July, 2010

Loewen R&D Provides
Improved Combine Parts..... 6
New Tractor & Combine
Parts Catalogs ...................................... 8
New Seymour, Missouri
Warehouse ................................................................. 12
A MOMENTOUS MOVE
. . . . . . . . . . . . . . See Page 10
In This Issue
Inspect!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
NEW Combine Parts Program . . . . . . . . . . . . . . . . . . . . . . 5
Research & Development of Combine Parts . . . . . . . . . . . 6
NEW Tractor & Combine Catalogs . . . . . . . . . . . . . . . . . . . 8
What's New on the B2B?. . . . . . . . . . . . . . . . . . . . . . . . . . 8
NEW Elevator Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A Momentous Move. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
NEW Seymour, Missouri Warehouse Opens. . . . . . . . . . . 12
NEW CabCAM Adapter for Trimble Monitors . . . . . . . . . . 12
From Faded to Fantastic: Dakota Shine. . . . . . . . . . . . . . 13
NEW Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
NEW Cab Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Tech Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Combine Inspections
A 20 Point Plan to Prevent Breakdowns.......................
pg. 2
A&I Products, Inc.
July - September 2010
Vol. 10, No. 3
2
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INSPECT!
A&I Products Archives
The Combine Doctor shares a 20-point plan to diagnose potential breakdowns.
Article By Dave Mowitz
Photography & Images By A&I Products
From Successful Farming, © [August 2009] All rights reserved. Used by permission and protected by the Copyright Laws of the United States.
F
ew people appreciate the value of
planned preventative maintenance
more than Earl Knuth. Years of field ex
experience and a desire to maintain combines at peak operating performance
have led Knuth to refine the process of
detecting breakdowns before they occur.
The fleet of harvesters he manages
for MachineryLink serves as an ideal
planned preventative
maintenance
proving grounds for combines.
Knuth strongly urges you to "become good friends with your dealer's
combine technician. You can learn a lot
and develop a relationship that comes in
very handy when you are trying to troubleshoot a problem in the shop or field."
E
arl Knuth is hard-pressed to guess
how many combines he has worked on
during his 30-plus-year career. But for the
past six years with MachineryLink, Knuth
has overseen the inspection of well over
2,000 harvesters by a crew of technicians
he not only trained, but who also follow the
detailed 350-point inspection checklist he
developed. "When a combine leaves one
of our MachineryLink locations, it must be
100% field ready," Knuth says.
prEsEasoN rEpair iNtErroGatioN
Knuth and his expert team of combine technicians have put together a
preseason inspection plan for your harvester. On the following pages you'll
find a 20-point checklist of key preventative maintenance points as well as 9
expanded inspection details. A far more
detailed plan is on the Web at www.agriculture.com.
Also, look for Knuth conductiong
walk-around inspections of combines in
future segments of the Successful Farming® Machinery Show appearing on RFDTV.
"An invaluable inspection guide can
be found in your combine's bible - the
owner's manual," Knuth says. "Interrogate it prior to harvest to create your
own inspection plan"
Knuth offers one last bit of invaluable advice about cleanliness.
"You can never spend too much time
cleaning a combine," he contends. "Beyond the effect it has in keeping your
combine's threshing, separating, and
cleaning activities at peak capacity, the
process of cleaning can reveal a potential breakdown in the making and is invaluable at preventing a combine fire."
www.aiproducts.com
Your Combine's
20-PoinT
Inspec TIon
check lIsT
HEadEr HEiGHt coNtroL
1
Beyond discovering broken and
worn parts, focus your inspection on
the mechanical aspects of a height-control system. Problems in this area can result in sluggish and inconsistent height
control. Check cutter bar movement,
suspension springs, and support runners on platforms. Recon feeler paddles
and wands, adjusting as necessary.
HEadEr auGEr
2
After checking auger flighting for
wear, take the time to open the auger finger cover (on cutting platforms)
and inspect the fingers, being sure to
lubricate nylon bearings.
FEEdErHousE compoNENts
3
Often taken for granted, the feederhouse has a huge influence on
threshing on how well it presents the
crop in an even stream, Knuth explains.
Check that all slats are operating parallel to each other and are in good repair.
