Major characteristics of an excellent motor grader mechanic

Hence, it is extremely important to get the machine fixed from time to time from an excellent motor grader mechanic.

Here, it is imperative that the owners consult a well-trained and experienced mechanic. In fact, the presence of a mechanic on the site is not at all limited to just equipment damage repair but they are also required to perform regular maintenance of the equipment so that it performs with maximum efficiency. This requires presence of certain qualities in a motor grader mechanic. Owners of motor graders need to be very cautious when choosing the mechanic for the equipment.

Generally, motor grader mechanics repair, troubleshoot, adjust, overhaul and maintain the equipment. We list down some of the major characteristics of an excellent motor grader mechanic…

1. Natural aptitude for machinery: An excellent motor grader mechanic should be able to feel as well as see and hear the equipment.

2. Sharp observation skills for identifying the problem: One of the basic qualities of a motor grader mechanic is that they should be capable to identify the main problem in the equipment and recognise the underlying troubles by sharply observing and noticing the symptoms. It goes without saying that attention to minute detail for equipment repair is extremely necessary. Typically, motor grader mechanics should have the troubleshooting skills i.e., they should be able to look at the mechanical, hydraulic and electric systems to identify the problems.

3. Ability to resolve the problem of the equipment: For an excellent motor grader mechanic, merely identifying the problems; be it with the electric wires or the hydraulic system, is not enough. If the mechanic is not able to repair the equipment quickly, then he is not fit to be a motor grader mechanic. This is because of the fact that the longer it takes for the mechanic to identify the issue, provide a solution and carry out the necessary repair, the longer the machine is non-productive leading to considerable project delays and huge losses. Hence, the motor grader mechanics need to be well-trained to adjust the equipment and repair or replace defective parts, components or systems using hand and power tools. They should not only be able to repair the main machinery system but should also be able to service the attachments and other working tools of the equipment.

4. Awareness of the latest technology: Since new technologies are continuously coming up and introduced in the heavy machinery like motor graders, it is imperative for the motor grader mechanics to be abreast about such innovations and up-gradations in the field. An excellent motor grader mechanic needs to be well-aware of these latest technologies, software and various other innovations so that he is not only able to fix the equipment but improve its productivity and efficiency as well.

5. Strong communication skills: An excellent motor grader mechanic should have good communication skills as well so that he is able to communicate with the owner of the machine and explain clearly his points to fix or repair the equipment as soon as possible. He should also be a good listener so that he understands what the owner is saying and carries out his instructions at all times. A good owner-mechanic relation is always beneficial and motor grader mechanic should be able to nurture this relationship.

6. Mechanical skills: An excellent motor grader should be well-aware of the various parts and components of the complex machinery and engines. He should also know about the various tools so as to fix the equipment easily.

7. Technical skills: Knowing only the mechanics of the equipment is not enough for the motor grader mechanics. They should be familiar with the electronics of the equipment as well and should be able to use electronic diagnostic equipment to troubleshoot the repairs.

8. Physical stamina: Repairing motor graders can be physically strenuous and demanding, hence, physical strength and stamina is also very important for the mechanics so as to enable them to skilfully handle the equipment for long hours. They often have to work with grease, oil, dirt and diesel fuel and are exposed to fumes and noise. Hence, being physically strong only helps them in their work.

9. Manual dexterity is also important for motor grader mechanics: It is extremely essential for the motor grader mechanics to have good hands and great hand-eye coordination. This helps them to do the repair job quickly.

10. Willingness to work and strong work ethics are equally desirable: A great motor grader mechanic should have good work ethics and should be committed to quickly solving the problem and repairing the equipment.

11. Honest with his work and the owners of the equipment: Good motor grader mechanics should be polite and courteous with the owners and should be honest in their work.

12. The necessary certifications: While it is not a mandate that every motor grader mechanic should have the necessary certificate as their experience is more important, however, if the mechanic has the necessary certifications, it is always good. It proves that the mechanic has full understanding of the equipment and the industry and is up-to-date with the latest technologies and techniques.

In a nutshell

Motor graders are undoubtedly very expensive and highly technical equipment. Since they are highly technical, it is obvious that they would need trained and experienced mechanics who have the expertise in safely repairing the equipment as it goes without saying that any wrong action on their part can cause heavy damage to the equipment.

There are a lot of motor grader mechanics that are experts, but if they lack in the qualities that are mentioned above, then they would not be able to repair the equipment effectively and can cause further problems. Hence, it is always advised to have a trained and experienced motor grader mechanic at the jobsite.

Motor Grader: Repair or Rebuild?

Earlier, the traditional solution to this was seen as buying new equipment. However, it is not unknown that heavy equipment like motor graders have a high purchasing cost and too much of initial investment. Thus, the trend of equipment repairing and rebuilding is now gaining momentum.

