LOWER YOUR OPERATING COSTS
Consider these options when seeking ways to reduce fuel costs
Contractors know today’s marketplace is more competitive than ever and any edge can make a big difference. With record-high fuel prices, one chief concern now is how to bid
a project, knowing that the job may not start for months. Do you bid at current prices and
hope they stay stable, or do you plan for price increases?
Either way, there are methods to combat the rising costs of running your equipment. Some may be things you’re already doing, some may be things that are easy to implement and some may be suggestions you had never thought of before. They apply to all types of machines, from a dozer moving massive amounts of material in mining operations, to a compact excavator digging water services for houses, to anything in between.
“There are many ways to save fuel,” said Les Scott, Manager of Komatsu’s Working Gear
Group. “Implementing any one of them will show results. It’s a matter of what works best
for the individual user.”
One of the easiest ways to save fuel may be the most simple: don’t idle the machine during
non-production times. At these times, turn the machine off. Based on just one hour of idle
time per day, you could save more than five gallons of fuel per month.
Reducing travel speed is another quick and easy step to lowering fuel consumption. While
it may seem logical to move around a jobsite as quickly as possible, the added speed does
consume more fuel. By slowing down 10 percent you can improve fuel efficiency by 8 percent.
Regular maintenance is essential
Regular maintenance is vital to the longevity and performance of equipment. Following
recommended guidelines for routine service, such as changing filters, keeps machines
running smoothly and helps reduce serious problems. A well-maintained machine doesn’t
work as hard, thereby reducing the amount of fuel needed to get the job done.
You may want to consider using a preventive maintenance plan or a PM contract, through
your distributor. The plans offer comprehensive services, including changing all oil, filters and fluids at regular intervals. During a routine service, trained technicians thoroughly inspect machines for both visible and hidden problems that may potentially lead to a serious loss of time. Addressing these issues in advance reduces emergency downtime and keeps
equipment in top working condition, which makes it more efficient and productive.
“Regular maintenance is extremely important, and it’s one of the easiest things
an equipment owner or operator can do,” said Komatsu Senior Product Manager Tom
Brakeall. “Any step you can take to eliminate significant downtime is worth it. A PM contract
will ensure your machinery is serviced on time and properly, so you can concentrate on
getting more work done without worrying whether a machine is going to break down.
Most distributors do the PM after hours, when the machine is down anyway, so there’s no
downtime involved with the service work.”
Eliminate inefficiencies
Eliminating and reducing unnecessary and/or inefficient movement go hand in hand
with travel speed. Plan ahead to avoid moving the machine around the jobsite in haphazard
fashion, such as moving from one area to another then back to the original location.
Instead, look for ways to keep the machine in the same area as long as possible and move
across the site a little at a time.
You can further eliminate inefficient and unnecessary movement while the machine
is performing. For example, in truck loading, reducing swing angle from 90 to 30 degrees
will improve fuel efficiency by 3 percent. Speeding up production by shortening
cycle times through improved excavation techniques can provide as much as 8 percent
better fuel efficiency.
In quarry applications, a scale on the loading machine is an advantage because it helps
eliminate unnecessary loading and dumping.
“A scale on the machine tells the operator exactly what he’s putting in the truck. That
eliminates a trip to the scale house where the truck driver may find out there’s too much or
not enough on the truck,” said Scott. “If that’s the case, the driver has to return to the quarry and adjust the load accordingly. A scale on the machine takes the guesswork out of the equation, so trucks can be loaded faster and more accurately.”
Along with shorter cycle times, you should maintain smooth digging, which can save
more than 18 gallons of fuel per month. An operator can dig smoothly by not constantly
pulling the control lever to try to lift a load that’s too heavy. That action relieves oil
pressure, which in turn increases the amount of fuel needed to perform the task.
While it may be important to get the task at hand done as quickly as possible, you could
consider lowering engine speed. Ten percent less speed will reduce fuel consumption by 12
percent. Although you do lose about 7 percent in productivity, there is still a net gain in fuel
efficiency, making the move cost effective in the long run.
Many equipment users also truck their own materials, which only adds to the fuel bill. But,
there are ways to reduce those trucking costs as well. As with heavy equipment, a welltuned truck engine is vital. Other factors, such as maintaining proper tire inflation, will also help. Remember, over- or under-inflated tires can cut efficiency significantly.
Consider new technology
If you have older equipment, it may be time to update it. Older equipment tends to be
less efficient. New equipment has technology designed to increase productivity while
reducing fuel consumption and emissions. Fuel savings and better production will help offset
the costs of switching to more efficient machines.
“The new Tier 3 engines have shown significant improvement in fuel economy
compared with previous models,” pointed out Scott. “At the same time, they’re more
powerful than before, so the production and efficiency benefits are outstanding.”
Komatsu’s new ecot3, Tier 3 engines were designed to give the user increased power, while
at the same time using less high-priced fuel. Fuel savings can easily be 10 to 15 percent or
more. The ecot3 engines are available in a wide variety of new Komatsu equipment, including excavators, wheel loaders, dozers and trucks.
These new machines were specifically designed to maximize fuel efficiency. For
example, Komatsu’s new Dash-8 series of hydraulic excavators comes with an “eco-gauge,”
which serves as a guide to efficient operation, giving the operator instant feedback regarding load and how it impacts fuel consumption. It also lets him know if he’s idling too long.
New wheel loaders have technology such as an “E Mode” for maximum fuel economy, and
come standard with a newly designed variable displacement piston pump that combines with Komatsu’s Closed-center Load Sensing System (CLSS) to deliver only the necessary amount of flow needed for hydraulic function. It prevents wasted flow, which in turn provides better fuel economy.
GPS systems can boost productivity
You can also use technology to save time and be more accurate in material placement with a global positioning system (GPS) such as Topcon’s 3D-GPS+. A GPS system allows users to upload job design into a control box, which then receives machine-positioning signals from the radio antenna, GPS receiver, the blade-mounted GPS antenna, and a cross-slope sensor.
The control box continuously compares actual machine and blade position and
calculates corrections that are sent to the hydraulics, creating fully automatic grading
of the jobsite. All the operator does is control direction and speed while the GPS creates the
final grade. The result is reduced staking and surveying costs. Plus, it takes fewer passes to
reach final grade.
“The system has been proven to increase productivity by 30 to 60 percent,” reported
Randy Noland, Topcon’s Machine Control Product Manager. “If you can get to grade
faster and place material more accurately you’re going to use less fuel. It’s really a nice
benefit. With a Topcon system, users are going to recoup their initial investment in labor and material savings, but they certainly will save on fuel by getting to grade in less time.”
Making changes pays off
It may not be feasible to implement all these changes at once, but making just one could
benefit you in both the short term and the long run. They will help you remain competitive
and could increase your profitability through increased production and more efficient
operation.
“It’s hard to predict what will happen to fuel prices in the future, but you can always find
ways to reduce your costs,” concluded Scott. “Even if you only save a little, it’s still more
money in your pocket.”
11 comments - Posted by Jon Rossi at 11:06 AM - Categories:
