Agricultural Tractor and Machinery Safety Training Robert Grisso Biological Systems Engineering Virginia Tech

Machinery Hazards Injuries can occur when a machine has one or more of the following hazards: pinch point crush point wrap point pull-in point shearing, cutting points

Pinch point Two or more parts move together with one moving in a circle. Example: pulley belt

Crush point Two components move toward each other. Example: three-point hitch hydraulic cylinder

Wrap point Exposed, rotating components. (Nicks, mud or rust increase wrap potential.) Example: PTO shaft auger

Pull-in point Mechanism designed to pull in crops or other material. Example: baler pick-up combine feed grinder conveyor

Shearing, cutting points Two parts move across each other, or one part moves across a stationary object. Example: cutter bar auger feed mixer fan blade

Nature of Injury (Virginia 1990) Nature of injury% of injuries Amputation 2.3 Bruise 6.8 Burn 2.3 Cut27.3 Crushed/mangled 4.5 Fracture13.6 Puncture 9.1 Sprain/strain15.9 Multiple injury 6.8 Other/unknown11.4

Work Injury by Body Part (Virginia 1990) Body part% of injuries Hand/wrist18.2 Leg/knee15.9 Arm/shoulder13.6 Finger13.6 Back11.4 Foot 6.8 Multiple 6.8 Head/Neck 4.5 Eye 2.3 Chest/trunk 2.3 Other/unknown 4.5

Work Injuries by Accident Type Type of Accident% of Injuries Contact with sharp object20.5 Struck by or against object11.4 Struck by flying object 6.8 Struck by falling object 2.3 Caught between objects 9.1 Caught under object 4.5 Caught in object 2.3 Fall from elevation 6.8 Fall from same level 2.3 Overexertion 6.8 Other/unknown27.3

Major Causes of Accidents and Average Workdays Lost CauseNo.% injuriesAverage workdays lost……. Animals Machinery Work surface Hand tools Power tools Tractors Plant/tree Liquid Chemicals Unknown

Activity When Injured Activity% of injuries Livestock handling31.8 Field work11.4 Machinery maintenance 11.4 Building maintenance 9.1 Routine chores 4.5 Other27.3 Unknown 4.5

Injury Rates (Virginia Farmers 2006) Cause of injury Number of injuries Hours of exposure Injuries / 100,000 hrs Falls72, Heavy lifting423, Horses16, Operating machinery641, Power tools219, Livestock11148, Hand tools231, Operating tractors7143,

Diagnosed health problems Medical Diagnosis Percent of respondents Allergies 31.0 Hypertension 30.9 Arthritis 30.7 Hearing problems 27.8 Eye problems 21.8 Cardiovascular disease 17.8 Cancer 16.1 Foot problems 13.8 Diabetes 12.6 Heart attack 7.6 Asthma 7.3 Ulcers 7.3

Diagnosed health problems Medical Diagnosis Percent of respondents Migraine 6.5 Stroke 3.4 Yellow jaundice 3.1 COPD Emphysema 1.5 Kidney disease 1.5 Hip fracture 1.1 Cirrhosis 0.8

Death Rates Number of Death per 100,000 Workers

Agricultural Fatalities by Age

Agricultural Fatalities (Virginia 2006) u One farm accident fatality reported for the month of July, 2006, a tractor overturn. In addition, there were two farm accident fatalities reported in July that occurred in June, both tractor run-over. u Tractor overturns continue to be the #1 killer in farm accidents, accounting for four of the seven fatalities for 2006.

Agricultural Injury (Virginia 2006) u One farm accident injury reported for the month of July, 2006, in which a farm worker was knocked down and injured by a steer. u In addition, an injury that occurred in May was reported in July in which a young man was using an ATV to herd cattle and side-swiped a farm building. u The total number of farm accident injuries reported for 2006 is now thirteen.

Livestock Behavior

Livestock injuries u Livestock related deaths and injuries are a major problem. u 20% of all farm injuries serious enough to need hospitalization are livestock related.