Today, motor grader repair as well as rebuild is seen as the best solution to increase the life and use of the equipment. Here, factors like age, cost, labour, time and others play a deciding role in deciding whether the equipment should be rebuild or just repair would work.

Below are the pros and cons of each of the two options and the key criteria that should be considered for adopting any approach…

What is motor grader repair?

Repairing a motor grader is quite easy and a fast process as essentially it involves identifying the problematic parts and components like what is broken or worn out and fixing or replacing with a new part. Generally, an experienced mechanic is called to identify the problem and apply the practical quick fix to the components of the motor graders that have failed, broken or worn out.

Advantages of motor grader repair

There is a list of advantages of motor grader repair. They include:

1. It is generally cheaper or more economical to repair the equipment’s parts or components rather than rebuilding the machine completely. However, what part is affected and the difficulties involved in repairing or replacing it play an important role here.

2. The equipment can be put to use as soon as the repair is done which generally takes very less time. Hence, you might not face losses or project delays due to equipment repair.

Disadvantages of motor grader repair

1. Repairing is not a permanent solution to the problems and the same problem can arise soon or motor grader may malfunction or break down again. Even if there is warranty of the new part, problems can arise.

2. After you repair or replace any particular part of the equipment and put it to use, there are chances that other components which have been subjected to same stress over the same number of years may give up any time. So, again you have to spend time and money in repairing that part.

3. Repairing does not aid in machine’s overall life or to its potential resale value.

4. Last but not the least, if the equipment demands constant and multiple repairs, then there are chances that the repairing cost may exceed the cost of having a motor grader reconditioned and rebuilt. In fact, if your grader is too old or subjected to difficult operating conditions most of the times, then it is expected that such a time will come soon.

What is motor grader rebuild?

Rebuilding or alternatively called as reconditioning is more than repairing and does not involve just fixing what is broken but it is a systematic approach where in a controlled environment, a skilled technician restores the equipment as ‘New’. In the equipment rebuilding process, new software and engineering upgrades are incorporated into the equipment and it can become even better than before. Generally, the motor grader rebuild process includes the following stages…

1. Machine evaluation: In this stage, tests are conducted on the machine and visual inspection is done to identify and analyse the problem, come up with a solution and decide on the cost.

2. Dissembling the machine: The various machines parts are dissembled, general components are replaced with new and other remaining components are tested and replaced wherever necessary.

3. Reconditioning: The parts are inspected and reconditioned to the required standards, hydraulic system is overhauled to deliver original levels of performance and various other tasks are performed.

4. Reassembly: The equipment is reassembled and repainted.

5. Performance testing: Quality control functions are performed at this stage. Safety and functional tests are performed and the equipment is fine-tuned based on the results.

Advantages of motor grader rebuild

The list of advantages includes:

1. Motor grader rebuilding process help the equipment to deliver better performance and make the machine more reliable at a fraction of the cost of a new machine.

2. If the rebuilding process is conducted in the right manner by an experienced team, then it gives a second life to your equipment.

3. Rebuilding the equipment can even increase the resale value of the equipment as the equipment not only looks good but performs efficiently as well.

Disadvantages of motor grader rebuild

1. Rebuilding the equipment is costly process than repairing.

2. It might take very long to rebuild the equipment completely as against merely repairing what has gone wrong. This might result in project delays and losses as equipment cannot be used till the rebuilding process is complete.

So, which is a better option?

Both the options have their pros and cons. So, in order to decide as to whether to repair or rebuild the motor grader, you need to consider factors like the age of the equipment, the way it was used, the present overall condition of the equipment and what parts are needed to be repaired or replaced. If you find out that merely replacing or repairing some parts will do and can improve the efficiency of the equipment and if you have less time in hand to complete a project in addition to limited finances, then definitely repairing the equipment make sense. However, if you find out that most of your equipment parts are not working, machine has become too old but its use is definitely expected to increase in future, then rebuilding the equipment is a better option. Typically, it makes more sense to rebuild the motor grader if it is too old as this can increase the equipment’s productivity for a longer period of time. However, the choice to rebuild or repair the motor grader is completely yours!

How to Increase the Life of a Motor Grader?

Hence, it becomes imperative to use the equipment in the right way, maintain it properly and take all the possible steps to increase its life. The same is the case with heavy equipment like motor graders/road graders/graders as well which are majorly used in the construction and maintenance of roads and for making smoother surfaces, fine grade, levelling soil and shifting small amounts of dirt.

