Farm Safety Association, Inc.
Much
of Ontario's hay crop is now harvested as large bales. Adoption
of big package haying systems has been very rapid, largely
because of the major labour savings it provides.
Along
with the big bale benefits have come a number of hazards.
The equipment used for large bale formation and handling harbours
familiar dangers that are associated with all farm machinery.
Round balers do feature some unique hazards, and the horsepower
involved is usually greater than was required with more traditional,
small, square baling systems.
However,
the biggest risk -- and the one responsible for most of the
serious injuries and deaths - is the physical nature of the
balers themselves. A compact package of hay or straw weighing
from 500 pounds to 1.5 tons (225 kg - 1300 kg) definitely
poses some threat to human life and limb at every stage of
handling! And because some bales are round, they can roll
relatively freely and will gain momentum if the path of travel
is downhill.
Equipment
manuals should be part of every farm's safety program.
It is every farmer's responsibility to know the specific requirements, precautions and hazards associated with a particular operation. The manual that is provided with every piece of equipment is the primary source of information on safe, efficient operation. Anyone who runs the machinery should review this material. It is the responsibility of the farm owner or manager to make sure that all employees are well trained in the operation of equipment they will be using.
Comprehensive maintenance in advance of the major use season can minimize downtime in the field. In addition to improving harvest efficiency, this pre-season preparation may also prevent an accident.
Following
is a checklist of procedures which can help detect potential
hazards and improve the efficiency of your baler:
- Clean
the baler thoroughly to remove crop residues, mouse nests,
and other debris. Lubricate according to manufacturer's
specs.
- Check
for loose or missing nuts, screws, guards, or damaged pickup
teeth. Replace missing guards and shields.
- Inspect
all belts and chains for evidence of wear or breakage. Belt
tension should be matched to prevent slippage, which can
cause plugging and damage due to heat buildup. Before replacing
a belt or chain, consult the manual for instructions on
securing the upper chain or removing load from the belt
tension springs.
- Hydraulic
hoses should be clean, in good repair and hooked up correctly.
Check the twine feeding and cutting mechanisms for proper
operation. Also check the slip clutch, roll scraper, and
rear gate latch to make sure they are adjusted and functioning
according to the manufacturer's recommendations.
- Check
lights, reflectors and SMV. Properly operating fire extinguishers
should be mounted on both tractor and baler.
Operators
must have in-depth knowledge of the tractor and baler they are
using. It is important to understand how all components and
systems are activated on both machines.
- All
protective devices should be in place and securely fastened.
- Before
starting equipment, check for broken, missing, or damaged
parts. Check the condition of tires. Inspect the hydraulic
system, using a scrap of wood or cardboard (not your hand!)
to detect leaks. Make all necessary repairs before heading
for the field.
- Dry
crop materials are flammable. Remove trash from behind shields,
covers and from around machinery components.
- Lubricate
according to directions in manufacturer's manuals.
- Check
and adjust components in accordance with instructions in
the manual.
Never
attempt to clean, lubricate, or adjust the baler unless the
tractor engine is turned off, the PTO disengaged, and the ignition
key removed.
Walk
around the equipment before starting. Check that the rear
gate is securely closed. Make sure there is no one in the
vicinity. Let others know you are starting up, and don't do
so until everyone is clear of the danger area.
Remember
- this is a one-person operation! Never allow anyone
to ride with you on either the tractor or the baler.
Most farmers
are familiar with hazards in and around their own fields. Extra
caution is needed on slopes, around ditches, or near overhead
power lines which could be a hazard when raising the baler's
rear gate. If someone else will be operating the baler, make
sure that they are thoroughly familiar with the hazards.
The pickup
should be adjusted to provide adequate ground clearance. If
tines contact the ground, the operator could be showered with
earth and stones, and the baler won't feed properly. Engage
PTO while the equipment is stationary and look and listen
for any signs of trouble. Cycle all baler hydraulic systems
to assure proper functioning. Check twine feeding and cutting
mechanism for proper operation.
Obviously,
the material to be harvested must be in suitable condition
for baling (20 percent moisture or less). Excessive plugging
is likely if the crop is wet.
Ground
speed should be matched to crop conditions and windrow size.
Keep the pickup high enough to aggressively deliver crop into
the baler inlet. If the machine is equipped with feed rolls,
maintain recommended clearance and pressure setting. Operator's
manuals provide information on correct adjustments, operating
procedures for various crops and conditions, etc.
Never
try to unplug, clean out or adjust a baler while it is operating.
Severe injury or death could be the result. Wait until all
machine motion has stopped before approaching the baler.
Don't
try to feed material into a machine by hand - the hay will
be taken in faster than you can let go!
Refer
to the operator's manual for bale tying instructions. Resist
the temptation to produce oversized bales, which can make
bale discharge difficult or damage components.
Correct
procedure for discharging bales is described in operator's manuals.
It is important to always keep in mind the fact that round bales
can roll downhill! Serious injury and/or extensive property
damage could result from careless ejection. Whenever possible,
discharge bales on flat, level ground. No one should be near
the rear of the baler at time of ejection.
If it
is necessary to open the tailgate for manual bale removal
or unplugging, shift the tractor to neutral or park, lock
the brakes, and disengage the PTO. Raise the tailgate hydraulically,
lock it in place, then shut off the tractor engine and remove
the ignition key.
