PREVENTATIVE MAINTENANCE AND PRE-OPERATION CHECKS

Learning Goals

• To conduct pre-operation checks on a

daily basis to reduce repair costs and

downtime

Related Task Sheets:

Fuel, Oil, Coolant Levels

4.6.1

Lead Acid Batteries

4.6.2

Tire and Wheel Condition

4.6.5

The Operator Platform

4.6.6

John is a part-time farmer. Two

years ago he purchased a small

utility tractor with backhoe and

scraper blade for $12,000. He

wanted to push snow, clean the

barn, and do odd jobs on his

property. While driving his tractor

down the road, the engine

overheated, began to make noise,

lost power, and shut down. A

neighbor stopped by and John

asked, “What could be the

problem?” He was already pouring

water in the radiator. “Could it be

the hydrostatic transmission?” he

asked as he checked that dipstick.

The neighbor suggested the engine

oil, but John didn’t know where to

find that dipstick, which turned out

to be hidden by the high-lift arms.

The dipstick registered no oil at all.

Performing tractor maintenance is

a critical task for every tractor

operator. This task sheet discusses

the proper way to maintain a

tractor to avoid costly and

unnecessary repairs.

A good operator uses a daily

checklist of items and systems to

inspect before starting the tractor.

This is often called a pre-operation

checklist. Many drivers write down

what needs to be inspected and

then check off the list as they

examine each item.

Introduction

If you were to buy a

new, expensive

tractor, what would

you want your

friends to check

before they started

the engine?

PREVENTATIVE MAINTENANCE

AND PRE-OPERATION CHECKS

NATIONAL SAFE TRACTOR AND MACHINERY OPERATION PROGRAM

HOSTA Task Sheet 4.6

Pre-Operation Checks

Things to check include:

• Fuel level

• Coolant level

• Engine oil level

• Hydraulic oil level

• Battery condition

• Lug nuts and wheels

• Tire condition

• Loose or defective parts

• SMV emblem

• Fluid leaks

• Operators platform/steps

• Seat/Adjustment

• Seat belt

• Fire extinguisher

• Lighting/Flashers

• Visibility from operator’s seat

Some Practical Hints

Here are several things to look for

as you perform a pre-operation

check:

• Low tires and leakage from the

valve stem

• Oil or hydraulic leaks on the

ground beneath the tractor

• A frayed or worn fan belt

• Corroded battery terminals

• Loose bolts or lug nuts on

wheels

• Dirty cab windows that

obstruct your vision

• Headlights or warning lights

with broken bulbs or glass

• An SMV emblem that is faded

or distorted in either color or

shape

• A fire extinguisher with a

pressure gauge in the

“recharge” range

• Several tools or supplies on the

operator platform

Cooperation provided by The Ohio State University and National Safety Council.

Core

1. Farm and Ranch Safety Management, John

Deere Publishing, 1994.

2. Safe Operation of Agricultural Equipment,

Student Manual, 1988, Silletto and Hull, Hobart

Publications.

3. Owners’ Manuals for specific tractors.

References

Page 2

PREVENTATIVE MAINTENANCE AND PRE-OPERATION CHECKS

1. Make a chart of maintenance items to be done on your tractor. Use the following format, or develop your

own chart. If you have a computer, make a spreadsheet or database project to help with maintenance

records.

Tractor Maintenance Log

Date Item Checked Problem Found Corrective Action

2. Help someone change the oil and oil filter on a tractor.

3. Help someone change an air filter on a tractor.

4. Call a tractor dealer/service center, and ask for any maintenance charts or record forms that they can send to

you.

5. Memorize the “pre-op” checklist, and recite this list as you conduct a pre-operation inspection for your class

or an interested adult.

6. Math Problem: You forgot to check the engine oil in the tractor before starting. When the oil light came on,

you continued working. Now the engine must be rebuilt to the amount of $5000. This is the only tractor that

can pull the forage harvester and chop 40 acres per day for the next 5 days. An estimated nutrient loss value

of $10 per acre will occur due to the delay in harvest. Calculate the dollar loss to the producer.