If you intend to increase the life of your motor grader, then the most basic step is having a proper maintenance plan and applying proper operating techniques. We list all the steps that can help to increase the life of your motor grader at the construction site…

1. Have a proper preventive maintenance plan in place:

In order to increase the life of heavy equipment like motor grader, it is necessary to have a proper maintenance strategy in place that can identify all the faults before they happen. For that, the first step is to formulate a plan detailing all the minute things. You need to create and follow a maintenance schedule which would have notations on how often each part of the machinery should be inspected for problems, repairs and general maintenance. Further, during each scheduled service, the machine should be examined from top to bottom and special attention should be paid to possible weaknesses, defects or component faults. By proactively detecting and repairing flaws, you can save your considerable time and money.

2. Carry out checks in between the maintenance schedule:

If you see any change in certain conditions like reaction time, vibration or temperature, it is usually indicative of a developing problem. Hence, it is necessary to carry out checks in between the maintenance schedule to rectify the defects as soon as possible.

3. Maintain the equipment for extreme operating conditions

If your motor grader is exposed to extreme operating conditions like extremely rocky terrain which puts extra pressure on the cutting edge and leads to fine dust clogging up in the air filter, thereby compromising the blade slide and turntable functionality, then you may have to readjust your maintenance schedule and carry out maintenance more frequently. Due to extreme operating conditions, you may have to check the blade more frequently for wear or change the oil filter and lubricate or replace slide guides and other small moving components.

4. Check the equipment on day-to-day basis

Apart from having a regular maintenance schedule, it is extremely necessary to maintain and inspect the equipment regularly so as to keep it safe, corrosion-free and in the best condition. The day-to-day machine inspection list should include the machine frame, circle, tyres, wiring, cylinders, hoses, tools and any areas susceptible to damage or wear and tear. Also, check for leaks and any noticeable abnormalities. If you hear any unusual sounds from the engine, then take it as a warning sign. Always keep the motor grader properly greased during winters.

5. Hire an experience motor grader

Being highly technical equipment, motor graders demand well-trained and experienced operators who can handle the equipment wisely, maintain it regularly and identify defects and malfunctioning of the equipment. In fact, a good machine operator is extremely necessary to increase the life of your grader. By using the proper techniques, an experienced motor grader operator can keep the cutting edge sharp and even, position the mouldboard for optimal performance and adjust the tools to align with the conditions. Also, a skilled and experienced motor grader is well-aware of the techniques to reduce wear on the cutting edge. Here are some steps that trained operators need to take so as to help increase the life of the equipment:

a. Since, the motor grader easily face wear and tear or malfunction or damage due to harsh or rocky terrain, operators need to know as to how to handle the equipment at any such site and prevent any unnecessary damage to the equipment.

b. The operators should essentially know about the correct positioning for the moldboard. The mantra is that it should be always kept straight up and rolling the grader blade forward to make the edge blunt.

c. Operators should never roll the moldboard back as it can negatively affect the final grade and ultimately produce low quality results. Thus, in order to avoid any damage, operators need to keep an eye out for both sides of the edge.

d. While grading along gutters and curbs, operators need to pay extra attention to the task as any slight error can result in the machine running up against the curb and the edge being chipped as well as the mouldboard being highly affected. They need to switch from left lead to right lead to minimise wear on the blade.

e. During the fine grade operations, the mouldboard should be tilted sporadically to ensure more even wear of the blade. Further, operators can even change the blade to the back position to sharpen the edge and achieve a better grade.

f. Operators should never articulate the grader when operating on steep slopes. Grader can roll over and sever personal injury or death can be caused.

g. Operators need to note and avoid all hazards and obstructions such as over-hands, ledges, slide areas, electrical lines, underground cables, water mains or gas lines.

. Rebuild or recondition the equipment for a new second life:

Last but not the least, in order to extend the life of your motor grader and breathe new life into it, you need to recondition or rebuild the equipment. With this, your machine will be re-engineered according to the original specifications, properly tested and thus, will be able to work for long.

So, if you own a motor grader, then do take the above mentioned steps to increase the life of your equipment and use it happily for some more years without any of the major wear and tear!

Constant Servicing is the Key to Maintaining Machines Integrity

Constant servicing also helps to keep the machine in good working condition for a longer period of time and boost its efficiency and productivity. This greatly impacts the resale value of the equipment as well.

Hence, machine maintenance and servicing is a must. For that, you need to check the equipment thoroughly and have complete and accurate records and service checklists in place. The parts/components or things that should form a part of your service or maintenance checklist for keeping heavy CE in good condition includes:

1. Lubricant: You need to have good lubrication maintenance schedule to extend the life of the machinery and its parts. Make sure to look for any signs of excess grease build-up on pistons and leaks around the oil seals. There can be several joints in CE that may require daily or weekly greasing schedule, so you need to take care of that. Further, too little as well as too much lubrication can be harmful for the machine. So, you need to lubricate the equipment wisely with the recommended grade of grease. It is always better to follow manufacturer’s guidelines in this case as there are specific kinds of oil and grease for every component. In some cases, checking the lubricants can also help to diagnose various problems. In fact, experts can analyse the various particles in the used oil and tell which part is suffering from major wear.

