is actually done will differ as well, depending on who is doing the repair and on customer preferences.

Common practice with a recondition is to replace every single wear item on a breaker, as well as to perform a complete and thorough inspection of the unit. Bushings, tools and retainer bars are replaced, while the piston, cylinder and pressure accumulator are inspected. The repair work is usually topped off with a paint job.

Occasionally a breaker that has not been heavily used will be brought in for a recondition. Such a machine may not have experienced much wear and tear, so the customer may be given the option of replacing some parts while trying to get more life out of others.

The customer still has the option of leaving these parts in, but doing so would mean a return trip to replace the parts just weeks or months later once they have run their course. In addition to being more convenient, another upside of immediately replacing all the items is that the manufacturer may offer a renewed warranty since the breaker has essentially been refurbished up to near-new condition. The same guarantees may not apply if some parts are not replaced and something goes wrong before the next repair.

It’s generally recommended to take a breaker to the manufacturer, distributor or another qualified professional for a rebuild or recondition. However, many hydraulic breakers, especially the smaller varieties, are designed so that they can be more easily maintained. Therefore, end users with the appropriate training or experience can certainly take on the task of refurbishing their own breaker.
Automatic Maintenance

Having a breaker than can handle some aspects of maintenance on its own can create a more profitable situation. "Automatic" is a big-time buzzword for today’s equipment. Incorporating a number of automatic technological features, hydraulic breakers are no different.

A number of systems utilize a hose that runs from the carrier to apply consistent lubrication to the breaker. Some manufacturers produce breakers that come standard with a lubrication cartridge mounted directly onto the breaker itself. With this system, literally all that is required of the operator is to change the tube when it’s empty. Even with the "automatic" lubrication system the operator still needs to periodically check for grease film on the tool to ensure the system is operational and properly adjusted.

More lubrication than normal is needed for particularly dusty applications. Some breakers feature an optional system to protect the breaker from dust penetration by providing an additional seal that prevents debris from entering the unit. This system also keeps chisel paste where it belongs to allow the breaker to run longer without risking wear and tear from a lack of chisel paste.

Found on some larger breakers, a power management system is a tremendous preventative maintenance asset in jobs where lighter material is being broken. Rather than unleashing a full-power blow, a breaker equipped with power management can limit itself to 50-percent power until it hits against hard material that dictates a need for full impact energy.

Conversely, in applications where extremely hard material must be broken, damaging shock waves can be reflected from the material into the breaker’s tool and piston. One unique system allows this rebounded energy to be collected in a high-pressure accumulator, which effectively protects the internal components from the shock waves. As an added bonus, the breaker can then deliver the accumulated energy in the next blow.
Treat It Right

Some contractors take the approach of using a breaker when they need it and throwing it to the side when they don’t because "it’s just a hammer." In actuality, hydraulic breakers are specialized machines that require maintenance just like any backhoe, carrier or other piece of machinery on the job site. Through new design and technology, manufacturers have simplified breaker maintenance to make it a user-friendly task.

In the 1960s, GlaxoSmithKline, a leading pharmaceutical company, pioneered the Tasmanian poppy industry. This unique industry has now become one of the great success stories in Australian agriculture and manufacturing.

For centuries, poppies have been grown as a source of ‘opium gum’, a powerful pain reliever.

Back in 1806 the complex chemical responsible for pain relieving properties was isolated from opium gum and called ‘morphine’.

Nowadays, GlaxoSmithKline (GSK) and our Tasmanian farmers supply 25% of the world’s medicinal opiate from poppies, which is then used in a range of pharmaceutical and prescription medicines.

Each year GSK contracts about 800 Tassie farmers to grow approximately 8000 hectares of poppy crop. They purchased their first Fendt Vario tractor three years ago, a 210hp FD920 with reverse console.

The Fendt is fitted with a poppy harvester that has been specially designed and built by GSK, with help from local Fendt dealer, Tasmania Farm Equipment.