Understanding cattle behavior u Sensory characteristics Sight: –Poor depth perception: Cattle need time to adjust to changes in lighting, flooring etc. –Blind spot and kick zone Hearing: –Sensitive hearing: Cattle are agitated by shouting, barking dogs and any sudden noise.

Understanding cattle behavior u Blind spot and kick zone –All grazing animals have wide-angle vision but can’t see behind themselves. –Nature’s way of protecting the blind spot is for the animal to kick into that space.

Tractor Accidents 1. Rollover 2. Turn over 3. Hillside 4. Run over and Crushing

Tractor Related Fatalities

Tractor Stability

Tractor Stability - Side over turn

Tractor Overturns- Causes Driving on steep terrain

Tractor Overturns- Causes Going over rough ground (holes and stumps)

Tractor Overturns- Causes Driving too fast (especially when turning)

Tractor Overturns- Causes Driving into ditches or embankments

Backward Roll

Hitch only to Drawbar

Tractor overturn

Tractor Overturns - Causes Improper hitching (too high, or to the axle) Improper operation of front-end loader Lack of knowledge of operational controls

Tractor Overturns - Prevention Slow down on steep slopes, rough ground and sharp turns Slow down on steep slopes, rough ground and sharp turns Keep wheels spread wide whenever possible Keep wheels spread wide whenever possible Counter-balance weight (front and rear) for more stability Counter-balance weight (front and rear) for more stability Stay clear of ditches, embankments and large obstacles (stumps) Stay clear of ditches, embankments and large obstacles (stumps)

Overturn Hazards Tricycle Front End No ROPS or Seatbelt

Tractor Overturns – Prevention Always hitch the load to the tractor drawbar Travel with the bucket low at all times Lock brake pedals together for road travel Know the controls of the tractor Have ROPS installed and wear seatbelt (only with ROPS)

Tractors on the Road

Entanglement injuries are among the most traumatic events seen in hospital emergency departments. –Major lacerations –Crushed or fractured limbs –Amputations –Head and spinal cord injuries –Permanent disability

PTO Entanglement

Tractor Loader

No Riders in the Bucket

Tractor Loader

No Extra Riders

Proper Playground

Personal Protection

Communication

Shutdown all Equipment

Operator’s Manual Tractor Manual

Know the controls

Control Types: 1. Foot controls - these controls are operated by the operator’s feet. 2. Hand controls - these controls are operated by the operator’s hands. 3. Combination controls - these controls can be operated by the operator’s feet and/or hands. The most common is the engine speed control.

The nine basic controls common to all agricultural tractors are: 1. Brake control - this gives the operator control over stopping, turning, and parking. 2. Clutch control - this allows the operator to engage or disengage power to moving parts of the tractor. A clutch control can be considered the go-no-go control. This includes: traction controls, combination traction and brake controls, PTO controls, and field implement controls.

Basic Controls cont: 3. Engine speed control (throttle)- this allows the operator to regulate the revolutions per minute (RPM’s) of the engine. 4. Ground speed and directional controls (transmission gears)- these controls give the operator control over ground speed (how fast you are traveling) and direction (forward or reverse). 5. Differential lock - this control locks together the rotation of the main drive wheels. Control types continued:

Basic Controls cont: 6. Steering control - better known as the steering wheel - gives the operator the ability to turn right or left while moving in either a forward or reverse direction. 7. Electrical controls - these controls are either on or off. Electrical controls activate accessories such as the engine starter and lights.

Basic Controls cont: 8. Engine stop controls - on gasoline engines, it stops the spark going to the spark plugs; on some gasoline and all diesel engines, it shuts off the fuel to the engine. Stop controls can be either electrically or manually (push-pull) activated. 9. Lift controls for implements or equipment - these are typically hand type controls and give the operator the ability to position or maneuver any attachments into a desired position.

NOTE: u To find out the specific types and the operation of controls on your tractor, read the operator’s manual.

Instruments u Instruments are the devices that allow the tractor to communicate with the operator and notify him/her of safe and/or unsafe conditions. Instruments may be in the form of a warning light, analog gauge, or digital display.

