Motor Grader Start-Up and Shutdown Procedures
Be it experienced or non-experienced operators, all are required to note and observe the proper motor grader operating as well as starting and shutting down procedure very well.
So, how do you go about starting and shutting down the machine? Here is a basic guide for the same…
Starting procedure for the motor grader
Before starting the motor grader, it is extremely essential to ensure that all the pre-start procedures have been followed. These include visually inspecting controls, engine, compartment, cooling system, gear boxes, hydraulic parts and other parts if they are worn out or broken; walking around the equipment and checking loose bolts, trash build-up, oil or coolant leaks and damaged tires; checking for any defects or potential problems while greasing the machine; checking all the attachments of the motor grader and ensuring that all the safety equipment are working and clean. In addition to it, it is equally important to look at the fuel, coolant and oil levels, the power-steering reservoir and power-shift transmissions. Apart from this, it is extremely essential that you read the operators’ manual and perform all the checks suggested in it. After all these pre-start up checks, you should be ready to start the equipment. So how to go about it?
Well, in neutral position and with the parking brake on, you need to open the throttle to a quarter and turn the starter. Then, the clutch should be depressed to ease the starter load. Here, it should be noted that you should not press the starter for more than 30 seconds and if you do so, allow two minutes for cooling before starting again. This is because an overheated starter could cause a fire. After this, when the motor grader has started, wait for few minutes and check the gauges. If everything is fine, then check the controls and wait for some time till the hydraulic oil is warmed up.
Tips to be kept in mind while starting the motor grader
1. Check all the signals, lights and flags on mouldboard and cab.
2. Take precautions so as to prevent overflowing the tank or spilling fuel.
3. Walk around and ensure that there is no one next to, under, or on the machine.
4. Ensure that the controls are in neutral position.
5. Check the horn sound.
6. Test all controls, brakes, steering and accelerator before starting the equipment.
7. Listen and report unusual noises, if there is any.
8. Recheck lights, back-up alarms and other warning or safety devices.
9. Make sure the machine is equipped with a lighting system that is adequate for the job conditions.
10. Adjust seat for proper height and pedal reach.
11. Inspect and adjust mirrors.
12. Inspect, adjust and fasten seat belt. Adjust the seat so that full pedal travel can be achieved with the operator’s back against the back of the seat.
13. Turn engine start switch to the ON position.
14.Turn the key start switch to START, crank engine and release when engine starts.
Shutting down procedure for the motor grader
When it comes time to shutting down the motor grader, it is extremely essential to give the equipment few minutes to cool down. Typically, two to three minutes are enough for it. While parking the machine, clearly ensure that you park the machine as near to level as possible. Make it a point to lower all hydraulic equipment to the ground and set the parking brake.
Once the machine is completely shut down, make it a practice to walk around the machine looking for any leaks such as leaks in the hydraulic system hose or connections, fuel, coolant, grease or oil leaks or loose and worn parts. In addition, you should perform few tasks as a part of the post-shutdown quality check. These include checking for any blade wear and tear i.e., they should be wearing straight and not cupped in the middle. Further, the oil, coolant and fuel level should also be checked. Last but not the least, checks should also be performed for finding any dirt or mix and they should be cleaned well so as to prevent any hindrances to the sliding surface, lubrication point or pivot setting.
Tips to be kept in mind while shutting down the motor grader
1. Reduce the engine speed.
2. Apply the service brake to slow the machine.
3. Keep the transmission neutral.
4. Allow engine to cool gradually.
5. Lower all equipment to the ground and activate any control locks.
6. For parking, select level ground wherever possible.
7. If the grader is disabled and cannot be moved from the roadway, then put out flags and flares (flares are mandatory at night and during periods of poor visibility).
8. Have the grader removed from the roadway as soon as possible.
9. Remove ignition key when leaving grader.
10. Turn battery disconnect switch to OFF.
11. Secure machine to prevent unauthorised starting and movement.
12. Dismount machine using 3-point contact.
13. Conduct post-operation walk-around inspection.
14. Refill the fuel for make the equipment ready for next operation.
To sum up
By following the above mentioned start-up and shut down procedure, you can operate the motor grader smoothly and swiftly and also avoid dangerous injuries to men and machine. These small but important tips can help to increase productivity as well as efficiency of the machine to a very large extent. Be it any type of motor grader, the above mentioned start-up and shut down procedure remain same and should be followed at any cost. This not only increases the life of the motor grader but also improves jobsite efficiency. Hence, always ensure that the motor grader operator knows about these practices very well and always observe the above mentioned rules at any cost.
Know the Fundamentals While Operating a Motor Grader
Motor graders are generally used for road construction and maintenance. Although, motor graders are highly versatile, yet they are very complex equipment and operating them is not at all easy. Hence, the operators need to know certain fundamentals before and while operating the motor graders.
Factors to be considered before operating motor graders
1. Your requirement: Since buying motor grader is a costly affair, you need to have a clear understanding of what it can and cannot do and whether it is the right equipment for the job that you are planning to perform with it. Various types of motor graders can be used for performing similar but different grading tasks. So, before buying any type of motor grader, you need to know your exact requirement and determine the purpose for which you will be using the motor grader. Generally, motor graders can be used for construction work, forestry and mining applications. It is advisable to use small graders if you wish to perform tasks like maintaining roads or building landscapes.
