Fair-Weather Care: Summertime Maintenance for Collection Vehicles

How many times has it been repeated that trash trucks—which operate in some of the harshest conditions, with constant stop-and-go operation—need a routine maintenance schedule to keep them in good running order? Every fleet owner understands that well-maintained collection vehicles are the foundation of a profitable collection business.             

Routine maintenance in the form of quarterly PMs has many benefits:

·      Reduces unplanned downtime due to equipment failure

·      Decreases fuel consumption through improved engine performance

·      Improves safety by avoiding mechanical failures

·      Lowers repair costs

·      Prolongs equipment life by avoiding major damage and excessive wear and tear

·      Lowers the cost of ownership

·      Builds a company’s reputation for reliability            

Preventative maintenance is key, emphasizes Jerry Milano, director of field service for Autocar LLC, manufacturer of severe-duty vocational trucks. “Regardless of the season, the cornerstone of fleet upkeep is a preventative maintenance inspection program.” He suggests following a documented checklist and service interval schedule. 

He also advises following the manufacturer’s recommendations for both the chassis and body. Original equipment manufacturers develop maintenance intervals based on years of experience; following their guidelines keeps trucks running longer and better.

Change of seasons

Seasonality shouldn’t be ignored when it comes to maintenance. Both cold and hot weather impose additional requirements for maintenance.             

“We recommend the removal of any winterization items, such as winter fronts [and] tank heaters,” notes Michael Cox, vice president of HQ Services for Battle Motors (formerly Crane Carrier). Because materials tend to reduce in size when cold, he also advises a thorough check of clamps and fasteners on the engine and chassis for proper torque.          

Changing fluids to the factory-recommended type for summer operation is another task that Cox says needs to be done. Sampling oil and coolant in the spring provides time to change filters and fluids before hot weather strikes. It’s also a cost-effective way to avoid unplanned downtime and becomes even more important as summer temperatures climb.             

“Winter can be tough on a hydraulic system,” says Carl Pezold, field service manager for New Way Trucks. Especially in cold climates with varying temperatures, he says it’s important to service hydraulic systems when “decent weather rolls around.”             

The hydraulic system on a collection vehicle includes the pump, PTO, PTO shaft, hydraulic tank, hydraulic fluid filter, high-pressure hoses, valves, and cylinders.  

As the weather changes, he continues, the hazards also change. “If it’s freezing one day and pleasant the next, the engines will ‘sweat.’” This unwelcome moisture can cause problems. In modern automated side loaders, for example, the hydraulic systems are much more delicate than in traditional rear loaders manufactured 40 years ago, according to Pezold. “Wiring goes to everything nowadays. Giving the hydraulic system the TLC it needs will keep you from becoming stranded on the side of the road.”             

Start by inspecting hydraulic hoses for rust. “If a hose rubs and the rubber, wire braid [and] wire braid structure break down to expose the innermost wire, those wires will rust,” Pezold explains. Salt and calcium chloride used to treat roads only exacerbate the rusting process. “Sometimes, hoses will get abrasions or crack. As the hose flexes on a rusted wire, the wire will break.”              

Next, check the hydraulic fluid reservoir for any foreign objects that contaminate the fluid. Check the hydraulic fluid filter and replace as needed. Look for leaks; a leak anywhere in the system results in less power due to reduced pressure. If you find a leak, clean the area, and use a fluid dye to discover the source of the leak. If a pump or cylinder has failed, clean or replace the oil.             

Maintain the proper level of oil: too low causes inadequate lubrication, resulting in premature failure; overfilling ruins seals. 

Cool it

Summer heat typically directs attention to cooling system maintenance. When the temperatures start to rise, it’s important to ensure that the cooling system functions properly. To ensure that cooling systems are operating at peak efficiency, Cox reminds operators to grease slack adjusters daily because heat increases wear on these components.

“Overheating severely reduces engine and component life,” Milano observes. Although many coolants now offer extended life, he suggests checking coolant condition and changing the coolant if it’s compromised or according to the manufacturer’s recommendation.