Inspect the drive chains for wear and
proper tension. "A lot of operators miss
inspecting the keepers on connecting
links to make sure they are secure,"
3
Knuth says. "While you're at it, scan the
top drive sprockets and the bearing of
the front drum." Finally, examine the
chain guides and replace if worn.
FEEDERHOUSE DRIVE SYSTEM
4
Completely disassemble and inspect the variable-speed drive pulley (sheave) assembly (if your combine
is so equipped) on an annual basis,
Knuth recommends. "It's not easily taken apart but not something to be afraid
of," he says. "And it will reveal problems with the cams that can greatly affect the speed adjustment operation of
the feederhouse and header reverser."
When greasing the variable drive (on
a daily basis), make sure your zerks are
located in the 12 o'clock and 2 o'clock
positions so grease flows through ports
to the drive's internal cams. Next, start
up the combine and exercise the drive,
speeding it up and down three times
to completely distribute grease on surfaces of the cams.
FEEDERHOUSE BELTS
5
Unlike typical V-belts, the belts
powering the feederhouse are of a
special design and are engineered to
tranasfer a lot of power. Much of the
work they do requires power to be
transferred strictly on the sides of the
belts. As such, closely examine the
belts for burnt spots, grooves in their
sides, missing pieces, and for separation, Knuth urges. Replace worn belts
instead of relying on dressing to extend their life. After inspection, adjust
belt tension according to the owner's
manual.
THRESHING ELEMENTS, RASP BARS
6
Such components require scrutinity to detect excessive wear, missing hard surfacing, and damage to serrations. Chips on these components
can increase grain damage, retard
threshing, and boost threshing power
requirements. Also scan the paddles
on the transition cone for wear and replacement. Worn paddles and impellers affect how crop is presented to the
cylinder or rotor.
CONCAVES
SHAKER ARM
Remove the concaves to perform a
thorough inspection, Knuth says.
Look for rounded bars, missing wires,
foreign objects, and residue buildup.
Clean the concaves and reinstall them,
making sure the units are level. Finally, check to see that the seals on covers
are intact so they don't leak crop during threshing.
As stout as it appears, the arm
assembly that propels the chaffer and sieve can bend. "This sets up
a fierce vibration in the cleaning shoe,
which leads to premature bearing failure, for starters, and can even damage
the chaffer and sieve," Knuth warns.
7
SEPARATION TINES
8
Tines and related crop-engaging devices can wear. "Once the hard surfacing is gone, it doesn't take long for
the base metal to erode rapidly," Knuth
says. "Worn tines retard crop flow and
allow poor separation of grain."
SEPARATOR VANES
9
Survey the directional vanes mounted on the separation housing(s) for
wear and damage. Replace as needed.
CHAFFER, SIEVE ELEMENTS
10
Key recon points include missing wires, misshaped elements,
and damaged high-crop dividers.
CHAFFER, SIEVE FRAMES
11
Pay attention to frames for deterioration. "We've seen situations
where a corner of the chaffer dropped
into the shoe," Knuth says. "The shaking mechanism pounds the frame,
eventually destroying it and damaging
the shoe."
CLEANING SHOE
12
Inspect the pan for holes and the
mounting frame (for the chaffer
and sieve assembly) for stress cracks.
CLEANING SHOE FAN
13
Scrutinize all the vanes for damage. "Today's fans turn at a high
rate of speed," Knuth says. "A piece of
residue sucked into the fan can bend
a vane, jeopardizing its operating balance, which will eventually destroy a
fan."
CLEANING SHOE AUGERS
14
Adjust augers to operate level as
opposed to bowed. Examine the
bearings and drive gears for damage.
15
CHOPPER MOUNTINGS, BELTS
16
Recon the hinge points for stress
cracks. Cracking indicates excessive vibration or imbalanced operation.
Examine the belt for wear.
CHOPPER KNIVES
17
Balance is key to long chopper
life, Knuth stresses. Missing
knives or failure to replace knives in
matched sets can set up vibration that
could cause a chopper to self destruct.
TAILBOARD VANES, SPREADERS
18
Often overlooked, worn vanes
can be damaged. When that
happens, the distribution of residue
is compromised. Rotate traditional
spreaders by hand to see that they operate smoothly (do not wobble) and
check for wear on their distribution
vanes.