2. Ground conditions: Considering the ground condition is very important too as it can help you to select the right type and size of the motor grader. Certain ground conditions put tremendous pressure on the motor grader’s blade and vice versa. It is recommended that you use heavy motor grader at the sites which are full of rocks and gravels because such a terrain can hugely impact the machine’s pins and basic structure.
3. Other considerations: For road maintenance, motor graders which have wider and thicker edges should be used as such graders have better features such as superior abrasion and collision resistance ability. Motor graders with curved edges give better performance in terms of superior infiltration and rolling action beneficial for fine grading and finish work. Apart from this, there are various other points that should be considered.
4. Basic understanding on part of the operators
a. Operators should not operate the grader until they completely read and understand the warnings and instructions written in the operating manual. Failure to follow the instructions or understand the hazard alerts, safety signs and precautions can result in machine damage, injury or death.
b. Operators should also know proper techniques. For example, 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.
c. Also, a skilled and experienced motor grader should be well-aware of the techniques to reduce wear on the cutting edge.
d. Operators should also know about using latest technologies such as GPS and laser control system.
e. Further, motor graders require different blades to fulfil different jobs and it is the operators who should clearly know about which blade to be used for which job.
f. Understanding of various motor grader attachments and their uses should also be known to the operators.
Factors to be considered while operating motor graders
1. Generally, the task of grading the site should be done with those motor graders which have hydraulic engines with cooling fans to improve the cooling performance of the motor grader while operating it in hot weather. It is the cooling fans which prevent the machine from getting overheated.
2. It is advisable to use less RPM to grade the construction sites as it is fuel-efficient and also increase the productivity of the motor grader.
3. The mouldboard should be always correctly positioned. The mantra is that it should be always kept straight up and rolling the grader blade forward to make the edge blunt. This also results in better rear visibility and the operator can finish the task easily.
4. Operating speed of the motor grader highly affects the quality of work. So, while ditching or blading, there should be no hurry. Higher speed can sometimes cause the motor grader to bounce and gauge the surface rather than smoothen it. Sometimes, in extreme cases, bouncing can cause the operator to lose control of the grader, producing a potential accident situation. So, the machine travel speed should be low enough to prevent machine bounce (generally 3 to 5 mph).
5. When sacrificing or ripping across a slope, operators need to keep the mouldboard parallel with the front axle, centred to the frame and lowered close to the ground to provide protection against rolling over.
6. When using the ripper, they need to lower the teeth into the ground with the grader in motion. If the rear wheels lose traction, operators need to raise the ripper until the wheels regain traction.
7. Only required amount of downward pressure should be applied to accomplish any task as excessive unnecessary downward pressure on hard and dry surface can cause rapid cutting edge wear and will require more horsepower and fuel, thereby, reducing productivity.
8. When turning around the motor grader, the wheels should always be leaned in the direction in which the turn is being made. This will help the motor grader to turn with ease.
Thus, above mentioned are some fundamentals that the operators should know before and while operating the motor graders, so as to operate the equipment smoothly and efficiently and get the best out of it.
Tools to Develop Motor Grader Talent
Thus, it is always better to employ an operator that is well-trained and has years of experience to bank upon. However, there is always lack of skilled and experienced motor graders.
Given that there is no substitute at all for the experience of motor grader operators, still these days motor grader manufacturers are constantly trying to address the critical shortage of qualified operators by offering enhanced features to simplify motor grader operation as well as various training aides such as simulators.
Various tools that help the motor grader operators
Gone are the days when learning motor grader operation was considered as an art, today there are various options and smart features that are incorporated in the equipment itself that help the operators perform efficiently. Here is a list of tools and methods that help in developing motor grader talent…
1. Machine control technology: The first and most important tool that helps in developing motor grader talent is machine control technology that is simple and intuitive. Through machine control, even less-experienced operators are able to work easily and achieve grade characteristics similar to those with more field experience. So, while experienced motor grader operators can maintain efficiency levels throughout the day, less experience operators can definitely be more productive and produce better results with advanced machine controls. Also, machine control and other automations help to reduce operator fatigue.
2. Joystick controls: In the past, motor graders were equipped with controls which were not at all simple to learn and often scared the new operators. However, those traditional level-operated controls are now replaced by joystick controls that are simple and intuitive and help in easing the operating task. Joystick controls also help in improving the ergonomic experience of the operator, increase grading performance and even improve accuracy to a great extent. Further, such controls provide better visibility to the operator, thereby, increasing their productivity. Thus, simplified controls can easily reduce the learning curve of the operators and simplify what has traditionally been a complex task.
3. Grade control: Grade control systems can greatly help in offsetting productivity losses from less experienced operators. The most useful tool to an operator is the accessibility of a control box in the cab of the machine which indicates where the operator needs to grade on the project. Further, there is no need to add multiple controls such as levers, switches etc., to activate the modern-day grade control systems. Thus, grade controls can simplify machine operation regardless of the skill level of the operator. Through grade control, motor grader operators can clearly focus on blade rotation and blade pitch as required for the particular grading task and steering the machine. Precision and productivity are also increased through the automated grade control systems. Overall, grade control system help operators work more confidently and achieve targeted grade or slope faster in very few passes using very less material.
4. Cross slope: Most of the modern motor graders offer cross slope and an open architecture approach to grade control. Cross slope makes it very much possible for the operator to adjust to a grade and maintain that grade with just one hand. This helps the operator in keeping a correct slope and managing the material easily.