Fendt is a brand of Agricultural giant, AGCO, whose other brands include Massey Ferguson, Iseki, Gleaner, and Valtra. Peter Brewer, the Engineering Co-ordinator from GSK explained that choosing the Fendt over other machines was not a difficult decision to make.

They were looking for a reliable tool with a reverse console and Fendt was the only brand that offered this in the horsepower category that they required.

The reverse console design is an important feature as it improves visibility and meets OH&S standards.

Their Fendt Vario from the AGCO Corporation provides excellent control of functions and even has the ability to make adjustments to ground speed and chopper speed while on the go.

This is a huge benefit, especially during harvest time.

By maintaining the correct ground and PTO speed, the Fendt Vario also ensures that crops maintain top consistency into the bin while harvesting.

This prevents the crop from getting damaged, which generally affects the seed part of the crop.

And while the seed is a by-product (used on foods such as bread rolls), it has significant dollar value.

Operator comfort was also a big draw card for GSK.

The cab suspension, front axle suspension and design of the controls allow the operator to spend many hours in the cab and concentrate on getting the job done properly.

What’s more, the large fuel tanks and excellent fuel efficiency means that the Fendt spends more time working and less time re-fuelling.

“It just doesn’t make sense”, confessed Peter Brewer, “It has more horsepower than the other tractors in the fleet and it’s more fuel efficient”.

With a continual interest in developing new poppy varieties and improving growing and harvesting techniques, GSK rely on their Fendt as a valuable research tool.

It’s precise control over ground speed, chopper speed and PTO speed is used to determine the exact settings needed for the best results.

Using this information, other tractors in the fleet that only offer fixed speeds via conventional transmissions can then be set at the right speeds, making them more efficient and economical as well.

GSK have eight tractors in their fleet and also call upon the services of local contractor, Michael Brett, who owns a 240hp Fendt Vario 924 tractor.

Michael’s tractor is used in air-seeder applications for planting; and during the harvest season is fitted with a poppy harvester, also designed and built by GSK.

http://www.fatcow.com.au/articles/B7/0C042EB7.aspx

 

In Valtra’s homeland of Finland, the Raininko brothers have achieved considerable business success in agriculture and contracting work.

Valtra is a leading brand of the AGCO  Corporation who also own brands Massey Ferguson, Fendt, Gleaner, Iseki and Challenger.

Their company name Kikaju Oy combines the first two letters of each of the three brothers’ first names: Kimmo, Kari and Juha.

The family’s organic farm and peat production operations are currently run by Kari and Juha, as Kimmo has focused on other areas of the agricultural business since the end of the 1990s.

Organic farming introduced in 1995

The Raininko brothers do not mess about.

When the time was ripe for switching to organic farming in 1995, all 300 hectares of the family’s fields were converted.

Since then the area of cultivated land has been further expanded.

All the fields are situated within a radius of approximately 6 kms from the farmhouse, which is quite a luxury for farms of this size.

The family’s organic fields in Southwest Finland are used primarily for growing clover, peas, rye and wheat.

Camelina and rape are also cultivated in smaller quantities.

The clover is used for plant protection and is grown in five-year intervals, one of which is also used for peas.

New challenges and lessons

“There is no going back to traditional farming, as long as economic conditions and the EU’s agricultural policies remain pretty much the same.

Organic farming is certainly more challenging; we learn from our mistakes,” explain Juha and Kari in turns.

According to the brothers, there is still a lot to learn about organic farming in general.

For example, soil compaction is not just the result of heavy machinery but the reduction of organic activities due to the chemicals used in traditional farming.

Nitrogen fertilisation is also a major cause of plant diseases.

Land of bogs and peat

Finland has 9 million hectares of peat bogs, representing alongside forestry an important national energy resource.

Around 55,000 hectares of peat is currently cultivated.

The Raininko family business has cultivated peat for the past 26 years, providing the brothers with a wealth of experience and knowledge about how to produce energy and agricultural peat efficiently.

The Raininko’s peat team produces each year an average of 150,000 cubic metres of energy and agricultural peat.