Most Common Instruments used include: 1. Engine speed indicator (tachometer)- this indicator identifies the engine speed in revolutions per minute (RPM). 2. Oil pressure indicator - the oil pressure indicator will either tell the operator the actual oil pressure or warn of low oil pressure during engine operation. 3. Engine temperature indicator - the engine temperature indicator will either indicate actual operating temperature or notify the operator of an unsafe operating condition.

Most Common Instruments cont. 4. Electrical system condition - this is commonly referred to as the battery condition indicator. However, it’s actual purpose is to indicate if the electrical charging system is supplying adequate voltage to maintain all electrical components while in operation. 5. Miscellaneous instruments - some manufacturers include a variety of other instruments. Some additional indicators may include: fuel gauge, coolant level, air filter condition, transmission temperature, hydraulic oil level and many more.

Operator symbols u are visually recognized figures used to transmit information free of words of explanation (ASABE, 1995). The operator symbols are used to identify operator controls, instruments, and servicing locations and/or devices.

Hand signals u are used when the operator is being assisted by another person. The hand signals become the method of communication between the operator and assistant when noise or distance prevents the use of normal voice communications.

Safety signs u are a visual alerting device in the form of a decal, label, placard, or other marking such as an embossing, stamping, etching, or other process that advises the observer of the nature and degree of the potential hazard(s) that can cause injury or death. Safety signs can also provide safety precautions or evasive actions to take, or provide other directions to eliminate or reduce the hazard (ASABE).

Three basic types of Safety Signs: u DANGER - indicates a threatening hazardous situation that, if not avoided, will result in death or serious injury. The signal word “DANGER” is to be limited to the most extreme situations, typically for machine components that, for connection purposes, cannot be guarded (ASABE).

Safety Signs cont. u WARNING - indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. The signal word “WARNING” may also be used to alert against unsafe practices (ASABE).

Safety Signs cont. u CAUTION - indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. The signal word “CAUTION” may also be used to alert against unsafe conditions (ASABE).

Pre-operational Check u Battery condition - when checking the battery, safety has priority over everything you do. When checking the battery the operator should:

Pre-operational Check (battery safety) u wear the proper safety equipment. (gloves, apron, face shield, etc.) u keep fire or flame away from the battery. u inspect for loose and/or corroded connections.

Pre-operational Check (battery safety cont.) u inspect electrolyte level (fluid level). (not required on maintenance free batteries) u inspect battery hold down. -- Battery should be secure and unable to move around.

Pre-operational Check (battery safety cont.) u inspect condition of cables (cracked, chaffed, torn, or melted insulation). u look for cleanliness of the battery top. --No build-up of trash such as leaves.

Pre-operational Check (Fuel, coolant and oil levels) u Maintaining adequate fluid levels is important to keeping the agricultural tractor running. u Fuel level - check the fuel level by removing the fuel cap and visually checking the level in the tank. The fuel level may also be read from a fuel gauge if the tractor is so equipped.

Pre-operational Check (Fuel, coolant and oil levels cont.) u Coolant - check the coolant level by removing the radiator cap and visually checking for the proper level. WARNING - NEVER REMOVE THE RADIATOR CAP IF THE ENGINE IS HOT. Allow the engine to cool until the radiator is cool to the touch.

Pre-operational Check (Fuel, coolant and oil levels cont.) u Oil (engine) - check the oil level by removing the dip stick and reading the level indicated on the dip stick. u Oil (hydraulic) - Check the transmission and hydraulic oil levels according to the operator’s manual.

Pre-operational Check (Fluid leaks) u Check for any wet or damp areas on the machinery as well as any puddles on the floor or ground under the agricultural tractor. u WARNING: When a fluid leak is identified, have the problem corrected before operating the tractor.

Pre-operational Check (Tire condition and pressures) u Check tire condition by looking for cuts, bruises or breaks in the sidewalls, excessive weathering, uneven tread wear, damp spots on tires filled with fluid, and air pressure. See the operator’s manual for correct air pressure.

Pre-operational Check (Tractor Tires Servicing procedure:) u attach an unpressurized air hose to the tractor tire valve stem. u stand to the side, not in front of the tire, and slowly add air pressure using a regulator to avoid excess pressure. u with the desired air pressure registering on the gauge, shut off the flow of air to the tire and remove the air hose form the valve stem. Note: some air may escape while removing the air hose depending on the type of connector used.

