to PDF of full document 3.6.3 Motor Grader

PLANT OPERATOR TRAINING MANUAL

MOTOR GRADER

Trainee name

: …………………………………………

Date

: …………………………………………………….

Version 1: May 2015

Table of Contents

Introduction to plant operator training .............................................................................. 2

1.

Plan operator works............................................................................................... 2

2.

Health, Safety and Environment ............................................................................ 3

3.

Preventive maintenance of plant ......................................................................... 14

4.

Simple administration tasks ................................................................................. 21

5.

Work place communication ................................................................................. 22

Motor grader operator training ....................................................................................... 23

Movements of grading implements................................................................................ 26

Safety First

– Procedures .............................................................................................. 34

Pre

– Start procedures .................................................................................................. 36

Starting procedures ....................................................................................................... 37

General Shut-down procedures and End-trip checks .................................................... 37

Motor Grader Operating Techniques ............................................................................. 38

1.

Leveling ............................................................................................................... 38

2.

Bush clearing ....................................................................................................... 40

3.

Ripping ................................................................................................................ 41

4.

V- Ditching ........................................................................................................... 42

5.

Side slope cutting ................................................................................................ 44

6.

Finish grading ...................................................................................................... 46

7.

Crab Steering ...................................................................................................... 47

8.

Spreading material .............................................................................................. 48

9.

Material mixing .................................................................................................... 50

THE TARGET IS TO INCREASE THE NUMBER OF HIGHLY SKILLED AND COMPETENT PLANT OPERATORS IN UGANDA.

1

Introduction to plant operator training

Road works plant operator

A person who is certified to drive or use a road works machinery/ equipment/ appliance as the manufacturer intended and carries out road construction and related works and performs basic maintenance servicing to it.

A plant operator must be able to carry out the following mandatory tasks before operating any kind of plant;

1. Plan operator works

2. Perform occupational health and environment precautions

3. Perform preventive maintenance

4. Perform simple administrative tasks and

5. Participate in workplace communication.

1. Plan operator works

Under this section, a certified operator must have undergone training in the following areas; a) Assessment of site status (e.g. terrain, pits etc) b) Selection of plant, tools and materials to use c) Establishment of plant status/ operating condition d) Organisation of the work area e) Development of operator work schedules f) Participation in budget formation g) Participation in preparation of departmental procurement plan h) Requisition for consumables (e.g. fuel, oil, grease, lubricants, wear parts, road signs) i) Displaying of road safety signs


2

2. Health, Safety and Environment

Learning outcomes

On completing this section the learner should be able to: a) Identify the major types of accidents and their causes. b) Identify the consequences of accidents c) Explain how to dress safely in the workshop and in the field/work site. d) Identify personal protective equipment in the work shop/field e) Explain how to identify and correct unsafe work condition both in the workshop/field. f) Identify unsafe work procedures. g) Carry out a worksite risk assessment

In this chapter will shall cover the most importance of safety; a) Learn how to dress safely b) Learn how to work safely c) Learn how to maintain a safe working environment. d) The safety precautions given here are intended to help you avoid accidents as you perform plant operation under your supervisor instruction e) Learning good safety practices will give safely habit at all jobs in the failure. f) Here we shall examine various type of unsafe machine operators working condition and work practices we shall discuss ways to correct or avoid them.

Preventing accidents

a) Stop accident before it can stop you. b)

Never start a machine if you don’t know how to stop it (if you don’t know how to control) c) Safe working conditions and safe procedures protect the plant operator, plant and equipment, the people around, the other plant units around the worksite and the workshops.

Accidents are unplanned events that can occur without anyone intending them to happen. The consequences of an accident are also unintended such as property damage and injury.


3

There are many kinds of accidents. The most common accidents in the worksite and work place can be prevented. The following shows how foresight and common sense can eliminate the cause of common accidents;

1. Falls from slipping on a wet or oily floor or equipment access steps.(an unsafe floor working condition)

2. Fires and explosion caused by flammable substances contacting a heat source

(petrol, gas, etc. unsafe condition).

3. Asphyxiation caused by exhaust fumes or refrigerant gas ozone gas building up in a closed space.

4. Injury of the body parts such as hands, arms, face, head or feet from moving parts or being caught under heavy parts.

5. Strain and sprains from lifting heavy parts improperly.

6. Burns from contract with coolants, oil, exhaust pipe and hot metal.

7. Chemical burns from battery acid or parts cleaner

8. Electrical shock from ungrounded electrical supplies (overhead and underground).

In addition to the above accidents a careless operator can be exposed to substance which cause long term health problem this include:



Emphysema and lung cancer from inhaling brake or clutch lining dust for a period of years



Skin cancer from prolong exposed to use motor oil, brake fluid and some detergents.

From what you have seen above there are many ways to be injured or to be the killed when working as an operator with those heavy plant, under poor unsafe conditions. So it is a good practice to find out how accidents happen and how to avoid them.