Additional suggestions he offers include:

·       Pressure-test the coolant system for leaks

·       Check all hoses; replace as needed

·       Check belts, tensioners, and the fan clutch

·       Clean the radiator, AC condenser, and trans coolers    

Milano underscores the harsh environment these trucks operate in, which includes transfer stations and landfills, where they can pick up dust and debris that reduce the cooling system’s performance, as well as high idle times that impact operation. Thus, conducting a “spring cleaning” to eliminate the grime that accumulates on the radiator fins can benefit operation of the radiator and prevent engine overheating.

“It isn’t unusual for debris to find its way into the truck’s inner workings in the refuse industry,” Milano continues. Therefore, daily inspection and cleaning of the radiator and the AC condenser are critical.

One easy and inexpensive maintenance trick to help maintain the correct pressure levels in a cooling system is to replace the radiator cap.

Lowering the thermostat

The engine isn’t the only thing that needs to keep cool during hot summer months. Ensuring the HVAC system is working properly will reduce potential heat stress and discomfort for the operator.    

In addition to checking for leaks, it’s important to service AC units before they get a lot of use in warm weather. That includes changing the cabin air filter as needed. Dirty, dusty environments can shorten their life, resulting in poor airflow in the cab.    

Condensation caused by cooler winter temperatures can also cause problems, so it’s something to examine.

Tires: under pressure

Tires are a critical element because of the heavy loads a collection truck carries. In the summer, trucks often pick up heavier loads as homeowners set out yard waste and bulky items from house and garage clean-outs. Loads can easily top 10 to 15 tons.    

Hot air expands; as it does, it can change tire pressures. That’s why daily monitoring is even more important in the summer. “Too little air can create weaknesses in the tires when the roads are hot, causing premature damage and blowouts,” Milano says.

Improper pressures can lead to premature wear, especially as tires pick up heat in warm weather. In addition to catastrophic blowouts, worn tires can cause increased braking distances and reduced steering control.

While inspecting the tires, it’s wise to check the wheels, rims, and even the undercarriage and frame.

Body work

Refuse trucks take a pounding—often, quite literally. Heavy loads take a toll, increasing stress and wear and tear on moving parts. Therefore, it’s important to lube or grease all metal-on-metal components, cylinders, forks, arms, blades, slides, and rollers. Pins and bolts should be scrutinized for stress and cracks. All metal parts should be checked for fatigue.

Brake time      

Brakes are a priority in the refuse industry due to the stop-and-go operation of trash trucks, which creates excess wear and tear on brakes. Summer heat compounds the problem.     

Inspect the entire brake system, making sure it’s free of debris. Check pads. Replace shoes and drums as needed. Look for seal damage or leaking: a sign of brakes overheating. Take the opportunity to listen for leaks in the air springs and ensure they’re also free of debris.     

Cox shares a tip for enhancing the cooling capability of the equipment: change routes. “A route that requires less stopping and more time moving down the road reduces the heat buildup on the brakes, resulting in longer brake life.”

Engine      

To help avoid engine overheating, make sure it’s clean. Milano points out that oil and debris can prevent the exchange of hot air. Thus, it’s important to check the evaporator core in order to ensure proper airflow.    

An engine inspection should include checking the transmission mounts. Transmission oil and engine oil and filters need to be changed periodically.

The emissions system should not be ignored, because repairs can be almost as expensive as an engine replacement. Examine the passive and active regeneration history and soot levels; if they are too high, they could be causing the engine to consume additional fuel or degrade components in the emissions system. Idling can increase regen frequency.

Other fuel-consuming issues might include clutch fans that are constantly engaged, leaks in the turbo boost system, thermostats stuck open, or PTO pumps running.

Diesel exhaust fluid levels also need to be checked, particularly in summer, and DEF filters should be changed routinely.

Cleanliness is next to …

“The secret to properly preparing and maintaining equipment is to keep it as clean as possible,” Cox reveals. This makes it easier to detect issues during visual inspections before they become serious problems. For example, if trash or other debris gets caught behind the packer blade, it can prevent proper operation and lead to shorter life.   

