grader operation tips

8/12/2019 Grader Operation Tips

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Operating Tips


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Operator tips

Remember these few operating techniques and tips are

things that need to be done to make you and your machine

more productive;

We will go over the next four things:

Differential lock

Torque converter

Draw bar position

Mole board position

Wheel lean

articulation

Ripping


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Differential Lock

Lock the differentials whenever the mold board is on the ground, except when bladingthrough a turn.

Always unlock the differential before turning.

Never lock the differential when tandem tires are spinning. Reduce RPMs until tandemsstop spinning and then lock the differential


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25. Torque Converter Lock IndicatorThis indicator

illuminates in order to show that the torque converter

lock is disengaged.

Torque Converter

Operating Tips


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General Tips

Drawbar Positioning

When processing material, shift the drawbar in the direction of the

heel of the moldboard. This allows a steep moldboard angle and

gives enough moldboard coverage to safely deposit material outside

the tandem tires. (figures 1,2 and 3)

Slight adjustments to moldboard side-shift and drawbar center-shift

can improve visibility to critical areas.

Trucks must use caution when straddling windrows generated by the

a grader.

Drawbar adjustments will have a large effect on the cross slope.

Operating Tips


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Figure 1

Material discharging to the left and

drawbar shifted left

Figure 2

Drawbar Positioning

Figure 3


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Moldboard Pass Coverage

Pass coverage is reduced as the moldboard angle increases.

Deposit material at least 18 from the tandem tires to prevent potential

sidewall damage from sharp rocks in the windrow.

Use caution with moldboard angles close to 36 degrees. This steep angle will

deposit the windrow of material too close to the tandem tires.


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20.9

30

Angle

24

0Angle

Effect of Moldboard Angle on Pass Coverage


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Straight Frame


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Crab Steering


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Articulated Turn


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Operating Tips

General Tips

Moldboard Positioning

Tip the moldboard forward to cut hard packed material and tip it back for

processing, carrying, and combing out oversized rock.Use the thinnest cutting edge that material and conditions will allow.

This will improve material rolling action and increase moldboard

penetration down forces. It will also require less horsepower to power

the grader through the cut, improving both fuel consumption and tire

wear.


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Operating Tips

General Tips

Wheel Lean

Use articulation and wheel lean in combination when turning around.Turning radius is reducedwhen using this method. Turning with straight

frame gives a bigger turning radius. This method eliminates the need for

3-point turnarounds, a possible safety hazard on busy haul roads. Note:

Using max. wheel lean and a full turn can create interference with the

steering stops and the front axle.

Wheels leaned in the wrong direction during a turn around cause the tires

to roll over onto the sidewalls of the tire, potentially damaging the tire andincreasing turning radius.

Use wheel lean to counteract material side draft forces. Lean top ofwheels toward the heel of the moldboard. (figure 1)


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Wheel Lean

Figure 1

Keep adequate distance

between windrow

and inside of tire to

prevent sidewall damage

from sharp rocks


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Articulation vs. Straight Frame


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Operating Tips

Ripper Usage:

Rip in 1st gear only and begin at low throttle.

Use the ripper indicator gauge in the cab to determine the depth of

penetration. This will allow the operator to concentrate on the conditions in

front of the grader.

Proper use of the ripper (cutting high spots and fracturing hard packed

material) can help lengthen moldboard cutting edge life. Use the heal of the moldboard to smooth the previous pass


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QUARTER CROWNS SHOULD BE RIPPED PRIOR

TO REMOVAL TO EXTEND CUTTING EDGE LIFE

Ripper


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Operating Tips

Haul Road Maintenance

It is important to pull enough material from the berms to build up the road

surface and fill in low areas.

Leave rocks smaller than 2in diameter on the road surface to provide

additional traction to trucks when the road surface is wet.

Comb the larger rocks off the road surface. These can slow the flow of

water in the ditches and retard erosion.

Always begin road maintenance at one end of the working section.

When possible, make the initial pass in the same direction as truck traffic.

The windrow will serve as an indicator to an approaching truck that a

grader is ahead. This technique prevents leaving bends in the windrow,

from maneuvering around oncoming truck traffic, which could cause

safety hazards and production inefficiencies.


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Moldboard Tip

Moldboard racked all the

way back

Difference in cutting edge depth in rolling MB back and tipping forward

is 280 mm, (11 inches).

Moldboard tipped forward

Cutting Position: top of

moldboard slightly ahead of

cutting edge

Moldboard racked all the

way back


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Mold Board Pitch

Standard Position

Top of Mold Board 2 to 3

inches in front of the

cutting edge.


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Penetration Position

The sharptip of the

cutting edge is used for

penetrating the surface to

cut high spots in grade.

Mold Board Pitch


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CarryPosition

With the moldboard rolled

back, it is used to carry and

process material and combout oversized rocks.