TAILINGS, GRAIN ELEVATOR
19
Beyond scanning for worn
chains and paddles (particularly
paddles with rounded corners), adjust the tension on these conveyors so
that their paddles don't sag backwards
in operation. "This is called backlegging (grain cascading back down the
elevator), which severely limits the capacity of the elevators and can cause
the cleaning shoe to overload," Knuth
points out.
CLEAN GRAIN AUGER
20
All augers wear in time, and
the massive flighting filling the
clean grain tank is no
exception.
Look
for
edges
that are
rolled
back and
sharp.
Quality
l
Service
l
Value
4
Your Combine's
20-PoinT
Inspec TIon
checklIsT
FramEs
+
B
eyond detecting dislodged or missing deflector flaps, pay particular
attention to chaffer and sieve frames by
examining sides and corners for looseness, then tighten them to the torque
specified in the owner's manual. "And
only use the proper grade of bolt specified in the manual when replacing fasteners," warns Knuth.
cams
C
ompletely disassemble the variable
speed drive (if your feederhouse is
so equipped) and inspect the surfaces
where cams meet and slide against
each other. "They should not be rusted
or galled," Knuth says. "If so, shine up
the surface. Rust or galling indicates
you are not getting grease between the
interface of the cams."
wEar aNd tEar
H
ard surfacing treatments do wear
and can be chipped like threshing elements, rasp bars, and separation
tines. Such wear not only compromises
efficient harvest but also can damage
crop. To detect such problems, open up
a combine and inspect each part.
BENt sLats
F
eederhouse slats and their accompanying drive chains often act as
the first line of defense against foreign
objects that skipped the rock trap and
are heading to the thresher. As such,
they are particularly prone to assault
and therefore deserve a close perusal.
"A bent slat jeopardizes the smooth delivery of crop to the thresher," Knuth
warns. "A bent slat is an open invitation to disaster such as the slat becoming loose and jamming, possibly damaging the feederhouse."
rEcoN BELts
to HEad oFF
BrEaKdowNs
U
nless belts are obviously frayed
or showing signs of separation,
they are often only given a cursory
inspection. "Considering the job they
must perform in transmitting power,
the entire length of every belt on the
combine should be scrutinized prior
to harvest," Knuth urges. In that effort,
examine the cover for separation, look
for chunks that are missing, and survey the sides of belts for burnt streaks.
Discovering such a problem calls for
the belt to be replaced, of course. But
it can also indicate a problem with misadjustment (of an idler or tensioning
pulley) or an impending parts failure
(such as a bearing going bad).
sprocKEts
C
upped teeth with distinct hooks
on their ends reveal the need for
a new sprocket. But this condition
also shows that the roller chains are
likely misadjusted, Knuth says. "Cupping affects the smooth opperation of
the chain. Chains tend to crawl on the
sprocket, and the hooked teeth won't
readily release rollers," he explains.
Below: To inspect the cleaning shoe area, the chaffer and sieve need to be removed to get a thorough look inside.
A&I Products Archives
www.aiproducts.com
duLL KNivEs
W
orn knives not only do a poor job
sizing (chopping) residue, but
also they cause chopper operation to
drag, consuming more horsepower. Of
course, new knives are needed. Knuth
warns that chopper knives must be replaced in sets. "Otherwise, the chopper is thrown out of balance, which can
cause the entire unit to self-destruct,"
he explains. Take time to check the
tailboard vanes for cracking and wear
since they are critical to evenly distribute chopped material. Finish the
chopper inspection by scrutinizing
the unit's mounting hinge points for
stress cracks and the rotor bearings for
smooth operation.
crawL iNsidE
A
s dirty as the job is, there is only
one way to inspect the cleaning
shoe area. "Remove the chaffer and
sieve and crawl inside," Knuth says.
"Begin the inspection process by thoroughly cleaning the entire area. Next,
survey the pan for rust, cracks, and
holes (they retard grain flow)." While
you are in the shoe, peruse the cross
augers' flighting to see if it is sharp or
rolled back. Check to see that the augers
are not bent or bowed, as this greatly
diminishes their ability to move grain,
which leads to shoe plugging. Knuth
also advises taking a similar journey
inside the threshing and separation areas of your combine, if possible. a
I
n all the years he has been involved with
combine repair, Knuth is still amazed by
the stories MachineryLink technicians tell
of the foreign objects they discover inside combines. "Actually, I don't consider
rocks or sickle sections foreign anymore,"
he laughs. "Not when they are compared
to such objects as tree limbs, fence posts,
dead animals (they mostly get chewed
up and spit out), tools (crowbars are the
worst), and believe it or not, tires."