Accidents

How accidents happen?

Some of the accidents described earlier are caused when a machine operator wants to take short cuts instead of following normal operating procedure.

Other accidents occur when an operator allows unsafe work conditions in the wrong area.


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Accidents are always caused by;



Unsafe acts



Unsafe conditions

These two lead to other actions for example spilled oil on the floor left unattended to

(unsafe condition)

Results of accidents

1. Injuries keep you off work and make you lose your pay.

2. Death

3. Damage to the plant and equipment (your livelihood)

4. Damage to other properties

5. Down time

6. Low production

7. No availability of the equipment

8. Long term disability


5

Personal Protective Equipment (PPE)


6

Keeping safety in mind

Rushing carelessly because of job pressure to complete the job in time can easily lead to a serious accident for these reasons an operator must keep safety in mind at all the times.

Reducing the possibility of accidents

While it’s true that some accidents are unavoidable it makes sense to reduce the possibility of their occurrence as much as possible.

Most of the accidents occur because of the following reasons;

1. Wearing improper clothing.

2. Not using protective equipment.

3. Failure to keep working environment clean (The plant and equipment and the work site)

4. Improper service procedure(operating procedure)

5. Combination of all the above.

What you need to protect (personal effects);

Head, Hand, Ear, Eye, Skin, Feet, Nose, All body parts

Fire

We need fire extinguishers in the worksite.

Fire extinguisher classes

1. Class(A) for ordinary fire such as from paper or woods

2. Class (B) fire from flammable like liquid such as petrol and oil gas.

3. Class(C) Fire from electricity

The following safe work procedures may seem to be simple; however, they are often disregarded with tragic results.

1. Wear proper clothing and use protective equipment when called for.

2.

Study work procedure before beginning any job that is unfamiliar to you doesn’t assume that the procedure you have used in the past will work with a different type of plant.


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3. Always work carefully speed is not nearly as important as doing the right job and avoiding injury. Avoid people who will not work carefully.

4. Use the right tools for the job.

5. Learn to use new equipment properly before using it.

6. Do not drink or smoke while working.

7. Do not run any type of engine, even for a short of time in a close area without a good ventilation (carbon monoxide which cannot be seen or smelt can kill instantly)

8. When working on or near running engines keep away from moving parts or rotating parts as these can cause injury.

9. Do not leave a running engine unattended the plant may slip into gear or overheat when you are away. When you must work on a running plant, shift the transmission into parking/neutral and set the parking brake and also check the wheels in both directions i.e. forward or reverse

10. When driving to the work site obey all the traffic laws, be alert for the actions of the other drivers.

Protective devices provided by the manufacturer

Caterpillar companies have equipped their heavy plant equipment with well designed protective structures, ie ROPS, TOPS, and FOPS

1. ROPS

– Roll over protective structures

2. TOPS

– Tip over protective structure

3. FOPS

– Falling objects protective structures

4. It should be noted that while those structures are provided the operator can only be protected in case of accident when he

5. Has seat belt fastened and helmet on his head.

6. The three points Contact , Hand rails and the steps,(Entering the cabin you face the cabin ,Coming out you face the cabin

7. Seat belts


8

Cab

– Roof re-enforcement (ROPS, TOPS & FOPS)

Seat belts

In the two cases down accidents have happened. The operators could be safe on condition that they in had fastened their seat belts and had helmets worn.


9

Climbing on and off the machine



When climbing on and off the machine, the operator should always face the machine.



Use the three point contact method when climbing: Two hands and a foot or two feet and a hand.

Conclusion to health and safety procedure



Work procedures are the actual diagnosis and the major components of the operator operation.



You may be called upon to do all sorts of procedures in your job as an operator.

It is vital that you do them safely and correctly.



Improper procedure includes using wrong tools or methods to perform machine operations, using defective or otherwise in appropriate tools. Not wearing protective equipment when necessary.

Not paying close attention while operating the machine whenever any work is performed. It should be performed in a safe manner before any other considerations.


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Environment

The following issues are of major concern in road

Infrastructure development and managing road use:



Air pollution



Biodiversity



Cultural heritage



Fire management



Greenhouse gas emissions



Land use management



Resource consumption



Social equity



Soil contamination



Soil erosion and sediment management



Drainage and storm water management



Vegetation control and management



Vehicle and traffic noise



Visual amenity



Water pollution



Weed management

This strategy aims to integrate these important environmental issues into the planning and operational stages of developing road infrastructure and managing road use.

Environmental impacts of roads, management responses, and research gap

Below, road-related impacts are grouped to identify effects on:

(1) Soils, water, and aquatic wildlife and Habitat; and

(2) Terrestrial wildlife and habitat. The final subsection highlights other road effects.