Safety Activities

Safe Starts

Some newer utility or lawn tractors

may have safety start systems. If

so, the owner should also have in

good working order one or both of

the following items:

Seat Switch/Safety Interlock that

prevents starting the tractor if the

operator is not in the seat

Neutral-Start Safety Switch that

prevents the tractor from starting if

the tractor is in gear

A good operator

takes

responsibility for

the tractor he or

she operates.

Don’t start the

engine until you

have completed the

“walk-around”

inspection and are

sure all systems are

ready to work for

you.

National Safe Tractor and Machinery Operation Program

The Pennsylvania State University

Agricultural and Biological Engineering Department

246 Agricultural Engineering Building

University Park, PA 16802

Phone: 814-865-7685

Fax: 814-863-1031

Email: [email protected]

Contact Information

Developed, written and edited by WC Harshman, AM Yoder, JW Hilton and D J Murphy,

The Pennsylvania State University. Reviewed by TL Bean and D Jepsen, The Ohio State

University and S Steel, National Safety Council. Version 4/2004

This material is based upon work supported by the Cooperative State Research, Education, and Extension

Service, U.S. Department of Agriculture, under Agreement No. 2001-41521-01263. Any opinions, findings,

conclusions, or recommendations expressed in this publication are those of the author(s) and do not

necessarily reflect the view of the U.S. Department of Agriculture.

Credits

Cooperation provided by The Ohio State University and National Safety Council.

Learning Goals

• To understand how to check fuel

levels of common engines

(alternative fuels excluded here)

• To safely check coolant levels of

liquid cooled engines

• To correctly check oil levels of any

engine

Related Task Sheets:

Tractor Instrument Panel

4.4

A tractor is a huge investment to

make farm work more efficient.

Even a mid-size tractor may cost

$40,000 or more.

The tractor must be kept in top

operating condition. Downtime for

engine and tractor repairs are

costly. An engine rebuild may cost

over $5000 in parts and labor. A

crop in the field may be lost

because of harvest delays. Crop

losses can lead to increased costs

to purchase replacement feeds or

protein supplements.

Therefore, tractor and equipment

pre-operation checks are an

economic necessity. A damaged

engine or an empty fuel tank at the

farthest field from the barn is no

excuse for the skilled operator.

This task sheet discusses the

importance of checking the fluid

levels of the

• fuel

• coolant, and

• oils

before you touch the tractor

ignition switch. Developing this

habit will help you to understand

that the tractor engine is ready for

field work.

What to Do

Introduction

Figure 4.6.1.a. Before driving the tractor to the field, check for the possibility of an empty fuel tank.

If you run out of fuel during a workday, you are causing downtime losses.

Save an engine from costly

repairs; check the fuel,

coolant, and oil levels

before starting the engine.

FUEL, OIL, AND COOLANT LEVELS

NATIONAL SAFE TRACTOR AND MACHINERY OPERATION PROGRAM

HOSTA Task Sheet 4.6.1

Fig. 4.6.1.b. Check the fuel level.

Fig. 4.6.1.c. Check the oil level.

Fig. 4.6.1.d. Check the coolant level with

the engine cold.

Cooperation provided by The Ohio State University and National Safety Council.

Page 2

FUEL, OIL, AND COOLANT LEVELS

1. Safety Management for Landscapers, Grounds-

Care Businesses, and Golf Courses, John Deere

Publishing, 2001. Illustrations reproduced by

2. Farm and Ranch Safety Management, John

Deere Publishing, 1994.

3. Owners’ Manuals of Several Tractors.

References

1. Park the tractor at the farthest field from the barn, and time your walk back to the farm shop or fuel area.

This is wasted time or downtime when cropping work could be completed.