2. Oil: You need to opt for oil analysis at regular intervals as it can help you zero in on the top four engine killers i.e., fuel dilution, soot, coolant and dirt, before it’s too late.

3. Fuel level: You need to check the fuel levels and document the periodic refills so as to enable the maintenance personnel to detect potential operational problems at an early stage.

4. Seals and filters: The various seals and filters which are fitted in the CE to keep the dirt and debris out of sensitive areas should be inspected regularly. Broken seals must be repaired immediately, breathers must be kept clean and all filters should be inspected regularly and changed when they become dirty or clogged.

5. Tyres and axle: Debris such as loose gravel or mud may get stuck in the tyre and impact it’s working. So, removing these materials can help in boosting the operational efficiency of the equipment. You also need to check that each of the tyre has the right pressure as this can help in lessening tyre wear, improve stability and reduce the fatigue of the operator. Also, you need to check for any cuts and replace the tyres when needed. Additionally, checking the axles can avoid problems in the field.

6. Gearbox: They should be checked for any vibration and damage to parts.

7. Bolts: Bolts can elongate and creep over time. Hence, torque checks should be run on the bolts.

8. Valves: You should check the valves for any leakage and repair them as soon as possible to prevent the machine from further damage.

9. Drive train components: You need to check pulleys for alignment and wear. Also sprockets should be checked for correct meshing with chains and for breaks.

10. Electrical wiring: Rain water can have a strong impact on the electric wires and other electronic components of the equipment, so, you need to protect your equipment at all times to boost its productivity and lifetime. You need to cover the critical wires properly or shelter the whole equipment under a covering or keep the equipment in shade so as to protect the wear and tear on the electrical components.

Apart from taking care of all the components/parts of CE listed above and their constant servicing, you need to pay attention to other wear and tear as well. Some common signs of wear and tear include…

a) Vibration that is caused by out-of-aligned gears and belts.

b) Shock which comes due to poor operating technique as well as accidents.

c) High temperature due to extended use of the equipment, friction, poor lubrication and worn parts and few other reasons.

d) Age which can impact various components of the equipment like it can lead to belts to wrap and bolts to loose and stretch out of shape.

The above mentioned factors can result in breakdowns easily. So, such issues should be fixed as soon as possible and there should be necessary replacement of the worn parts.

Have your own maintenance, servicing and inspection list

Definitely, you need to pay attention to all the above mentioned points, however, it always pays to have your own set of rules and guidelines based on your past experience or your maintenance expert. It is because the operating environment of the heavy CE may not be the same everywhere and based on this, the maintenance and servicing procedure and schedule can highly vary and who would know better than an expert or the operator of the equipment. Hence, it makes sense to ask the expert to conduct the study of the equipment and come up with the required maintenance and servicing schedule which is needed by the particular machinery.

Overall, if appropriate maintenance schedule is maintained and there is constant servicing of the important components of heavy CE, the machine’s integrity is maintained and this leads to various other benefits as well.

Benefits of constant servicing of the CE

1. The equipment downtime is reduced drastically and the number of repairs and cost associated with it is also decreased.

2. The life of the equipment increases and this eliminated the need to replace the machinery or equipment quite early. This in turn, reduces operational cost.

3. The equipment is able to give good results in minimum time leading to reduction of overtime costs.

4. The safety of the equipment and employee is improved at the job site.

Thus, constant servicing can extend the life of heavy CE and improve your Return on Investment (ROI). So, do pay head to constant servicing and maintenance of the heavy CE.

Motor Graders: Equipment Inspection Tips

Their most common use is in the construction and maintenance of roads with its main function being preparing the topmost layer for laying asphalt on top of it.

Structure

Typical motor grader models have three axles with the engine and cab situated above the rear axles at one end of the vehicle and a third axle at the front end of the vehicle with the blade in between.

Types

A small motor grader within a range of 80-150 horsepower is perfect for jobs that need to be completed in a tight spacing environment, while larger motor graders can be used in broader spaces. Self-propelled machines with an adjustable blade, motor graders are broadly classified into two categories i.e., Rigid Frame Motor Graders and Articulated Frame Motor Graders.

Inspection tips

Be it small or large motor graders or Rigid Frame or Articulated Frame Motor Graders, if you are planning to buy any one of the above used equipment, you need to ensure that you inspect the equipment properly. You need to carefully draft your inspection list and take a thorough look at all the motor grader components.