The target for this year is almost 170,000 cubic metres, of which 70 percent had been produced already by the first week of July thanks to excellent weather.

Kikaju Oy employs 10 tractors and 15 to 16 drivers to cultivate peat.

The machinery includes two vacuum trailers, of which one is currently the biggest produced in the world.

This tandem model sucks up to 80 cubic metres of peat at a time into its container.

Other equipment includes four 9-metre production millers, three 18-metre harvesters, a conveyor loader and five trailers.

Around one inch of peat is taken at a time, and each harvest produces around 40 cubic metres per hectare.

First Valtra N and T Series tractors

At least half of the Raininko’s tractors til now have been heavy-duty US models.

A caterpillar tractor with rubber treads has been used by Kikaju for the biggest tasks on fields and in bogs since 1998.

The brothers have always used a variety of different makes, and this year they took delivery of their first Valtra tractors.

Kikaju ordered a total of three Valtras last spring: two T190s and one N141 to replace three 190-horsepower American tractors that weigh more than Valtra’s T Series.

All three Valtra tractors were driven straight to the peat bog, with field work reserved for later.

The brothers soon recognised the greatly improved fuel economy of their new tractors.

At the time of this interview, the T Series tractors had already run for 500 hours and the N Series for 700 hours.

Light but powerful

“The light weight of our Valtra tractors is a big advantage – they are ideal for peat work.

In fact, the Valtra tractors can be used for all agricultural and peat bog tasks.

The weight distribution is also good – our old American tractors tended to have a heavy rear bias.

Peat work requires ground speed PTO, which is available on Valtra tractors, so the trailers did not have to be specially adapted.

What other 200-horsepower tractor offers ground speed PTO?

The cooling system of the tractor also has the capacity to handle dusty peat bogs.

The engine’s air intake is very well designed and does not get clogged.

Valtra may well be “the best tractor in the world for peat bogs”, at least based on our own experiences compared with other brands,” claim the brothers.

“So far we have not experienced any small problems or leaks. An efficient spare parts service is also important to us,” they add.

The Raininko brothers admit that they have been positively surprised by Valtra.

The new Common Rail engines offer a lot of power with relatively low fuel consumption.

Power and torque are available in sufficient quantities from as low as 1000 rpm.

The quietness of the cabs has also been appreciated.

The T190 has already been used to pull a heavy 6-metre fertiliser driller on the organically cultivated fields.

Thanks to its excellent power to weight ratio, the Valtra leaves the soil unmarked; tyre tracks could not be seen on the ploughed field.

Unfortunately the brothers did not take a photo to prove this!

New technology adopted, but with caution

“We try to be far-sighted. The machinery we buy has to suit the intended purpose and be functional and long lasting.

We usually keep our tractors at least five years. We always need more efficiency, but the tractor should still be agile.

I doubt that we will ever stick to one single brand with our demands, simply because we do not believe that wheeled tractors with over 200 horsepower are better than caterpillar tractors. Valtra has been a positive surprise for us.”

http://www.fatcow.com.au/articles/D1/0C042CD1.aspx

The desire to put more grass in front of his grass-hungry harvesters saw Manawatu contractor Daljeet Singh invest in a self-propelled mower with a working width of 8.5 metres from Landpower.

Daljeet, who runs Feilding-based Rural Contractors, bought the Claas Disco 8700 mower last year to boost the mowing capacity of his operation.

The Claas Disco 8700 is distributed by Landpower New Zealnd and is a self-propelled mower comprising three separate mower units mounted to the front of a power plant like a Claas Jag harvester. Its enormous mowing capacity means it is ideal for farmers and contractors who need to cover big areas in the shortest possible time

Daljeet ran his 8700 on the front of a Claas Jag 850 and used it alongside four Claas Disco 8500 mowers to mow around 2800 hectares of grass silage in the 2005/06 season.

He was very impressed with the mower’s reliability and its ability to provide exceptional mowing performance while reducing labour, time and fuel costs.

"The Jag 850 has plenty of power to drive the mower and so its very fuel efficient," he says.

