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How
to Make Fuel Savings Pay Big Dividends
Fuel Economy Basics From Caterpillar® Field Service Coordinator
Jim Booth Jr. and Powertrain Technical Steward Brian Coe
With energy prices continuing to rise and no end in sight,
fuel is without a doubt the largest operating expense for
trucking companies today. It's vital that truck owners have
a basic understanding of the many variables that affect
large truck fuel economy
Factors with the most impact on fuel usage include aerodynamics,
gearing, tires, load, speed, climate, idle time and driving
techniques, according to Brian Coe, powertrain technical
steward, Caterpillar® Global On-Highway.
"Good fuel economy isn't a mystery-it's the result of a
combination of variables that, if managed effectively, can
deliver the best fuel mileage possible for that particular
truck," Coe said.
Aerodynamics
Aerodynamics of any vehicle is a major contributor to
fuel economy performance, especially when it comes to
larger vehicles. Many exhaustive tests have been run
over the years to confirm the effects of certain truck-
and trailer-mounted aerodynamic devices. Industry studies
testing the differences in fuel economy advantages or
disadvantages between all types of semi-truck components
have found that the most aerodynamic tractor can have
as much as a 15 percent fuel efficiency advantage over
the least aerodynamic vehicle.
The whole objective in improving aerodynamics is
to increase the ability to move the tractor and trailer
through the air while causing the least amount of
air disturbance, and therefore improving fuel efficiency.
When pulling high cube trailers such as dry vans and
refrigerated trailers, the smooth-sided trailers cause
the least amount of air turbulence. Aerodynamic tractors
with smooth-flowing roof fairings and smooth-sided
cabs can push the air around the nose of the trailer.
The more traditionally shaped tractor, with its squared-off
edges and externally mounted air cleaners and exhaust
systems, causes a greater amount of air turbulence
that negatively impacts the benefits of the smooth-sided
trailers, in both fuel efficiency and overall engine
performance.
When pulling trailers that cause a greater amount
of air disturbance, such as livestock trailers or
car haulers, the aerodynamic effects of the tractor
are much less noticeable. In these applications, the
extreme air disturbances caused by the larger trailer
will have a much greater impact on the aerodynamic
drag of the total package than that of the smaller
tractor.
Something else to consider when pulling high cube
dry vans or refrigerated trailers is the tractor/trailer
gap. Decreasing a trailer gap from 65 inches to 25
inches can improve fuel economy by as much as 5 percent.
Gearing
The gearing of a large truck includes not only the
rear-end axle ratio and the transmission type, but
also the drive tire size as well. Choosing the proper
gearing of a large truck can be a daunting task since
gearing can affect both the performance and fuel efficiency
of the vehicle. Selecting the proper gearing for a
truck is about finding that balance between fuel efficiency
and performance that works best for each individual
application. There is no such thing as a "one spec
fits all." It boils down to personal preference for
your particular application.
A truck spec'ed for optimum fuel economy will typically
be geared to run at a very low engine rpm while at
cruise speed, the so-called "Gear Fast Run Slow"
concept. Driven correctly, trucks with drivetrains
set up for GFRS will deliver good fuel economy and
good performance, as long as they are not geared too
fast and running at too low of an rpm at cruise speed.
A truck geared more for performance will be geared
to run the engine at a higher engine rpm at cruise
speed than the GFRS setup. Talk to your Caterpillar
dealer representative for more information about the
correct gearing solution for your particular application.
Additional information can be obtained by visiting
our Web site at http://ohe.cat.com/drivingtips.
Tires
Tire manufacturers basically sell three different
types of drive tire tread design. Deep lug tires deliver
the best traction and long life but have high rolling
resistance. Shallow lug tires have less tread depth
to decrease the rolling resistance. Rib tires lack
good traction but provide the least amount of rolling
resistance, maximizing fuel economy.