Soils, water, and aquatic wildlife and habitat

Increased fish mortality caused by expanded angling pressures, poaching, and management actions



Disrupted turtle and amphibian migration patterns and population connections and increased road kills where roads bisect wetlands



Displaced and compacted soils resulting in loss of biomass productivity



Altered conditions that change soil pH, plant growth, and the vegetative community structure (i.e. light levels and water retention; soil displacement, temperature, and compaction; and dust)


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

Reconfigured landforms can result in changed hydrologic regimes (e.g., altered water table position; interrupted groundwater flow diverted to surface systems; increased water temperatures; changes in the timing of runoff; drained natural wetland habitats; unintentional artificial wetlands; and restricted or altered channels which can result in altered streambed materials)



Altered stream flow, particularly the timing and

Terrestrial wildlife and habitat



Increased wildlife road kills and injuries (e.g., roads warm up quickly and hence are attractive to reptiles and amphibians for basking; this can increase the incidence of road kill)



Increased road-kill carrion that may become attractants to carrion-feeding wildlife and result in more collisions



Increased mortality (and injuries) because of expanded hunting and trapping pressures, poaching, and management actions



Loss of species, habitat, and vegetation (particularly when roads are in riparian areas)



Fragmented wildlife habitat



Altered and disrupted habitat caused by logging, human-induced fire ignition, fire suppression and exclusion, fencing, fuel-wood collection, and recreation



Diminished habitat suitability adjacent to roads caused by edge effects

Maintenance of roads involves activities that could cause environmental damage.


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Roadsides provide important habitats for fauna. Animals Insects

–Monkey, Guerilla, bees etc (above)

Road construction and maintenance activities often generate some amount of dust.

Watering is carried out as work progresses.


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3. Preventive maintenance of plant

Maintenance

At the end of these lessons;

The learner will understand his/her roles as far as the physical being of the machine and the mechanical conditions of the machines are concerned. And will report correctly to mechanical supervisor any defects noted at preventive stage of operation and correct some which he/she is mandated to do so.

Maintenance definition

Work undertaken to keep or restore a facility to an acceptable standard



When maintenance is properly done it will be ensured that machines services and equipment are operating at the level of productive efficiency and available when required.



This function is of service to the production function. (but not a mere supplement to production)

Who are responsible for the maintenance of our equipment?

In the past, it was thought that maintenance work was only for “mechanical department”.

Where by even the operator was not part of mechanical department that was a big mistake.

Let us look at people involved in the preventative maintenance.



The mechanical department (inspect and repair)



The operator (Daily pre-operation machine walk around inspections and report)



The machine owner (provide the money for spares and services)

The duty of the maintenance department (mechanical)

Pure maintenance



Carry out work to keep or restore plant and equipment to an acceptable standard. (maintain an exist plant equipment, recondition the old plant and equipment)



Install and alteration of plant and equipment services


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Forms of maintenance



Replacement



Planned



Breakdown



Preventive

Replacement maintenance



Replace old equipment with the modern ones Instead of repairing due to technology changes.



The aim is to affect the work of inspections, servicing, and adjustment and so prevent failure during operation.



Some items are designed not to be repaired.



Cheap to replace than to repair.

Planned maintenance



This is an important component in plant and equipment maintenance in road maintenance and construction industries, factories, motor vehicles etc. The manufacturers of equipment have set predetermined intervals throughout the life span of a plant (equipment) to cover lubrication, adjustment, servicing, replacement, major overhaul.

Break down maintenance



Operate to failure if you can safely do so (Light bulbs are an example)



The cost of preventive maintenance may be more than the cost of break down maintenance (i.e. when the engine component are all worn out

–where by engine oil topping is likely 10 liters per day with poor production)



However this is most common in workshops operating machines.

Preventive maintenance (this where by the operators role is key)



The aim is to effect the work of inspections servicing, adjustment and so prevent equipment failures during operation



It is the anticipation of failures and the adaptation of preventive action before they occur (the cost of failure may be high and dangerous, (i.e. engine level, low water level in the radiator, low or no brake fluid in the reservoir) From the above information we can see how important it is for the operator to know his roles as


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far as maintenance is concerned. In preventive maintenance the operator is about 80% involved;



Inspection/ records



Correct (i.e. add brake fluid, add water, add engine oil etc)



Report what she or he can not to the mechanical department.

In planned preventative maintenance; the mechanical department plans all the schedules of a plant or equipment. And operator must have a copy. I.e. the operator who is working in the field full time must know how long a full service and greasing will take. He/she is the one reading the hours from his/her machine. He/she has to report to the mechanical department in advance so that the spare parts required such as the engine oil, filter, etc. are purchased in time. The operator therefore has a big role to play in the undertaking. The benefits of good maintenance procedure include;



Safe equipment operation



Improved efficiency



Reduction in down time



Improved production and efficiency



Value for money



Improved earnings for operator (production bonus)



Improved earnings for the company



Good accountability and cost efficiency.