Here are some inspection tips for motor graders…

1. Check the frame of the motor grader thoroughly: You should always make it a point to take a walk around the motor grader carefully observing the frame of the machine. Through this way, you will be able to locate any fishplates which are generally metal reinforcements placed over or even behind a repaired crack. Make a note of it and do confirm with the seller if the repair was done by a qualified welder and when.

2. Pay attention to the motor grader’s circle: On the motor grader’s circle, moldboards are mounted and the angle and tilt of this moldboard can be manipulated by the equipment operator by manipulating the position or angle of the circle. It goes without saying that without a properly maintained and operating circle, the motor grader operator will not be able to carry out the fine grading tasks easily and it could become extremely difficult for him. Further, the circle’s surface should also be checked for any signs of uneven wear. If the circle is improperly aligned, then pinion gear teeth may see uneven wear and tear. Generally, uneven wear and the resulting vertical play do not happen through the use of shims. If shims are used, then start up the equipment and put the circle through its full range of motions so as to check for any play.

3. Have a thorough look at the moldboard: Inspect the moldboard and ensure that the cutting edge of it which is bolted along the bottom of moldboard and along the sides is always straight. There is no doubt that the rock and soil will lead to wearing down of the centre of the cutting edge which will eventually need to be replaced. Generally, it is seen that the cutting edge used to maintain rocky and unfinished roads do not last long. So, always ensure that the cutting edge is replaced at the right time and is in the right position. While buying the equipment, make it a point to see how much cutting edge is remaining on the moldboard. When the cutting edge is just half an inch or maybe less, then it should be replaced along with the bolts that are used for holding it in place. Always remember that it is better to replace the cutting edge than the moldboard as the later is very expensive and you would not want the moldboard to do the work of the cutting edge.

4. Look for any wear in the articulation point and linkage system: The scale of wear in the articulation point depends on the type of work performed by the motor graders. In case of rocky, rough and uneven ground, the wear is always more. Further, you need to ensure that the front and back half of the motor grader is in line and there is no difference in the level i.e., if the cab is sitting higher than the engine compartment or vice versa, this means that the articulation point is bent or loose. You need to ask the seller to repair this as soon as possible. Also, you should check the linkage system at the front of the equipment. This is because any strain and stress can be caused when tires are turned and leaned and this could damage the frame as well as the linkage system. Do pay heed to the inside of the frame and on the front axle for any evidence of damage. Check the steering component as well to ensure everything is upright.

5. All should be well with hydraulics, cylinders, lines and hoses: For checking the health of hydraulics correctly, look at the ground beneath the machine for any fluid leaks as you can easily spot it here. After checking under and around the equipment, observe all the cylinders, lines and hoses within the engine compartment, circle drive housing etc. Make a note if there is any leak or damage that will need to be checked.

6. Check for strange noise or incorrect behaviour of the brakes- Test the working of the brakes as sometimes the original ones are replaced by cheap quality ones. This may result in incorrect behaviour or strange noises, thus, hampering the work at jobsite. So, you need to start the machine and check the noise level. If the engine makes strange noise, then it means that the machine may not give good results.

Apart from the above mentioned inspection list, one also needs to look at the overall structure and exteriors of the equipment. For example, you need to pay attention to the tires and underneath and finally check the cab and other general operations of the motor grader. So, select the equipment with caution. Inspect carefully and compare different models before you make the purchase decision. Do remember the above mentioned tips.

Tips to Solve the Unexpected Transmission Issue of Motor Graders

In fact as per Off-Highway Research, the motor grader market is expected to grow from 750 units in 2016 to 850 units by 2020. Thus, indeed the future of motor graders looks bright and it only makes sense to learn more about this equipment.

So what is a motor grader? Well, motor graders are absolutely necessary equipment at any construction site. They are usually self-propelled machines with an adjustable blade. Typical motor grader models have three axles with the engine and cab situated above the rear axles at one end of the vehicle and a third axle at the front end of the vehicle with the blade in between.

Generally, motor graders are used to finish grade (refine, set precisely) the rough grading performed by heavy CE such as scrapers and bulldozers. A small motor grader within a range of 80-150 horsepower is usually enough for most jobs. While, the smaller graders are perfect for jobs that need to be completed in a tight spacing environment, larger motor graders can be used in broader spaces. Larger machines are known to use a direct drive or a torque converter drive transmission system while the smaller ones are hydrostatically driven.

Undoubtedly, motor graders are costly equipment and that is the reason they rarely encounter any major problem. However, most of the times, the motor grader operators face problems with the transmission system which is surely, one of the most vital organs of the equipment. Transmission system’s purpose is to take the productivity from the engine and operate it to manage the swiftness, direction and torque and if there are any problems with the transition system, then the equipment may fail to work in the best possible manner.