Milano agrees about cleanliness, adding, “You need to inspect everything.” That means inside and out.

Battery test

Snow-melt products can corrode a battery, so a spring cleaning of batteries, harnesses, connectors, sensors and cables after a long, messy winter can prevent problems later on.

In addition to cleaning, it’s also important to do a load test on the battery because it will discharge more during hot weather.

Safety first

Just because inclement weather may not be as much of a worry in the summer months, does not mean that haulers and municipalities should skimp on their maintenance programs, Cox says. “No cutting corners!” He advises completing a pre- and post-trip inspection of the equipment that meets the Department of Transportation’s standard of certification and the OEM’s recommendations. “Operating the equipment as outlined in the operator’s manual is essential.”

The beginning of warmer weather is a good time to give collection vehicles the once-over of safety features. That can include checking for:

·       Burned-out bulbs in all interior and exterior lights

·       Seat belts

·       Mirrors

·       Windshield wipers

·       Horn

·       Steering

Spring safety should include repairing damaged guards, repainting moving parts for better visibility, and reapplying hazard labels that have become worn.

Beyond taking care of vehicle components, Cox cautions truck operators to be cognizant of their surroundings in warmer weather when more people are outside. “This is especially true for residential routes in neighborhoods with lots of children,” he points out. “Keeping an eye out for joggers, dog walkers, kids on bikes and skateboards, kids playing in the street, and any stray animals is more important in nice weather than when everyone is cooped up during the winter.”

Similarly, Pezold says, “When operating an ASL, operators shouldn’t always be focused on what’s dumped when emptying a can, but rather the bigger picture and their surroundings. If there’s a kid on a Big Wheel a few houses up, you’ve got to pay close attention because you have no idea where he may end up by the time you get to his family’s can to empty it.”

Daily inspections

“The secret to maintaining equipment is inspecting it regularly,” Pezold adds. “Refuse equipment is not like any normal consumer vehicle.” Unfortunately, operators don’t always inspect the trucks during bad weather. “Cutting corners on regular inspections when there are wide variances in weather [from] freezing [temperatures] at the beginning of the day in spring into the 50s or 60s by the end, for example, can result in missed frozen air lines, fuel that’s gelling, snow and slush in places you don’t want it to be.”      

Like any other time of year, Milano says, a Driver Daily Inspection Report should be completed in the summer, and any issues discovered during routine inspection should be addressed as soon as possible to avoid equipment breakdown and unscheduled downtime.

Additionally, it’s crucial to set up a preventive maintenance program consisting of a checklist, routine inspections, scheduled servicing, and necessary repairs. This can be based on mileage, engine hours, or fuel usage—taking into account the needs of the season.     

As part of both the daily and the PM checklists, Milano believes in the value of records, documentation, and communication between the drivers and the maintenance personnel. “There really aren’t any secret tips to taking care of your fleet,” he says. “Do the basics. If you’re not doing the basics in your maintenance program, you’ll have breakdowns that lead to more significant problems.”

Summertime maintenance is key

“We can’t reiterate enough how important a good service program is to the well-being of refuse collection fleets,” Pezold emphasizes. “Regular, thorough inspections are as crucial as can be.”

Trash collection is a dirty job—and can be even dirtier in the summer. The most successful operations spec the right equipment, hire skilled operators to run it and, perhaps most important, maintain it through seasonally-adjusted routine maintenance. Regular preventative maintenance keeps the trucks rolling, the downtime to a minimum, the costs under control, and the customers happy.

Operators and fleet managers ignore seasonal routine maintenance at their peril. Trucks can break down, which means collections are late or missed and customers are upset. It can also mean expensive—and extensive—repairs.

“Above all,” Pezold concludes, “a good servicing and inspection will go a long way in maintaining fleets and setting hauling operations up for success – not just in the summer months, but year-round. This is a bit of a lost art with many folks. Nothing can take the place of thorough, regular inspections.” No matter which season.