37 minute read
5 BASICS OF AIR COMPRESSOR MAINTENANCE
Air compressor service could be the difference between a successful application or a costly breakdown.
As with any piece of equipment, a strong maintenance program for air compressors will ensure a longer life and optimal performance. Not only that, but properly caring for them will maximize the time they’re available to use on your jobsite.
“Proper maintenance extends equipment life, reduces unexpected breakdowns and improves resale value,” says Bryan McCarron, Mi-T-M Air Compressor Division manager. “Good running equipment provides the customer a good experience.”
Fortunately, these worksite staples don’t require a lot of expensive upkeep or time-consuming fixes. However, because of that, it can be easy to forget or neglect them, which makes for a costly oversight.
To help keep air compressors up and running over the long run, here are some top maintenance tips from suppliers.
TIP #1: READ THE OWNER’S MANUAL
important. Air compressors differ significantly from model to model, so checking the manual first will make sure
you’re maintaining it properly for that distinct model’s specifications and factory maintenance intervals.
The manual will detail simple tips that will help you get a longer life out of your compressor and will highlight important steps that you might not have known about otherwise. It will also point out specific time intervals during which maintenance items need to take place in order to avoid costly equipment failures or breakdowns. While some may think they’re smarter than the manual, it’s safe to say that your equipment’s future will be better off if you take the time to read it.
ABOVE: Kaeser Compressors offers an auxiliary diagnostic tool that allows the user to view additional information, which can be helpful in evaluating higher level messages from the equipment prior to contacting the local service provider for support. LEFT: To ensure proper maintenance of the compressor, units should be inspected daily for fuel level, oil level and battery voltage.
TIP #2: DAILY PRE-CHECKS
Checking your equipment every day will help you avoid costly equipment failures. It’s important to thoroughly check equipment for any damage that might have occurred during prior use.
When it comes to daily prechecks, check hoses for kinks, inspect electrical wiring for cuts and fraying, examine tubing and piping for damage and make sure connections are tight. Then, look over controls, gauges, accessories and instruments, making certain there are no loose mountings or damage.
Before use, run through the list of basic maintenance checks to ensure the unit is functional. “These preventative maintenance checks only take a few minutes, but they can add months or years to the service life of a machine,” says Dan Leiss, president, Jenny Products.
TIP #3: CHECK OIL LEVELS
Like your car, many air compressor models feature oil and either a dipstick or an indicator (like a sight gauge) to monitor its levels. According to Tehran Browne, product engineer, Mobilair, Kaeser Compressors, compressor oil is extremely important to the function of the compressor.
“Compressor oil lubricates the rotors, seals the rotors to prevent air leakage and removes heat from the air. One underrated quality of compressor oil is that oil is also responsible for cleaning the air of dust and particulates that make it past the air filter,” Browne explains.
Compressor oil should be checked daily prior to operation in order to ensure it is topped off and clean. You should be changing the oil completely if it’s contaminated, or on an annual basis to ensure maximum functioning. Regardless, it’s critical to use the compressor oil specified in the service manual.
“Compressors are designed with a specific type of oil in mind in regards to heat absorption, and incorrect compressor oil can lead to overheating or
Kaeser Compressors
potential damage to the compressor rotors,” says Browne.
It’s also important to use lubricants with the correct viscosity. A high lubricant viscosity might prevent the compressor from coming up to speed fast enough or at all.
High oil consumption indicates a potential problem. “This could be caused by a light duty cycle; damaged piston rings or excessive end gap; or a plugged oil crankcase vent,” Leiss notes. “If the compressor becomes excessively hot, check the inlet filter and discharge line filter for dirt and ensure the lubricant level and type are correct.”
TIP #4: INSPECT FILTERS
The air around a construction site contains millions of particles of dirt, dust and other contaminants. These pollutants can become a problem for air compressors, causing valve malfunctions, obstructing lines or inflicting unnecessary wear and tear.
A dirty air filter ultimately hurts the compressor and forces it to work harder than it needs to, decreasing energy efficiency. Therefore, it’s imperative to inspect, monitor and change air filters. They should be checked for excessive grime buildup each week, with filters changed per manufacturer recommendations. This can be every six weeks or 1,000 to 2,000 operating hours, depending on the model.
The environment will also play a factor in filter changes. Depending on the climate, air filters may need to be changed at higher frequency than what’s listed in the maintenance schedule. In high-moisture or humid conditions, service might be required more often.
In addition to checking the engine oil, coolant and fuel levels, Browne advises checking air inlet filters and the fuel water separator. A clogged air inlet filter can lower efficiency and increase operating temperatures. If the filter is lightly contaminated, you can blow it off. If it’s deeply contaminated or hasn’t been changed in the last year, replace it.
