Harvest Readiness: Avoid the Downtime

The best time to discover a worn bearing, cracked belt or failing sensor is weeks before harvest — not with a full grain tank, a line of trucks waiting and rain in the forecast.

Of course, growers know that — in theory. Reality, however, can be a bit less practical. Harvest preparation often gets squeezed between spraying, irrigation, haying and a laundry list of other jobs demanding attention and waiting in line to be addressed.

In reflection, though, most of us know the frustration of waiting on parts in October; finding that the combine that was fine when it was parked last fall suddenly won’t cooperate; or the gut-wrenching realization that a half-million-dollar machine can be brought to its knees by a $5 bearing. The inescapable fact is that a few days spent inspecting equipment before the crop is ready can prevent many of the breakdowns and delays that rob valuable harvest time later.

As harvest specialist Tony Steinke of Case IH notes, “more days of harvest without unnecessary downtime” starts with thorough preseason preparation. The key is to look at harvest as a complete system. Although the combine gets most of the press, a combine is only as productive as the header feeding it, the equipment supporting it and the storage facilities receiving the crop. Follow these steps now to ensure that the entire system is in top form, ready and waiting to go when the big show begins.

Start With a Clean Machine

Before inspecting a single component, start with a thorough cleaning. Dust, chaff, grain residue and even rodent nests have a way of finding their way into lots of harvest equipment during the off-season. Besides creating a potential fire hazard, that buildup can hide worn components and make inspections more difficult.

A clean machine also makes it easier to spot hydraulic leaks, damaged wiring, loose hardware and other issues that might otherwise go unnoticed until harvest is underway. In addition, university extension specialists recommend removing old grain and debris from equipment and storage systems to reduce the risk of contamination and insect problems later in the season. Crop residue also tends to accumulate in engine compartments and cooling systems as well as grain tanks and unloading augers. Pay particular attention to these.

A half-million-dollar machine can be brought to its knees by a $5 bearing

The Header Often Has a Story to Tell

When growers talk about harvest losses, the combine usually gets the blame. In reality, though, some of the most expensive losses can occur at the header before grain ever reaches the threshing system. That’s why many experienced operators begin their preseason inspection at the front of the machine.

Inspect sickle sections, guards, hold-down clips and wear plates for excessive wear. On draper and platform headers, check belts, chains and drive components. For corn heads, examine gathering chains, deck plates, snapping rolls and stalk rolls. Iowa State University Extension notes that header losses can be significant when worn or improperly adjusted components fail to gather and feed the crops efficiently. It’s a relatively inexpensive repair when done in the shop that can prevent substantial losses in the field.

Small Parts Can Cause Big Delays

A modern combine is a remarkably sophisticated machine, but harvest is still frequently interrupted by relatively simple components. Belts, chains, bearings and sprockets operate under heavy loads for long hours. When one fails, even briefly, an otherwise productive harvest day can come to a standstill. Inspect belts for cracking, glazing and fraying. Check chains for wear and proper lubrication. Spin accessible bearings by hand and look for roughness and excessive play as well as discoloration or other signs of overheating.

Many technicians follow a simple philosophy: if a wear item looks questionable before harvest, replace it. The cost of preventive maintenance is usually far less than the cost of downtime when crops are ready and weather conditions are favorable.

Work Through the Combine Methodically

Once the machine is clean and obvious wear items have been identified, move through the combine according to the manufacturer’s maintenance schedule. Change fluids and filters as recommended. Then inspect feeder houses, threshing components, rotors, concaves, sieves and cleaning systems. A very effective approach is to follow the crop’s path through the machine — from the header all the way to the grain tank. This often prevents important components from being overlooked.

Modern combines also rely heavily on electronic systems. Yield monitors, moisture sensors, loss monitors, cameras and onboard diagnostic systems should all be checked as part of the readiness regimen. In addition, it is highly recommended that a short test run be performed. This is a very useful way to uncover unusual noises, warning codes or performance issues while there is still time to make repairs and order parts.