5
www.aiproducts.com
sales@aiproducts.com
800.657.4343 Ph.
800.511.0516 Fax
Order your Combine Parts before August 1, 2010
and receive 60 Days Dating!
Order a minimum of $2500.00 in Combine Parts per order
...In July - Get 60 Day Dating
No limit on number of orders, order as many times as you need!
Specify program “V” when ordering.
Cannot be combined with any other discount programs.
Only items listed in the Combine Catalog are eligible for this dating.
Orders may be placed via the B2B Website, by Phone, Email, or Fax.
QuaLity
l
sErvicE
l
vaLuE
6
RESEARCH & DEVELOPMENT PROVIDES IMPROVED COMBINE PRODUCTS
Creating a new, improved combine part entails a multi-step process to ensure quality.
W
ceptable design is finalized, specific
hen A&I Products' Loewen
files are exported in a format which
Manufacturing facility in Alcan be read and replicated by CNC
tona, Manitoba goes to work buildmachines such as a laser cutter to
ing a new product for the combines
cut out the components from raw
working in the fields of the world
materials.
today, a number of steps must take
The next step is to order mateplace before the new product is
rials and components to assemble
ready to serve the farmer.
a prototype. In the interim, before
The absolute first step in creating
supplies and materials are received
a new product is identifying a need
at the Altona facility, the R&D team
based on research of which items are
works to design a set of procedures
the most often replaced, and where a
that are applicable for each individuspecialty item may benefit the farmer
A 3D SolidWorks2010 model of both a standard concave and a helical al manufacturing step. When a proover a standard replacement. When bar concave. Wires have not yet been added to the models. All bars cess and methodology is devised,
there is a solution, A&I Products will are hardened on both concaves and the standard concave has thicker focus shifts to the design of dies and
move forward by sourcing an OEM bars than OEM.
jigs. This work is also done utilizsample product.
ing SolidWorks2010. The complete
where standard OEM bars are thinner
The sample product is evaluated
design
process of the jigs, fixtures, and
and not hardened. The OEM "extended
by the A&I Products Research depart
departdies
is
done
in-house at the Loewen fawear" concave is hardened, but with
ment in Rock Valley with assistance by
cility.
All
of
the
fabrication of these vital
thinner bars than the A&I Products stanthe Tech department and Management.
jig,
fixture,
and
die
pieces are also done
dard version and a lot more expensive.
Collaborative efforts between the staff
right
there
at
the
A&I
Products Loewen
A&I Products also offers a more aggresin Rock Valley and the Research & DeManufacturing
facility.
The ability to
sive helical bar version, OEM does not.
velopment staff in Altona will generate
make
these
items
on
demand
and conAfter improvements have been
methods to improve components of a
trol
the
details
on-site
ensures
quality
planned, the next step is for the R&D
part. Often the goal is to make the part
control
and
minimizes
production
time.
Drafting department to create three diserviceable for the customer and longer
The
entire
manufacturing
process
is
demensional solid computer models out of
lasting while utilizing efficient producveloped
with
the
goal
to
make
the
end
each individual component with Solidtion procedures to keep costs economiWorks2010, a mechanical design soft
soft- product cost-effective for the purchaser,
cal. An example would be the instance
efware. Within this program, the R&D so making everything work the most ef
of thicker material on wear sections - the
ficient
way
possible
is
very
important.
department can analyze and simulate
standard A&I Products 7010/8010 CaseWhen the prototype has been dethe components as they would be used
IH concave has thicker hardened bars
veloped,
the critical measurements that
in real-world situations. When an ac-
www.aiproducts.com
7
need to match that of OEM are measured and compared with the original
OEM sample. Bolt patterns and specific
clearances are among the items that are
rechecked after the prototype is made.
When everything is verified, the R&D
team takes the finished prototype to a
local A&I Products dealer and test fits
the new product on a machine at one of
these facilities. If there is an adjustment
that needs to be made, the drawings are
changed and a new prototype is made.
