David
E. Baker
University of Minnesota Extension Service
The
key to safe and efficient large round bale systems is an operator
who knows the hazards involved and who follows safety practices
that can prevent large round bale accidents. Operators must
be constantly alert for situations that may cause injuries
to themselves or others. On top of pain and suffering, accidents
contribute to higher costs in terms of unnecessary down-time
or costly machine repairs. Alertness and safety consciousness
can result in more efficient and profitable baling and handling.
Developing
your safety awareness begins with the operator's manual. Take
time to read the manual and become reacquainted with the machine
at the beginning of each season. Insist that all operators
are trained and acquainted with all the safety precautions
in the manual. Initial training of employees and annual training
thereafter is a legal requirement for certain operators of
large farms as part of the Occupational Safety and Health
Act standard (29 CFR 1928.57) for the Guarding of Farm Field
Farmstead Equipment and Cotton Gins.
Allow
only responsible, trained persons to operate the baler or
bale handling equipment. Operators should become familiar
with machinery maintenance and operation procedures, including
crop conditioning and bale handling equipment and techniques.
Especially important is a thorough knowledge of attachments
required to bale different materials and types of windrows.
Safe
operation during baling depends in part on how well the baler
is prepared for use before the season starts. This preparation
may reduce field down time and also may prevent an accident.
This pre-season preparation will also allow necessary lead time
to get needed replacement parts and to do a thorough preparation
job. Before servicing, performing a pre-operational check, unplugging,
or adjusting the baler, always disengage the power takeoff,
shut off the tractor engine, and take the ignition key with
you. This will prevent someone from starting the equipment while
you are servicing, repairing, or unplugging it.
Your
pre-baling preparation should include these procedures, which
can help detect potential safety hazards and improve the efficiency
of your machine8
- Thoroughly
clean the baler to remove any accumulated field trash, bird
nests or other debris and lubricate all parts according
to the manufacturer's recommendations. Proper lubrication
can reduce unnecessary wear on parts and prevent overheating
that could cause a fire.
- Carefully
check for loose or missing nuts, screws, guards or bent
pickup teeth. Replace missing guards to prevent accidental
contact with the components they guard. Replace bent or
missing pickup teeth to ensure effective feeding of material
into the feed rolls.
- Inspect
all belts or chains for evidence of wear or breakage. Maintain
belt tension according to the manufacturer's recommendations.
Belt lengths should be matched to prevent slippage which
can cause plugging and belt damage due to heat buildup.
Belts that must be spliced should be trimmed and laced squarely.
New belts should be checked periodically until they are
run-in and length has stabilized. Before replacing a belt
or chain, consult the operator's manual for instructions
on securing he upper chain or removing the load from the
belt tension springs.
Make
sure the hydraulic hoses are clean and in good repair and
hooked up correctly. Check the twine feeding and cutting mechanisms
to make sure that they are working properly and that your
twine is in good condition. 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.
Finally,
check all lights and warning reflectors and clean your slow-moving
vehicle (SMV) emblem. Check your fire extinguisher to make
sure it is in proper operating condition. For help in the
selection and use of a fire extinguisher, ask for a copy of
MU publication G01906, Selecting and Using a Fire Extinguisher,
at your local University Extension center.
Repeated
plugging of the baler may cause the operator to become impatient
and to try unplugging the baler while it is running. Never try
to unplug the baler until you have disengaged the power takeoff
and shut off the tractor engine.
Best
results for forming a good bale core and reducing plugging
begin with a properly formed windrow. The material should
be well cured (20 percent moisture), and the windrow should
be uniform, moderately heavy and about equal to half the width
of the pickup, or about equal to the full width of the pickup.
Use special care on residue crops such as corn stalks and
straw, and consult your operator's manual for special instructions.
Vary
tractor throttle settings to match crop conditions and windrow
size. Operator manuals give information on tractor throttle
settings and driving techniques for the material being baled.
Always maintain the engine speed so that the pickup can operate
efficiently to prevent bunching and slug feeding. Adjust the
pickup for maximum ground clearance to allow for clean pickup
and to avoid excessive pickup of rocks and debris.
After
cleaning out a plugged machine - remember, never unplug a
machine while it is running - spread the bunched material
in a windrow for pickup in a normal manner. Never attempt
to feed the material into the baler by hand or feet. One slip
could be deadly!
Also
never attempt to hand feed or remove twine from the machine
while it is running. Simultaneous introduction of hay and
twine can correct a failure of twine to enter the baler.
After
you have completed the bale but before you eject the bale
or open the rear gate, make sure everyone is a safe distance
from the rear of the baler. Bales are a hard, tightly rolled
mass, weighing as much as 3,000 pounds, and they could injure
or kill bystanders by crushing them. Discharge the bale on
level ground to prevent injury or property damage from an
out-of-control rolling bale; position the bale so it won't
roll.
If for
any reason you must work around the gate area or in the bale
chamber, disengage the power takeoff, stop the engine, set
the parking brake and remove the ignition key. Engage the
mechanical gate safety lock before starting to work in the
gate area.
Also,
instruct everyone to stay away from the tractor and hydraulic
controls while you perform the necessary service.
Now
that you have this large round bale, you have to handle it mechanically.
As with
any new system of materials handling, there are a number of
different handling ideas. Some are good and some can cause
problems. When selecting a handling unit, look for ones with
safety features that meet your use and storage practices.
For example, could the one with the impaling shaft also accidentally
pierce a person? Is your power unit big enough to handle the
bale, or will you be overloading the tractor? Does the manufacturer
have safe handling procedures outlined in the owner's manual?
Center
of gravity is important in handling big round bales. The load
should be kept as low as possible. A top-heavy condition can
lead to a backward or side overturn.
When
moving a bale, make sure to use controls smoothly, avoiding
"jerky" movements. Do not travel too fast and make sure that
there is adequate ballast on the front and rear to counterbalance
the load.
Keep
the load as low as possible. Avoid steep hillsides as much
as possible. Severe braking of a tractor while going at an
angle down a slight embankment can cause the tractor to overturn.
When picking up a bale on a steep hillside, work from the
downhill side. Always be aware that the bale could roll down
the hill.
Using
a regular front end loader to move bales poses a problem since
the bale can roll out of the bucket and down the loader arms
onto the operator. Do not lift round bales with the standard
loader unless you have proper bale restraining devices. In
general, agricultural tractor roll-over protective structures
(ROPS) are not intended to protect against falling bales.
Failure to follow these instructions may result in serious
crushing injuries or death for the tractor operator.
Movement
of agriculture equipment on highways and roads requires special
care. Moving a number of large bales at one time can cause braking
problems. Always make sure that the load being pulled is no
heavier than the pulling unit. Also, use the same gear going
down a hill as you would going up a hill. Keep in mind that
most tractors have only two wheel brakes. Five or six bales
on a trailer may give a weight of 9,000 to 10,000 pounds.
Make
sure the load you are moving is not too wide. As a general
rule, if you are moving bales for your own use, you are exempt
from the wide load requirements. But if you are moving bales
that are sold or hauling them to a sale, you will need a wide
load permit. Finally, be sure that your slow-moving vehicle
emblem, reflectors and lights are in proper working order
and meet state requirements. For your own protection, check
with the highway patrol or sheriff concerning the movement
of agriculture equipment and bale loads on public roads.
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
This document
is
GO1957
,
a series of the University Extension, University of Missouri-Columbia,
Columbia, MO 65211. Publication date8 October 1993.
David
E. Baker, Department of Agricultural Engineering, University
of Missouri-Columbia, Columbia, MO 65211.
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