The fuel water separator and fuel filters ensure clean fuel is delivered to the engine. If fuel has too much water, it can wear off the lubricants on the fuel injectors. Contaminants can cause wear and tear on the engine and compressor components. Thus, making sure the compressor has the cleanest fuel possible will keep it running the most efficiently and will prevent unnecessary engine and compressor failures.
Jenny Products
Before use, run through the list of basic maintenance checks to ensure the unit is functional. Such checks only take a few minutes, but can add months or years to the service life of a machine.
TIP #5: DRAIN MOISTURE FROM THE TANK
Air compressors have a receiver tank, which is responsible for collecting the moisture from the air that accumulates while the compressor is in use. Most tanks have a valve or two for draining this moisture, and your maintenance program should include draining them every day.
“At the end of each day, if not more frequently, drain condensation from the air tanks,” says Leiss. “Begin by disconnecting the power source. If the unit is portable, move it into an inclined position with the drain at the lowest point. Slowly open the drain and bleed the air from the tank(s). When the pressure drops to 10 psi, the valves can As a quick check, remove the oil fill plug and check the level, then insert a screwdriver into the crankcase. Inspect the oil on the screwdriver for signs of contaminants, such as water and dirt, and change the oil if contamination is found.
be fully opened and the tank(s) drained. The condensate may contain oil, so it should be collected and disposed of properly.”
The key to this step is to slowly open the compressor’s release valve(s). Opening them carefully helps to prevent scale, rust or debris from being expelled at a high rate of speed.
DESIGNED FOR EASE OF SERVICE
Serviceability is an important factor for any equipment. Manufacturers like Sullair are working to make that easier for air compressors.
“Some portable air compressors, like the Sullair 375, now include access (doors) on all four sides of the compressor. This allows a technician ample space to work on the machine and quickly and easily access every component,” says Navendu (Nav) Sharma, director of product management.
Certain compressor models feature electronic controllers that alert users when maintenance is needed. For example, all 185-cfm and largADDITIONAL SERVICE TIPS er Kaeser Mobilair Other important maintenance items include: compressors come equipped ˜ Inspect the belt guard and ensure proper belt tensioning. with electronic ˜ Listen for unusual noises or vibrations. controllers that ˜ Tighten all fasteners and bolts. provide the user ˜ Check hoses regularly and watch for leaks. with fault mes- ˜ Test the safety shutdown system. sages and service ˜ Clean the fuel tank. interval reminders ˜ Clean the heat exchangers. for each mainte- ˜ Check vibration pads. nance item (oil, ˜ Check operation of system controls. filters, etc.). The ˜ Test release valves. controller will also display battery voltage and fuel level. Make sure to check the compressor’s electronic controller for any service-related warnings and address them as needed before use. Also, make sure you’re maintaining appropriate battery voltage. Low voltage can lead to unexpected errors on an electronic controller. It can also prevent the compressor from starting. According to Sharma, Sullair compressors include a battery disconnect to help ensure that battery drain does not occur when the machine is in between jobs or not in use. With newer technologies and smartphones now more prevalent on jobsites, some companies have turned to QR codes to help with maintenance. For example, Mi-T-M places a QR code on each compressor, which will direct the user to the owner’s manual for easier reference for any service and maintenance questions. ET
SIX QUESTIONS
Doing due diligence and information gathering can ensure you are properly sizing the generator to the application.
to Correctly Size a Generator
The answers to these simple questions can ensure you have the right generator for your jobsite.
Correctly sizing a generator is vital to ensuring optimal power for your project. You want to make sure you have enough power, but not so much that there will be issues with light loading, inconvenient regens or lockouts.
Following are six simple questions to help ensure the generator you select is right for the application.
1. Will the load be singlephase (1Ø) or three-phase (3Ø)?
This is one of the most important items to know before starting. Understanding what phase the generator needs to be placed in will address what voltage requirements are needed to properly operate on-site equipment.
2. What is the voltage required: 120/240, 120/208 or 277/480?
Once the phase requirements have been met, then you can set and lock the appropriate voltage per the generator’s selector switch. This presents an opportunity to fine-tune the generator to the voltage for proper operation of the equipment. There is a minor voltage adjustment knob (potentiometer) conveniently located on the face of the control unit to do any minor voltage modifications once the unit is on site.
3. Do you know how many amps are required?
By knowing what amps are required to run the piece of equipment, you can properly utilize the correct generator size for the job. Having this information can be vital to the success or failure of the application.
Too big a generator for the appropriate load and you will under utilize the generator’s potential and cause engine issues such as light loading or wet stacking. Too small a generator and the equipment may not run at all.
4. What is the item you are trying to run (motor or pump, its horsepower, etc.)?
In all cases, when sizing a generator to a particular application, assessing what will be operated is extremely helpful. Identify what type of equipment you will be running at the location and build a “load profile” based on this information.