Reduce on planned maintenance costs



Environmental compliance



Warranty assurances


16

Specific Maintenance


17

Preventive maintenance guidelines

The guidelines are for quick and handy use by the equipment operators and technicians. They are intended to enhance management, maintenance and operation of road equipment. Additionally the guidelines will be used in conjunction with the manufacturer’s manuals where further details can be accessed. It’s imperative that the guidelines indicated below be implemented to give road equipment longer life span and minimize operational costs.

A) The daily routine checks that the responsible operator will be required to undertake before starting the equipment.

1.1 Check for leakages of either water or oil.

1.2 Make sure that the coolant is at recommended level.

1.3 Drain fuel sediment reservoir of water and sediment

1.4 Check tyre pressure.

1.5 Check the following: all warning indicators at the dash board, brake play, brake fluid level among others.

1.6 Check engine oil level and top up if necessary.

1.7 Check and remove any foreign objects that may be lodged on the engine, before starting the equipment.

1.8 Clean area around dipstick (gauge) and check for oil leakage.

1.9 Check engine oil filler cap and clean.

1.10 Check water pump belts for looseness.

1.11 Check for any loose units within the engine hood e.g. bolts, nuts, battery carrier e.t.c.

1.12 Check for abnormal tyre wear and damage on wheel rims.

1.13 Check battery electrolyte level.

1.14 Check battery terminals for tightness

1.15 Clean battery, check battery cap vents and unblock where necessary.

1.16 Carry out necessary remedies / report to the supervising technician for necessary repair intervention.

1.17 Maintain a record book for the routine checks remedies undertaken.

NOTE

Details refer to the manufacturer’s manual.


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B) Maintenance Schedule

Every 50 Hours

(Weekly)

1.1 Grease the circle and the guide rail.

100 Hours (For new machine)

1.1 Tighten transmission shaft bolts.

1.2 All controls 1.2 All controls

1.3 Check transmission oil level.

Every 250 Hours

(Monthly)

1.1 Change engine oil and oil filter.

Every 500 Hours


1.3 Check transmission oil level.

1.4 Check shift control system working equipment and parking brake.

1.5 Check chains and tracts. 1.5 Clean air filter.

1.6 Check all nuts. 1.6 Check and adjust belt tensions.

1.7 Clean air filters.

1.2 Check hydraulic oil level.

1.3 Check transmission oil levels.

1.2 Check hydraulic oil level.

1.4 Check transmission oil

1.4 Check all fluid level. levels.

1.4 Check all fluid level.


1.8 Check engine oil level and 1.8 Tighter nuts. top up if necessary.

1.5 Clean air filter.

1.5 Check and adjust belt tensions.


1.8 Tighter wheel nuts.


1.9 Check shift control system, working equipment.

1.10 Grease all applicable parts and components

(nipples, circle gear, guide rail, transmission shaft)etc

1.11 Check bolts and welded sections of chassis frame.

1.10 Grease all applicable parts and components (nipples, circle gear and guide rail, transmission shaft)etc

1.11 Check bolts and welded sections of the chassis frame.

1.9 Check shift control system, working equipment.

1.10 Grease all applicable parts and components

(nipples, circle gear and guide rail, transmission shaft)

1.11 Check bolts and welded sections of the


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1.12Check hydraulic oil levels. chassis frame.

1.12 Tighten all junction bolts of the chassis frame including bolts for other key parts.

1.13 Check all electrics

1.14 Check tyre and

oil pressures

NOTE


B) Maintenance Schedule Continued

Every 1000 Hours


Every 2000 Hours

1.2 Change transmission oil and clean the oil tank.

1.1 Change engine oil and filters.

-Clean oil sump.

1.2 Change transmission oil and filter.

-Check transmission and torque converter.

-Clean transmission oil casing/housing.

1.3 Change fuel filter and clean fuel tank. 1.3 Change fuel filters and clean fuel tank.

1.4 Change hydraulic oil and its filter.

Clean hydraulic oil tank.

1.5 Grease all application parts and components (nipples, circle gear, guide rails etc).

1.4 -Change hydraulic oil filters.

-Clean hydraulic oil tank.

1.5 Grease all applicable parts (nipples, circle gear, guide rails, blade shift guide and transfer shaft).

1.6 Clean air filter, replace if necessary. 1.6 Clean air filter(s), change if necessary.

1.7 Check and adjust tyre pressures. 1.7 Check and adjust tyre pressure.

1.8 Tighten wheel nuts.

1.9 Tighten all junction bolts of the chassis frame including bolts for other key components.

1.10 Check all electrics.

1.8 Tighten wheel nuts.

1.9 Tighten all junction bolts of the chassis frame including bolts for other key components.

1.10 Check all electrics.

1.11 Check bolts and welded sections of 1.11 Check bolts and welded sections of working


20

working equipment including sections of the chassis frame.



1.14 Check shift control system, working equipment and parking brake.

1.15 Check and adjust the clearance of the parking brake, flexible shaft and brakes. equipment including sections of the chassis frame.