5. The Global Positioning System (GPS): This technology can help the motor grader operators to achieve precise levelling that too in all weather conditions. Most of the advanced motor graders having GPS-based grade controls possess in-cab touch screen monitor that provides the operator with a plan view, cross-section view and cut/fill information, driving efficiency and accuracy in projects. In fact, GPS-based grade control systems make the task of grading very easy and result in 30 per cent improvement in efficiency and speed and cost savings.
6. Telematics: Even telematics can help the motor grader operators to a very great extent by capturing real-time data such as engine hours, fluid levels, operating temperatures and other information. Through telematics, operators can also track the equipment hours on a day-to-day basis and this helps them in equipment maintenance and identifying the problems with the equipment before they happen.
7. Stimulators for improved performance: These days, even simulators are used to help the motor grader operators to learn the controls and techniques without burning much of fuel and risking the valuable equipment. There are a variety of training exercises designed to address each of the skills associated with operating actual motor graders and they are represented in different work environments such as construction or mining.
8. Training mechanism for the operators: Last but not the least, one of the best ways to develop motor grader talent is training them. Companies like Mahindra Construction Equipment (MCE) can help improve productivity and safety through the delivery of heavy equipment operator training services i.e., if you buy the motor grader from MCE, then as part of its post-sales services, the company will offer few days’ dedicated training for the operators, in which they are personally trained on various features of the machines by professional trainers. Apart from this, MCE has 6 regional training centres across the country which imparts expertise and provides training on equipment operation, daily, weekly and monthly equipment maintenance and safety parameters. Also, adequate practical training is provided here to the students. What more? MCE has also tied up with an authorised institution in this regard.
In a nutshell
Given the fact that motor graders are very expensive and highly technical equipment, it is imperative that they are operated by trained and experienced operators. However, in present scenario, there is huge lack of such operators. Here comes the importance of various tools and enhanced features that are incorporated in the modern motor graders that greatly help in developing the motor grader talent.
Motor Grader Operation: Skill Earned by Training Despite Machine Control
Well, yes, to some extent machine control technology reduces the need of the contractors to find the right operators and then train them as even less-experienced operators are able to work easily and achieve grade characteristics similar to those with more field experience; however, it is the experienced and skilled motor grader operators that help in performing all the tasks at the jobsite with ease and efficiency. Thus, it always makes sense to have an operator that is well-trained and has years of experience to bank upon. As for the motor grader operators, it is very important for them to learn the operating skills through training and not just depend on the machine controls only.
Benefits of experienced, skilled and trained motor grader operators
The host of benefits include…
1. Trained motor grader operators can operate the machine independently, safely and responsibly.
2. They are well aware of the pre-checks and start-up checks to be conducted while operating the equipment.
3. They know very well about various functions and use of the equipment and its various attachments.
4. Experienced and skilled motor grader operators also know about how to operate graders in the most challenging working environments so as to get best results.
5. They not only know about operating the equipment but are also aware about how to maintain, troubleshoot and store the equipment.
6. They know about the workplace safety requirements and procedures very well.
7. They are well aware of the new technologies. Since new technologies are continuously coming up and introduced in the heavy machinery like motor graders, experienced and trained motor grader operators are abreast about such innovations and up-gradations in the field.
8. The trained motor grader operators have good communication skills which help them in communicating and directing their co-workers to perform the relevant tasks.
9. The trained operators also possess physical strength and stamina which help them in skilfully handling the equipment for long hours.
10. Trained motor grader operators also know about good work ethics clearly.
11. While it is not a mandate that motor grader operators should have the necessary certificate as their experience is more important, however, most of the trained motor grader operators have the necessary certifications which is always good. It proves that they have full understanding of the equipment and the industry and are up-to-date with the latest technologies and techniques.
That said, the point to be noted here is that there aren’t enough skilled and trained motor grader operators in the market. In fact, most of the times, the motor grader operator are novice without having any formal training. Also, there is lack of heavy equipment training and relating institutes in India at the present. Even if there are few government-backed institutes, then the training that the students get at these institutes is inadequate to meet the standards of work and efficiency that the industry demands. Also, in these institutes, only theoretical training is given and practical training is lacking.
Private players like MCE’s initiative
With a growing skills gap in the country and most of the experienced motor grader operators aging out, it’s becoming harder for the contractors and construction companies to find skilled operators to operate their motor graders. Realising this growing need for operator training for heavy equipment like motor graders, various private heavy construction equipment manufacturers in the country are coming up to bridge the skill gap by establishing their own training centres in various parts of the country in addition to introducing various certification courses for operator training. One such manufacturing giant in India is Mahindra Construction Equipment (MCE).
MCE has 6 regional training centres across the country which imparts expertise and provides training on the below mentioned aspects…
1. Equipment operation
2. Daily, weekly and monthly equipment maintenance
3. Safety parameters
Also, adequate practical training is provided here to the students. Thus, through this initiative, MCE aims to develop and enhance skills of the heavy equipment operators like motor grader operators with its expertise. What more? MCE has also tied up with an authorised institution.
Apart from this, if you buy any equipment from MCE, then as part of its post-sales services, the company offers few days’ dedicated training for the operators, in which they are personally trained on various features of the machines by professional trainers.
In a nutshell
The main task of motor grader operators includes driving and controlling the equipment safely and as per schedule. They also should be able to operate various attachments as applicable and should know their respective functions. Motor grader operators are also held responsible for the maintenance of the equipment. Apart from this, motor grader operators should also be able to identify defects and malfunctioning of the equipment and in such a case, they are required to take immediate action in terms of lodging complaints and getting the defects fixed. Well, all these tasks can only be performed well by trained and experienced motor grader operators. Hence, it is always advised to have trained motor grader operators at the jobsite.