"We averaged around six hectares an hour, but on good smooth contour it could comfortably get up to 10 hectares an hour. It can mow as much as two five-metre mowers and so it effectively saves us one tractor and one driver."

The 8700 is easily detached from the harvester, allowing the Jag 850 to be recommissioned into harvesting if required.

"What we normally do is send all our mowers out in the morning for three to four hours, then the guys come back and jump into the harvesters. With all our mowers working we can mow a total of about 100 hectares in that time."

Daljeet says the 8700 is a great machine to operate because the driver is sitting behind and above the mower units, "so you have excellent visibility over the whole mower. And because it is front-mounted and attached to the steering system of a harvester, you are less likely to mow over areas you have already mown at the headlands."

This type of efficiency is very important to contractors who have to mow large areas as quickly as possible to keep their harvesters and staff operating at maximum capacity.

"Contracting is a very weather-dependent business, so when the weather is right you want to be able to cover as much ground as you can," says Daljeet.

He says the 2005/06 season was a challenging one for contractors in his region, making harvesting capacity even more crucial. "We had a lot of rain in December and January, which held us up a bit, but we still managed to get through about 3500ha. That was an extra 500ha than we did in the previous year."

Daljeet believes mowers like the 8700 are likely to become increasingly popular as contractors strive to improve their harvesting capacity while maximising labour and fuel efficiency.

"We’ve definitely come a long way since the days of the single three-metre mower," he says.

Claas Disco mowers are distributed by Landpower New Zealand.

http://www.fatcow.com.au/articles/CB/0C0452CB.aspx

The Autofarm A5 from Gps-Ag continues to deliver the ultimate in vehicle control in a fresh new hardware package even more modular and portable than before. The A5 is stacked with technology to set you up for the future.

Technology

Novariant are world leaders in the development of GPS technology. Their patented roof array models the motion of the tractor cab in three dimensions and delivers extraordinary performance without the need for gyros or tractor movement. The AutoFarm A5 system features a standards-based architecture built using Controller Area Network (CAN) bus technology that opens up a world of compatibility with other manufacturers’ equipment. CAN bus is essentially a cable that distributes information between modular electronic components (user terminal, steering controllers, application rate devices, yield sensors, and other vehicle components) and it’s already widely used in farm machinery. AutoFarm employs a unique dual CAN bus design to ensure that high priority control data reaches critical electronics without delay.

Versatility

The AutoFarm can be moved from vehicle to vehicle with steering kits. All calibration data can be saved for each vehicle so within minutes you are operable. The AutoFarm will work on all types of tractors (wheel, track, articulated) and even work on harvesters to ensure maximum harvesting efficiency. With the A5 all you need to move is the user terminal and the quick release roof array, all the cables stay in place.

Benefits of 2cm GPS

The AutoFarm 2cm enables you to achieve benefits that are not possible with lower accuracy GPS systems:

1. Have total confidence in repeatability;

2. Accurate guess rows;

3. Precise placement of seed and fertilizer;

4. Inter-row sow and cultivate;

5. Maintain defined compaction zones.

Single and Dual frequency

The AutoFarm 2cm is available in two models—single and dual frequency. Whilst in autosteer mode, the steering performance of the single and dual frequency AutoFarm is identical, the dual frequency, however, improves the GPS acquisition time when starting the AutoFarm. The dual frequency AutoFarm typically takes 2-5 minutes to survey whereas the single frequency AutoFarm takes between 10-20 minutes. The single frequency AutoFarm is currently available in the GPS5001 (cab box) model only.

Step One

The AutoFarm Step One is an entry level to Autofarm precision vehicle control. It uses the same user terminal and hydraulic steer kit to the 2cm RTK model and a similar roof array, but instead of a base station you use DGPS from an external GPS receiver. This could be a receiver from a guidance system you already own. The Step one can later be upgraded to 2cm RTK using a base station. Step One is available in both GPS5001 (cab box) and A5 models.