All tires are least fuel efficient when new. As the
tires wear, the rolling resistance decreases and fuel
economy improves. Tests performed by leading tire
manufacturers have shown that once a tire is 50 percent
worn, you will see as much as a 6 percent increase
in fuel economy.
Another choice to make when choosing a tire is whether
to go with low profile or tall tires. Tall tires have
a little more rolling resistance than the low profile
tires because of the increased flex of the taller
sidewall. Low profile tires also have a weight advantage
over the taller tire, but a shorter life expectancy
because of the increased tire revolutions per mile.
Driving Speed
Horsepower demand increases substantially as vehicle
speed increases. It takes a lot of power to push a
large vehicle through the air. A good rule of thumb
to remember is that fuel economy will change about
one-tenth of a mile per gallon for every one mile
per hour over 55 mph road speed change. In other words,
decreasing overall road speed from 70 mph to 65 mph
can improve fuel mileage by around half a mile per
gallon. Actual fuel mileage increases will depend
on the aerodynamics and weight of the vehicle. As
speed increases, truck/trailer combinations with poor
aerodynamics will experience greater fuel economy
losses than those with better aerodynamics.
Climate/Fuel
Cold weather will cost you fuel economy. The difference
between 70-degree weather and 25-degree weather is
a 13 percent fuel economy loss. This is caused by
the thicker, denser cold air, as well as cold weather
fuels that have lower energy content. Another contributor
to cold weather fuel mileage penalties is thicker
lubricating fluids with higher resistance to flow.
High winds are another cause of fuel mileage decrease
and can decrease fuel economy by as much as 13 percent
compared to a calm day. Testing has shown that you
will see about a 3 percent penalty in fuel efficiency
when switching from straight #2 diesel fuel to a winter
blend fuel, depending on the blend.
Idle Time
An idling engine can burn somewhere between half a
gallon to one and a half gallons per hour, depending
on the engine idle rpm and accessories in use, like
the air conditioner. Drivers can minimize warm-up
times by idling only while doing the pre-trip inspection
and filling out the logbook. Once the coolant temperature
gauge starts to rise off the peg, it's okay to start
moving the truck. Just be easy on the throttle until
the engine reaches normal operating temperature. The
engine will warm up much quicker and the transmission,
wheel bearings and rear end will warm up at the same
time.
Driving Techniques
The industry has found that the most significant variable
to fuel economy is the driver. According to Jim Booth
Jr., field service coordinator, Caterpillar Global
On-Highway, the driver controls vehicle speed, shifting
techniques, idle time, acceleration, brake usage,
trailer gap settings and more. Studies have shown
that it is not uncommon for fleets with identically
spec'ed trucks to see as much as a 35 percent fuel
economy difference between trucks-a difference that
is solely due to variances in skills and attitudes
of the drivers.
Truck owners can minimize the effects of inefficient
driving by setting parameters within the engine ECM
that limit the vehicle speed and idle time. Customer
programmable parameters can also be set to help control
poor shifting techniques. While engine electronics
can provide some necessary tools to help improve fuel
mileage, the most important tool by far is driver
training. No matter how the truck is spec'ed or how
the customer parameters are set, the one thing that
is consistent in trucks getting good fuel economy
is a driver with a good attitude and good understanding
of proper driving techniques. For further information
drivers can contact their local Cat dealer, call the
Caterpillar Truck Engine Call Center at 1-800-447-4986,
or visit
http://ohe.cat.com/drivingtips.
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Top Five Driver Tips to Improve Fuel
Economy
5. Coast in gear whenever possible and for as long
as possible.
The objective here is to use the vehicle's momentum and
coasting ability. While coasting in gear, the engine consumes
no fuel. A driver can take advantage of this coasting
"free mileage" by backing out of the throttle earlier
when approaching exit ramps or slower speed limits. Down
shifting a couple gears or so while coasting in gear to
your stop or exit will get you the most "free mileage"
possible. Backing out of the throttle at just the right
time allows the vehicle to slow down to the proper speed
while using a limited amount of braking, either with the
service brakes or compression brakes.
