Fleet feedback on early EGR Diesels - Streetsmarts

Diesel Progress North American Edition, May, 2003 by Jim Winsor

How are the '02 truck diesels performing in the real world? That's what everyone attending the March meeting of the Technology and Maintenance Council of ATA (American Trucking Assns.) wanted to hear. There were representatives from fleets operating Caterpillar, Cummins, Detroit Diesel, Mack and Volvo engines.

What were their overall conclusions? The trucks and '02 engines were expensive to buy ($10,000 and up in some cases) and as predicted, fuel economy was poorer than pre-October engines. Speakers rightfully cautioned that their experiences were all with low-mileage engines mostly operated during winter months when fuel economy tends to be at its worst.

Joe Stianche, fleet manager at Sanderson Farms, a large Mississippi-based chicken producer, said he has 13 Cat Clean Power C-12s in International chassis. Some run over-the-road delivering dressed chickens; others are in local high GVW feed trucks and tractors. Seven of the short-had engines are getting 14.9 percent poorer fuel mileage in January than the year-long average of pre-'02 Cats. The six line-haul engines are down 7.5 percent, Stianche said.

These Cat engines were pre-ACERT engines but did have bulkier exhaust aftertreatment, which added to swing room clearance between tractor and trailer. He expected that after a year's experience, the fuel mileages would be more similar. Actual mpg is 5.95 mpg on long hauls and 4.95 on local/feed hauls. Drivers are very pleased with performance, Stianche reported.

Dennis Soch, fleet operations manager for Keebler Co. in Illinois, reported his experience with Volvo power in cubed-out trailer loads, some in two-axle, others in tandem-axle tractors. With only one month's experience, Soch said vehicles are ranging between 0.7 percent and 1.5 percent poorer mileage with the '02 EGR Volvo VE D12 diesels. "We've been quite impressed -- we thought we'd be hit a lot more," he said. Trucks are equipped with add-on bypass centrifugal oil filters to deal with anticipated increases in fuel soot in the oil. He's keeping PM intervals at 25,000 miles. Drivers have no complaints on power or noise, he said.

Sam Kennedy, the colorful chief maintenance officer for D.M. Bowman with headquarters in William-sport, M.D., near Hagerstown, said with his new Mack Vision tractors with high-rise sleepers and ASET Mack 12 L engines with EGR and rated 427 hp, fuel mileages are down more than 4 percent compared to pre-'02 engines. Tractors have between 75,000 and 125,000 miles with no maintenance problems to date, he said. He's going with 25,000-mile oil drains compared to 40,000 miles on older Mack E-Tech diesels. "Best truck I ever drove," one driver told Kennedy. Turbo noise slightly louder, another said.

Jeff Philpot, director of maintenance at Kirk NationalLease, said his new Peterbilt 387s with Cummins post-'02 ISX engines rated at 475 hp were getting between 5.4 and 6.2 mpg in January/February running on blended midwest winter fuel. Highest tractor mileage is 17,000 miles. Fuel economy is about a half-mpg worse that pre-'02 Volvos with VE D12 engines in Model 660 tractors with 170,000 miles on them. "Drivers like the quick response from the variable geometry turbos on the new Cumminspowered Petes," Philpot said. He added he had early injector failures in one ISX, but they had not reoccurred since being replaced.

Dwayne Hoag, VP of maintenance for Werner Enterprises, Omaha, Neb., said his 11 EGR'd 60 series Detroit Diesels in Freightliners are off 5.5 to 6 percent mpg. He has five preproduction engines now up to 80,000 miles, and five production diesels in the 40,000 to 45,000 mile range. "This is a much higher fuel penalty than we expected," he said. "Engines are running well and drivers are happy. No power complaints which makes me happy!"

Oil drains are in the 18,000 to 22,000 mile range, same as his other 60 series. He is measuring "fan on" time to see the differences between pre- and post-'02 engines and what impact this may have on fuel economy. "My other concern is if we'll have engine problems at high mileages and only time will tell]'

STREET SMARTS IS A MONTHLY COLUMN DEVOTED TO THE ON-HIGHWAY ENGINE MARKET. JIM WINSOR IS EXECUTIVE EDITOR OF HEAVY DUTY TRUCKING AND DIRECTOR OF MARKETING FOR NEWPORT COMMUNICATIONS.