Productivity

The AutoFarm enables less skilled operators to perform critical operations. Operating high capital items of machinery efficiently leads to cost savings in machinery rationalisation.

Payback

The AutoFarm investment starts paying for itself from day one. The AutoFarm has no annual costs so the benefits of eliminating overlap and working equipment accurately day and night keep adding up – day after day.

Data Logging and Scraper Leveling

The AutoFarm can record accurate elevation data during normal farming operations. This data can be used by your leveling contractor or used with AutoLevel, an add-on to your AutoFarm that can control the height of a leveling bucket – another way AutoFarm owners can stay ahead of the competition.

Reliability & Warranty

The Autofarm has no moving parts and is extremely reliable. It comes with a 12 month warranty is backed by local dealers and Australia’s widest reaching network of dedicated GPS field staff.

http://www.fatcow.com.au/articles/E7/0C043CE7.aspx

Up to 100% finance for plant & equipment to conserve your cashflow. Rabobank’s equipment finance provides a competitive, potentially tax-effective way of financing your plant and equipment to have minimal impact on your farm cashflow.

Finance is available for most agricultural related plant and equipment that is used predominantly in your farming enterprise, including:

Tractors, harvesters and cultivation equipment

Fruit picking and grading equipment

Commercial vehicles, trucks and materials handling equipment

Dairy equipment, automatic feed units and grain storage bins

Quality used plant and equipment, subject to age limitations

Our equipment finance products have been developed to allow you to grow and develop your business alongside the rapid advances in machinery capabilities, as well as maximise technology efficiencies.

http://www.fatcow.com.au/articles/1F/0C04361F.aspx

Daken is a 100% Australian Owned and operated company, committed to quality and service to rural Australia in manufacturing, importing & distributing a wide range of farm equipment. Our product range is inclusive of tractor implements, hay making equipment, electric fencing & animal care equipment.

Our 50 years of experience in manufacturing Electric Fencing products spans design, testing and servicing of an extensive range of Fence Energisers and components designed to perform in the harsh environment that Australia provides.

Daken also manufactures Tractor Implements - for example Slashers, Harrows, Post Hole Diggers, Forage Harvesters - in one of our two factories as well as distributing to the rural market Veterinary products and general farm items.

More recently Daken have commenced distribution of a new line of Bobcat telescopic handlers & Bobcat Utility Vehicles. Our product range is available from an extensive network of dealers as displayed on this web site - or - if you require further information, contact us directly.

Daken is a fully owned subsidiary of Clark Equipment Sales Pty Ltd, another 100% Australian owned company.

http://www.fatcow.com.au/articles/B1/0C043AB1.aspx

A harvester is a 4 or 6 wheel articulated machine
used to fell coniferous trees, remove branches and
cut the logs to prescribed lengths, maximising the
value of the end product. The machine, powered by
a diesel engine, is all wheeldrive and fitted with a
hydraulic loader onto which is mounted a harvester
head. This is equipped with a chain saw to fell the
tree and cut the log into lengths, feed rollers to move
the tree through the head, knives to remove branches
and a device to measure the length of the logs. The
process is controlled by an on-board computer, which
can be linked to the forest office, taking instructions
on the products required by the customer.

The operator sits in a robust air-conditioned cab, which
is constructed to provide protection should the machine
roll over or be hit by a falling tree. The windows are also
glazed with special ‘bullet proof’ material to provide
protection should the saw chain break and a fragment
hit the cab. A single machine is capable of harvesting
up to 60,000 tonnes of timber per year. It would take 24
chainsaw operators to match this output.

The majority of harvesters are manufactured in Scandinavia.
Mechanical Engineering Services provides and maintains 40
harvesters in use throughout the Forestry Commission. It has
been providing this service since the inception of mechanised
harvesting 30 years ago. In so doing it has amassed a wealth
of knowledge and expertise in the maintenance and repair of
these technically advanced machines. If you require harvester
maintenance or repair, contact your local Mechanical
Engineering Services workshops.

http://www.forestry.gov.uk/forestry/infd-6exl6q