1.14 Check shift control systems, working equipment and parking brake.

1.15 Check and adjust the clearance of the parking brake, flexible shaft and brakes.

1.16 Check rear transmission shaft nonspin differential, transfer chains etc.

1.16 Check rear transmission shaft non-spin

1.17 Check all operating parts of the hydraulic system.

NOTE:


4. Simple administration tasks

Under this section, a certified operator must have undergone training in the following areas; a) Participation in road survey b) Organisation of work area (display traffic signs, set traffic cones, and warning tape) c) Recruitment of workers (e.g. labourers and plant attendants) d) Assigning tasks e) Appraising subordinates f) Networking with peers on technical matters g) Conducting refresher training h) Resolving conflicts and execute disciplinary procedures i) Preparation of maintenance schedules j) Maintaining administrative records (e.g. log books, log sheets, job cards, defect forms, work order) k) Preparation of technical reports (e.g. on job status, service reports) l) Participation in meetings (e.g. technical, community, workers union, administrative, team) m) Administering first aid n) Managing waste disposal o) Perform fire fighting


21

5. Work place communication

Under this section, a certified operator must have undergone training in the following areas; a) Obtain and convey work place information b) Complete relevant work related documents c) Participate in workplace meetings and discussions


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Motor grader operator training

Remember that any kind of machine or mechanical device can be hazardous if not kept in good condition, or if operated by careless or improperly trained operators, or if operated in an irresponsible manner.

Motor grader Operator

A person who is certified to drive /use able to operate a motor grader and he or she is a

Level 3 road works plant operator under the Uganda Vocational Qualification standards.

A Motor grader is a self-propelled articulating or rigid framed wheeled machine, designed to cut, move and place construction materials using a centrally mounted rippers/scarifiers.

The blade and attachment controls are normally hydraulic: however they may be mechanical.

Motor grader attachments include; Cutting blade, Rippers, scarifiers, machine guidance system, Lazar levelling equipment, slash.

Summary of major tasks to be carried out by a motor grader

a) Mixing /Spreading materials b) Surface Levelling c) Slope cutting d) Scarifying / Ripping e) Form drainage f) Bush clearing


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g) Crab steering (Move material without running over it)

h) Load/Off load Plant.

Figure above shows motor grader components


24

Square blade Sharp blade

Some of the common terms used in motor grader operation

1. Sharp Blade: refers to the angle of the blade in relation to a line at right angles to the machine, and will be angle greater than 30 degrees from that line.

2. Square Blade: also refers to the blade angle and will be from the right angle line to 30 degrees from that line.

3. Pitch : the angle the cutting edge sits in relation to the road

4. Moldboard: what the blade is fastened to.

5. Cutting edges: the blade.

6. Ice Blades: serrated or saw tooth cutting edges.

7. Loose blade: refers to setting the blade so that it touches the surface, but the weight of the blade is supported by the machine.

8. Tight blade: refers to setting the blade so that it has some down pressure on the surface.

9. Float: the blade rests on the surface without any hydraulic pressure.

10. Toe of the blade: the leading end of the blade.

11. Heel of the blade: the following end of the blade.

12. Articulation: As used in this manual, it refers to a machine with a jointed main frame. This assists in steering the machine, allowing it to work in an angled configuration, yet move forward in a straight line.


25

13. Articulating frames: frames that pivot in the middle of the machine for better traction and handling.

Movements of grading implements


26

Two blade lift levers, right and left, are used to adjust the depth of cut and to position the blade for shoulder grading or bank cutting.

Blade sideshift lever is used to bring the blade into shoulder reach position. Side shifting of the blade is also used for clearing obstacles.


27

1)

Circle reverse lever is used to rotate the circle and blade to set blade position angle “A.”

2) For backward grading, the blade and circle are to be rotated 180

0

after the scarifier or its teeth are removed.

Circle centershifting a) Circle centershift lever is used to shift the circle and blade sidewise. when shifted to either side, the center of rotation of blade

(circle center) is off the centerline of grader. b) Centershifting is accomplished by a hydraulic cylinder. in some models, however, the hydraulic cylinder is not used for this purpose: instead, a manual link mechanism is used for centershifting.

