Loader Development

In 2001, after manufacturing high quality loaders for 30 years, we realized that the primary replacement parts we sold to our customers were pivot pins. It seemed that even if a loader pin was well maintained, it would eventually wear out. Additionally, if the worn pin was not replaced soon enough, more expensive damage to the loader was soon to follow. Our goal was to develop a loader that had zero pin problems. Our first idea involved using complicated grease-way systems similar to those used on off-road machinery like payloaders and other earthmovers. We decided that system would add too much cost to the loader. Another problem was that if the system failed or if it was not properly maintained with grease, the repair expense would be tremendous. The Design Engineering team then began to look at advanced material options that would make the pivot point completely greaseless and maintenance free. They soon found a supplier of composite bearings that had developed exactly what they were looking for. The composite bearings had been used many years with great success in the mining industry and on earth moving equipment. The composite bearings were not nylon or plastic. They are a made from a high-density fiberglass that has TWICE the compressive strength of plain carbon steel. The inner diameter of the bearing is interwoven with a Teflon liner, giving the bearing its self-lubricating property. The composite gives the bearing strength and the ability to withstand the heavy impact loads seen with farm loaders. The bearing is also immune to moisture and temperature extremes. The self-lubricating nature of the bearing would last for many years. If at some time the bearing needs to be replaced, they are inexpensive and easy to remove and install. We had found the right product to proceed with our “Greaseless” loader. The question was, how would our new “Greaseless” loader be tested? A few months later, in 2002, Miller Loaders unveiled the awesome PL-5 loader. We decided if we were going to test the composite bearings, we would REALLY test them. A dozen or so PL-5’s were built and put into service in severe-duty operations such as large feedlots and hay operations. A majority of the PL-5’s were fitted on Case MX180-240’s, but a few were also put on 8000 series John Deere’s, New Holland TG’s and Buhler 2160’s. These tractors have tremendous ground horsepower and hydraulic systems and would be excellent “guinea pigs” for testing our greaseless pin system. After two years of testing and not hearing any complaints, we pulled some pins from one of the loaders installed on a MX240. The PL-5 loader had accumulated 4400 hours in a large dairy operation. The chrome-plated pins displayed very little wear! In fact, with a little cleaning they looked practically new. The composite bearings definitely stood up to the loads, and the self-lubricating nature of the bearing was impressive. We decided that the greaseless pin system would be a great feature on our new loaders. After evaluating the service of several of the PL-5 loaders, there was only one change to the greaseless system that we decided to make. We added wiper seals on each open end of the bearing. This design would keep dust, dirt, sand and especially liquid manure out of the bearings, prolonging their life even more. The objectives for our “Zero Pin Problem” loader had been met, and the features can be found on any G-series loader: No grease required for pivot pins Less Pin “slop” Practically no pin maintenance Inexpensive bearing replacement (if necessary) Cleaner loader due to absence of dirt-attracting grease Longer loader life due to longer pin life More value