The End of our reliance on Blue Bird

This might be the last post on the Blue Bird Bed Bug Blog.


The Easy Trench Bed Edger spent time in the shop this summer after the main shaft broke. Other than a few belt changes, the Easy Trench had four years of rental customer abuse before the blade shaft failure. Last year I sold my last remaining Bed Bug I was keeping around as a back-up. With the EZ trench reliability, we saw no need to maintain a back-up machine.


I am disappointed that none of the last three owners of Blue Bird addressed my complaints or were willing to discuss my recommended fixes.


At one point, I had 4 Blue Bird Aerators in rental. I had updated all four Aerators to address drive reliability issues. About ten years ago, I purchased a Billy Goat Aerator to replace my oldest Blue Bird. The Billy Goat has been the first aerator in the rental line since new. It has been so reliable that we were able to reduce our rental inventory to just two aerators.


I have passed the address of this blog to rental peers looking to purchase lawn equipment. I am sure Blue Bird’s arrogance has cost them many sales.


Its too bad Blue Bird came so close to making a rental quality tool.

The reason I haven’t posted in a while is that I haven’t rented the Bed Bug as a Bed Edger since the Trenchmaster Bed edger has been working so well. The early belt failures on the EZ Trench must have been operator issues since we had no belt failures during 2017. We did replace the EZ Trench belts during our scheduled winter maintenance.

We purchased a new underground dog fence machine. We purchased the Brown Machine. We have had good luck with other Brown equipment and if this new fence machine works I will unload my last Blue Bird Bed Bug.

I didn’t stop into the Blue Bird Booth at the 2018 Rental Show. When I visited during the 2017 Rental Show the owner just ignored me. I could have been his best friend by helping him improve reliability and safety. Instead, this Blog is still his worst enemy. 

I broke a cutter wheel on my older Blue Bird Stump Grinder. The $400 wheel was less than a year old. It was clear that an improper hub weld crystalized the shaft. This was the last straw for that machine. We kept the engine and a few parts and scrapped the rest. 

Since I updated the sprockets on our Aerators the reliability has improved. I sold 1 and scrapped the second Blue Bird Sod Cutters. Our Classen sod cutter is so much more reliable I was able to replace 2 Blue Birds with one Classen Hydro. 

9/10/2015

The Trenchmaster Bed Edger is working well.  The Blue Bird Bed Bug has gone mostly unused.  The promise from the new owners of Blue Bird to look into the issues I highlighted in this blog has gone un-fulfilled.  We will keep our last Bed Bug as a back-up.  I will continue to post as issues arise. 

 First big update of the spring.  Number one the EZ trench is having belt issues we get about 2 rentals out of a $25.00 set of belts.  This may be operator error I need to do more investigating.  So far the blade has not broken and replacing the belts is a simple 10 min job. 

The Bed Bug is now our back-up machine.  We have had an oil leak on the Honda engine since last fall. We have replaced the oil pan gasket the clutch gasket and the seal on the oil drain plug.  These repairs did not alleviate the problem.  I suspect that the engine block has a crack.  I don’t have time to work on it so we borrowed an engine off of a Blue Bird Sod Cutter.

During the engine replacement we put on a new chain new bearing bolts and a new blade.  The machine just came back from its second rental since rebuild with a broken blade shaft. Also 3 of the 4 bolts on the outside bearing housing were broken off.

When I checked the clutch oil I noticed the dip stick is starting to melt.  I have talked to Honda several times and the only answer Honda his that it is the wrong application for the particular model engine.  

March 9 2014

A few weeks ago I went to the Rental Show and introduced myself to the new owners of Blue Bird.  Seems Husqvarna sold off the Blue Bird division.  Husqvarna has been buying up companies over the last 10 years I would demand to see a Car Fax before I would buy a division from Husqvarna.

Imagine driving off with a shiny used car and arriving home to learn it has problems.  I imagine this is how the new owners felt when I was done giving a presentation of all the Bed Bug issues.  I left behind a printed copy of my Blog and some enlarged pictures of broken parts.  