If a fire
starts in the baler, pull into a level, open area and eject
the bale. Drive clear of the fire area, call for help if possible,
then use your extinguisher to bring the fire under control.
Be sure
to obey all applicable traffic regulations when travelling on
public roads. Lock brake pedals together and use safety chains.
The baler should be equipped with required lights, reflectors
and a clearly visible SMV emblem.
A
well maintained baler will minimize breakdowns.
Serious
accidents associated with large bale systems seem to be happening
during the handling of the big hay packages.
A number
of operators have been seriously injured when improperly secured
bales rolled down the arms of front-end tractor loaders. It
is strongly recommended that tractors used to handle the big
bales be equipped with 4-post rollover protective structures
(ROPS), if available for your model of tractor.
Front
end loaders must be equipped with proper restraining devices
for handling large bales, such as this spear.
However,
we shouldn't be relying on ROPS to cushion the blow, and bales
shouldn't be moving down loader arms to begin with! A loader
should be equipped with a spear or grapple that is specifically
designed for handling the size of a large bale that is being
produced on-farm. Most importantly, the loader should incorporate
a restraining device that will prevent a bale that has come
loose from sliding backward.
The loader
tractor must be large enough and equipped with sufficient
counterweight to handle bales safely. Set wheels at maximum
width to increase stability.
Try to
avoid steep slopes and rough terrain when conveying bales
with the loader. If it is impossible to avoid sloping land,
approach bales from the downhill side.
As with
any loader operation, avoid sudden starts, stops or changes
of direction. Always keep the bale as low as possible for
maximum stability. A one ton bale puts the centre of gravity
at a precarious level when a loader is raised high. The risk
of a bale breaking free is also greater when the loader is
raised. Be extremely cautious, and travel only at low speed.
Insist
that other workers and bystanders stay well clear of bale
handling operations.
Use good
judgement when stacking bales in storage. High stacks mean
more efficient use of available space, but subsequent removal
could be very hazardous.
If bales
are to be handled with a 3-point hitch attachment, the tractor
must have sufficient front counterweight for stability and
safe handling. Practice extreme caution when backing up to
a bale. Keep everyone away from the bale and the forks.
A tremendous
variety of wagons, truck frames, etc. have been developed for
conveying loads of large bales. Some of these are quite sophisticated,
with provision for automated loading and unloading.
Such
purpose-designed equipment is safer for transporting round
bales. However, we recognize that many farmers will continue
to load their big bales on flatbed wagons that were originally
built for conventional square bales. If the majority of a
farm's harvest is likely to be in the form of large round
bales, the owner should consider replacing at least one flat
rack with a platform designed to carry round bales. Make sure
that the round bale platform won't encourage the building
of loads that exceed capacity of the running gear.
It is
very important for large bales to be well secured on a flat
rack. They should be tied down if the load is to be transported
on a public roadway. An innocent bystander was killed by round
bales that jolted loose from a flat rack at the top of a hill
on a township road.
Following
are some additional pointers for transporting loads of large
round bales:
- The
load being pulled should be no heavier than the pulling
unit.
- Inspect
the transporting unit before going on the roadway.
- Take
advantage of 'engine braking.' Use the same gear going down
a hill as you would going up. Keep in mind that most tractors
only have two wheel brakes.
- Wagons
used to haul bales should be of sufficient width and have
end racks to prevent bales from moving off either end during
transport.
- Hitching
should be secure. Use a top quality draw pin and safety
chain.
- Make
sure you can signal your intention to turn on the roadway
- use escort vehicles if necessary.
- SMV
sign should be clearly visible on the rear of the wagon.
- Never
carry a large bale on the front end loader while pulling
a loaded wagon.
Front
end loaders must be equipped with proper restraining devices
for handling large bales. Counterweights on the tractor may
help prevent tipping.
The basics
of equipment safety apply to large bale harvest and handling.
The major new risk encountered when switching to this system
of hay handling is the new forage package itself. These bales
can roll, and their tremendous weight is sufficient to crush
a human body.
Please
keep the following points in mind when working with large
bales:
- Good
maintenance and timely lubrication minimize the breakdowns
that can lead to frustration and carelessness.
- Never
attempt to unplug a baler or carry out adjustments and repairs
with power engaged.
- Place
bales in a manner that will minimize potential for rolling.
- Handling
equipment should be large enough and properly counterweighted.
- When
handling or transporting bales, use properly-designed equipment
that incorporates restraining devices. Avoid sudden motions,
and travel at low speed.
- Always
carry bales as low as possible with a tractor loader.
- Bystanders
and other workers should stay well clear of all big bale
operations. And remember, NO RIDERS!
- The
best instructions for safe, efficient use of equipment can
be found in the manual. Every operator should be familiar
with this information.
Disclaimer
and Reproduction Information: Information in NASD does not represent
NIOSH policy. Information included in NASD appears by permission
of the author and/or copyright holder. More
NASD Review: 04/2002
The information
and recommendations contained in this publication are believed
to be reliable and representative of contemporary expert opinion
on the subject material. The Farm Safety Association does not
guarantee absolute accuracy or sufficiency of subject material,
nor can it accept responsibility for health and safety recommendations
that may have been omitted due to particular and exceptional
conditions and circumstances.
Fact
Sheet
NO:
F-019
MARCH 1991
COPYRIGHT©
1991
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