Further, given the fact that motor graders are very expensive and highly technical equipment, it is obvious that they need trained and experienced operators who have the expertise in using the advanced machine controls in the equipment and generate better results and increase the ROI in the long run.
Thus, there is no doubt that for the contractors to win more and more big projects, it is required that they employ motor graders with advanced machine control technology. However, it is equally important that they hire motor grader operators who are skilled, trained and experienced to make the best use of the advanced technology and machine controls in the equipment.
Safety tips for common type of motor graders
Typically, observance of safety rules and alertness on the part of the operator on the jobsite can result in increased jobsite safety.
Here are some safety tips that should be kept in mind while operating the commonly used motor graders…
1. Pre-start checks:
a) The first step is to read the operators’ manual to get familiar with the controls of the equipment.
b) You also need to read the warning labels and stickers as well as maintenance information, specification charts and other important information posted around the machine.
c) Visually inspect controls, engine, compartment, cooling system, gear boxes, hydraulic parts and other parts.
d) Check all the attachments of the motor grader. See if everything is in its proper place.
e) Walk around the equipment and check loose bolts, trash build-up, oil or coolant leaks and damaged tires.
f) Always ensure that all the safety equipment are working and clean.
2. Checks to be performed when starting the motor grader machine:
a) Check all the signals, lights and flags on mouldboard and cab.
b) Always turn off the ignition and allow the engine and exhaust to cool prior to opening the fuel cap and refuelling the vehicle.
c) Take precautions so as to prevent overflowing the tank or spilling fuel.
d) Loosen radiator cap slightly, pause to relieve pressure slowly and then remove the cap.
e) Never pour cold coolant into the radiator if the engine is hot.
f) Walk around and ensure that there is no one next to, under, or on the machine.
g) Ensure that the controls are in neutral position.
h) Check the horn sound.
i) Test all controls, brakes, steering and accelerator before starting the equipment.
j) Listen and report unusual noises, if there is any.
k) Recheck lights, back-up alarms and other warning or safety devices.
l) Never operate electric starter for more than 30 seconds. Allow two minutes for cooling before starting again. This is because an overheated starter could cause a fire.
3. Motor Grader Operating safety tips:
a) Look behind the machine before moving and while backing up. Operators should ensure that the work area is absolutely clear before doing anything.
b) Make it a point to know and understand the width of the machine in order to maintain proper clearances from surrounding obstacles and obstructions.
c) Be aware of overhangs, electric wires, slide areas or other dangerous conditions.
d) Match speed with job conditions.
e) Stay in proper gear when travelling downhill. Never coast in neutral and use engine RPM to help maintain control.
f) Use parking brake when parking at all times.
g) Always operate controls from the operator station.
h) Use proper hitch equipment and technique when towing the grader.
i) When you stop the equipment, lower all the raised equipment parts.
j) Make sure that the machine is not left on a slope with the engine running as this may put the machine into motion.
4. Service and repair tips:
a) Read and understand the motor grader maintenance manual.
b) Keep hands and clothing away from moving parts.
c) Wear eye protection as fluids (fuel and oil) can damage your eyes.
d) Wear other safety equipment like hard hat, gloves, safety work shoes etc.
e) Operators should ensure that the engines are completely shut off and keys are removed before cleaning, servicing, checking belt tension, adjusting brake or clutch or working on hydraulic system.
f) As hot or damaged tires can be the source of a violent explosion, do not approach the vehicle in line with hot or damaged tires.
g) If engine must be run for a check, set brakes, have transmission in neutral, block the wheels and have one man at the controls and the other working on the engine.
h) Relieve all pressure (water or hydraulic) before opening or removing any caps, lines, valves or fittings.
i) Lower all hydraulically activated equipment parts before servicing the hydraulic system.
j) Lubricate all the moving parts of the machine well as they will fail if they aren’t lubricated properly. Too little as well as too much lubrication can be harmful for the machine. So, you need to lubricate the machine wisely.
k) Follow manufacturer’s instructions exactly when adjusting the brakes.
l) Block wheels before bleeding wheel cylinders.
m) Use only that brake fluid type that is recommended by the manufacturer.
n) Create and follow a maintenance schedule. Include notations on how often each part of the machinery should be inspected for problems, repairs and general maintenance.
o) Pay close attention to wear and tear signs as they may signal problems that can cause machinery to malfunction more often or result in costly repairs or component replacements before your regular inspection.
5. Tips for parking the motor grader
a) Select level ground wherever possible.
b) If the grader is disabled and cannot be moved from the roadway, then put out flags and flares (flares are mandatory at night and during periods of poor visibility).
c) Have the grader removed from the roadway as soon as possible.
6. Tips when shutting down the motor grader:
a) Lower all equipment to the ground.
b) Reduce the engine speed.
c) Keep the transmission neutral.
d) Set park brake.
e) Allow engine to cool gradually.
f) Remove ignition key when leaving grader.
g) Secure machine to prevent unauthorised starting and movement.
Thus, by following these simple safety tips, motor graders’ lifespan can be increased considerably and dangerous injuries to men and machine can be prevented easily. These small but important tips can help to increase productivity as well as efficiency of the machine to a very large extent. Be it any type of motor grader, the above mentioned safety tips remain the same and should be followed at any cost.
Are motor graders the hardest heavy equipment to operate?
