tips to boost

fuel economy
Saving money on fuel will never be less important than it is today. Diesel prices
have been rising virtually every week since early July, making $4 diesel the new
normal, and perhaps dirt cheap by standards a year from now.
Gaining even 1 mile per gallon means a huge savings. With diesel at $4 per gallon, an owner-operator averaging 6 mpg and driving 120,000 miles a year will
save $16,000 a year over one who averages 5 mpg.
See if you can apply any of these tips to your operation. Each one will add dollars to your bottom line.
By Todd Dills, Jack Roberts, James Jaillet and Aaron Huff
1 | Overdrive | November 2012

Use truck-routing tools. Choosing the

shortest, most practical truck route
can save hundreds of dollars a year in
fuel. Spoken, turn-by-turn directions will
take you directly to street-level addresses.
With a navigation aid, savings of 10 miles
or more a week is possible by eliminating
out-of-route miles.

Optimize fuel purchases.

Avoid traffic tie-ups. Rush hour, highway construction and traffic jams not
only suck hours from your on-duty
time, but they also require much deceleration and acceleration, which requires more
fuel. Check Traffic.com or other sites each
day to see potential construction and traffic on your route. Some smartphone apps
and GPS units also provide real-time traffic
information.

Plan fuel stops carefully. Some in-cab

navigation systems and smartphone
apps include real-time information in
their point-of-interest features that allow
drivers to search for the nearest fuel locations and cheapest prices on their route.

Whats the most effective

fuel-saving device youve
applied to the truck
in the past decade?
Josh Nileski: A 200-plus horsepower
chip from Pittsburgh Power. As long as
you keep the heat off her, you never
have to go above 1,600 rpm climbing
a hill.
Rich Rukstalis: Flow-through exhaust,
fleet air filters, reprogrammed ECM and
adjusting turbo wastegate. All these
add up not just one thing.
William McKelvie: 1) PDI exhaust manifold. 2) Fuel code reset. 3) Flow-through
mufflers. 4) PDI tune (coming soon).

10

Use shorepower when

its available.

Online software systems help maximize fuel savings by finding the cheapest locations to buy fuel. Systems such as this one from ProMiles compare
fuel prices minus IFTA fuel taxes. This is the only fair way to compare
fuel prices because owner operators get credit for IFTA taxes paid at the
pump and since tax rates vary widely by state.These optimal fuel plans
can save 4 to 11 cents a gallon. The systems factor in tank capacity, current fuel levels, truck stop preferences and other variables.

Consolidate
fuel purchases.
Fuel card providers have negotiated discounts with
truck stops, but just
as important, drivers and fleets can
use the data they
collect to compare
and to consolidate
fuel purchases to
negotiate more
savings.

Dont rely on
pump price.
Check online
sources for information on state
fuel taxes. Only
after subtracting
taxes from the
pump price do
you know the
true price of the
fuel.

Get the best

possible fuel
surcharge.
Surcharge terms
differ in various ways, such
as payment for
empty miles.
Make sure you
know how yours
is calculated.
If its not fair,
consider leasing
elsewhere.

Bypass weigh
stations and
toll booths.
Enrolling in
programs such
as PrePass and
electronic toll collection systems
enables you to
avoid burning
extra fuel by
stopping and
then accelerating
back to speed.

Anti-idling
Idling can cost $3,000 or more per year in fuel. This doesnt include
the added engine maintenance expense that results from excessive
idling, which is harder on your trucks engine than highway driving.

Turn off the engine. Avoid excessive warm-up times when starting the truck. Even
for a short stop, youll save money by not idling. Look for other times when you
have a habit of idling but cant justify it.
Many inverters and APUs come with a plug-in option that converts
incoming current to DC to charge the batteries, using AC to power
climate-control units and/or in-cab accessories. The truck stop electrification movement to help eliminate idling has gained steam in the past year,
with plug-in options available at many more parking spaces.