From Blue Bird I went to Honda engine booth with my pictures of melted clutch dipsticks.  The Honda people were concerned that the overheated clutches on the Bed Bug might be an issue.  The Honda people promised to look into the application to see what is melting a part in only one specific application.

From Blue Bird I wandered the show floor looking to purchase a replacement for the Bed Bug I sold last summer.  Particularly I was looking for a Bed Edging machine that I looked at last year called “E Z Trench”.  In talking with the Easy Trench rep he had seen my Blog and had passed it on.  I did purchase one of the E Z Trench Bed Edger’s.  The “Easy Trench” sales rep wanted to be included in my Blog.  (I am not sure that will be a good thing but if you believe in your product you have nothing to lose.)

I won’t get the machine for a few weeks but this is a picture.  

August 15, 2014

In a few posts including July 17 2014 I explained how I hold sloppily machined parts from the constant loosening.  Instead of using the supplied set screws I use hardened bolts and tighten them until the heads snap off.  The problem with correcting weak links on a machine with dozens of them is the failure happens at another weak link. 

Today’s failure fell in between 3 strengthened weak points.   The Husqvarna Blue Bird Bed Bug was being used as a dog fence wire installer.  We were using an experimental blade provided by the blade manufacture. So far this blade has been free of the bending and breaking of the Husqvarna supplied blade. This failure was the 3/4 inch mild steel drive shaft that broke at the blade mounting hub.  With our broken bold fix of the hub and the sprocket this is the next weakest point.  On most other brands the blade drive shafts are made of reinforced 1” steel, while Husqvarna Blue Bird only uses ¾ inch steel. 

We were able to save and reuse both the hub and the sprocket for only one reason; our tightening procedure kept both parts from loosening and wearing.  Cost of the repair was about $60.00 including the labor. 

  

However the customer refused to use our back up machine and blamed the breakage on our poor maintenance.  He might have felt differently if he knew the Bed Bug’s drive was rebuilt 2 rentals ago.  I would classify this customer as one who will never be back. 

July 17, 2014 Update

The customer’s complaint on the Bed Bug we normally keep set up for bed edging quit working.  A quick inspection revealed the tin idler sprocket failed and the chain came off the drive sprocket.  This Husqvarna Blue Bird Bed Bug would get a “Tractor Supply” solid steel sprocket.  The Husqvarna supplied cheap tin idler sprocket has been a constant point of failure across the Husqvarna Blue Bird line of products. 

We have used the “Tractor Supply” solid steel idler on Blue Bird Aerators, Sod Cutter and our other Bed Bug without a single failure.  This Bed Bug would also get the broken bolt replacement of set screw failures.  We have tried to keep set screws from loosening by using thread locking glues, and doubling up set screws with no success.  The machining of the shafts, hubs and sprockets are too sloppy for set screws to hold.  Our fix for the constantly loosening set screws is to use a 5/16 hardened bolt that is torqued to a point of breaking. This has solved much of the sprocket and hub loosening that we see on Bed Bug Bed Edger’s.  

In completing the repair we found a defective weld on the Blade we replaced in June. Half of the weld on a center tooth shows no penetration into the steel.  The Blade is made by a New York state Manufacturer; warranty claims on defective blades always fall on deaf ears.  The Manufacture claims they are not responsible because they supply blades built to Husqvarna specs.  Husqvarna is just a wasteland of incompetence.  

Cost is another $200.00 blade, $20.00 Tractor Supply Idler, $20.00 for a new chain and miscellaneous hardware. Total cost of repair with labor $300.00. 

June 4 2014 update

This particular blade broke on its third rental.  One tooth was torn off the tooth next to it was almost completely torn off and a third tooth has a slight crack a fourth tooth has a very tiny crack.  The vibration loosened the hub and the blade and blade hub came off the drive shaft. Fortunately the blade enclosure held the blade within it.  As describe further down in the posts if the blade hub was ether a one piece design or welded together the blade would not have separated from the drive shaft.

Cost is one more $200.00 blade and $40.00 labor to remount the hub. 

This is the first Blue Bird Bed Bug report of the season.  Both machines were serviced during our winter maintenance program.  On one machine we needed to replace a clutch cover gasket that failed to the overheating of the clutch oil caused by too small of a clutch for the application. 