For example, will you be using submersible pumps to move liquid products? Then, knowing the horsepower and/or the NEMA code of the pump is critical in choosing the properly sized generator for the task.
5. Is the application standby, prime or continuous?
One of the key components of sizing is the run time. The buildup of heat in a generator’s windings can cause a de-rate in ability. Both altitude and run times can have a dramatic affect on the generator’s performance.
In the simplest of terms, consider that mobile diesel generators are rated in prime power, operating for eight hours per day in a typical application. The longer the run times at higher loads, the more harm can occur to the generator’s windings. The reverse is also true. Long run times with zero loads can hurt the generator’s engine.
6. Will multiple items be run at the same time?
Knowing what types of loads will be running simultaneously is also a determining factor when sizing a generator. The use of multiple voltages on the same unit can create a difference in performance.
For example, if you plan to use a single generator for an application, what types of tools will need to be powered by it at the same time, including lighting, pumps, grinders, saws, etc.? If the primary voltage being used is three-phase, then only the convenience outlets are available for minor single-phase voltage output. Conversely, if the unit’s main output needs to be singlephase, then three-phase power will not be available.
Answering these questions before acquiring a generator can greatly increase on-site productivity. By doing due diligence and information gathering, you can ensure that you are getting the properly sized generator for your application.
Joseph Norris is national service manager for ANA Inc.
HELPFUL SIZING FORMULAS
Converting three-phase rating to single-phase rating for generator output 3Ø three-phase kVA x .58 = 1Ø single-phase kW (+/- 5%) 3Ø three-phase kW x .72 = 1Ø single-phase kW (+/- 5%)
Single-phase 1Ø Formulas kW = (volts x amps x Power Factor) ÷ 1,000 kVA = (volts x amps) ÷ 1,000
Amps = (kW x 1,000) ÷ (volts x Power Factor); use if kW is known
Amps = (kVA x 1,000) ÷ volts; use if kVA is known
Three-phase 3Ø Formulas kW = (1.732 x volts x amps x Power Factor) ÷ 1,000 kVA = (1.732 x volts x amps) ÷ 1,000
Amps = (kW x 1,000) ÷ (1.732 x volts x Power Factor); use if kW is known
Amps = (kVA x 1,000) ÷ (1,732 x volts); use if kVA is known
Generac MDG25 Generator
The MDG25 diesel generator provides three-phase 25-kVA prime power in a compact cabinet that is easy to maneuver and tow.
•Isuzu Tier 4 Final diesel engine requires no diesel exhaust fluid or DPF •56-gal. fuel capacity with 28-hour run time •Weighs under 3,000 lbs. to allow for easy towing with no trailer brakes required •Easy to use Deep Sea DSE7310 MKII controller provides full programmability and status screens •Rugged steel body design with 67-dBA sound rating •Optional 100% fluid containment www.ForConstructionPros.com/21123041
Mi-T-M AR1-PK37-M Compressor
The AR1-PK37-M rotary screw, singlestage air compressor produces 115 cfm at 100 psi.
•Compressor pump includes an integrated air/oil separator, integrated thermostatic bypass valve, banded four V-belt drive system, easy to read oil level indicator and high oil temperature shutdown •Electric-start gasoline engine comes with low oil level shutdown and a 10 1/2-gal. fuel tank for extended run time •Powder-coated steel frame with 1 1/4-in. roll cage, handle, four-point lifting hook, winch point and tie-down anchors •15-in. pneumatic tires www.ForConstructionPros.com/12182624
VMAC Stacked G30 Air Compressor
The stacked G30 rotary screw gas-driven air compressor produces 30 cfm at 100% duty cycle and features a 30-gal. air receiver tank, yet weighs under 210 lbs.
•Footprint of just 2.5 sq. ft. at 38 in. tall, 20.5 in. wide and 18.15 in. deep including the belt guard •Fits neatly into the existing rear compartment of most service trucks or in the bed of a pickup truck •Honda GX390 air-cooled, four-stroke OHV engine is EPA and CARB compliant and includes a 1.6-gal. fuel tank www.ForConstructionPros.com/21110946
Cummins C12D6RE Mobile Generator Set
The 12-kW C12D6RE is powered by a Tier 4 Final-certified, four-cycle, liquidcooled diesel engine and can operate reliably across extreme temperatures, heavy airborne dust and highly humid conditions ranging from -20° to 120° F.
•Enclosure incorporates weatherproof sound attenuation •Sound-controlled housing covers the cooling system and muffler, further simplifying the installation process •Features a rugged, robust design and heavy-duty trailer •Built-in self-diagnostic capabilities simplify troubleshooting www.ForConstructionPros.com/21122995
Makinex SKU: GEN-23-US-480 Three-phase Generator
The SKU: GEN-23-US-480 23-kW 480V threephase generator features permanent magnet brushless alternator technology with completely independent circuits for 120V and 480V.
