How do you reduce fuel consumption while maintaining output?

When we’re talking about heavy machinery like excavators and loaders, fuel consumption is a massive part of your operating costs. A typical 20-tonne excavator can guzzle anywhere from 15 to 40 litres per hour, depending on how you operate it. That’s why it’s crucial to understand how to keep your machine running efficiently without compromising on productivity.

Machine Selection and Sizing

First things first, you’ve got to make sure you’re using the right machine for the job. Using an oversized excavator is like using a sledgehammer to crack a walnut—you’re just wasting energy. For instance, if you’re working on a small residential project, an 8-tonne excavator might be perfect, consuming about 8-10 litres per hour, whereas using a larger 20-tonne machine would be overkill and waste fuel.

Regular Maintenance

Just like your ute needs regular servicing, your excavator needs proper maintenance to run efficiently. A well-maintained machine can save up to 10-15% in fuel consumption. Here’s what you need to focus on:

Engine Maintenance

Your engine is the heart of the machine, mate. Keep it healthy by:

• Changing air filters regularly: A clogged air filter can increase fuel consumption by up to 5%
• Maintaining proper oil levels: Clean oil reduces friction and helps the engine run more efficiently
• Checking fuel injectors: Faulty injectors can waste fuel and reduce power

Hydraulic System Care

The hydraulic system in machines like the Hitachi excavator series is crucial for efficient operation. A properly maintained hydraulic system can significantly reduce fuel consumption. Regular checks should include:

• Monitoring hydraulic oil levels and quality
• Checking for leaks in hoses and connections
• Ensuring proper hydraulic pressure settings

Smart Operating Techniques

How you operate your machine makes a massive difference in fuel consumption. For example, a machine can run efficiently or wastefully depending on your operating technique.

Engine Speed Management

One of the biggest mistakes operators make is running the engine at full throttle all the time. Modern excavators don’t need to run at full revs to deliver maximum power. In fact, operating at about 80% of maximum engine speed often provides the best balance of power and fuel efficiency.

Advanced Operating Techniques for Fuel Efficiency

Smart Excavation Patterns

When you’re digging with your excavator, whether it’s a 3-tonne unit or a larger machine, your digging pattern makes a huge difference. You want smooth, efficient movements rather than jabbing at it randomly. Work in sections and plan your movements to minimise swing angles. A good operator can reduce fuel consumption by up to 20% just by using efficient digging patterns. Excavator training can help you identify work patterns that improve your throughput and increase efficiency.

Idle Time Management

Many excavators spend about 40% of their time idling! That’s like leaving your car running while you’re having a cuppa. Modern machines have auto-idle features, but if yours doesn’t, make it a habit to reduce idle time. Even 10 minutes less idling per hour can save you several litres of fuel per day.

Load Management and Machine Position

The position of your machine relative to the work area is crucial. For example, when loading trucks, position your excavator so you’re swinging no more than 90 degrees. Every extra degree of swing wastes fuel and eats into your cycle time. Also, match your bucket load to the machine’s capacity—overloading strains the engine and wastes fuel, while underloading means more trips and more fuel used.

Terrain and Weather Considerations

Working on Different Surfaces

The ground you’re working on affects fuel consumption significantly. Soft or muddy ground can increase fuel consumption by up to 30%. When possible:

• Use ground protection mats in soft conditions
• Keep working platforms level and well-maintained
• Plan your route to avoid unnecessary travel over difficult terrain

Weather Impact on Machinery Fuel Consumption

The weather in New Zealand can be quite unpredictable, and it plays a significant role in how much fuel your excavator consumes. From the frosty mornings in Christchurch to the boggy clay conditions in Auckland, each weather pattern affects your machine’s performance differently.

Cold Weather Operations

When the temperature drops, your machine requires more attention and fuel. Cold weather increases fuel consumption for several reasons. Firstly, diesel fuel becomes thicker in cold temperatures, making it harder for the engine to atomise and burn efficiently. Secondly, hydraulic oil becomes more viscous, like honey in the fridge, requiring more energy to pump through the system.

Proper Warm-Up Procedures

Starting your machine in cold weather requires a careful balance. You’ll need to allow enough warm-up time for the engine and hydraulic systems to reach optimal operating temperature, but excessive idling wastes fuel. A good rule of thumb is to run the engine at low idle for about 5 minutes, then conduct your walk-around inspection while the machine warms up. This gives the oil time to circulate and warm up properly without wasting excessive fuel.

Oil Selection and Management

Using the right oil for cold conditions is crucial. Consider switching to a lower viscosity hydraulic oil during winter months—this is like using a thinner oil that flows more easily when cold. Many manufacturers recommend specific winter-grade oils that maintain proper flow characteristics in cold weather while still providing adequate protection. This can significantly reduce the strain on your machine during startup and early operation.

Machine Storage Solutions

Where you park your machine overnight can make a big difference. When possible, store your excavator in a covered area or under a machinery shelter. This protects it from the worst of the overnight cold and morning frost. If indoor storage isn’t available, consider using thermal blankets on critical components or parking against a windbreak to reduce heat loss. Some operators in particularly cold regions even use engine block heaters, which can significantly reduce warm-up time and fuel consumption during cold starts.

Weather Planning

Keep an eye on weather forecasts and plan your work accordingly. If you know a cold snap is coming, take preventive measures. This might include scheduling more demanding tasks during warmer parts of the day and lighter tasks during colder periods. This approach not only saves fuel but also reduces wear and tear on your machine.

Technology and Monitoring

Using Machine Technology

Modern excavators come with various fuel-saving technologies. For instance, many Hyundai excavators have multiple power modes. Use these wisely:

• Economy mode for light work and finishing
• Standard mode for general excavation
• Power mode only when necessary for heavy digging

Fuel Monitoring Systems

Keep track of your fuel consumption. Many modern machines show fuel consumption per hour. If your 8-tonne excavator suddenly starts using more fuel than its usual 8-10 litres per hour, it’s a sign something needs attention.

Training and Operator Skills

A skilled operator is your best tool for fuel efficiency. Proper excavator training can reduce fuel consumption by up to 25%. Focus on:

• Smooth operation techniques
• Proper use of machine features
• Understanding machine feedback
• Regular performance reviews

Long-term Planning and Maintenance

Preventive Maintenance Schedule

Develop a proper maintenance schedule. Regular maintenance might seem expensive, but it’s cheaper than running an inefficient machine or facing breakdowns. Keep detailed records of:

• Service intervals
• Fuel consumption trends
• Component replacement dates
• Performance issues

Remember, mate, reducing fuel consumption isn’t about working slower—it’s about working smarter. By implementing these strategies, you can significantly reduce your fuel costs while maintaining or even improving your productivity. The key is consistency and making these practices part of your daily routine.

Keep in mind that every machine is different. What works for one excavator might need adjustment for another. The important thing is to understand your machine and apply these principles in a way that works best for your situation.