2. Call a tractor dealer’s service department to ask about the cost to rebuild a tractor engine damaged from lack

of oil. Provide this information to your class and instructor.

3. Using a hydrometer (device to measure specific gravity of coolant or antifreeze for level at which the liquid

would freeze), test engine coolant for level of temperature protection that coolant would provide.

4. Explain the meaning of the term “oil viscosity.”

5. Describe the difference between diesel fuel and gasoline. How does the storage of these fuels differ?

Safety Activities

engine oil allows engine parts to

overheat, expands them, and

“seizes” the engine. Overfilling the

engine oil results in oil seal

damage.

Use the oil dipstick daily to prevent

engine damage.

Coolant

Coolant fluid (water and

antifreeze) carries engine heat

away from the engine. Air flowing

across the radiator then reduces the

coolant temperature. Lack of

coolant causes overheating of the

engine. Water used as a coolant by

itself will cause rust in the water

pump.

Check coolant levels while the

engine is cold to prevent severe

scalds.

Fuel

Check the fuel level before leaving

the barnyard or shop area. You

cannot assume that someone else

has done this job. Failure to check

the fuel level may result in lost

field time. Or it may result in the

need to mechanically bleed air

from diesel fuel lines in some older

tractors.

Be sure you do not fill diesel fuel

tanks with gasoline and vice versa.

Oil

Oil bathes metal surfaces to

prevent the heat of friction from

damaging the moving parts. Low

Why You Should

Check Fuel, Coolant

and Oil Levels

If the engine oil

light comes on

while you are

operating the

tractor, shut down

immediately.

Figure 4.6.1.e. Never remove a radiator cap

from a hot engine. Steam and hot water from

the radiator can scald your skin.

Safety Management

for Landscapers, Grounds-Care Businesses, and Golf Courses,

John Deere Publishing, 2001. Illustrations reproduced by per-

National Safe Tractor and Machinery Operation Program

The Pennsylvania State University

Agricultural and Biological Engineering Department

246 Agricultural Engineering Building

University Park, PA 16802

Phone: 814-865-7685

Fax: 814-863-1031

Email: [email protected]

Contact Information

Developed, written and edited by WC Harshman, AM Yoder, JW Hilton and D J Murphy,

The Pennsylvania State University. Reviewed by TL Bean and D Jepsen, The Ohio State

University and S Steel, National Safety Council. Version 4/2004

This material is based upon work supported by the Cooperative State Research, Education, and Extension

Service, U.S. Department of Agriculture, under Agreement No. 2001-41521-01263. Any opinions, findings,

conclusions, or recommendations expressed in this publication are those of the author(s) and do not

necessarily reflect the view of the U.S. Department of Agriculture.

Credits

Cooperation provided by The Ohio State University and National Safety Council.

Learning Goals

• To identify faulty tire and wheel

situations and take corrective action

to remedy the problem

Related Task Sheets:

Preventative Maintenance and

Pre-operation Checks

4.6

Tractors are traction machines!

Better traction comes from good

tires.

Tractor tires can cost several

hundred dollars each. Estimates

show that tractor tire repair and

replacement comprise nearly 30%

of the total repair costs during a

tractor’s lifetime.

You are responsible for protecting

this valuable traction component.

This task sheet discusses tractor

tire and wheel conditions for safe

tractor operation.

Tire and Wheel

Hazards

Tractors are not built for high

speed. High speeds on paved roads

reduce tire life. Unpaved roads can

do the same and also increase the

chance for large stones to damage

the tire as well.

Foreign objects can puncture tires.

All farms have their share of sharp

rocks, hidden field objects, and

construction debris. Fields near

rural roads may have glass bottles

and metal cans which can cut tires.

Be alert for those objects which

can damage tires.

Improper use can ruin tires.

Turning too tight and gouging the

tire into towed equipment leads to

cut tires. Most tractors have no

shock absorbers; so the tire must

absorb all ground shocks. Tire

sidewall breaks can occur when

objects are impacted.