Generally, out of all the heavy equipment, motor graders are perceived to be the most difficult vehicles to drive. This is because of the fact that they are a bit different from the others in terms of setting the controls such as the angle and height of the blade which requires certain skills, especially when setting them to obtain fine degree of result.
Well, agreed that motor graders are a bit different to operate but it is not that difficult. Be it a motor grader, excavator or backhoe loader, being able to work to fine measurements is part of the job. In order to produce finished results that perfectly match the desired level is a result of good training and experience behind the controls and understanding of the equipment and its various parts.
Decoding motor graders
Typically, motor graders can be used for making mix, laying a patch, widening shoulders, cutting back slopes, ditching, scarifying, drying material and removing snow. Before discussing the motor grader operating tips, it is important to understand the motor grader basics.
Motor graders are basically used to level or smoothen out an area. They have a long wheel base that can span short depression or humps. Typically, motor graders possess a centrally located blade that can be angled to cast out on either side. The part of the grader which is used to cut, mix, windrow and spread material is called the mouldboard. Mouldboard with the cutting blade is attached to the circular part of the motor grader located under the frame i.e., the circle. The mouldboard allows the blade to be adjusted for height, angle, pitch and reverse direction. Blade angle refers to the angle of the blade in relationship with the mainframe which generally represents a 180 degree or straight line. The mouldboard forms angles with the frame.
After understanding the motor grader basics, let’s take a look at some motor grader operating tips that can make them easier to operate…
1. Knowing about the correct positioning of the mouldboard is extremely important. The mantra is that it should be always kept straight up and rolling the grader blade forward to make the edge blunt. This also results in better rear visibility and the operator can finish the task easily.
2. When ripping across a slope, the mouldboard should be kept parallel with the front axle, centred to the frame and lowered close to the ground to provide protection against rolling over.
3. Motor grader’s mouldboard can be adjusted in a variety of ways. The mouldboard can be raised and lowered as little as a fraction of an inch to adjust to the grade being finished. The sharper the angle of the mouldboard, the more earth will spill off the heel.
4. For light and free-flowing material, mouldboard angles of 10 to 30 degrees should be used and when processing of wet and sticky material, mixing large windrows and ditching is required, higher mouldboard angles of 30 to 50 degrees should be used.
5. The motor grader should never be articulated when operating on steep slopes as the grader can roll over and sever personal injury or death can be caused.
6. Articulating the rear frame toward the toe of the mouldboard by 2 to 5 degrees helps reduce motor graders’ tendency to bounce and this is extremely effective when cutting out washboards.
7. When using the ripper, the teeth should be lowered into the ground with the grader in motion. If the rear wheels lose traction, operators need to raise the ripper until the wheels regain traction. For especially hard surfaces, the number of teeth should be reduced. To break old pavement, teeth under the pavement should be lowered and the ripper should be raised.
8. The quality of work performed with the motor graders is highly affected by the operating speed. So, the machine travel speed should be kept as high as possible for maximum productivity. However, it should be low enough to prevent machine bounce (generally 3 to 5 mph).
9. All the motor graders possess control levers which help in changing the position of the mouldboard and a clear understanding of these controls is extremely essential.
10. When turning around the motor grader, the wheels should always be leaned in the direction in which the turn is being made. This will help the motor grader to turn with ease.
11. Only required amount of downward pressure should be applied to accomplish any task as excessive unnecessary downward pressure on hard and dry surface can cause rapid cutting edge wear and will require more horsepower and fuel, thereby, reducing productivity.
12. When operating, it is imperative to watch both ends of the blade as lifting one end of the blade may cause the other end of the blade to drop about ¼ of that distance.
13. If the circle is not in a level, then the blade setting may change with the angle of the blade.
14. For cutting soft material, the blade should be pitched backward and for mixing, laying operation and cutting on hard surface, the blade should be pitched slightly forward. For spreading or maintaining surface material and for snow removal, the blade should be pitched farther forward.
15. For removing snow, always drive straight and never put so much down pressure that the front wheels are raised to a point that steering becomes ineffective.
These are just few of the common motor grader operating tips and the list is long. Well, by looking at the above mentioned steps, one can say that motor graders are the hardest heavy equipment to operate but it is not like that. Motor graders just need certain understanding of the equipment and some experience. Otherwise, they are fairly equal to other machines when it comes to operating them.
Construction and mining motor graders for productivity, efficiency and lower operating costs
Apart from that, motor graders are also used for levelling soil, shifting small amounts of dirt and to set native soil foundation pads. Due to the versatility of motor graders, they are one of the most important equipment at any construction and mining site. In fact, motor graders improve productivity and efficiency and even reduce the operating cost at the construction and mining sites.
Here is a look at the usage of motor graders at any mining site and the benefits offered by them…
1. Movement of men and materials
Motor graders are commonly used at mining sites like coal mining sites for easy movement of men and material. Jobsites like quarries and industrial sites in remote areas generally do not have proper roads leading to the site. This causes a lot of hassle for the movement of men and material. Here, comes the importance of motor graders as they can be used to create temporary roads leading up to the site to sustain daily operations and enable ease of transportation.