•Can run single-phase and three-phase equipment simultaneously •Weighs 410 lbs., fits through doorways and can safely be taken in internal/external elevators •50A, 30A and 20A outlets standard •Provides 10 hours of run time at 50% www.ForConstructionPros.com/21114611
Caterpillar XQ230 Mobile Diesel Generator Set
The 60-Hz XQ230 is a Tier 4 Final mobile diesel generator set rated at 182 kW and equipped with heaters, a battery charger and a permanent magnet generator (PMG).
•Optional 600V generator available •Able to produce power at 600V, 480V, 240V and 208V •Standard EMCP 4.2B control panel •Automatic paralleling controls available with optional EMCP 4.4 •Cat Connect technology available to monitor machine remotely www.ForConstructionPros.com/21061213
Allmand Maxi-Air Compressors
The MA100, MA375-DP and MA400 portable compressors have a heavy-duty, oversized rotary screw airend designed to run at lower rpm for longer life and improved fuel efficiency.
•Developed for ease of use and easy starting •Tier 4 Final engines •Deliver powerful airflow from 100 to 400 cfm in all climate conditions •MA375-DP and MA400 designed to meet high-pressure application demands with the MA375-DP featuring a flexible dual pressure design www.ForConstructionPros.com/21047378
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The RS generator range includes five Tier 4 Final-compliant models delivering prime power output of 56 to 500 kW (70 to 625 kVA).
•Designed to be towed with operating weights from 7,239 to 25,209 lbs. •Easy to access controls with automatic mains failure (AMF) and synchronizing capability, with touchscreen controls on larger models •Automatic voltage regulator adjustment can be made from the front of the control panel •Standard JCB LiveLink advanced telematics www.ForConstructionPros.com/21123054
Doosan Evolution Series Air Compressors
The Evolution Series includes four models equipped with the latest Doosan Tier 4 Final engines and an upgraded fuel system designed for reliable operation in dusty environments.
•Three models (including two in the 185cfm class) offer FlexAir technology for electronically adjusting air pressure to a wide psi range via the control panel •XP185-VHP165WDO-T4F can provide 200 psi at 165 cfm or up to 185 cfm and from 100 to 200 psi, plus an optional 4-kW onboard generator can charge handheld electric tool battery packs www.ForConstructionPros.com/21497080
Atlas Copco QAS 150 and QAS 200 Generators
The QAS 150 offers a power rating of 150 kVA/120 kW of prime power and the QAS 200 delivers 200 kVA/160 kW.
•Dual frequency capable and powered by a John Deere 6068 Tier 4 Final engine •AREP alternator excitation system offers quick and easy motor starting capabilities •335-gal. fuel tank allows for extended run times at 100% load •Standard variable-speed fan, voltage switch for switching to a new voltage within seconds and environmentally friendly spillage-free frame •Available in skid-mount or trailermounted configuration www.ForConstructionPros.com/21197307
Kaeser Mobilair M118 Portable Compressor
The Mobilair M118 portable compressor delivers up to 405 cfm at 100 psig.
•Standard power-saving Sigma Profile rotary screw airend •Heavy-duty Deutz four-cylinder, Tier 4 Final diesel engine •Onboard Sigma Control Mobil controller enables variable pressure ranges between 87 and 145 psig •Fully weatherproofed polyethylene canopy protects internal components •Includes wide-opening gullwing doors, a steel chassis, torsion bar suspension and oversized tires •High-capacity cold start battery www.ForConstructionPros.com/21138339
BOSS MechanX 150 Gas Compressor/ Generator/Welder
The 400-lb. MechanX 150 portable compressor/generator/welder comes standard with a 14-hp Kohler four-cycle, OHV gasoline engine with electric start capabilities and automatic engine idle.
•Heavy-duty, single-stage, cast iron, twincylinder compressor delivers up to 13.1 cfm (17.9 cfm displaced) at 100 psi •Welder features an auto resettable thermal overload breaker and provides 150 amps at 100%, 180 amps at 65% and 210 amps at 10% •Generator provides 4.0-kW AC continuous output •10-, 22- or 28-gal. remote air tank www.ForConstructionPros.com/21124183
Sullair Mid-Range Series Air Compressors
The Mid-Range Series Tier 4 Final portable lubricated rotary screw air compressors incorporate electronic spiral valve technology, which matches air supply to demand.
•Choice of a Caterpillar 7.1L or Perkins 1206J Tier 4 Final engine •Features include a 23-Series variable capacity airend, 7-in. Sullair Touch Screen (STS) and multiple service doors with push-to-close latches •800HH/900H model delivers 800 to 900 cfm at 150 to 200 psi and the 920H/1100 model delivers 920 to 1,100 cfm at 100 to 150 psi •Optional Airlinx for telematics and remote monitoring capabilities www.ForConstructionPros.com/21283152
TOP OF THE LINE COUPLING COMPONENTS
SINCE 1924
The 49.7-lb. MX FUEL CARRY-ON 3600W/1800W Power Supply provides 3,600 peak watts and 1,800 running watts of pure sine wave energy to power everything from high-demand 15A tools to sensitive electronics.