On the first rental of the season blade and hub detached from the drive shaft.  The drive shaft hub assembly is one of the weakest links on the machine.  This hub shaft and bearing assembly needs a major strengthening as I referred to on May 26^th of 2013. The Blade Shaft needs to be 1” in diameter with stronger and wider bearing support.  The Blade shaft and hub assembly are sloppy loose right out of the box.  This assembly needs to be a one piece unit or at minimum machined too much tighter tolerances. 

  While Jody Kerr of Blue Bird believes it is too expensive to fix this problem a simple tightening of the tolerances would only require an adjustment on the boring machine that bores the blade hub.  At the Rental Show I passed out the address to this Blog to Jody Kerr and some members of her staff.  

One of the issues is the two small set screws that hold the hub to the blade.  The set screw wrench will break before the desired torque is reached.  I have come up with a solution to try to solve the problem with blades and hubs flying off.  I replaced the set screws with grade 8 bolts.  I torqued the bolts until the heads break off.  

Husqvarna Blue Bird Beg Bug Blade Failure 10 2013

There has been 2 rentals since the last blade failure on this machine. On return our post rental inspection reviled one broken Tooth and one cracked tooth. It was evident that the customer continued to operate the Machine with an out of balance blade.

Other issues found was one broken bolt and one loose bolt on the inside bearing support. Set Screws on the Blade Hub, Both Bearings and the driven Sprocket were loose or missing. Also missing was the bolt that holds the blade shaft onto the outside bearing. The Vibration also destroyed the stamped Tin Idler Sprocket, the damaged idler also destroyed the chain.

Cost of Repair Blade $200.00

Heavy Duty Tractor Supply Idler Sprocket $19.95

Chain and connector Link $8.00

Labor $60.00

Rental Income Gross $176.00

Repair Costs $288.00

Profit Loss - $112.00

1. 

Husqvarna Blue Bird Bed Bug Update.  The Backordered Bed Edger blades still haven’t showed up.  I have 2 machines and only one blade to share between the two Machines.  Husqvarna delivery dates mean nothing they are always missed.  In the past it has taken up to 90 days to receive back ordered blades

Bed Bug update July 17 2013

Bed Bug update July 17 2013
Earlier this week we needed to repair an outside bearing on the rotor shaft.  With the sloppy tolerances bearings loosen up.  We placed an order for more Bed Edger Blades only to learn that they are out of Stock.  Ship date is July 31 however Husqvarna rarely ship’s on time.  I will keep you updated.

Husqvarna Blue Bird Bed Bug Damage report 7 10 2013.

It’s been a blade a month on the Husqvarna Shaper Blade this Season.  Yesterday was the 3rd Rental on a blade that was replaced in June.  One Carbide tip just broke off, by the damage to the remaining stub the tip more then likely was improperly welded and the tip was brittle and snapped the first time it was used.

The damage to the center tooth is very evident.  Fortunately the tip remained on the blade.  When the tips do come off the blade is out of Balance and the Vibration will destroy the outside Bearing Support. There is always a Safety factor when Blades come apart.

Shaper Blade $200.00 labor and documentation $25.00.  Rental Income $255.00.

It cost me more to keep the Bed Bug Maintained is equal to its Gross profit.  Figure in purchasing the Machine, Insurance and other overhead costs the Husqvarna Blue Bird Bed Bug is a looser.  Yet Husqvarna’s Jody Kerr still denies that there is a problem.

The new style Dog Fence blade that was provided by the Blade Manufacture has not been Rented yet.

Husqvarna Blue Bird Bed Bug Damage report 6/19/2013

Husqvarna Blue Bird Damage report 6/19/2013
Yesterday we lost the second blade in the last 4 weeks.  By the almost new condition of the paint and Carbide tips I assume it has been rented no more than 4 times.

The Pictures show 1 carbide tooth completely torn off; a second Tooth has lost two thirds of its support and has bent backwards. A third area of damage is on the backside of the blade.

Once a tooth is torn off the vibration takes its toll on the rest of the machine.  Two of the 3 thumb screws that hold the Safety Cover had vibrated loose, and there was a complete failure of the outboard bearing support.




