If everything passes the fitment test and
any necessary field test, the part is released for production. After being produced at the Altona location, the parts
are trucked to the primary warehouse in
Rock Valley, Iowa and then distributed
to regional warehouses and customers
accordingly.
A number of detailed steps make up
the start-to-finish process of producing
a new component for today's ag world.
Many people are involved in the planning, design, and manufacture of quality aftermarket replacement and improved combine parts. When it comes
to a particular model of combine take a
look at the A&I Products website or the
new Combine catalog to see all there is
to offer. a
Top Left & Right: New A&I Products elevator housings are test fit on combines at a combine salvage yard near the Altona, Manitoba manufacturing facility. The A-87470913 unit
on the top right is shown marked "OK" for production and is currently available. Bottom Left: A robotic welder is setup to weld a concave which is mounted on a jig designed and
fabricated at A&I Products' Loewen Manufacturing by the R&D team. Bottom Right: A SolidWorks2010 3D rendering of a functional multi-axis jig and fixture assembly for welding
and assembling concaves. On the right is a robotic welder.
QuaLity
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8
A great addition to your reference library
NEW Catalogs
CT587 Tractor Parts Catalog
CT588 Combine Parts Catalog
Ask your salesrep for your copies!
87
CT5
CT588
OVER 1250 Pages of TRACTOR & COMBINE Parts
What's new on the B2B Website?
Due to customer suggestions and the need to consolidate orders from a single
warehouse, you can now see part availability from all warehouses. This can be
seen from the price and availability screen in the parts search. Where we previously listed up to 5 warehouses, now all of them will be listed. Also we added this
functionality into the order form. From the "Edit Warehouses" screen, you can get
a selection box by hitting the new "check another warehouse" icon. This will show
the remaining warehouses with their part availability and will give you the option
to manipulate your order accordingly.
Left: Quantities are shown
at every US
warehouse.
Right: When
clicking the
"check another
warehouse"
icon, a selection box will
appear showing
quantities at
the remaining
warehouses.
www.aiproducts.com
9
New
A-AH96371
TAILINGS ELEVATOR
$439.10
John Deere COMBINE: 6600, 6601, 6602, 6620 (SN <610300),
6622, 7700, 7701, 7720 (SN <610500),
7721 (SN <610600)
A-AH149536
TAILINGS ELEVATOR
TAILINGS ELEVATOR
A-AH207172
$519.83
CLEAN GRAIN ELEVATOR
$746.97
$519.65
John Deere COMBINE: 8820 (SN 464351>)
A-AH112164
CLEAN GRAIN ELEVATOR
$519.65
John Deere COMBINE: 6600, 6620, 6622 (SN 610401>), 7700, 7701
(Lever), 7720, 7721, 8820 (SN <464350)
A-AH142180
UppER CLEAN GRAIN ELEVATOR
CLEAN GRAIN ELEVATOR
UppER CLEAN GRAIN ELEVATOR
$1192.85
CLEAN GRAIN ELEVATOR
$1122.60
John Deere COMBINE: 9560STS, 9570STS, 9650STS, 9660STS
9670STS, 9750STS, 9760STS, 9860STS
A-AH235321
LOWER CLEAN GRAIN ELEVATOR $483.60
John Deere COMBINE: CTS, CTSII, 9400 (SN 640101>), 9410, 9500 (SN
640201>), 9500SH (SN <640201), 9510, 9510SH
A-191778C2
TAILINGS ELEVATOR
Case-IH COMBINE:
1440, 1460, 1470, 1640, 1644, 1660, 1666, 1670,
2144, 2166, 2344, 2366
$407.15
A-87470913
TAILINGS ELEVATOR
$569.80
Case-IH COMBINE:
1480, 1482, 1680, 1682, 1688, 2188, 2377, 2388,
2577, 2588
$569.80
John Deere COMBINE: 9600
A-AH142185
$612.91
John Deere COMBINE: 9450, 9550, 9550SH, 9560, 9560SH, 9650,
9650CTS, 9660, 9660CTS
A-AH218602
John Deere COMBINE: CTS, CTSII, 9400, 9410, 9450, 9500, 9500SH,
9510, 9510SH, 9550, 9550SH, 9560, 9560SH,
9600, 9610, 9650, 9650CTS, 9660, 9660CTS
A-AH105850
LOWER CLEAN GRAIN ELEVATOR
John Deere COMBINE: (9600, 9610 (ALLw/Greenstar)