•Compact size, zero emissions and quiet operation allow use in confined indoor spaces, while roll cage provides durability for outdoor use •Push-button start •Can be powered by a single battery or two batteries for double the run time •Kit includes the power supply, MX FUEL REDLITHIUM XC406 Battery Packs and a detachable charger cord •Offers ONE-KEY compatibility www.ForConstructionPros.com/21206838
The 400-cfm AIRMAN PDS400SC-6E1 air compressor has a built-in aftercooler that cools the discharge air through a radiator and removes 70% of the water and oil from it.
•Standard powder-coat paint, stainless steel hardware, corrosion-proof air intakes and an antiwater intrusion door seal keep water and debris out and noise in •Curbside service and maintenance with convenient external fluid drains provide ease of service and safe operation www.ForConstructionPros.com/21203803
Miller Electric EnPak A60
The redesigned EnPak A60 power system features Advanced Auto-Speed technology, which automatically adjusts engine speed to match compressed air, battery charge and weld demands.
•Integrated multi-process welding provides up to 325 amps at 100% duty cycle •Available integrated hydraulic pump offers up to 16-gpm hydraulic output •Rotary screw air compressor offers 60 cfm of uninterrupted airflow •Provides up to 150 amps of DC power for 12/24-volt battery charging and up to 300 amps for crank assist •7,500-watt generator delivers continuous 120/240-volt, 60-Hz power www.ForConstructionPros.com/21563121
Sullivan-Palatek D900HAF Portable Air Compressor
The D900HAF is powered by a 300hp Cat C7.1 Tier 4 Final engine that delivers high power density suited for applications requiring powerful yet compact solutions.
•Electronic Control System enables users to dial in the exact pressure for precise, fuel-efficient operation •Large access doors for easy service •Rugged galvanneal enclosure designed to withstand harsh environments •Smaller size and relatively light weight enable loading onto a truck without the need for a high-capacity crane or forklift www.ForConstructionPros.com/21200979
Curb Roller Hydra-Pack HP1300
The Hydra-Pack HP1300 portable heavyduty hydraulic power unit has a 13-hp Honda GX390 engine and a 5- to 8-gpm hydraulic flow, providing the power to operate the Curb Roller CM4000 and Hydra-Screed HS3000 systems.
•Can also be used to power hydraulic hand tools or equipment for extended periods •Delivers two-way directional flow with up to 2,250 psi •11-gal., 12-gauge steel reservoir for hydraulic fluid and cooling capacity •13-in. puncture-proof, flat-free tires •Compact enough to fit in the back of a pickup or job trailer www.ForConstructionPros.com/21710620
Jenny Skid-mounted Air Compressors
Four models of skid-mounted air compressors are offered with single- and two-stage pumps and are powered by Honda GX-Series engines.
•30-gal. ASME-certified air tanks •Single-stage models provide 16.4 to 21.3 cfm at 100 psi or 16 to 20.9 cfm at 125 psi, while two-stage models provide 21 to 41 cfm at 100 psi or 17.6 to 34.7 cfm at 175 psi •Heavy-duty cast iron compressor pumps with large flywheels and directional air shrouds •“Ultimate Blue” synthetic pump oil with splash lubrication system www.ForConstructionPros.com/10565671
Chicago Pneumatic CPG 150 and CPG 200 Generators
The CPG 150 and CPG 200 offer dual frequency capabilities and are powered by a John Deere 6068 Tier 4 Final engine.
•CPG 150 has a rated prime power of 150 kVA/120 kW and the CPG 200 is rated at 200 kVA/160 kW •AREP alternator excitation system •Internal 335-gal. polyethylene fuel tank •Deep Sea 7310 controller with a 3-in. display •Powder-coated steel, weatherproof, corrosion-resistant enclosure •Standard dual axle trailer or optional skid-mounted unit www.ForConstructionPros.com/21259896
Vanair Aluminum Reliant RC40-L and RS85
The aluminum canopy and airend reduce the weight of the Reliant RC40-L onboard air compressor by 40% and the Reliant RS85 by 30% over the standard model.
•Rust-resistant, durable RC40-L offers 40 cfm of air power with hydraulic cooling assist for additional hydraulic systems •Include a relocatable instrument panel for mounting flexibility on and off the vehicle and reversible hinged hood for flexible positioning •Easy to read display panel available as a standard mechanical gauge or optional telematics-capable LED electronic panel provides maintenance, over-pressure and over-temperature alerts www.ForConstructionPros.com/21123087 Learn more online at: go.ThunderCreek.com/et1021 Call us at: 866.535.7667
Easy Financing: $1,500 down payment based on our jobsite ready, 690-gallon Multi-Tank Trailer and patented 100-gallon, 2-in-1 DEF system. Subject to approval. Offer valid until Dec. 31, 2021.