The picture without yellow paint was taken to show the almost new condition of the blade. The picture shows a small crack I missed in my first inspection. Further inspection revealed another crack.

Cost of this Failure is a Shaper Blade $200.00 Bearing Support $26.00 2 Thumb Screws $1.50 each and an hour of labor at $65.00.  Total cost of repair $294.00

Last week out of the Blue I received a phone call from the Company the Manufactures Blades for Husqvarna Blue Bird.  They had a new design for the Dog Fence Blade they were sending me to try.

A few years ago I had met with the Company President.  He contends that his hands are tied because they build Blades to Blue Bird Specifications.  Until Bluebird engineers redesigned the Blades he was powerless to make changes on his own.

Re-engineering Husqvarna Blue Bird Bed Bug would be a relatively inexpensive process considering it‘s already $2000.00 + price tag.  Adding strength and support to the blade.  Increase the size and length of the Drive Shaft and the support Bearings.  Add 360-degree support to the outboard bearing.  Build the drive shaft hub assembly as a single machined or welded part.  Increase the size of the Hardware and drill 3/8th in holes for 3/8th in bolts instead of 3/8th inch holes for 5/16th in bolts. 

For less then a $100.00 and 3 or 4 hours on my workbench I could triple the life of the Blade Support and Blade mounting.  However, because of Product Liability issues My Insurance Company prevents me from altering the Husqvarna Blue Bird design. 

Husqvarna is anyone Home?

I have been dealing with this company’s lack of support and lack of understanding of the Rental Industry and our needs.  From Judy Kerr on down I have not found a single person who takes Engineering, Safety or the Rental Industry seriously.  I spent considerable time on this posting I hope it helps. 

Blade Mount;
The Blade Mounting assembly on a Husqvarna Blue Bird Bed Bug is at best sloppy tolerances are so loose that it is impossible to hold the blade steady.  Husqvarna Blue Bird uses two small setscrews to attach the Blade Hub to the drive Shaft.  In reality, the setscrews only lightly hold the blade on until the machine is started.  After the Machine is running and in use it is only Luck and centrifugal force that holds the blade in place.  The 5-piece Hub and Drive Shaft assembly consists of a ¾” Shaft, Hub a ¼-inch square key and two set screws this is a single part on most other brands of Bed Edger’s. The Husqvarna Blue Bird design could have been more reliable if the parts would have been built with some precession.  The Shaft is undersize and the Hub is oversized out of the package, wobble starts day one, and gets worse with use.  This part is in serious need for a redesign if for no other reason than Safety.

Blade Support;
Holding the Blade and Shaft assembly to the frame of the machine is the job of two undersize bearings and ½ of a bearing support on the outboard bearing. The Blade is 4” wide 16” in diameter and weighs 8 pounds has minimal support.  Instead of 360-degree support for the outside, bearing the Bearing plate supports the bearing on two sides 90 degrees apart.  This Bearing Mount is a sight of frequent failures. It will loosen up because of the oversize Mounting Holes and the Bearing Mounting plate frequently breaks.  At one time, we welded and reinforced this plate currently; we just keep several in Stock at all times.

Debris Cover;
The job of the debris cover is to direct the ground contain rocks and because of the Blade Breakage Issues contain chunks of broken blades.  One would think with the importance of this part care would be taken in its manufacture.  I would suggest that heavier steel should be used however; we have never had an issue with the steel being punctured.  The issue with this part is that the mounting flanges are only tack welded.  I have noticed on the 2013 machines the welding seams have been increased.

Parts availability;
Husqvarna Blue Bird has had a major problem with Parts availability over the years.  We are early in our season and our Parts room has sufficient quantity of Husqvarna Blue Bird parts for our equipment.  In 2012, we had one Bed Bug out of service for 8 weeks because a wheel adjusting cable was out of stock.  Blades are often out of Stock. A few years ago, both of my Bed Bugs were out of Service for weeks because of “Lost Blades” The Husqvarna Blue Bird Parts Manager could not find 60 blades his inventory showed in the warehouse.