2. Constructing and maintaining haul roads
While drills, draglines, loaders and haul trucks are responsible for producing ore at the mining site, motor graders have a direct impact on how productively these machines can operate. This is because, generally, at the mining sites, motor graders are used to build and maintain haul roads so as to support maximum efficiency in mining operations. Well, haul road is a terms used for roads that are constructed for heavy or bulk transfer of materials at the mining site. These roads can also be constructed between mining operations and processing locations. Motor grader is one equipment that helps in constructing these haul roads easily. In fact, they have an essential role in haul road construction and maintenance, blasting cleanup, loading area cleanup and reclamation. Also, on the haul roads, motor graders help in creating and maintaining constant grade and proper drainage.
It is generally seen that when the haul roads are kept in a good condition, then the haul trucks can move easily over them at a fast speed. Here, it goes without saying that the good road conditions always play a key role in extending the life of the equipment like haul trucks in this case, reduce maintenance needs, lower fuel costs and reduces tire damage. This results in improved cycle times and producing of more ore at lower cost.
Generally, the haul roads begin at the loading face and ends at the dump point. Motor graders help to keep the floor smooth and remove debris in the load zone, so that the trucks and other equipment don’t drive over rocks and move at fast speed. As for the dump zone, there also motor graders ensure that the floor is smooth and trucks and other equipment are able to entre at high speed on it.
Apart from the above, motor graders perform various other tasks too at the mining site. Like certain graders with special attachments can be used for separate tasks like underground mining as well.
Motor grader at construction sites
Here is a look at the usage of motor graders at any construction site and the benefits offered by them…
1. Set the soil for construction
Motor graders are used to set native soil foundation pads to finish grade prior to the construction of large buildings. Also, in building construction projects, graders are used for levelling the parking areas.
2. Earthmoving
Motor graders are also used for moving the unearthed soil and debris or raw building materials from one location to another with the help of the front wide blade. In short, they can be used for earthmoving purposes as well.
3. Sacrifying
Motor graders can be used for scarifying the uneven and inefficient surfaces of the roads, lawns, landscapes etc. Sacrifying means complete removal of layer of soil and then spreading a new layer at that particular point.
4. Land grading:
Graders can perform land grading tasks like creating well-defined slopes and inclinations as well.
5. Levelling of soil or land
Graders can also be used for levelling of the soil so that the next layer of soil, gravel aggregates and asphalt or bitumen can be spread uniformly throughout the surface.
6. Mixing materials
Tasks like mixing of two materials used in construction projects can also be well-performed by motor graders with the help of the right attachments.
Apart from the above, graders can also be used for trenching, digging shallow holes, ditching and laying pipes. Be it any task at the building or road construction site, motor graders help in achieving reliability and precision in operations and reduce rework. As against the manual labour which takes a lot of time in completing the task, motor graders can perform the tasks fast and this saves the labour costs as well. Further, with advanced technology, telematics, machine control and integrated technology, they help improve jobsite safety and have a direct positive impact on the business margins or profitability.
The prime attachments
Be it the construction or mining site, motor graders use various attachments to perform the different tasks. Out of all, the two most important attachments of motor graders that help them perform most of the tasks at any construction or mining site include:
1. Rippers: They are used to cut through challenging ground conditions such as hard, compact or frozen dirt to loosen soil and improve productivity.
2. Dozer: This attachment of motor grader help with spreading.
In a nutshell
Overall, these days, motor graders are not only employed for road construction projects but they are even used extensively at the mining and building construction sites as they are highly versatile machines and can perform a variety of tasks easily and increase jobsite productivity and efficiency.
Use All of a Motor Graders Features to Build Roads Better
Motor grader’s main function is to prepare the topmost layer for laying asphalt on top of it.
Motor graders are rightly equipped to build better roads better, but it is the operator who must have all the skills to take full advantage of the motor grader features. Here is a look at all the motor grader’s features that can be put to use by a skilled operator to build better roads…
1. The grading process starts with selecting the proper speed and mouldboard angle. When doing delicate tasks, the speed should be slow and only the first two-three gears should be used. In case of knocking the rocks and washboard off a gravel road, the speed can be fast.
2. It should be remembered that most of the grading tasks are done at mouldboard angles from 10 to 45 degrees. If the angle is not right, then the motor grader may push material just like a dozer and not in the correct manner. When the material is rolling across the blade from the toe to the heel, then the grading is considered most efficient. If the material stops flowing, operators need to increase the blade angle.
3. Most grading passes should start with the mouldboard top positioned about 2 inches ahead of the cutting edge.
4. The depth of the cut across the entire mouldboard can be changed by tipping the mouldboard forward or back. This also helps to roll material smoothly across the blade. The cutting depth can also be changed by leaning the front wheels but this feature is much more important to keep the grader pulling in a straight line.
5. When working on side slopes or ditches, the front wheel should be set in a vertical position for better steering control.
6. Typically, when sacrificing or ripping across a slope, operators need to keep the mouldboard parallel with the front axle, centred to the frame and lowered close to the ground to provide protection against rolling over.
7. The wheels could be leaned down the slope when working across a slope using articulation to prevent the front-axle from reaching its oscillating limit.
8. Many of the grading jobs like finishing work, ditch cutting, ripping and sacrifice work can be done with the motor grader frame locked straight. Equipment’s manoeuvrability can also be improved by flexing the frame.
9. Grader’s side-slope capability can be improved by articulating the frame and steering the front of the equipment in the same direction. This also allows the tandems to be offset away from the edge fill to prevent rutting or keeps them on a smooth surface for faster finishing.
10. Machine’s tendency to bounce can be reduced by articulating the rear frame toward the toe of the mouldboard approximately 2 to 5 degrees. When cutting washboard from a road’s surface, this really helps.