Pre-operational Check (Defective and/or loose equipment) u Check for any loose or missing bolts, pins, wiring, or shields. Tighten all loose accessories and guards and replace anything found defective. u Air filter - check the air filter every day.

Pre-operational Check (Safety devices) u Includes fire extinguishers, first aid kit, and safety signs or warning labels. Also check for any safety switches that have been disconnected or bypassed. If a safety switch is not working, have it corrected before operating the tractor.

Pre-operational Check (Operator’s compartment) u Consists of the platform, seat, controls, instruments, and ROPS. u Platform - should be clear of any trash, mud or other clutter and have an anti-slip surface. u Seat - should be adjustable and positioned to where the operator can reach all controls comfortably. The seat should also be equipped with a seat belt if a Roll Over Protective Structure (ROPS) is attached to the tractor.

Pre-operational Check (Operator’s compartment cont.) u Controls - should all be identifiable and within comfortable reach of the operator and functional. u Instruments - should all be identifiable, functional, and readable from the operator’s seat. u ROPS - should be attached according to the operator’s manual with no unauthorized modifications.

Pre-operational Check ( Cab, if equiped) u Check for clean, cracked or broken windows. u Check for functional wipers, doors, and clutter that may block your view from any angle. u Check mirrors for adjustment and cleanliness.

Pre-operational Check (Equipment setup) u Check for proper ballasting (weights), u Check for properly attached connections, and that you have the proper size tractor for the job.

Pre-start Checklist (includes:) 1. Make sure everyone is clear: no one else should be on or next to the agricultural tractor. 2. If parked inside a building, open doors to allow for adequate ventilation during starting. 3. Properly mount the tractor and adjust the operator’s seat. 4. Fasten seat belt if tractor is equipped with a ROPS.

Pre-start Checklist cont. 5. Check all controls: – place hydraulic controls in a neutral or static position. – place three point lift control in a down or locked position. – put PTO in an off or disengaged position. – place brakes in a set or locked position. – set ground speed and directional controls in neutral or park position.

Pre-start Checklist cont. 6. Clutch pedal is in disengaged position. 7. Turn ignition switch to “On” position and check gauges and warning lights for operation. Starting a tractor from the ground can result in the tractor riding you instead of you riding it.

Pre-start Safety u DANGER: NEVER START A TRACTOR WHILE STANDING ON THE GROUND. ALWAYS START FROM THE OPERATOR’S SEAT. u DANGER: NEVER BYPASS START A TRACTOR FOR SAFE OPERATION OF TRACTORS:

Safe Operating Procedures u Watch where you are going, especially at row ends, on roads, and around trees and low hanging obstacles. u When backing, use a spotter to guide you when your vision is blocked. u Avoid upsets drive the tractor with care and at speeds compatible with safety, especially when operating over rough ground, when crossing ditches or slopes, and when turning corners.

Safe Operating Procedures cont. u Avoid operating the tractor near ditches, embankments, and holes. u Stay off slopes too steep for safe operation. u Travel straight up or down a steep slope rather than across it. u A bare tractor or tractor with rear mounted attachments should be backed up the slope in reverse and travel forward downhill.

Safe Operating Procedures cont. u A tractor with a front-end bucket (loader) should travel forward uphill and backed downhill with the loader bucket as low as possible at all times. u Lock tractor brake pedals together when transporting on roads to provide two wheel braking. u Keep brakes evenly adjusted to provide even braking when brakes are locked together.

Safe Operating Procedures cont. u Keep the tractor in the same gear when going downhill as used when going uphill. Do not coast or free wheel down hills. u Any towed vehicle whose total weight exceeds that of the towing tractor must be equipped with brakes for safe operation. u When the tractor is stuck or tires are frozen to the ground, back the tractor up to prevent upset.

