Energy Best Practice Guide for Tractors Fleet/Site Managers

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1 Further information Skanska AB Solna, Sweden Contact Noel Morrin, Senior Vice President Sustainability noel.morrin@skanska.se Energy Best Practice Guide for Tractors Fleet/Site Managers Introduction Climate change is one of the Greatest environmental concerns of our time and organisations in all sectors are coming underincreasing scrutiny to demonstrate commitment toreducing their use of fossil fuel derived energy and minimising the greenhouse gas impact of their operations. Skanska is one of the world sleading construction groups with expertise in construction, development of commercial and residential projects and public-private partnerships. Energy is one of four key areas that are prioritised in Skanska s environmental business plan and it is committed to reporting ongoing activities within this area in the hope that good practise may inspire others to implement and disseminate good examples. This best practice guide is aimed at fleet/site managers to provide useful information and tips on good practice in the operation, management, maintenance and procurement of wheeled loaders. The objective is to help drive down costs and reduce the impact on the environment by minimising fuel use and lowering CO2 Emissions. Tractor Fuel Efficiency Training and Management Managing and promoting energy efficiency as well as training your operators is essential in order to reduce fuel use and CO2 emissions. Equipment changes and operators may not necessarily be aware of the changes they need to make to keep up to date. In addition, habits develop that are not always of benefit to the efficient operation of the equipment. The following tips if implemented have the potential to encourage behavioural change and reduce individual and fleet wheeled loader fuel consumption. Assess fuel efficiency as part of driver s personal development. This will ensure that driver s skills are constantly being refreshed and updated preventing inefficient behaviour becoming ingrained. This will help to ensure that the equipment is operated fuel efficiently and also increase the life of the equipment. Generally the more fuel-efficient the operator the smoother and safer their work, which will also contribute significantly to reduced wear on the equipments components. Consider an incentive scheme based on fuel efficiency. Providing incentives can encourage operator buy-in to your fuel efficiency scheme and increase its success. Request up-to-date training from vehicle manufacturers. Ensuring operators fully understand their equipment is essential for them to operate equipment to its optimum efficiency. Communicate effectively with operators. Make sure your message is clear and is understood by your work force. Explain what you are doing, why you are doing it and what are the goals of the fuel efficiency campaign. Run driver league tables based on fuel economy averages. League tables can highlight the worst offenders and most fuel-efficient operators, which can motivate the worst offenders to change their behaviour. Consider a small incentive; perhaps award the best driver of the month with a symbolic prize, for example a lottery ticket.

2 Use on-board computers. These systems can be highly sophisticated and can highlight worn out components, system inefficiencies and monitor vehicle operation. Alternatively they can just have a simpler fuel consumption display providing information on current and average fuel consumption. Some systems can also be linked to fleet management systems that monitor the hours on a piece of equipment and alert the operators and fleet managers when maintenance is required. Appoint a Fuel Champion. They should have the role of promoting and communicating fuel efficiency within the work force. Who makes a good fuel champion? Here s what they need to be able to do: Understand how fuel consumption figures are generated, how errors occur and how to correct them Recognise the potential for fuel saving and how to fulfil it Understand how monitoring systems can be used to encourage fuel saving Communicate freely and easily with everyone involved in the fuel-saving programme, which probably means everyone in the company Know your fuel consumption and set improvement targets. Recording your equipment and site fuel consumption will allow you to monitor and analyse for inefficiencies. This can then allow you to set sensible benchmarks for operators to aim for and for you to assess your success in implementing your fuel efficiency programme. Selection of Tractor to Task You should size the Tractor to the job the smallest capacity machine suitable for the activity. It is important that the specification of the Tractor is appropriate for the intended activity. An undersized Tractor will wear out quicker due to the increased stress and may take too long to do the job, while an oversized Tractor may never be used to its full capacity and will be operating inefficiently. The amount of power that the Tractor requires will depend on the tasks that are being carried out and the conditions on site. Intended operation: When determining Tractor power requirements consider the power requirements of each operation, weight of loaded trailers, type of mounted implement being used, how often tasks are performed and how critical they are. Drawbar power is the most important parameter to consider, as power is lost through transmission, wheel slip and resistance. Drawbar power can be considerably less than engine power. Site conditions: Also consider the conditions on the site (e.g. muddy or slippery ground, roughness of terrain, slopes). Particularly boggy or rough sites may require the use of tracked vehicles. Implement selection: Ensure the most appropriate implement is selected to carry out the task, as this will ensure it is completed as quickly and efficiently as possible. Should ensure implements are attached to a Tractor of sufficient size for safety reasons and to avoid excessive wear of equipment. Track selection: Equipping your Tractor with the most appropriate track type will maximize productivity and minimize operating expense. Low Ground Pressure (LGP) track maximizes flotation while reducing overall machine weight and increasing payload capacity. Rubber tracks where possible will reduce vibration and fatigue while also allowing work on paved areas. Tire selection: It is important to select the most appropriate tire weight and tread pattern for the task. This will provide sufficient support to the Tractor whilst minimising resistance to movement over the ground. Use the minimum suggested tire pressure set by the manufacturer for the activity/load. This will increase the footprint of the tire, reducing rolling resistance and wheel slip improving fuel and tractive efficiency. The largest tire diameter should be selected that will carry the Tractor and load at the minimum pressure. Ballast: It is important to use appropriate ballast for the task and implement being used. Do not ballast over limits set by the manufacture as this will increase rolling resistance, decrease fuel efficiency and increase the chance of mechanical failure.