11. Motor graders centre-shift link bar helps to increase the mouldboard’s reach from the centreline of the equipment. Generally, all the road maintenance work is carried out with this centre-shift lock pin in the centre position and the drawbar and circle centred under the main frame. The repositioning of this link bar can help to increase motor graders productivity when ditching, backsloping and moving large windrows.
12. In the link bar, there are several holes or positions that allow the operator to choose as to how far offset the circle from the frames centre line. Generally, first and second holes should be used for cleaning shallow ditches and moving large windrows and combined with articulation to build narrow and flat-bottom ditches.
13. It is recommended to use the hole in the link bar farthest from the centre for cutting slopes and high banks, cleaning deep ditches, grading and dressing for slopes, disposing of sod/oversize rock on back slopes and for use with articulation to grade steep slopes.
14. For grading tasks, excessive down pressure should not be used as excessive down pressure on a hard and dry surface eats up the cutting edges, demands more horsepower and fuel and cuts productivity.
15. When using the ripper, operators need to lower the teeth into the ground with the grader in motion. If the rear wheels lose traction, operators need to raise the ripper until the wheels regain traction. For especially hard surfaces, they should reduce the number of teeth. To break old pavement, teeth under the pavement should be lowered and the ripper should be raised. The ripper should not be used when turning.
Well, looking at the above mentioned points, it cannot be denied that motor graders are the best for building good roads. If as a contractor or constructor, you are assigned the task of building roads, then definitely you must opt for motor graders to perform the grading task efficiently.
All said and done, motor graders do build better roads and understanding of all the features of the equipment can make the task further easy!
Technology Inside the Cab Helps Operators Boost Productivity
However, one thing that makes the major difference is technology inside the cab that helps operators boost productivity. It is for the same reason that these days most of the Construction Equipment (CE) like Backhoe Loaders (BHLs) employs built-in advanced technology and features to help you meet the deadlines and increase productivity.
Further, at a time when there is lack of good operators, comfortable machines with advanced systems and controls to optimise performance regardless of skill level has become the need of the hour. Thus today, seat-mounted or fully adjustable controls with critical machine functions located at the operator’s finger tip have become normal for the present-day highly advanced BHLs. Also, integration of the operator interface with improved ergonomic design into the machine controls has evolved substantially over the past decade.
When talking about the technologically advanced CE, then Mahindra Construction Equipment’s (MCE) Mahindra EarthMaster BHL model cannot be over looked. Here is the list of all the technologies that is employed by MCE’s Mahindra EarthMaster BHL models inside the cab to boost the overall productivity at the jobsite…
1. Intelligent REMOTECARE feature: The revolutionary REMOTECARE feature of Mahindra EarthMaster VX model allows operators to get complete control over the equipment. It is an intelligent communication system that keeps the business owner or operator constantly informed about the machine through mobile phone based SMS updates. Be it business information like daily work reports or warnings like low fuel, filter clogging, engine oil pressure, operators can get constant updates about their equipment 24*7. Since this is preventative in nature, it helps prevent major breakdown of the equipment.
2. Joystick operated effortless power controls: The VX model of Mahindra EarthMaster also offers specially designed Joystick operated effortless power controls that are not only easy to use but also minimise fatigue. Also called as pilot controls or pilot joysticks, joystick controls increase the productivity considerably by reducing wrist and arm force and hand and wrist movement, thereby, enabling the operator to work for long hours. These controls are usually used to manoeuvre the complex system to make heavy duty work seem much easier and effortless than it actually is. Overall, the joystick controls make for accurate and smooth power control. Thus, gone are the days of pushing manual levers, joystick controls have come to make the life easy, simple and less tiring for the operators.
3. New age digital cluster with audio-visual warning in six different languages: Mahindra EarthMaster VX model comes with a Radio with a 2-way speaker system that helps the operator identify and troubleshoot problems. It facilitates communication with the operator and through him, with people on the site. It is supposed to be the most effective and useful technology in congested and large sites without mobile network. This technology efficiently helps in improving the communication system of the complex BHL. Further, operators in different regions of India can read messages and hear warnings in six different languages through this.
4. Power steering:Mahindra EarthMaster also possesses front wheel hydrostatic power steering, with priority function and pressure relief setting of 145 bar. This helps the operators in not cranking their arms as much to get the machine to turn, which reduces operator fatigue and makes it easier to manoeuvre the equipment.
5. Powerful braking system: The braking system in Mahindra EarthMaster is hydraulic power braking system.The service brakes are hydraulically-actuated, self-adjusting, maintenance-free, oil immersed multi-disc services brakes on the rear axle. They are operated by the independent foot pedals and joined together for normal operation. On the other hand, the parking brakes are hand-operated and inbuilt on the rear axle and are low-maintenance too.
6. Safe electrical and electronics: Mahindra EarthMaster possesses dust-proof switches, ignition controls for engine start, horn and reverse alarm and water and dust-proof electrical connectors.
7. Ergonomic layout and seating: Mahindra EarthMaster is highly comfortable and convenient to use. It has ergonomic layout and seating and has 21st century styling with plush car like interiors.
8. Efficient cabin structure: Not only the technology used inside the cab of Mahindra EarthMaster is praiseworthy but the cab structure of the equipment is worth noticing. Mahindra EarthMaster possesses ergonomically designed cab with day and night time visibility, rear view mirror, multiple storage options, two door access, sliding rear window, stowable doors and an integrated tool box. Further, the cabin frame is built with sturdy tubular sections and protected with CED technology for longer rust protection. Then there is fully adjustable premium operator seat with safety belt. Also, the equipment possesses excellent leg space, conveniently positioned control levers and pedals and low line curved hood to enhance operator visibility.