Blade tilting a) Tilting the blade forward increases, and tilting it backward decreases, the cutting angle. b) When tilted all the way forward, the blade has a maximum cutting angle. When tilted all the way backward, it has a minimum cutting angle. For normal grading, the blade (plane containing top edge and cutting edge) is practically vertical. c) The standard device for tilting the blade is guide bracket consisting essentially of notched washer and rack, which permits the blade to be tilted more or less by hand. optical tilt cylinder which is to be attached to the circle permits the operator to tilt the blade without leaving his seat. d) By centershifting in combination with blade can be set in any position for shoulder grading, backward decreases, the cutting angle. g) When tilted all the way forward, the blade has a maximum cutting angle. When tilted all the way backward, it has a minimum cutting

6. Articulating


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a)

Articulating of the frame permits selection of steering modes for best match to job. b)

ARTICULATED, with frame fully articulated and front wheels leaned, provides shortest turning radius for easier maneuvering in close quarters, quicker turnaround at the end of pass and an ability to carry a full blade load around a curve. this mode also helps back out of a dropoff or ditch or maneuver around an object. c)

CRAB. With frame fully articulated and front wheels turned parallel to tandems, helps compensate for side drift when turning a window, keeps tandems on firm footing when cleaning a wet ditch, increases stability for side slope work and side thrust when using a snow wing.


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8. Leaning

Front wheels can be leaned up to 20

0

to brace the motor grader in a bank cut or in a shorter-radius turn.

1. They can be leaned to control side drift when the blade is loaded and keep the tires from rubbing the bank in a ditch cut.

2. They can be leaned to or away from the bank for heavier or lighter cuts while maintaining the same slope.

3. They can be leaned back to hold them vertical when the front axle tips to one side to counter side-slipping tendency of the front end.

4. They can be leaned with the frame articulated to make turns shorter and easier.

9. Sacrifier lifting


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

Scarifier lift cylinder, controlled from the scarifier lift lever, is a means of adjusting tooth penetration (scarifying depth) “A” of scarifier teeth.



The scarifier is used for mixing breaking up base courses, asphalt, slabby and frozen material.



The teeth can be set in a total of five different positions, three by holes in the link and two by teeth themselves.



The ripper shanks are used for heavy ripping and the scarifier shanks for light works where maximum surface fracture is desired. Both sets of shanks can be stored on the top of the bar to give maximum lift height.


32

Scarifiers and Ripper attachments


33

Safety First

– Procedures

Prevention of accidents involving powered equipment is completely dependent on the person operating the equipment. No power-driven equipment, regardless of the type or the purpose for which it is used, can be safer than the operator. The manufacturer can incorporate feature to make the operator’s job safer, and controls to make it easier, however:

AVOIDING SITUATIONS THAT MAY PRODUCE ACCIDENTS

IS SOLELY UP TO THE PERSON AT THE CONTROLS,

THROUGH FORETHOUGHT, JUDGEMENT AND SKILL.

A careful operator is the greatest safety device there is. Stop accidents before they stop you.

Most graders have been designed to incorporate every safety device possible. Even with all these safety features, however, there are still dangers. The operator must be extremely careful in the operations of a big machine like this. In order to help prevent accidents the following safety rules should be observed at all times.

1. Become well acquainted with the piece of equipment, the Operator’s manual, and

Maintenance Manual. Know where all controls are located and what they operate.

2. All power equipment should be operated only by those who are responsible and delegated to do so.

3. In areas of possible danger, obey the decals located on the grader.

4. For safe operation observe proper maintenance and repair of all pivot points, hydraulic cylinders, hoses, snap rings and main attaching bolts and inspect prior to each day’s operation.

5. Keep the operato r’s platform free of debris.

6. Be sure no one is under or around the machine before starting.

7. Always face the machine when mounting and dismounting the grader.

8. Never jump from any machine.

9. Always maintain a firm grip on the hand holds while entering or leaving the machine, and until you are in the seat or your feet are on the ground.

10. Clean your shoes of slippery materials to prevent slipping on steps, or off the pedals.

11. Keep windshield, windows, and mirrors clean at all times.

12. Pull the keys before servicing or repairing grader.


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13. Check all controls to be sure they are operating correctly before putting the machine to work.

14. Do not leave the machine unattended when the engine running.

15. When shutting down, always cool engine 3 to 5 minutes. Lower all the hydraulic equipment to the ground and set parking brake before leaving the cab.

16. Never coast the machine when transmission is in neutral or with clutch disengaged. Maintain a ground speed consistent with the conditions.

17. Avoid operating too close to the banks or over hangs.

18.

Be sure to shut the engine off when refueling, and don’t smoke.

19. When you must work with hydraulic equipment raised, be sure to block it securely with blocks that will not crush.

20. Never operate the machine in closed shed or garage: establish good ventilation and open the doors.

21. Do not oil, grease or adjust the machine when the engine is running, unless the operator manual specifies how to perform that operation.

22. Drive at speeds slow enough to insure safety and complete control, especially over rough terrain.

23. Increase the power gradually when pulling a heavy load or when driving out of a ditch or excavation.

24. Reduce speed when making a turn or applying brakes.

25. Keep brakes in proper adjustment. If you can’t stop the machine don’t start it.

26. Never make repairs or tighten hydraulic hoses or fittings when the system is under pressure, when the engine is running, or when cylinders are under a load.