There should be no cutting

of surface to prevent

unnecessary wear to back of

cutting edge.

Mold Board Pitch

ld d h


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With the mold board pitched all the way forward and using only the

pitch

lever to roll it back, there is approx. 9 inches of grade change.

Using only the pitchlever will not compromise the profile of the road!

Mold Board Pitch

d i S ???


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Production vs. Support???

R d C S i T


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Road Cross-Section Terms

Crowned Cross Section Use on straightaway

shoulder shoulder

crown

travel wear surface

high bank slope

flat bottom

ditch

V-ditch

back-slope

width

slopeslope

M R d C S i T


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More Road Cross-Section Terms

width

shoulder

shoulder

super elevation

Travel wear surface

high bank slope

V-ditch

back-slope

Super Elevation Cross Section

Use on curves

slope

V-ditch

H l R d D i R lli R i t


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Haul Road Design Rolling Resistance

Hard, well-maintained road . . . . . . . 1.5%

Well-maintained road with flex . . . . . . 3%

25 mm/1 in tire penetration . . . . . . . . .4%

50 mm/2 in tire penetration . . . . . . . . .5%

100 mm/4 in tire penetration . . . . . . . .8%

200 mm/8 in tire penetration . . . . . . .14%

Tire penetration

Ti C id i


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Tire Considerations20 24Tire Penetration = 30 35% Rolling Resistance

Over the life of the truck you will spend the initial


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Over the life of the truck, you will spend the initial

purchase price of the truck in tire related cost.

Ti C id ti


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Tire Failure ModeCut 45%

Impact 29%

Separation 11%

Worn out 7%

Other 8%100%

Tire Considerations

Source:Actual data, world-class metal mine

D i f S f Mi H l R d


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Cross Slope:

Design of Surface Mine Haulage Roads

Rapid removal of water.

Recommended rate: 1/4 -1/2 in/ ft (2%-4%). Surface texture. Ice or mud.

Single-lane - - governed by land features.

Crown appropriate for multiple-lane construction.

Dit hi


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Ditching


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8

Haul Road Design Corners


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Haul Road Design - Corners

Use maximum practical radii.

Employ super elevation for higher speed operations.

Use super elevation >10% with caution.

Haul Road Design Horizontal and Vertical Alignment


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Haul Road Design Horizontal and Vertical Alignment

Design corners and crests that allow excellent visibility at normal

travel speeds.

Use worst-case scenarios.

10

1

Haul Road Design Drainage & Safety Berms


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Haul Road Design Drainage & Safety Berms

Berm size - at least one-half wheel height.

Drainage

1/2 wheel height

Haul Road Design R d Width


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Haul Road Design- Road Width

One way - 3 truck widths.

Two-way straights - 3.5 truck widths. Two way corners - 4 truck widths.

One-way (Straights/corners)

Two-way (In Straights)

Two-way (In Corners)

Points to Remember


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Points to Remember

Over-Watering Haul Roads:

Softens and makes slippery

Surface susceptible to damage

Water often scarce

Set up/adjust water trucks

Watering


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Watering

Rut formationhigh RR

Excess water sprinkling

Haul Road Visual Inspection Main Haul Road


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Haul Road Visual Inspection- Main Haul Road

Road is free of puddles, potholes, ruts, gullies.

Passing room is adequate.

Corner radius allows safe operation at high speed.Spillage is removed quickly.

No rubber deposits on tight, rocky turns.

High braking forces not necessary on corners.

Expected road speeds are achieved.

Points to Remember


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The best haul roads have crowned straight sections, super-elevated

curves, safety berms and drainage ditches on both sides.

Because excessive water is a detriment to any road, the most importantitem (for many sites) in road maintenance is providing and maintaining a

good drainage system.

Points to Remember


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Haul Road Visual Inspection - Dump Zone


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Haul Road Visual Inspection- Dump Zone

Floor is smooth.

Trucks enter at high speed, parallel to edge.

Trucks brake in straight line, then turn and stop to reverse to dump. Safety berms are regulation height.

Is dump stable enough to dump over safely or should you dump short and

push off.

Points to Remember


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What to look for?

Points to Remember

The haul road begins at the loading face and ends at the dump point.

Once a road deteriorates, it takes five times as long to repair it to good

condition again. Fix it once, fix it right!

If one can travel comfortably in a light truck at 35 mph, then road surfaces

are good.

Good roads improve production, extend tire life and reduce overall

operating costs.

Haul Road Support !


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Haul Road Support !

Drawbar Circle Moldboard Protection


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Standard equipment on all motor graders

Protects the DCM area from damage due to

horizontal shock loads.

Can be adjusted to match operating conditions

Circle Drive Slip Clutch

Drawbar, Circle, Moldboard Protection

grader operation tips

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