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5 Ways to Keep Your Truck Out of the Shop
A Service Manager's Thoughts
(Editor's note: Fleets do not like to have their maintenance programs
scrutinized by a dealer, especially since the dealer is believed to be looking for repair work and not geared for preventative maintenance. But the following observations by a dealer Service
Manager can help many users save on the road aggravation and expense.)
Maintenance and service on the road is at best inconvenient, at worst expensive and can
be very disruptive to operations.
Experience shows that many of the faults and failures that cause problems on the road
are manageable and in many cases avoidable.
In fact, many of the service problems we deal with can be prevented through proper
preventive maintenance and inspection.
Battery and Electrical System Maintenance
Today's vehicles rely on a properly maintained electrical system for virtually every
vehicle function from lights and radio to proper operation of major components such as engine and transmission.
Most electronic components must have a minimum available voltage to operate properly
and even though the batteries may show adequate voltage unloaded, voltage drops across corroded connections or bad grounds can spell trouble for electronic systems and components.
In fact, one major component manufacturer will not even discuss a system problem until
batteries have been load tested.
And electrical problems can be masked as other problems. Recently we helped a
major leasing company who had changed injectors and wiring harnesses to correct an engine miss only to find that low alternator output was the real culprit.
Be sure batteries are load tested with every PM and keep connections clean and tight.
Don't use grease on battery terminals. The grease acts as a dirt magnet and will
only cause troubles down the road.
Fuel System Maintenance
The fuel systems on today's vehicles have very stringent filtering requirements due to
the very small tolerances of injectors and control systems and depending on fuel quality may need very rigorous maintenance.
And, as with the electrical system, fuel systems maintenance problems may show up in
surprising ways. One of the most common complaints today is the inability for the DPF (Diesel Particulate Filter) to regenerate. 40-50% of the vehicles that we see with this complaint are
unable to build fuel pressure and in most cases this is caused by a plugged fuel filter.
Depending on fuel quality, it may be necessary to change fuel filters between oil
changes, but the cost of a filter and a few minutes labor is small compared with the expense (and schedule disruption) that comes with a road call and tow bill.
Cooling System Maintenance
At least a couple of times per week, we solve a customer problem by installing a new pressure cap.
Cooling systems are simple in concept, but critical in operation and something as
simple as a $10.00 pressure cap can disable a truck and cause a late or missed delivery.
In addition, regular cooling system maintenance will prevent much more expensive
problems down the road. Today's cooling systems need to have the proper mix of anti-freeze and coolant conditioner to prevent corrosion and cavitation that can destroy engine components and
lead to expensive repairs.
Driver Maintenance
Many service visits are simply the result of mis reading or misunderstanding of
information in the cab of the truck.
For example, on trucks equipped with DPFs, a High Temp Light comes on while the enine
is doing a Driving Regeneration. This light is normal during the regeneration process and does not indicate an engine overheat or performance problem.
Be sure Maintenance Personnel and Drivers understand how the vehicle operating systems
operate and what the various in-cab indicators show.
An investment in operator training, with the help of your truck and vehicle supplier
will also pay dividends in fuel efficiency and reduced wear and tear on the equipment.
Tire Maintenance
In addition to the vehicle and operation related issues above, companies that provide
emergency road service report that as many as 50% of road calls are tire failure related. And of those, nearly half are the result of improperly inflated tires.
Under inflation by as little as 10% can dramatically shorten tire life and thumping
tires with a club will not help you find an under inflated tire.
Tires need to be gauged at least weekly, including trailers to give the best tire life
and prevent on the road failures.
And, don't forget your Auxiliary Power System. All of the issues relating
to your vehicle power system are also true for your APU. Regular PM and inspection will ensure that your APU delivers cool air in the hot summer time and a warm cab in arctic winter weather.
Summary
In summary, many of the problems that occur on the road and cause a visit to a dealer
or service shop can be prevented through careful attention to Preventive Maintenance and Daily Inspection.
In addition to oil change and lube, every PM should include:
- Battery and Electrical System Maintenance including battery load test
- Fuel System Maintenance including filter change. And if necessary due to
fuel quality, be prepared to change fuel filters between PMs.
- Cooling System Maintenance including inspection/test of coolant and components
such as the pressure cap
- Tire Maintenance – Proper inflation pressure should be checked at least
weekly at all tire positions, including trailers.
The key to trouble free performance of virtually all vehicle systems is a planned and
well executed Preventive Maintenance and Inspection program.
Back your PM program with a comprehensive training program for your drivers and
maintenance people that helps them understand system operation and maintenance needs and you will all but eliminate emergency road calls and unscheduled service visits.
Jason MurphyService MangerCharlotte Truck Center
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