3 Maintenance of Tractors Preventative maintenance is the key to prolonging the life of your equipment and ensuring it is operating to its optimum performance, which will reduce fuel use and CO2 emissions. Get operators/supervisors to do daily walk round inspections of the equipment to spot any defects/faults/excessive wear. Spotting these early will prolong the equipment life and ensure that it is working to its optimum performance. Checks should be made for the following: Fuel or oil leaks Missing seal in fuel tank cap or signs of fuel spills around filler neck Tire wear suggesting faulty steering or axle alignment Tire damage from rocks and other debris Track tension should be adjusted to the value as specified by the manufacturer and checked regularly to ensure efficient operation. Greased components are sufficiently lubricated Power Take Off (PTO) attachment is free from foreign material and in sound condition. Should be lubricated to manufacturers specifications Three point linkage components are in sound condition Fluid leaks from hydraulics Maintenance records showing rapid wear of clutch or brake friction material Traces of black smoke in exhaust suggesting fault with engine s air-intake and/or fuel injection system Missing or damaged air-management equipment Excessive engine oil consumption (no leaks) suggesting oil is being burnt as a result of internal wear. Identify when the last time the air filter was changed. Repair/replace as soon as reasonably practicable any identified faulty/worn out/defective components. This action also assists in safety management. Carry out full service on equipment at scheduled intervals as outlined in the Tractors operating manual. This should include replacing oil, oil filters, air filters and hydraulic fluids, and adjusting brakes, clutches and drives. This should help to maximise the longevity of the Tractor and optimise its performance. Ensure that implements are regularly maintained and properly fitted. The condition of the implements can effect how well the Tractor can carry out its tasks and how efficiently it operates. The following tips could lengthen the life of the Tractor, reduce fuel use and CO2 emissions: Front end/rear end loader Tips near the bucket/fork corners usually wear the fastest. Rotate worn outer tips to the centre and vice versa. When rotating, roll the tips over to get all of the available wear life and keep tips sharp. Mowers/disc cutters Inspect implement to ensure free movement of working parts and that blades are in sound condition. Worn blades should be replaced. Worn blades reduce cutting ability, increase wear on the other components and are less efficient. Cutting height should be checked and adjusted as appropriate to avoid overworking. Scrapers/graders Depth should be set at a level that avoids overworking of equipment. Tillers Inspect implement to ensure free movement of working parts. More compacted soils require slower tilling speed. Depth should be set to a level that avoids overworking of equipment. Trailers Distribute loads evenly over the largest area possible. Do not overload the trailer as this increases stress on components, reduces tire life and fuel efficiency. Replace missing or damaged hardware Inspect and tighten loose hardware. Operating with loose hardware will elongate boltholes. Inspect the surface where the retaining nut will land it should be solid, smooth and flat. If it is not, it will be impossible to keep the hardware tight. Power Take Off (PTO) The PTO shaft between the Tractor and the implement should be maintained in good working order and correctly fitted and lubricated in accordance with the manufacturers instructions.