John Deere COMBINE: 9560STS, 9650STS, 9660STS, 9750STS,
9760STS, 9860STS
A-AH169233
A-AH156596
$363.97
A-1317376C9
CLEAN GRAIN ELEVATOR
John Deere COMBINE: CTS, (SN <670400), 9400 (SN <670100), 9500,
(SN <670548), 9500SH (SN <670548), 9501
Case-IH COMBINE:
1640, 1644, 1660, 1666, 1670 (Hillside SN
JJC0080540>), 2144, 2166, 2344, 2366 (w/o AFS)
A-AH153741
A-1317456C6
CLEAN GRAIN ELEVATOR
Case-IH COMBINE:
1680, 1682, 1688, 2188, 2377, 2388, 2577, 2588
A-367308A5
CLEAN GRAIN ELEVATOR
Case-IH COMBINE:
(2377, 2388, 2577, 2588 (ALL w/AFS))
A-367708A4
CLEAN GRAIN ELEVATOR
Case-IH COMBINE:
2366 (w/AFS)
UppER CLEAN GRAIN ELEVATOR
$569.80
John Deere COMBINE: 9610
A-AH153743
UppER CLEAN GRAIN ELEVATOR
$569.80
John Deere COMBINE: CTS (SN670401>), CTSII, 9400 (SN 670101>),
9410, 9500 (SN 670549>), 9500SH (SN<670548),
9500SH (SN 670549>), 9510, 9510SH
$659.37
$678.30
$621.34
$610.40
Pricing is dealer cost in US dollars, subject to change without notice.
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Left: Totes carry products
from their shelves to the
shipping area; 1: After being pulled at the original
warehouse, parts were
brought to the cubing area;
2: Company President Anden Van Beek loads a trailer with parts ready to head
to the new warehouse; 3:
After parts were removed
from the North warehouse,
racking was disassembled
and large combine parts
put in place.
A Momentous move: Moving Days, Mornings, & Nights
New Rock Valley warehouse now in operation.
M
ay 3rd marked the day A&I Products began transferring nearly every part from the original 110,000 square
foot North warehouse in Rock Valley,
Iowa to the newly constructed 165,432
square foot addition to the South warehouse facility just across US Highway
18. All hands on deck were put to work
as manufacturing and office personnel
joined with the warehouse staff in an
effort to transport nearly all 85,000 part
numbers, in multiple quantities in just
a matter of a couple weeks. The parts
have made the transit and the conveyor
system is now up and running.
For two weeks (May 3 - 15), employees put in extra hours to help with the
moving process. While the standard
day is typically scheduled from 7:00 am
to 5:00 pm CST Monday through Friday,
during these two weeks there were two
shifts to accomodate the move. Half of
the employees came in at 2:30 am and
worked until 5:00 pm and the other shift
started at 7:00 am and continued until
9:30 pm. A six-hour Saturday was also
scheduled both weeks with half working the first and the other half handled
their tasks on the second Saturday.
Besides an immense amount of
preparation by the IT staff and management, the first job at hand was to
remove parts from the shelves at the
original north warehouse. This was
accomplished by utilizing pickers and
forklifts to reach elevated shelves and
bins and placing parts in totes or on pallets. Next, they were transported to the
shipping area of the warehouse for the
parts to be "cubed" with a Cubiscanner,
a computerized scanner that measures
the dimensions of an object, or manually
with a tape measure so that they could
be designated a type of bin location in
the new warehouse based on their size,
shape, quantity, and popularity.
Once finished at the "cubing station," the items were loaded on a 53'
semi trailer and hauled across the road
to the new warehouse facility. There
they were unloaded and placed onto
the conveyor. The conveyor is equipped
with laser scanners that can read the
barcodes assigned to labels on the totes.
The scanners can then identify where
the tote needs to go and kicks them off
on that track as needed. When received
at their station, workers scanned the
totes with their handheld device and
unloaded the totes and placed them in
bins or on shelves as needed or directed.