Safe Operating Procedures cont. u Always check overhead clearance, especially when transporting the tractor or towing high objects. u When operating at night, adjust lights to prevent blinding an oncoming driver. u Make sure seat belt is fastened if ROPS is installed. u Do not permit others to ride on the tractor. Tractors have only one seat for one person.

Safe Operating Procedures cont. u Operate the tractor smoothly - no jerky turns, starts or stops. u Hitch only to the drawbar and hitch points recommended, and never above the center line of the rear axle. u When the tractor is stopped, be sure the brakes are securely set. u Never use attachments unless they are properly matched to your tractor. u Operate controls only from the operator’s seat.

Safe Operating Procedures cont. u Never leave the tractor unattended with the engine running. u Pay attention to what you are doing, don’t let a day dream turn into a permanent dream. u Never operate nor allow anyone else to operate agricultural tractors or machinery while under the influence of alcohol or drugs.

Safe Operating Procedures cont. u Do not let your tractor bounce. You may lose steering control. u Do not brake suddenly. Apply brakes smoothly and gradually. u Never use a tractor to round up farm animals.

Prevent Roll-overs by: u operating the tractor with care and at speeds compatible with safety, especially when operating over rough ground, when crossing ditches or slopes, and when turning corners. u avoiding operation of the tractor near ditches, embankments, and holes. u staying off slopes too steep for safe operation. u traveling straight up or down a steep slope rather than across it.

Prevent Roll-overs by (cont.): u backing a bare tractor or tractor with rear mounted attachments up the slope in reverse and travel forward downhill. u traveling forward with a front-end bucket (loader) uphill and backing downhill with the loader bucket as low as possible at all times. u staying away from ditches and embankments a distance equal to or greater than the depth of the ditch or embankment.

Roll-over Warning u DANGER - Carelessness on hillsides, around ditches, near embankments and holes can lead to serious injury or death.

TRANSPORTATION OF EQUIPMENT AND LOADS - never exceed the rated load capacities of your tractor. - be sure the tractor is properly ballasted for the equipment and/or load. - select a safe ground speed. - always let the engine assist with braking when going down hills.

TRANSPORTATION cont. - lock the brakes together. - slow down when making turns and make wide gentle turns. - place all implements into their narrowest transport configuration. - avoid transporting equipment and loads along hillsides and near ditches and holes.

TRANSPORTATION cont. - use proper safety hitch pin with safety clip retainer. - raise all implements to their transport position and lock them in place. - allow sufficient clearance for oversize loads. - watch overhead clearance when moving high loads or equipment.

TRACTOR TO EQUIPMENT CONNECTIONS u Connections can be classified as a(n): - single point connection (drawbar connection) - three point connection - PTO connection - hydraulic connection - electrical connection - multiple connection consisting of two or more individual type connections.

PREPARING FOR HIGHWAY TRAVEL - Refer to the operator’s manual for transporting instructions. - Lock the brake pedals together. - Raise all implements to their transport position and lock them in place. - Place all implements into their narrowest transport position. - Disengage PTO and differential lock.

HIGHWAY TRAVEL - Make sure tractor and towed equipment are equipped with SMV (slow moving vehicle) emblems. - Make sure any required clearance flags or hazard lights are in place and in working order. - Make sure you use a proper safety hitch pin with safety clip retainer. - Make sure any towed implements are equipped with a safety chain linking tractor and implement.

HIGHWAY TRAVEL - Clean off all reflectors and road lights, front and rear, and be certain they are in working order. - Familiarize yourself with -- and obey-- all local, state, an federal laws appropriate to your class of equipment. - Allowing passengers to ride can become a deadly mistake.

RULES OF THE ROAD u WARNING: Do not allow any riders on the tractor or towed equipment. u Know the route you are going to travel. u Use flashing lights when traveling on roads, day or night, unless prohibited by law.

RULES OF THE ROAD u Use caution when towing a load at transport speeds. If the towed equipment is not equipped with brakes: u DO NOT TOW equipment weighing more than twice the tractor weight. u Do not exceed 10 MPH (16 KPH) if the towed equipment weighs more than the tractor. u Do not exceed 20 MPH (32 KPH) while towing equipment that weights less than the tractor.