4 Procurement of new Tractors Increasing legislation by governments on air quality and greenhouse gas emissions are forcing manufactures to continually improve the efficiency of their equipment, which means that they are more fuel efficient, reliable and need less maintenance than older equipment. The following are some general considerations when buying a new Tractor and can be useful when renting or sub contracting the equipment. This advice is important for ensuring the correct equipment is selected and minimising its environmental impact: Versatility of Tractor, including its suitability to perform a variety of tasks Correct sizing of Tractors to implements and tasks ensures the Tractor is not being over or under worked. Tires that provide the traction necessary to pull loads and operate implements effectively. Choosing the correct tires for the site/job is critical to ensuring the Tractor operates at its optimum performance, maximising grip for certain conditions and minimising drag for others. Pulling load, weight of implement and counter weight, which affect the machine s manoeuvrability and stability then in turn its efficiency. Key advanced design features to look for when buying/renting/sub contracting a new Tractor that can impact on ease of use, fuel efficiency and environmental emissions are: Emissions-compliant engines - With electronic fuel-injection controls, turbochargers and aftercoolers. These are becoming more fuel-efficient year on year. Continuously variable transmissions (CVT) Provides better fuel economy as the engine runs at the most efficient speed for the activity. Touch screen terminal Can allow for transmission ratios to be configured. Maximum output settings adjust the speed of the engine to the load for maximum fuel efficiency. Single-joystick controls - For multiple machine functions. This can improve the ease of use of the equipment making it simpler and quicker to train operators. Can also increase performance and efficiency, and reduce time for frequent manoeuvres. Limited-slip differentials - Some offer torque-proportioning differentials. These can reduce the likelihood of spinning wheels on softer surfaces. Improved cabs - More glass, better heating and air conditioning, and often a better seat. Better cab conditions can improve the motivation and job satisfaction of an operator, which in turn can improve their performance and increase fuel efficiency. Easier maintenance - Grouped grease fittings, fluid drains and filters can be serviced from ground level. Easier to maintain Tractors can ensure that the operators and mechanics spot and fix problems early. Manufacturers are also turning to hybrid engine technology to include in their Tractors in a bid to further reduce fuel consumption and environmental emissions. These are still a few years off, but once introduced they could have the potential to massively reduce fuel consumption. Case have stated that hybrid technology has the potential to substantially cut fuel consumption. They have also identified technology whereby energy produced from braking could be converted to electrical power, which could be used to drive implements. Procurement of Bio-diesel Fuel 1 Fleet Operator s Guide to Reducing Emissions from Diesel Vehicles, Energy Saving Trust 2003 Many fleet managers are now considering bio-fuels as a way to reduce CO2 emissions. Bio-fuels, including bio-diesel, are made from biomass rather than fossil fuels. Manufacturers are increasingly designing wheeled loaders to utilise bio-diesel. The following are some key points when considering switching to bio-diesel: Bio-diesel is normally sold blended in with standard mineral diesel; typically this is 5% bio-diesel and 95% mineral diesel 1. Blends with greater than 5% bio-diesel may affect the warranty of certain equipment, as blends with more than 5% are not currently permitted in the EU due to a EU fuel standard (there are proposals to change the standard to allow blends of up to 10%). These can be used in most engines without modification. Blends with greater than 5% bio-diesel may affect the warranty of the vehicle. Using bio-diesel should reduce the lifecycle emissions of CO2, as the carbon is absorbed by growing the biomass used to make the fuel.

5 2 Fleet Operator s Guide to Reducing Emissions from Diesel Vehicles, Energy Saving Trust 2003 Reductions in overall emissions of CO2 for 5% blends are likely to be between % 2. Blended fuel with 5% bio-diesel should have a similar fuel economy to pure diesel. In Sweden there has been problems with diesel with 5% Fatty Acid Methyl Ester (FAME) form of bio-diesel during really cold days. When the temperature has dropped to lower than -15 to -20 C, (5 to 4 F), the FAME bio-diesel has precipitated and clogged the fuel filter. The reason isn t fully known, but it can depend on the quality of the FAME bio-diesel that has been used and if the diesel has been in storage for long periods and/or in containers that have been insufficiently maintained. 5% blends are generally priced at parity with normal diesel or at 1p/litre (UK or equivalent to /litre and 0.02 $/litre) higher. Also available as higher blends or neat from processors and manufacturers. Older equipment (out of warranty) can be modified (new seals etc) at minimal cost to run on these higher blends. With a growing shortage of normal diesel, suppliers are looking to extend supplies with the inclusion of 5 per cent bio-diesel. Links to Tractor Manufacturers For more information on suitable Tractors from key manufacturers please see the following links: Case - list of full Tractor range Caterpillar list of their track-type Tractor range Claas - list of Tractors in range JCB John Deere epage&location=tractor - list of full Tractor range Massey Fergusson - list of full Tractor range New Holland 511&line=

6 Worldwide Energy Efficiency Government Departments, Agencies and Support Organisations The following are a list of relevant Government departments and Non-Governmental Organisations that provide policies, support and promotion of energy efficiency and the reduction of CO2 emissions. Country Department/Organisation Czech Republic Ministry of Industry and Trade of the Czech Republic Ministry of Environment Finland Ministry of Trade and Industry - Energy Ministry of Agriculture and Forestry Norway Ministry of Petroleum and Energy Ministry of the Environment Poland Ministry of the Environment Polish National Energy Conservation Agency (KAPE) The Ministry of Economy, Labour and Social Policy Polish Foundation for Energy Efficiency (FEWE) Sweden Swedish Energy Agency Swedish Environmental Protection Agency Consumer Agency Swedish Agency for Innovation Systems Swedish Research Council for Environment, Agricultural Sciences and Spatial Planning Swedish Research Council

7 United Kingdom Department of Business, Enterprise and Regulator Reform (BERR, formerly DTI) Department of Environment, Farming and Rural Affairs (DEFRA) The Department of Transport The Carbon Trust The Energy Saving Trust USA U.S. Department of Energy ENERGY STAR Environmental Protection Agency Clean Air Website