The empty totes were placed back on the
conveyor and reused to load up more
parts.
This process was repeated a countless number of times to transfer the
product. At the same time, the now
empty racking in two sections of the
original warehouse was disassembled
and removed to make room for large
crated combine parts.
Many of the daily activities will
operate the same way it did during the
move. New items checked in by the receiving department will be loaded in
totes and distributed to their appropriate
zones and unloaded and placed in their
location by the individuals stationed at
www.aiproducts.com
the shelving zones.
General orders start at the induction
area where totes are loaded onto the conveyor and assigned a tote sheet which
lists what parts need to be placed into a
particular tote. The barcode on the totes
are scanned and allocated to the order.
As the totes travel on the conveyor, barcode readers scan the labels on the totes
and identify which zones a tote needs to
travel to. Totes are automatically moved
off of the main conveyor line at those
appropriate locations. The totes are
scanned at the individual zones with a
handheld device by the person stationed
at that particular zone. The handheld
computer identifies how many of each
specific part is needed from that zone
and the person stationed there pulls the
item(s) off the shelves or from bins and
places them in the tote(s) sending them
back down the main conveyor line. After the order has made it to every zone
in which it needs to go, the totes travel
along the conveyor to the shipping area
and are packaged and labeled to ship
and then loaded in the appropriate truck
according to the shipping carrier and
method of shipping. Stock orders for the
other A&I Products regional warehouses and kit assembly orders follow much
the same itinerary.
The move went fairly quick with the
number of extra hours put in by every
full-time employee. The integration of
the new processes is underway as A&I
Products continues to offer the world's
most complete selection of aftermarket
tractor and combine parts. a
11
1
2
3
4
5
6
7
8
4: Warehouse Manager Brad Dykstra, Diana Vanden Bosch, and Lenora "Bugs" Davelaar pose by the old rolltop desk before moving to the new facility. They all have worked in
the old facility since it was new in 1991. 5: Parts are loaded into totes in the induction area so that they can be placed into inventory on the shelf. 6: Employees work in individual
zones pulling orders and stocking shelves. 7: An order makes its way to the shipping area. Notice the barcode on the side of the tote that is read by scanners identifying where it
needs to go. 8: The shipping area marks the end of the line. Here items are packaged and sent out.
Quality
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12
NEW MISSOURI WAREHOUSE
Offering expanded coverage to Midwest.
W
hile there is a shakeup and uncertainty in the college sports world,
A&I's own Big 12 just got stronger as
Seymour, Missouri is the location of a
new 50,000 square foot warehouse. It
is the newest addition to A&I Products'
twelve total North American warehouse
locations. The city of Seymour is situat
situated about thirty miles east of Springfield,
Missouri on US Highway 60 and only
16 miles from Interstate 44, making it a
good logistical location.
At 50,000 square feet, the new Sey
Seymour facility is the largest remote warehouse among all of the A&I Products
warehouses. Only the warehouse facilities in Rock Valley, Iowa are larger.
Extensive research of the A&I Products customer base indicated that the
next day service area would be broadened by moving inventory from previous warehouses in Sikeston, Missouri
and Memphis, Tennessee to Seymour.
The new
lo c at io n
is strategically
located to
offer considerably
greater
next day
service
to
A&I
Products
d e a l e r s The new warehouse facility in Seymour, Missouri will allow A&I Products to offer greater next day
in the re- service that now includes Eastern Kansas, Northeast Oklahoma, and Southwest Illinois.
gion that
now includes the eastern half of Kansas, due to the expanded next day delivery
Northeast Oklahoma, and Southwest Il- area and economical operating costs in
the city. The building was also designed
linois.
Since a suitable building meeting to allow for possible future expanision.
Five new employees have been addthe criteria required by A&I Products for
the new warehouse was not available, ed to the A&I Products staff to fulfill the
the structure was built from the ground duties at the new warehouse and are
up. Seymour was an excellent choice poised to serve the region. a
Make Precision Farming more Precise.
See for yourself. Connect a wired CabCAM™ camera
to a Trimble AgGPS FM 1000 display with this new 20'
adapter cable from A&I Products. Up to four cameras
can be used and one cable is needed for each camera.