27. Be careful removing the radiator cap when the radiator is hot.

28. Be very careful when using cold weather starting fluid. Wait at least ten minutes before using starting fluid if you have attempted to start the engine with a manifold heater. Crank the engine 5 to 10 seconds before attempting to use a manifold heater if you have used starting fluid first.

29. Always disconnect the battery ground strap before making adjustments on the engine or electrical equipment and before welding on any part of the unit. This will prevent dangerous sparks which create a fire hazard and may cause harm or damage. Disconnecting the battery also prevents accidental operation of the starter, or battery explosion.

30. Never permit persons other than the operator to ride on the grader.

31. Sound the horn before moving the grader.

32. Always look behind the grader before backing up.

33. Always be sure of water, gas, sewage, electrical and telephone line locations before you start any cut operations.


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34. Always check overhead clearance, especially when transporting the unit.

(Knowing your maximum height before transporting.)

35. When deadheading the grader, always have the blade toed to the off traffic side, and carried high.

36. To prevent highway accidents, use workzone traffic control signs. Turn on yellow flashing cab lights whenever working on road surf aces. Display the “Slow Moving

Vehicle” emblem.

37. Practice good housekeeping and clean out the cab at the end of each day.

38. It is the responsibility of the operator to make an inspection of the grader each shift. The use of defective or unsafe equipment is forbidden.

39. Look for leaks and check fluid levels.

40. Use safety equipment provided with the machine for your protection.

*Use common sense and good judgement.*

Pre

– Start procedures

1.

Grease the machine according to the Operator’s manual. As you grease the machine check for loose, worn, or broken parts; hydraulic system leaks; worn hoses; and leaks under the machine.

2. Check engine oil level.

3. Check coolant level in the radiator.

4. Check belts for adjustment and wear.

5. Check hydraulic oil level if equipped with hydraulic controls.

6. Check power steering reservoir.

7. Check air cleaner and connections and dump the dust cup if the machine has one.

8. Check fuel level and drain water from the fuel tank.

9. Check transmission oil level on power shift transmissions.

10. Lubricate the blade circle with graphite, diesel fuel or a mixture of diesel fuel and motor oil, according to the Operator’s manual recommendations.

11. Check tires and wheels.

12. Check starting motor oil level if machine has one.

13. After starting, check gauges, clutch free play, steering, lights and controls. Other checks indicated in the Operator’s Manual may be necessary on certain types of machines, but these points cover the general checks. Drain the condensate from the air tank.


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Starting procedures

1. Make sure the parking brake is set and place the transmission in neutral.

2. For machines equipped with electric starting, open the throttle ¼ and use the starter.

3. Always depress the clutch to lighten the load on the starter

4. Never operate the starter continuously for more than 30seconds. Then wait 2 minutes before using the starter again.

5. After the motor starts, check all gauges to see if they are operating. After

3minutes or 4 minutes of idling, set a fast idle to complete the warm-up.

6. Work the controls to make sure they operate and warm up the hydraulic oil.

General Shut-down procedures and Endtrip checks

1. Always cool out the engine for 3 to 5 minutes before shutting down.

2. Before leaving the cab lower all hydraulic equipment to the ground and set the parking brake.

3. Make a walk-around check including;



Loose, worn or broken parts



Hydraulic system hose and connection leaks



Any oil, grease, coolant or fuel leaks

4. After shutting down, check fuel, oil, coolant levels and blade wear; needed items can be brought out in the morning. If your blades are cupped in the middle and are not wearing straight, chances are you are not operating properly.

5. Clean accumulations of dirt or mix that might hinder the proper functioning of any sliding surface, pivot point or lubrication fitting. Hardened mix can be removed by pouring diesel fuel on the build-up area and allowing the mix to soften.

6. Always park the machine as near to level as possible.


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Motor Grader Operating Techniques

For the purpose of illustration, the grader here will be assumed to have its blade angled for left-side working that is with the left-hand end of the blade set ahead of the righthand end. Of course, the blade can be angled the other way round for right-side working. In countries where the keep-to-the-left rule for vehicle traffic prevails, the grader is more often operated for left-side working.

1. Leveling

The position indicated here is good for a wide range of operations on level ground, including cutting, shaping, spreading, ditch backfilling and snow removal.


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Levelling exercise


39

2. Bush clearing


40

3. Ripping

To maximize productivity, use straight frame mode operation and lower the riper shanks as dip as possible to a uniform depth to the end of the exercise. Raise the riper shanks fully out of the ground before turning to avoid shank damage.

Ripping exercise


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4. V- Ditching

Drainage ditches and side ditches are usually dug with the grader set in this position.

Raise the rear side of the blade to match the ditch slop angle, the front end of the blade gives V shape to the ditch bottom. Move the material up to the road shoulder as desired. Generally, ditch digging is a heavy-duty job for the grader.