Problems associated with transmission system and tips to solve it

The motor graders face a variety of issues with the transmission system. If you too are worried about the same problem, then here are some common transmission problems identified and quick tips discussed to solve them…

1. The gears might not work properly after some time. The gear problem can hamper the speed of the equipment and may not allow the motor grader to move fast on the terrain. In such a case, you can change or replace the gear. However, the ultimate solution is removing the side covers of the motor grader and cleaning all the trans-electrical connection and hoses with the solenoids.

2. You also need to immediately check the oil quality because if the oil quality is not good enough, then also the problem can pop up. If the oil is contaminated, then it can result in transmission problems. So, the oil in the equipment should be regularly changed to keep the engine up-to-date. Ensure that you use the transmission oil which is mentioned by the manufacturer. In order to avoid transmission problems, you can also perform the fluid analysis.

3. There may be times, when the gear would work but the gear system would not move beyond a certain point. This is mainly because they are not getting the right voltage in the coil system. Also, on major occasions, the coil may not work due to excessive heat in the internal system. A quick solution to this problem is that you should change the coil system.

4. You should also invest your time in reading the user instruction manual which does mention about managing the transmission system woes. It can not only help the customers to gain knowledge about transmission but also recommend some maintenance tips that can enhance the productivity of the equipment and avert any problems.

5. If all the above tips do not work, then you should call the expert to fix the issue as who would know it better than them. The experts from the company have clear understanding of the equipment and they can solve the transmission system woes easily in no time. You can even go to the manufacturer’s outlet and get the issue sorted at the earliest.

So, if there is an unexpected transmission issue with the motor grader, then you should not waste any time and repair it as soon as possible.

General tips

In addition to the above mentioned tips, you need to follow certain general rules also so as to have your equipment functioning in a proper manner at all times.

1. Equipment like motor graders are prone to a major and minor problems more often. So, in order to solve these problems including the transmission system woes, you need to service the machine regularly.

2. The motor grader operators should be trained so that they can maintain, troubleshoot and store the equipment.

Next time, when you use a motor grader, do remember the above mentioned tips.

Construction Equipment Assessment Tips – Motor Graders

While not everyone can afford a new machine, even old machines in good conditions can prove to be quite a boon if assessed properly before buying it. While these sophisticated machines are not rocket science, they do require assessment by a trained eye. Here are some of our assessment tips that will help you make the most of your machine.

It starts with the frame: A sturdy frame is a must have for any kind of heavy duty construction equipment. The motor grader is no exception to this. Always check the frame for strength and stability before considering buy the machine in question. As a matter of fact, especially when it comes to buying second hand machines, one must ensure that there arent any fish plates on the machine. Fishplates are usually welded behind cracks to distribute the load around and away from the cracked part. An in case there are fishplates present, ensure that a professional welder has done the job to ensure maximum life of the said part requiring the fishplate.

Circle right: Mouldboards that function as the prime grading part of the machine are usually fixed with the circle of the grader. The circle has to be maintained properly for the machine to carry out a good grading job on the site. Any issues in the alignment in terms of the positioning and or angle will make it difficult for the operator to carry out a fine grading job. The circle should be checked for any marks of irregular wear to ensure that the machine has not been abused by the operator. the pin gear teeth will end up with an irregular abrade if the circle is lined up incorrectly. Using shims can reduce and even bar upright play resulting from rough wear in an appropriately lined circle.

Moldboard does it: A Moldboard is a prime part of a motor grader and at the front line when grading a job site. it goes without saying that a good moldboard in a good condition is required when using or assessing a machine. Ensure that the board is free of any cracks and repairs. It is particularly important to ensure that there is no wear and tear to the top and the bottom of the moldboard. The cutting edge bolts should be checked that all of them are present and levelled. The side rails at the top of the moldboard must be level and free of any kind of damage.

Articulation point and linkages: Abrades to the articulation points will highly depend on the surroundings that the motor grader was used in. Rocky terrain and rough grounds make for harsher abrades as compared to that of smoother grounds.So check for abrades if any and its extent. Next come the linkage system that need checking. The linkage system should be checked moving towards the obverse of the motor grader to check for damage. Additionally even the frame should be checked for damage due to pressure and strain. Next up are the tyres that need to be checked for leaning and turning for any kind of damage in addition to checking the directing modules.