A-VS1C110
A-BWC86
A-SVC402
A-CAM87
A-ASC635M
A-BC644
A-LPC634
A-SVC134
Check out www.aiproducts.com or the CT580 CabCAM
Booklet for more information about these cameras.
www.aiproducts.com
ONLY $20.35 each
13
INCREASE RESALE VALUES
IMPROVE THE APPEARANCE
OF YOUR FLEET
Dakota Shine is a simple spray on solution that interacts with
color pigments and restores them to the surface, creating a
shiny, refreshed appearance. No need to mask, no need
to reapply decals, no need to spend excessive amounts of
money and time on a new paint job.
Just prepare the surface with Dakota Prep, use exact-match
paint to fix any scratches, chips, etc. in the surface and then
apply the Dakota Shine to bring the finish to a luster.
Check out the selection online at www.aiproducts.com or
request a CT539 Dakota Shine Flyer for more information.
FADED
FANTASTIC
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Replacement for
casE-iH
Replacement for
JoHN dEErE
Replacement for
JoHN dEErE
Replacement for
casE-iH
Replacement for
Ford/NH
Replacement for
JoHN dEErE
Replacement for
casE-iH
Replacement for
Ford/NH
Pricing is dealer cost in US dollars, subject to change without notice.
www.aiproducts.com
Replacement for
JoHN dEErE
Replacement for
JoHN dEErE
15
New
FOR AG &
INDUSTRIAL
APPLICATIONS
Pricing is dealer cost in US dollars, subject to change without notice.
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Notice: All prices are in U.S. Dollars and reflect
Dealer Cost. Due to fluctuating pricing within the
industry out of A&I’s control, prices listed within
this literature are subject to change.
PRSRT STD
U.S. POSTAGE
PAID
PERMIT NO. 550
W
WATERTOWN
, SD
A&I Products
P.O. Box 8, 1020 22nd Ave.
Rock Valley, Iowa 51247
Tel: 800-657-4343
Fax: 800-511-0516
Web: www.aiproducts.com
CT590
TRouBLeShooT SympTomS
S To pR
pReVeNT a
aN
N
addiTioNaL TuRBoChaRgeR FaiLuRe
Carl Elbers
Parts Research/Tech
Any further questions?
Email Carl at:
celbers@aiproducts.com
or contact the A&I
Tech Department:
800.657.4343
sales@aiproducts.com
When needing to replace a turbocharger, A&I
Products offers a number of direct replacement options for tractors, combines, skidsteers, construction
equipment, even pickup trucks and more! It may be
necessary to replace a turbo if it is just plain worn out,
but a turbo can become damaged due to other factors,
too. Just replacing a turbocharger may not remedy the
entire problem.
In an effort to help you prevent another failure,
we offer a simple troubleshooting guide that can help
you pinpoint a possible cause of failure. When viewing
the turbocharger you need on the B2B website, you can
click on "Technical Bulletins" and pull up the TM0080
Turbocharger Troubleshooting Guide. The guide is
comprised of a chart that includes symptoms, possible
causes, and remedies. An example of one of the many
possible scenarios is below.
EXAMPLE
Symptom causing old turbocharger to fail:
Oil leaking from turbo seal
Possible Cause 1: Obstructed turbocharger oil
drain line
Remedy: Remove obstruction or replace line
as required.
Possible Cause 2: Obstructed engine crankcase vent
Remedy: Refer to engine manufacturer's manual,
clear obstruction.
www.aiproducts.com
Possible Cause 3: Turbocharger center housing
sludged or caked
Remedy: Change engine oil & filter, replace turbo.
Possible Cause 4: Worn piston rings or liners (blowby)
Remedy: Refer to engine manufacturer's manual &
repair engine as required.
Possible Cause 5: Internal engine problem
(valves/pistons)
Remedy: Refer to engine manufacturer's manual &
repair engine as required.
Possible Cause 6: Dirt caked on compressor wheel
and/or diffuser vanes
Remedy: Clean using non-caustic cleaner & soft brush
Find & correct source of unfiltered air & change
engine oil & oil filter.
Possible Cause 7: Damaged
Remedy: Identify and correct cause of failure,
replace turbocharger.
By identifying possible causes of failure before installing a new turbocharger, you can eliminate the possibility of damaging a new one from A&I Products. Save
time and keep your customers happy by following this
helpful guide.