9. Other features: The front cluster features include speedometer and turn and head light signals among others. The right side cluster includes LCD display screen indicating RPM, kilometres run, hours run, fuel level and temperature.
In addition to the above, the cab shell structure of the Mahindra EarthMaster is modular in design with better strength. Its aesthetic surfaces are free from welding. It allows for better heat dissipation due to a corrugated design.
In a nutshell
At a time, when productivity and uptime are crucial drivers in the CE industry, where machine downtime can cost more than $1 million per day, it is highly desirable to opt for technologically advance CE. It is good to note here that the Mahindra EarthMaster is loaded with highly advanced technology inside the cab to help operators boost productivity. So, it should be definitely on your list when you are considering to buy a technologically advanced equipment for your next project!
The Importance of Operator Training and Resources Available to You
ies, the heavy CE sector in the country is bound to grow at a fast rate. Adding to that various projects like Smart Cities development, Make in India Campaign, Housing for All by 2022’ scheme and affordable housing development among various others are further expected to provide a boost to the demand for heavy Construction Equipment (CE) and its operators.
In fact, the Indian Construction Equipment Manufacturers Association (ICEMA) states, “The Indian construction industry is expected to grow to $5 billion by 2019-20.” And, if everything goes fine, India is poised to be worlds 3rd largest construction market by 2025. As per another report, the Asia-Pacific region is believed to register the highest growth in the earthmoving and construction equipment segment from 2016 to 2021 with India projected to be the fastest-growing market in the region. Other reports claim that the sale of CE is expected to grow at a CAGR 6.18 percent in the coming year. Thus, the need for skilled operators to operate the heavy CE is expected to increase drastically in near future.
Importance of operator training in present times
It goes without saying that Heavy Construction Equipment are very expensive and highly technical equipment. Since they are highly technical, it is obvious that they need trained and highly qualified operators who have expertise in safely handling the equipment as any wrong move can cause heavy damage to the operator, equipment and even the people on the jobsite.
Some of the compulsory qualifications and attributes of the heavy CE operators include…
1. Equipment operators should have the ability to independently operate the equipment safely and responsibly.
2. Since the operators are required to move the equipment from one site to another site on a commercial trailer or hauler, they must have a valid Heavy Commercial Vehicle Driving License (HCV).
3. Operators should also have experience of working in industrial environment involving moving earth or mining.
4. Operators should have on-the -job training or apprenticeship in the required equipment operations with the construction company.
5. Operators should also know about carrying out pre-checks for various equipment operations.
6. It is also required of the operators to have knowledge of various functions and use of the equipment and its various attachments.
7. Not only knowing how to operate the equipment is important for the operators but they should also know about how to maintain, troubleshoot and store the equipment.
8. It is equally important for the operators to know about the workplace safety requirements and procedures.
However, the point to be noted here is that there aren’t enough skilled and certified heavy machinery operators in the market complying with all the above mentioned rules to meet the increasing demand. In fact, most of the times, the heavy CE operators are novice without having any formal training. In addition to that since the heavy CE sector is highly unorganised, it further leads to lack of good talent.
Lack of heavy CE operators and operator training programs in India
While the Indian heavy CE industry is witnessing a technological revolution and the machinery are becoming increasingly sophisticated and automated and machine communication is gaining prominence, the lack of understanding of complex machine mechanism and latest technology on the part of the operators is resulting in a major set-back for the industry. Simply put, at a time, when the Indian heavy CE industry is jam-packed with top of the line equipment to get the job done as efficiently as possible, the lack of safe and skilful handling of these tools by certified operators is resulting in considerable losses for the industry.
The scenario is such that today the buyers are becoming increasingly educated and demanding but the operators are not that skilled to live up to all the expectation of the buyers.
Generally, heavy CE operators require training before they can apply for their license. However, there is lack of this training and relating institutes in India at the present. Even if there are few government-backed institutes, then they have outdated syllabus and the training that the students get at these institutes is inadequate to meet the standards of work and efficiency that the industry demands.
Private players putting their foot forward for imparting operator training
Realising the growing need for operator training, the various private heavy CE manufacturers in the country are coming up to bridge the skill gap by establishing their own training centres in various parts of the country in addition to introducing various certification courses for operator training. One such manufacturing giant in India is Mahindra Construction Equipment (MCE).
MCE’s initiative
MCE has 6 regional training centres across the country which imparts expertise and provides training on the below mentioned aspects…
1. Equipment operation
2. Daily, weekly and monthly equipment maintenance
3. Safety parameters
Typically, the curriculum at these 6 institutes is updated on a regular basis to stay relevant and practical training is provided to the students. Thus, through this initiative, MCE is aiming to develop and enhance skills of the operators with its expertise. What more? MCE has also tied up with an authorised institution.
Apart from this, if you buy any equipment from MCE, then as part of its post-sales services, the company offers few days’ dedicated training for the operators, in which they are personally trained on various features of the machines by professional trainers.
In a nutshell
Given the technicalities involved in operating various complex present-day heavy CE, choosing an operator that is well-qualified and skilled is extremely important. And to promote operator training in India, a massive-scale joint effort by the government and private players is required. Till the time that happens, the opportunities offered by companies like MCE should be leveraged upon in the best possible manner.