Hydraulics are king: Hydraulics are some of the most integral parts in all sorts of construction equipment and the motor grader is no exception. The hydraulics should first be checked visually for any damage, leak or blockage. Leaks are usually visible as a dirty layer alongside the hydraulics. The next thing on the list os to check under the grader. If there is a leak or damage to the hydraulics, you will most likely find proof when you look under. If none is found it can be pretty safe to assume that any massive damage or leaks are highly unlikely. Once the hydraulics are done, one should check the cylinders, lines and hoses for any signs of damage or leak. Any leaks in the hydraulic system can affect the machine’s performance drastically. Any damage or leaks will have to be noted for repair before using the machine further.

As a rule of thumb, machines that are regularly assed and maintained do not require much work or expenditure for the machine to perform. Having trained and experienced operators use the machine, storing it safe from environmental factors, making repairs when the issues are small will all prove to be very beneficial in the long run. It will not only have the machine work well but also fetch a good price when being sold off.

How to Maintain Earth Drill for Maximum Uptime

1) Hydraulic earth drills: These drills are created to withstand extreme conditions and have relatively fewer parts. Like any other attachment and machine these also need to maintained regularly to ensure maximum up time.

2) Hydraulic Fluid: Always make sure that the hydraulic reservoir is filled till the top of the sight gauge. The return line filter and the hydraulic oil need to be kept clean at all times. Always ensure that all the connecting bolts and fasteners are properly in place and tight. Loose fittings can cause premature wear. The hydraulic oil and return line filter need to be replaced and cleaned on regular intervals as specified by the manufacturer.

3) Hoses and disconnects: The Hoses quick needs to be cleaned regularly before and after the drilling is done. Once a job is completed and the drill is being taken apart the hydraulic output hose needs to be disconnected onto its input coupler and vice versa. This helps keep the hydraulic system clean and free of any dust. Should the disconnect fitting start leaking, the coupling will require to be replaced. The drill hoses and pipes need to be regularly checked for cracks, leaks and abrasions. In case any of these are present the parts need to be replaced. The drill works best when the hose connections are kept properly tight and fit.

4) Drill Blades and points: If the blades or points get worn out or dull, then they need to be replaced. Pre and post drilling check ups are a must for the blades and points. A worn out blade requires prompt replacement failing which it may cause damage to other parts and eventually require costly replacements and or repairs.

5) Control valve: Any hydraulic leaks observed by the operator, require the power to be cut off. After cutting off the power, the hydraulic pressure needs to be relieved by moving the control valves in both directions, which will in turn opens up the hydraulic flow. The screw fittings at both ends of the hoses need to be screwed tightly in place. In case the leakage doesnt stop, it could indicate that the hose assembly needs to be replaced. The seal kit might need to be replaced if the control valve leaks around the spool shaft.

6)Torque Tube: The tube needs to be checked before and after each use. The attachments need to be checked to see if they are secured in place. In case of a bend or break, it needs to be replaced.

7) Storage: Once used, the drills need to be thoroughly checked and stored in a clean dry place protected form moisture to avoid rusting. Storage is a very important part of the maintenance process to increase the life of the drill.

8) Mechanical Earth drills: These are usually used for relatively smaller jobs. Similar to the hydraulic drill, simple maintenance of the various parts can help increase its uptime.

9) Transmission and gear box: Should it start making any unfamiliar sounds or heat up more than usual, it needs to be checked and repaired or replaced. Unusual sounds are usually the first indicators of something being wrong and can easily cause the motor to start locking up when in use. Heat can be detected by the operator through the smell of burnt oils and or extreme heating. Either of these can be a sign of low oil. Leaks around the bottom seal, along the top of the transmission and lower output shaft, the fluid in the gearbox needs to be checked and an oil change may be required if deemed necessary.

10) Drive Shaft: The driveshaft needs to be cleaned and greased regularly as specified by the manufacturer. Torn wires, deep cuts, or torn wire braids warrant the shaft housing to be replaced. The core of the shaft might need replacing in case sharp kinks, broken wires are found or in case gear box doesnt turn despite the running motor. An appropriate amount of grease should be used, not too much or too little. A dried out cable might break or burn damaging the outer housing.

11) Clutch: The clutch needs to be checked regularly as and when the drive shaft is lubricated. The shoes and drums need to be cleaned as well. A jerking drill is an indicator of a problem. A clutch lacking a padding will continue working but with a reduced efficiency while the engine runs at full speed. The auger spinning at idle or overheating is indicative of a clutch spring requiring replacement.

12) Points and Blades: Similar to the hydraulic ones, the points an blades need to be checked regularly for any kind of wear and tear. The blades need to be kept sharp to ensure that the drill works efficiently failing which the point will wear out and become cone shaped thereby reducing efficiency.

13) Engine: Mechanical drills may be different from the engine that powers it. However its a sensible thing to check the engine oil on a daily basis and changed regularly as instructed by the manufacturer. Air Filters need to be changed similarly to protect the internal engine parts from dust and dirt.