Don’t Forget the Supporting Cast

The combine may be the star of the show, but even a perfectly prepared combine can spend too much time sitting still if the supporting equipment isn’t ready to go. Grain carts, augers, conveyors and trucks deserve the same attention as the combine itself. Tires, wheel bearings, brakes, lights and hydraulics should be carefully checked. Inspect augers for worn flighting, damaged tubes and failing bearings.

As equipment continues to grow in size and capacity, the entire harvest system must work together efficiently. A bottleneck anywhere in the flow chain can slow progress. This can be especially frustrating when conditions are ideal and every hour counts.

Don’t Overlook Grain Storage

Preparing grain bins may not be as fun or interesting as servicing a combine, but it can have just as much impact on profitability. So, it’s critical to remove old grain, fines and debris from bins, unload systems and aeration ducts. Extension specialists consistently identify sanitation as one of the most important defenses against insects and grain spoilage.

Inspect bin walls, roofs, ladders, doors, motors, fans, heaters and electrical systems. Run aeration fans to verify proper airflow and check temperature monitoring systems to ensure they are functioning properly.

The goal is to protect grain quality after it leaves the field. Problems discovered after bins are full are usually much more difficult — and expensive — to correct.

Keep Common Replacement Parts on Hand

Nearly every grower has a story to tell about losing valuable time while waiting for a relatively inexpensive replacement part.

Belts, bearings, chains, sickle sections, hydraulic hoses, filters and common fasteners are all worth adding to the preseason inventory items. Reviewing repairs from previous seasons can help identify which parts are most likely to be needed again. Of course, no one can stock every possible replacement component, but keeping commonly used items on hand can turn what would have been a day-long delay into a quick repair.

Make Safety Part of the Readiness Plan

Long days in the field, along with fatigue and the pressure to keep the process moving, can create ideal conditions for accidents to happen. Before harvest begins, do your due diligence to ensure that all safety precautions are taken. Inspect fire extinguishers, verify that lighting systems and reflective markings remain visible and review emergency procedures with all operators. 
Grain bin safety, lockout procedures and safe machinery shutdown practices should also be part of preseason preparation. A few minutes spent discussing safety before harvest can help prevent incidents when the season is at its busiest.

Dealer Inspection Checklist

Many growers perform much of their own maintenance and repairs. Even so, a professional inspection can sometimes identify developing issues that are easy to miss during day-to-day operation. As one example, many CLAAS dealerships offer an annual 350-point inspection program for CLAAS LEXION and TRION combines. While inspection programs vary among manufacturers and dealerships, they are designed to identify wear items, maintenance needs and potential failure points before harvest begins.

A dealer inspection should typically include the following areas:

Engine & Powertrain

• Engine diagnostics and fault codes
• Fuel and cooling systems
• Belts, pulleys and driveline components

Harvesting & Grain Handling

• Feeder house components
• Concaves, threshing elements and cleaning systems
• Elevators, augers and grain handling equipment
• Bearings, chains and drive components

Headers

• Cutting components
• Gathering systems
• Draper belts and rollers
• Gearboxes and hydraulic components

Electrical & Hydraulic

• Wiring harnesses and sensors
• Monitors, displays and cameras
• Hydraulic hoses, pumps, valves and cylinders

Safety & Transport Components

• Tires, steering and brakes
• Lighting and warning systems
• Shields and guards
• Fire extinguishers and safety equipment

Even growers who prefer to handle most repairs themselves may benefit from having a trained technician look over the machine before harvest starts.

The Goal Is Simple

Every preseason inspection comes down to one objective: find problems in the shop — and fix them — instead of in the field. Cleaning equipment, replacing worn components, servicing machinery, preparing grain handling systems and checking storage facilities all help reduce the chances of downtime when crops are ready to harvest.

As a practical matter, growers know that, despite the most diligent of readiness, harvest time will still bring a few surprises. The goal of preseason preparation isn’t to eliminate every problem — it’s to avoid the preventable ones and keep the machines rolling as smoothly as possible when the weather and crop conditions are finally right.