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The cutting blade behaviors during a V-ditch digging operation

The positioning of the cutting blade when carrying out V-ditching operation


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5. Side slope cutting

As per the diagrams below, use the frame articulation to allow the grader to be operated on a steep slope for safety. Here are some of the tips:-

1. Use low ground speeds for maximum control of the machine.

2. Use accelerator pedal than a hand throttle.

3. In an emergency, releasing the accelerator will result in immediate reduction in the engine rpms and ground speed.

4. Keep the differential locked while working on slopes.

5. Deposit the windrow between the tandem tires and keep the upper tandem tires above this windrow to reduce slipping.

6. For the slope less than 2.5:1, start at the top of the slop. Cast the windrow material outside the rear tandem tires to help prevent rear tires from slipping.


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Side cutting at an angle of 90 degrees

Side cutting at an angle of 60 degrees

Back slope cutting


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6. Finish grading

The surface is finished by pushing the material with the blade at an angle of around 80-

90 degrees as the diagram illustrates below. This helps in letting the material roll over across the entire length of the blade and keeping the cutting edge raised a little to allow the material to spill out uniformly under the cutting edge. The blade should be so elevated that little or no windrow will form at either end.

Keep down the speed. Fast driving is likely to splash gravel.

Hold the cutting edge line parallel to the surface with both ends of the blade raised to provide the same amount of spreading clearance.


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7. Crab Steering

Crab steering

— articulating the frame and steering the front wheels in the same direction

— improves the grader's side-slope capability, and allows the tandems to be offset away from edge fill to prevent rutting, or keeps them on a smooth surface for faster finishing.

Articulating the rear frame toward the toe of the moldboard approximately 2 to 5 degrees (1 to 1½ times the width of the tire) will often reduce the machine's tendency to bounce. This crab mode is extremely effective when cutting washboard from a road's wear surface. In the crab mode, the grader's front axle is no longer perpendicular to the direction of travel. This puts one front tire slightly ahead of the other. One tire rides up on top of a corrugation in the road while the other is still in the bottom. As the tires roll up and down through the washboard, the front axle will pivot, keeping the front frame stable. The degree of articulation required to make this technique work will vary with the space between corrugations.

Be careful: Caterpillar warns against using crab mode when scarifying washboard roads. Because the frame is not traveling parallel to the direction of travel in crab mode, it could bend the scarifier shanks or linkage.


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Another caution for operators who have little experience with articulated graders is to watch both ends of the blade when articulating.

"If you're delivering a nice windrow right outside the rear tires, the blade's heel is going to be near that front tandem," says Mennenga. "You have to make sure the blade is far enough away that when you do articulate you don't slash the tire with the blade."

8. Spreading material

1. Blade positioning angle is approximately 40-60 degrees.

2. Working speed should be around 4 to 8 km/hr.

3. If piles are small spaced close, spread the material to each side first and spread it ahead at center next.

4. If piles are large and spaced far apart, push one pile after another first and then spread to each side.

5. Position and hold the grader blade at 90 degrees angle when spreading at the center.


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An illustration of a motor grader spreading material


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9. Material mixing

1. Deposit the roughly mixed material in a uniform row.

2. Operate the grader by positioning the grader blade at an angle which suits the material.

3. Working speed should be around 6 to 10km/hr.

4. A thin row of the material can be cast in a single pass.

5. A large row must be cast by two or three passes.

An illustration of a motor grader mixing material


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Item

Operator Trainee Notebook:

Notes


51

References

Motor grader operator’s hand book 2000 (Montana Association of County Road

Supervisors)


52

to PDF of full document 3.6.3 Motor Grader

Introduction to plant operator training

1. Plan operator works

2. Health, Safety and Environment

Maintenance of roads involves activities that could cause environmental damage.

Roadsides provide important habitats for fauna. Animals Insects

–Monkey, Guerilla, bees etc (above)

Road construction and maintenance activities often generate some amount of dust.

Watering is carried out as work progresses.

3. Preventive maintenance of plant

Details refer to the manufacturer’s manual.

Details refer to the manufacturer’s manual.

Details refer to the manufacturer’s manual.

4. Simple administration tasks

5. Work place communication

Motor grader operator training

Remember that any kind of machine or mechanical device can be hazardous if not kept in good condition, or if operated by careless or improperly trained operators, or if operated in an irresponsible manner.

Movements of grading implements

Safety First

– Procedures

AVOIDING SITUATIONS THAT MAY PRODUCE ACCIDENTS

IS SOLELY UP TO THE PERSON AT THE CONTROLS,

THROUGH FORETHOUGHT, JUDGEMENT AND SKILL.

Pre

– Start procedures

Starting procedures

General Shut-down procedures and Endtrip checks

Motor Grader Operating Techniques

1. Leveling

2. Bush clearing

3. Ripping

4. V- Ditching

5. Side slope cutting

6. Finish grading

7. Crab Steering

8. Spreading material

9. Material mixing

Item

Operator Trainee Notebook:

Notes

References

Motor grader operator’s hand book 2000 (Montana Association of County Road

Supervisors)

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