Maintenance of Heavy Earth Moving Equipment

1. Trained handlers – For most part of their shelf life, the heavy machinery go through most damage due to mishandling by unexperienced people. Most people handling the machines are not qualified enough to use the machines appropriately. Ensure that your machines are handled by company trained or appropriately certified operators to minimise the wear and tear on the machine due to man handling. People responsible for regular maintenance of the machinery should ideally be certified by the OEM to handle the machine, problem shooting and its up keep or be working with a certified service centre.

2. Regular maintenance – This is the best preventive measure one can take to keep the machines at their best performance over time. Regular maintenance of heavy earth moving equipment means catching the problems while they are still small and starting and solving them in the bud before they can cause major damage. Incase most machines in your fleet belong to the same company, its best to get a maintenance contract in place with the company’s service centre on a yearly basis. Having the machines regularly maintained by certified people will increase your machine’s shelf life by a good couple of years in addition to reducing its cost depreciation over time.

3. Regular cleaning and storage: Heavy machinery usually work in a very soiled environment and gets muddled more often than not. If dirt and grime get into any sensitive areas it can lead to malfunctioning and break downs. Any seals either broken or damaged should be replaced immediately failing which the sensitive parts of the machine will be damaged. The machines should be kept clean of any dirt and debris once the job for the day is done. The machines should be stored in closed areas away from water to keep environmental damage at bay.

4. Lubricate well – Lubrication can single handedly make or break even the best of heavy machinery over time. All moving parts of the machine should be kept properly lubricated at all times to prevent wear, tear and damage to the parts due to friction. Under lubrication will lead to frictional wear and tear while over lubrication will increase grease deposit, issues with the seals and loss of energy. Similarly its important to use a good quality company approved lubricant for best results. Using the wrong type of lubricant will do more damage than good.

5. Track wear and tear – Seasoned operators at good at noticing signs that might point to wear and tear in the machines during regular operations. Keeping an eye for the smaller details will help one catch problems before they become big enough to require repair or replacement of parts. Common signs of wear and tear are excessive heating, abnormal vibration and belt shape etc. Its best to fix any issues that are noticed immediately before they become huge. Excess heating may point towards lubrication issues while vibration may be caused due to glitches with the gears and alignments of the belts etc. Misshapen belts are another red flag that needs attention.

6. Using the right parts and tools – While cheap parts and tools will say you money in the short run, it will cause heavy expenses in the long run. It best to use original company manufactured replacement parts when required.

Essentials of Oil Analysis on Earthmoving Equipment

op four engine killers i.e., fuel dilution, soot, coolant and dirt, before it’s too late.

Essentially, the oil analysis is important for the earthmoving equipment because these are heavy equipment and their repairing cost is too high. What more? If they stop working, then the whole project gets delayed resulting in major loses. Hence, before buying used equipment, oil analysis assumes very much importance. Not only at the time of purchase but oil analysis can be performed on your working equipment too which is being used regularly to know the problems in advance.

What to do for oil analysis?

Make sure you give the correct information about the oil sample such as engine type, unit from which the sample is taken, equipment manufacturers name, model number, application, OEM standard maintenance guidelines and other details. Other information that needs to accompany each individual sample include the hours on both engine and oil, any recent oil and filter changes, what oil you’ve used to top off with and how much and the sample date. If any of this information is missing, then the resulting report could offer an incomplete picture. So, give these details carefully.

When sending the oil samples, you should also review the maintenance history of the unit from which the sample is taken and provide the laboratory with as many specified details as possible.

What does oil analysis report indicate?

The oil analysis report include information such as the name of the lubricant manufacturer, type and grade of the lube, filter types and their micron ratings, sump capacity, date received and date returned. The report also specifies recommendations if any like something as simple as an oil change or the report might suggest specific actions to be taken such as running a check on the account of significantly high levels of silicon and other dirt found in the sample.

The oil analysis report also identifies the type and amount of wear particles, contamination and oil additives in the oil. If the report suggests that maintenance action should be taken, then first, you should consider all other available diagnostic information such as vibration, in-line sensors etc. After that, if the issues still persist, then you should do what is recommended or perform more tests.

You should immediately send a second sample to the lab to verify results, if resampling is suggested. If there are no recommendations or resampling suggested, then monitor the unit and take oil samples at normal intervals.

Summing up

Well, there is no doubt that an oil analysis can help in identifying major issues with the equipment but you should also keep in mind that no test is perfect. Each one has its limitations. Hence, you should never tear down an equipment based on one oil analysis report alone. In fact, you should run more sophisticated tests and track the trends before taking the unit apart. Also, you should send a follow-up sample to the lab to confirm the results or use other diagnostic tools to further investigate the problem.