4. Use progressive shifting.
Progressive shifting keeps the engine rpm as low as possible. It means to use only enough rpm to get into the next highest gear and still pull that gear. For instance, in the low side of the transmission you may be able to upshift at 1,000 rpm and still pull the next gear. When in the high side of the transmission, the road speed increases. Since the horsepower demand increases with the road speed, it requires the driver to use a little more rpm to upshift into the next gear. You may be able to upshift at around 1,200 to 1,400 rpm while in the high side of the transmission. This depends on the load you are pulling. Heavier loads that pull harder than a lighter load require a little more rpm to get into the next gear and still pull that next gear.
3. Stay in high gear as long as possible.
Do not downshift too early-only downshift when necessary. If you can get over the hill without falling below 1,200 or 1,100 rpm and not downshift, take advantage of it. Less rpm used to get over the hill means less fuel used. Let the engine do all the work, instead of the driver working to keep the engine rpm within a certain range.
2. Limit idle time. Obviously there will be times when idling the engine is a necessity. The trick is to concentrate on eliminating the unnecessary idle time. A good rule of thumb to keep in mind is anytime you think you will be parked and away from the truck for more than five minutes, shut the engine off.
1. Slow down.
The single most effective thing a driver can do to improve fuel mileage is slow down. Driving a little slower is also safer, extends tire life and minimizes the wear and tear on the truck, trailer and driver. Unfortunately, slowing down is also the last thing a driver wants to do.
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Caterpillar®
FCC Equipment Financing Releases Annual Outlook on
Transportation Industry
FCC Equipment Financing Inc., a subsidiary of Caterpillar®
Financial Services Corporation that provides lending
solutions for new and used equipment to the transportation
market, recently released a comprehensive transportation
industry report.
The report, titled "FCC 2008 Economic Insight: An
Annual Outlook on the Transportation Industry," was
produced by Caterpillar's economists and provides
a compilation of viewpoints on the current and future
status of the U.S. economy and the North American
transportation industries, including trucking, rail
and motor coach.
Highlights of the report include:
- With many industries that lead the economy in
decline and no clear sign of imminent and significant
monetary stimulus, the United States economy is
expected to grow only 1.5 percent in 2008.
- The implication for the trucking industry is that freight will be flat to down about 1 percent in 2008.
- New heavy duty vehicle purchases in the United States will be approximately 140,000 vehicles-up from 135,000 in 2007-and largely for replacement.
- Demand for midrange trucks will be down 17 percent in 2007, with about 120,000 vehicles purchased. In 2008, demand will be down another 10 percent from 2007 levels at 108,000 vehicles.
- Continued weakness in the housing sector will decrease demand for transportation related services for this industry.
- Motor coach trips have increased almost 10 percent from 2005 to 2006. Group travel is especially strong, and this is the bread and butter of the industry.
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"FCC has an in-depth understanding
of the transportation business, including equipment
values, enabling us to create tailored financing structures
for customers," according to John Marino, FCC's
national sales manager for transportation. "We
have industry specialists who call directly on transportation
management and provide an unequaled level of customer
service, plus we have the strength and staying power
of Cat Financial."
FCC provides financing for mid-size to large private
fleets and common carriers throughout the United States
with medium or heavy-duty trucks (classes 6, 7 and 8),
trailers and related transportation equipment. The company
provides fixed and floating rate loans, TRAC leases
and revolving lines of credit. These products can be
used for equipment acquisition, working capital, debt
consolidation and debt restructuring.
The full report can be downloaded in a pdf format at http://www.fccef.com/economicinsight.asp. Companies can also register to receive the report and quarterly updates in the mail, on the Web site or by calling FCC at 1-800-207-9286.
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Issue
57 4/10/08 To learn more about Caterpillar On-Highway Engines, please
visit:
http://www.cattruckengines.com/.
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