RULES OF THE ROAD u Use extreme caution when transporting on snow covered or slippery pavement. u Wait for traffic to clear before entering a public road. u Beware of blind intersections. Slow down until you have a clear view. u Make wide, gentle turns. u Signal your intent to slow, stop, or turn.

RULES OF THE ROAD u Shift to a lower gear before going up or down hills. u Keep tractor in gear. Never coast with clutch disengaged or transmission in neutral. u Stay out of the path of oncoming traffic. u Drive in the right hand lane as close to the edge as possible.

RULES OF THE ROAD u If traffic builds up behind you, pull off the road and let it go by. When pulling off the road, pull completely off the road staying away from ditches and embankments. u Drive defensively. Anticipate what other drivers might do. u When towing a load, start braking sooner than normal and slow down gradually. u Watch out for overhead obstructions.

GENERAL MOUNTING AND DISMOUNTING SAFETY PRECAUTIONS u face the tractor at all times. u use the three point contact method. u never mount or dismount a moving tractor. u always use the designated hand holds and steps. u never use control levers as a hand hold and do not step on foot controls when mounting and dismounting.

Safety Precautions cont: u never mount or dismount a tractor from the rear. u clean your shoes and wipe your hands before mounting. u never jump off a tractor. u remove any trash or obstructions on the steps or operator’s compartment before mounting.

Mounting procedures: 1. Clean shoes of any mud, oil or any other residue preventing firm contact with the steps. 2. Be sure hands are free of any oil or other residue preventing a firm grip of hand holds. 3. Face the tractor operator’s compartment and secure a firm grip with both hands.

Mounting procedures cont: 4. Place one foot on the first step, then while using both hands and foot to pull yourself up, place the other foot on the next step. 5. With both feet firmly on the steps, move one hand to secure a second hold and then move the lowest foot on the steps to the next step. Repeat this procedure until you have both feet on the operator’s platform.

Mounting procedures cont: 6. With both feet on the operator’s platform and a firm grip with both hands, turn and move one foot to the opposite side of the operator’s platform having the seat behind you. 7. You can now sit in the operator’s seat, and lock the seat belt if the tractor is equipped with a ROPS.

Procedures for dismounting a tractor are: 1. Unlock the seat belt, if provided, secure a firm grip with both hands and stand in front of the seat. 2. While still maintaining a firm grip with both hands, move both feet to one side of the operator’s platform. 3. Turn facing the operator’s compartment and while looking at the steps, place one foot on the top step, keeping a firm grip with both hands.

Dismounting Procedures cont. 4. Obtain a new grip with one hand if necessary, then move the other foot down to the next step. 5. Repeat step 4 until you have both feet firmly on the ground. 6. Release both hand holds, turn facing away from the tractor and walk away.

Controls u Controls are devices (typically levers and switches) designed to give the operator a means of communication with the tractor and the ability to regulate and command the tractor to perform all desired responses. The controls are located within reach from the operator’s seat. Agricultural tractors have three basic type of controls.

Agricultural Tractor and Machinery Safety Training Self-Propelled Machinery

Self-Propelled Machinery Defined In order to be classified as self-propelled machinery it must: 1. have its own power source built into the machine, 2. be designed to perform a specific task or job, and 3. be able to propel itself from one location to another using an on board operator and/or remote/radio controlling device.

SELF-PROPELLED EQUIPMENT CLASSIFICATIONS u CHEMICAL APPLICATORS. Chemical applicators are those pieces of machinery designed to apply fertilizer, lime, pesticides, fungicides, herbicides, and insecticides. u HARVESTING EQUIPMENT. Harvesting equipment is the machinery used for some aspect of crop gathering. In some applications, more than one type machine may be involved in harvesting certain crops.

SELF-PROPELLED CLASSIFICATIONS cont. u FARM MAINTENANCE. Farm maintenance includes any machine used to construct and/or maintain roads, clean animal storage buildings and feedlots, maintain fields and construct or maintain structures. u FEEDING OPERATIONS. Feeding operations equipment is any machine used specifically for the purpose of feeding animals.

ATV’s on the Farm

Safe Farm Shop

Fatigue and Stress