As manufacturers prioritize production of high profit margin consumer trucks and SUVs, commercial trucks struggle to keep up with demand due to continued microchip and component shortages.
WORK TRUCK SHORTAGES LIKELY TO LINGER
Supply chain challenges continue to restrict truck availability, so decide what you need for 2022 and act now.
When it comes to work trucks, there is not much inventory left on dealer lots.
Lead times for new truck purchases have increased and there are often no guarantees of when the truck will actually arrive.
If you are struggling to find new work vehicles, you are not alone. There is currently limited availability coupled with elevated prices.
It’s no secret that supply chain shortages, most notably microchips, have rippled through the automotive industry, emptying inventory on dealer lots and creating long lead times for new vehicle orders. This has created a perfect storm as demand continues to rise and inventories are near all-time lows. For commercial customers, the problem has been compounded as manufacturers place an emphasis on directing the available resources to higher-profit vehicles, making work trucks of all sizes even more difficult to source.
Major commercial truck dealerships are feeling the pinch. “In-stock trucks are very hard to find,” says Ray Pannemann, Ford Truck Sales Manager, Badger Truck & Auto Group. “Inventories are at alltime lows. Fleet work trucks can be up to 10-month lead times.” Product availability has become unpredictable. “Any estimates regarding lead times would be considered unreliable information.”
As the supply chain continues to recover, we may have already seen the worst of the shortage. “Availability has made a slight improvement,” says Pannemann. But don’t expect major improvements for a while. “As far as when we will see availability improve, it will take at least a year.”
Anticipating future needs and putting a plan in action to proactively acquire trucks is a strategy that can help ensure you don’t get caught short. “Planning is very important,” says Pannemann. “Anticipate your needs and make purchase decisions far in advance of the need. Inventory can, and is, running out.” USED TRUCK VALUES SKYROCKET
Don’t count on a supply of used trucks to solve the supply issue. The net result of the new truck shortage is that used truck valuations have risen dramatically.
“The value of used trucks has experienced a significant increase,” says Pannemann. “With the shortage of new inventory, a rise in interest to purchase a used truck becomes an alternative. All of this is driven by the need for the services the trucks are used to accomplish.”
According to ACT research, on a year-over-year basis from June 2020 to June 2021, the average value of a used Class 8 truck is 68% higher, with average miles and age lower by 5% and 2%, respectively.
“For the first time since we started following the used truck market almost 20 years ago, the average price of three-year-old trucks with 300,000 to 400,000 miles on them broke the sixfigure barrier,” says Steve Tam, vice president at ACT Research. “The feat is made even more impressive when one considers prices for these late-model trucks started the year at just over $70,000.
“Arguably, the trucks did not change to justify the increase in price,” he continues. “Rather, the simple law of supply and demand has created a scarcity situation, and there is no viable substitute to the venerable Class 8 truck. Hence, prices are through the roof with no relief in sight.” HOW DID WE GET HERE
You may be wondering how the ongoing inventory crisis happened in the first place. The slowdowns at the component manufacturing plants due to the COVID-19 pandemic were, of course, the main reason. But there are several contributing factors, including worldwide outsourcing of key components, the just-in-time supply of components and a fire in one of the largest vendor plants.
Over the years, vehicles have become much more sophisticated with advanced electrical systems that increase safety, productivity and comfort. The microchip has become a basic building block for these electronic systems. Key components of these microchips are the semiconductors. There are literally millions of semiconductors used on each microchip, depending upon the complexity of the task. The semiconductors utilized in microchip production have become in short supply due to production disruptions during the pandemic, a disaster and increased demand.
It is important to point out that the United States currently only produces around 12% of the world’s supply of semiconductors. This creates a foreign dependency that is difficult to address. While there have been proposals to increase U.S. production of these components, the reality is that this is a longterm strategy that will have no impact on the current situation. The raw materials for the semiconductor business often come from Japan and Mexico, with many of the chips made in Taiwan and China, according to a report by the BBC.
The semiconductor manufacturing rate was reduced during the pandemic due to COVID restrictions. Couple this with just-in-time manufacturing practices and the fact that Renesas, a Japanese semiconductor manufacturer that supplies almost 30% of the chips for the auto industry, experienced a fire in mid-March, and you have a perfect storm. While production has been restored and the semiconductor industry has ramped back up, it will take a while for the supply chain to fully recover. Auto customers are likely to feel the impacts until at least the second quarter of 2022.