Introduction

Figure 4.6.5.a. Tractor tire components include the tire, the rim or wheel, an inner tube with valve,

and, many times, a calcium solution filling about 80% of the inner tube.

Some rear tractor tires

are filled with a calcium

solution to add weight to

the tractor to improve

traction.

These simple activities can extend

the life of tractor tires:

• Check tire pressure regularly.

• Use wheel weights to reduce

excess slippage, which can

damage the tire.

• Drive carefully to avoid

damaging objects.

• Make tire repairs promptly.

Tire Basics

TIRE AND WHEEL CONDITION

NATIONAL SAFE TRACTOR AND MACHINERY OPERATION PROGRAM

HOSTA Task Sheet 4.6.5

Tire

Rim

Calcium fill

line is 80% if

calcium solu-

tion is used.

Valve Stem

Cooperation provided by The Ohio State University and National Safety Council.

Page 2

TIRE AND WHEEL CONDITION

1. Farm and Ranch Safety Management, John

Deere Publishing, 1994.

2. Safe Operation of Agricultural Equipment,

Student Manual, 1988, Silletto and Hull, Hobar

Publications.

References

1. Call a local tire dealer who specializes in tractor tires, and ask for the price of a tractor tire that fits your

tractor. For comparison purposes, call several dealers.

2. Have an adult mentor, leader, or teacher show you how to check air pressure in a calcium-filled tractor tire.

3. Find out how much a rear tractor tire weighs when it is filled with a calcium solution. You can use the

Yellow Pages of the phone book to find a tractor tire repair service or tire dealer.

4. Ask a local tractor tire dealer what the recommendations are for filling tractor tires with liquid ballast (or

calcium solution).

Safety Activities

Tire and Wheel

Defects

Tractor tires are

expensive. They may

cost hundreds of

dollars to repair or

replace.

Fig. 4.6.5.b. Worn treads and dry rot

make for poor traction and risk for

downtime due to a blowout.

Fig. 4.6.5.c. Damaged rims from

careless use may cause damaged tire

beads and flat tires.

Fig. 4.6.5.d. A leaking valve stem

released calcium solution which

rusted the rim. A major expense will

be incurred, as well as a severe

safety hazard in using this tractor.

National Safe Tractor and Machinery Operation Program

The Pennsylvania State University

Agricultural and Biological Engineering Department

246 Agricultural Engineering Building

University Park, PA 16802

Phone: 814-865-7685

Fax: 814-863-1031

Email: [email protected]

Contact Information

Developed, written and edited by WC Harshman, AM Yoder, JW Hilton and D J Murphy,

The Pennsylvania State University. Reviewed by TL Bean and D Jepsen, The Ohio State

University and S Steel, National Safety Council. Version 4/2004

This material is based upon work supported by the Cooperative State Research, Education, and Extension

Service, U.S. Department of Agriculture, under Agreement No. 2001-41521-01263. Any opinions, findings,

conclusions, or recommendations expressed in this publication are those of the author(s) and do not

necessarily reflect the view of the U.S. Department of Agriculture.

Credits

Cooperation provided by The Ohio State University and National Safety Council.

Learning Goals

• To understand the need to keep

steps and platform clear of tools and

debris at all times

• To adjust the tractor seat and seat

belt to safely reach all controls while

your seat belt is buckled

Related Task Sheets:

Preventative Maintenance and

Pre-Operation Checks

4.6

If you compare the tractor operator

platform to the cockpit of a jet

fighter plane, both the tractor and

jet fighter have:

• Steps to climb on board

• Adjustable operator seat

with seat belt

• Multiple controls at hand and

foot positions

• High visibility from the

operator’s seat

Keep these similar work areas free

of obstructions for safe operation.

Could the pilot of the jet plane be

able to fly to our defense in a

moment’s notice if:

• The steps were covered

with mud and manure?