Curt Bennink
OEMS CONTINUE TO FACE UNCERTAINTY
The current supply chain issues are creating pricing and supply uncertainty on critical components for the truck manufacturers as ordering for 2022 progresses. Don Ake, vice president of commercial vehicles
A shortage of Class 8 trucks has pushed the value of used trucks to record levels.
for FTR, explains, “July ordering was similar to June in that OEMs took a limited number of orders for delivery in 2022.
Fleets need a significant number of new trucks right now and they perceive this need will continue throughout next year. However, OEMs are having difficulty establishing reasonable 2022 pricing, with commodity and other costs elevated. It is uncertain if current higher production costs are transitory or will persist into 2022.
“Also complicating the situation is that shortages of semiconductors have limited Class 8 production,” Ake continues. “It is estimated that supply of trucks is falling approximately 25% behind market demand. We are running out of time for OEMs to catch up. Most of the unproduced orders will roll into the first quarter of 2022. If those months are already booked solid, it creates even more headaches for the industry. Things won’t approach any degree of normalcy for months. Until semiconductors begin flowing into the OEMs in sufficient quantities, we will be playing catch up.”
— Ray Pannemann, Badger Truck & Auto Group
The industry forecast of new orders of Class 8 trucks is expect to remain robust. “U.S. and Canada Class 8 industry retail sales are estimated to be in a range of 260,000 to 280,000 vehicles,” says R. Preston Feight, CEO, PACCAR. “As has been discussed in recent months, industry truck production has been tempered by the undersupply of semiconductor chips. Kenworth, Peterbilt and DAF had a good [second] quarter and delivered 40,100 trucks with an additional 6,500 awaiting key components.
“While it’s very dynamic, we currently anticipate supplier constraints improving toward the end of this year,” he states. “There was a lot of uncertainty around the supply base and the deliveries in the third quarter and beyond. Alot of that will depend on the ability of the supply base to deliver, especially in the semiconductor area.”
Short-term availability of trucks is sold out and availability of microchips is anyone’s guess. “We have excellent demand... We’re sold out through the year in all our markets,” says Feight. “So, with this great demand, great market — need for trucks around the world really — customers are looking for trucks as quickly as they can get them. And we’re building them as quick as we can get [the components].
“We had a good second quarter in our deliveries at 40,000. Obviously, you can do the math; there’s several thousand sitting there that are waiting for a component. And as we get the components, which is unclear on the semiconductor front, we complete the trucks and get them to our customers,” he continues. “We wish we could give you more clarity on how that semiconductor supply is going to proceed through the third and fourth quarters, but we just don’t have any more than that right now.”
Dealer inventories are limited, which will extend the market, as well. “We have about 1.6 months of inventory at the dealers. And I think the industry is 1.9 or 2,” says Feight. “It’s less than we’d like it to be, of course, but that does bode well for a strong extended demand cycle.”
Many manufacturers have mostly completed trucks waiting around for missing components. “We’ve had some trucks that we built minus components and we received a batch of components for those and have shipped those out only to find ourselves in different circumstances, like the Malaysia COVID outbreak, which then causes a constraint of a different component,” notes Feight. It’s a very dynamic situation.
DEMAND KEEPS ADDING PRESSURE
As a result of high demand and component shortages, manufacturers have been forced to make strategic product decisions. Some have idled factories and stopped making select vehicles in order to allocate chips to in-demand and highly profitable vehicles such as pickups and SUVs.
To keep plants running, Ford and General Motors both resorted to building vehicles without chips and parking them until the parts arrive. In order to conserve the limited availability of microchips, manufacturers have also taken to de-contenting vehicles. Some premium features are temporarily unavailable.
Adding pressure to a seller’s market, auto sales have mostly recovered to pre-pandemic levels. Overall U.S. vehicle sales came in at 8.3 million units in the first half of 2021. This is just 95,000 shy of the same period in 2019 before the pandemic, according to J.D. Power. The data shows that 14% of the vehicles were sold to fleet customers compared to 22% in 2019.
Major manufacturers are all reporting a recovery in vehicle sales during the second quarter. For instance, General Motors announced it sold 688,236 vehicles in the U.S. in the second quarter of 2021 — an increase of 40% compared to a year ago — in a unique market that has seen strong demand, but has been constrained by low inventories resulting from the global semiconductor shortage. Chevrolet Silverado and GMC Sierra pickup sales are up a combined 36%.
General Motors expects strong demand to continue coupled with very tight inventories. “The agility and creativity of our supply chain, purchasing, engineering and manufacturing teams, in collaboration with our suppliers and dealers, have helped us continue to satisfy customers and gain market share in some of the highest demand segments of the market,” says Kurt McNeil, U.S. vice president, sales operations. “Although the situation remains fluid, we’re focused on continuing to leverage every available semiconductor to build and ship our highest demand products.”
Given the current supply and demand forecasts, it is safe to assume that the vehicle shortage will continue to be acute in the work truck segment well into 2022. If you will be needing to add trucks to your fleet, procrastination is not a viable strategy. You will have to be proactive and order well in advance. In certain situations, you may need to get creative about alternative ways to source your work truck fleet until some form of normalcy returns. This may include a strategy to extend the life of your existing trucks. ET
A MASTER PLAN for Technologyenabled Earthmoving Efficiency
Rummel Construction is a Scottsdale, AZ-based construction company that specializes in mass earthmoving, relying on skilled operators and advanced technology to deliver smooth surfaces to specifications. It’s a mindset that would come in particularly handy on a recent project.
In support of an almost 3,500-acre master planned community project, the company was contracted to excavate 659,000 cu. yds. of material and finish 773,000 sq. yds. Shaun Tindell, GPS manager at Rummel, says, “Nearly every type of our technology-enabled equipment — from GNSS rovers to machine-controlled graders to drone mapping systems — was used on this site development.”
Specifically, the crews relied on the Trimble SPS986 GNSS Smart Antenna as a rover system to complete site layout, verify survey and check grade. Then, the company’s motor graders, dozers and scrapers — nearly all of which were outfitted with the Trimble Earthworks grade control platform or the GCS900 3D grade control system — went to work excavating and finishing surfaces, while a drone above helped track the material quantities.
“Grade control in particular really pays off when balancing material ahead of finished grading on a project this size. It’s a one-and-done process that leaves a beautiful, finished product that is exactly to spec,” says Tindell.
This is just one of many projects that have benefited from Rummel’s technology-forward approach to projects, a quest that began about 16 years ago. TECHNOLOGY EVOLUTION
The economic downturn in 2007 hustled Rummel into a strategic shift. “When residential work dissipated, we moved to more commercial and mining work, and then to heavy civil and highway work. That move really facilitated our interest and investment in technology,” says Tindell.
With help from SITECH Southwest, Rummel was introduced to Trimble’s machine control family of products.
“We tried the GCS900 3D grade control system on a rental dozer and motor grader on a roadway slope repair project in Page, AZ,” Tindell notes. “Our operators said that it was pretty user friendly, and by the time we were done, we were so impressed that we decided to purchase several platforms.” Today, Rummel has grade control systems on a large majority of its equipment, a fleet that numbers in the dozens, as well as about 21 base and rover kits for surveying. “We transitioned to six Earthworks systems in the last few years for motor graders and just got our first Earthworks-equipped dozer,” says Tindell. “Even better, three of the motor grader systems are mastless, which is amazing for both flexibility and safety.”
The mastless grader system gives operators an improved range of blade motion, allowing for machine control in applications where it was previously not possible. The system puts one GNSS receiver on the cab and one on the gooseneck of the machine to eliminate the tangle of masts and cables traditionally located on the blade.
“And we don’t have operators hanging out of the cab to put an antenna on,” Tindell adds.
All of Rummel’s rovers are equipped with the Siteworks software, which Tindell says is very efficient at handling the 3D data sets. PARTNER ADVANTAGE
When asked about training on the rovers, grade control systems or associated software, Tindell says it’s been pretty much on the job.
“We’ve never sent operators to a class, or anything. We’re just too busy,” he states. “That’s where our relationship with SITECH Southwest has been terrific, especially with the new Earthworks systems. They provided a manual for the routine operations, but they’ll show up on our jobs and walk us through more advanced stuff depending on if we’re working on a road alignment or a community development.”
This responsiveness has been particularly valuable as Rummel has grown. “Not only has the scope and scale of our jobs grown significantly, but so has our fleet,” says Tindell. “We went from 10 blades and five rovers eight years ago to now having 66 pieces of equipment.”
In December 2019, Rummel added a drone division complete with Trimble Stratus with Propeller RTK platform for mapping topographical information and capturing highquality project photography and videography. While use of the drone was limited in 2020, the potential is substantial on large projects such as the master planned community development.
“This is an enormous community that we will likely be working on for another 10 years. Right now, we use our drone almost exclusively for calculation of excavation quantities, and occasionally to shoot a few pictures or videos for an owner,” Tindell says. “We believe that will expand this year to include site progress mapping and management.” No matter the scope and scale of the project, Tindell believes the benefits are clearly evident in the bottom line and the finished product. “We’re easily 20% to 30% more efficient today than just five to 10 years ago,” he points out. “That’s the clear value of technology.” ET The mastless Trimble Earthworks system eliminates masts and cables, giving operators an improved range of grader moldboard motion.
Vicki Speed is a freelance writer specializing in the architecture, engineering and construction space. All of Rummel’s rovers are equipped with Trimble Siteworks software, which has proven very efficient at handling 3D data sets. Nearly all of the earthmovers used on the community development project were outfitted with the Earthworks grade control platform or the GCS900 3D grade control system, with a drone above helping to track material quantities.