• The cockpit was filled

with chains, grease guns,

tools, and hitch pins?

• The windows were

covered with pesticide

spray drift or other materials?

• The pilot could not reach the

controls because of a poorly

adjusted seat?

This task sheet discusses the need

for a clear tractor operator platform

and an adjustable seat to safely

reach the operating controls.

Operator Platform

Workplace

Figure 4.6.6.b. Falls account for many farm

injuries. Keep the steps and platform clean of

mud, manure, and tools.

Figure 4.6.6.c. Tractors with ROPS come

equipped with seat belts. Use them.

Figure 4.6.6.d. Keep windows and mirrors

clean for good visibility.

Introduction

Figure 4.6.6.a. The operator’s platform is not a tool box. You must have room to operate hand and

foot controls. PTO levers, differential locks, foot throttles, and brake locks have to be engaged from

the floor position. Soda cans and tobacco snuff containers can roll under control pedals and prevent

correct, timely operation.

The tractor

platform serves

as the cockpit

of this farm

tool.

THE OPERATOR PLATFORM

NATIONAL SAFE TRACTOR AND MACHINERY OPERATION PROGRAM

HOSTA Task Sheet 4.6.6

Cooperation provided by The Ohio State University and National Safety Council.

Page 2

THE OPERATOR PLATFORM

1. www.cdc.gov/niosh/injury/trauma

2. Owners’ Manuals for Specific Tractors.

3. Farm and Ranch Safety Management, John

Deere Publishing, 1994. Illustrations reproduced

References

1. Select any tractor at the farm where you work, and clean the tractor steps and platform. List how many

different objects you can find there.

2. Use the NIOSH website to locate data on injuries due to falls in agricultural work. Are falls from getting on

or off tractors considered a problem? If so, describe how serious it is.

3. Conduct a farm survey in the area with the help of your club or class members to determine how many

tractors have seats or seat belts that can be easily adjusted.

Safety Activities

Figure 4.6.6.f. The steering wheel should be

adjusted as soon as you are seated. In the

correct position, your arms are bent at a 90-

degree angle as you hold the steering wheel.

Your legs should remain slightly angled while

the foot pedals are fully depressed.

Each person who operates the

tractor will be a different size and

weight. Check and adjust the seat

adjustment so that you can

comfortably reach all controls.

Seat controls may be levers or

knobs and will be black in color.

They may:

1. Release the seat to tilt it away

from rain if the tractor is sitting

outside.

2. Position the seat higher, lower,

closer, farther, or to a different

tilt position from the steering

wheel and foot pedals.

3. Adjust the seat for the weight

of the operator.

4. Be sure the seat belt is also

adjusted for the seat.

Seat Adjustment

Seat belts keep

tractor drivers from

being thrown out of

the cab or off the

seat during

roll-overs.

Wear your seat belt!

Figure 4.6.6.e. Locate seat adjustments and

know how they work. You may need the

Operator’s Manual.

Farm and Ranch Safety

Management, John Deere Publishing, 1994. Illustrations

National Safe Tractor and Machinery Operation Program

The Pennsylvania State University

Agricultural and Biological Engineering Department

246 Agricultural Engineering Building

University Park, PA 16802

Phone: 814-865-7685

Fax: 814-863-1031

Email: [email protected]

Contact Information

Developed, written and edited by WC Harshman, AM Yoder, JW Hilton and D J Murphy,

The Pennsylvania State University. Reviewed by TL Bean and D Jepsen, The Ohio State

University and S Steel, National Safety Council. Version 4/2004

This material is based upon work supported by the Cooperative State Research, Education, and Extension

Service, U.S. Department of Agriculture, under Agreement No. 2001-41521-01263. Any opinions, findings,

conclusions, or recommendations expressed in this publication are those of the author(s) and do not

necessarily reflect the view of the U.S. Department of Agriculture.

Credits

Cooperation provided by The Ohio State University and National Safety Council.