November 2012 | Overdrive | 2

67 tips to boost fuel economy

11

Buy a diesel-powered APU. While your trucks engine can

use a gallon of diesel per hour idling, recent estimates indicate
a diesel auxiliary power unit burns about a fifth of that.

12

Get an electric APU.

These systems typically utilize electric
power from a bank of highcapacity absorbed glass mat
batteries often replacing
your trucks starting batteries to power climate
control units and in-cab
accessories. Often, a dieselfired heater is included in
the system for heating. The
systems cost roughly half
to two-thirds of most diesel
APUs. They wont cover
your power needs over a
34-hour restart, but for
drivers getting home once
a week they could be most
appropriate.

17

13

Purchase a dieselpowered heater.

Operators in northern climates may not need
to shell out up to $9,000 for
a full-function diesel APU
because a less expensive
diesel-fired heater can keep
the cab plenty warm while
burning around a quarter of
the fuel an APU uses.

PROFIT OFF THE

SURCHARGE. Try to beat
the miles-per-gallon your
fuel surcharge is based
on, typically 6 mpg. If you
can do better, you pocket
the extra money.

SMART DRIVING. Of
the many factors affecting fuel efficiency, such
as aerodynamics and tire
maintenance, more than a
third is attributed to drivers skills.

15
16

Get an engine block heater. If you find yourself

operating far enough north that you often idle a
lot to warm your engine, you might save in the
long run by getting a block heater.

14

Use a DC air conditioner. If your need

for cooling when resting is low, battery-powered
air conditioners can be paired
with high-capacity batteries
and a fuel-fired heater for a
comprehensive cab climate
control alternative to idling.

Use an inverter. It will convert direct current from

your batteries to alternating current to power incab accessories. If your idle time needs are limited,
installation of an inverter can supply adequate electricity
to power in-cab electrical devices.

Get a mobile generator. Like diesel APUs, gasoline- or diesel-fired generators

can be installed on the frame rail and utilized, often costing a fraction of an APUs
price, to power in-cab accessories and HVAC systems.

18

Use your reefer for climate control.

The unique reefer-based Idle Free
Electric APU, developed initially by
Overdrive 2006 Trucker of the Year Robert
Jordan, uses the power capacity of the reefer
unit to function much as a diesel APU would
running cab accessories and climate control devices when the truck is idle as well as
charging truck batteries.

19

Install an automatic engine startstop system. These can be set up to

shut down the engine after a certain
amount of idle time or, tied to a thermostat, to turn on when the cab goes above or
below a certain temperature. Entering the
market late this year, the Idle Smart system
will measure internal and external temperatures and interact with truck cooling and
heating sources, outside air and engine block
heat to keep the cab comfortable.

3 | Overdrive | November 2012

20

Avoid revving the engine between shifts.

Ease into each new gear, and dont be in a
hurry to climb through them.

21

Adjust shifting patterns

22

Download engine data to compare your

shifting behaviors RPMs at shift point
to the optimal RPM torque bands
for your engine. Adjusting your shifting
to fit the make and model of engine can
make a big difference. Every 1,000-rpm
reduction in engine speed delivers a 1
percent gain in fuel economy.

Run in your engines sweet spot. Once you reach cruising speed,
operating in the peak torque zone gives you optimum horsepower,
so the engine runs most efficiently. It takes only about 200 horsepower to maintain 65 mph.

67 tips to boost fuel economy

23

29

Maintain an
extended following
distance.

Use truck stops atop hills.

Driving uphill toward the truck stop allows

natural deceleration and going downhill to
re-enter the highway requires less fuel.

It helps to prevent unnecessary

acceleration due to frequent braking.

24

Anticipate traffic
signals . If you can
approach slowly
and avoid a complete stop, it
saves fuel and reduces equipment wear.

25
26

Minimize AC use.
Running the air
conditioner delivers
a 210 to 410-mpg hit.
Dont punch the
throttle. Gradually
put your foot into
it, pretending theres an egg
between the pedal and the
floorboard. Use smooth,

30

Keep up with oil and

oil filter changes.
A well-maintained
engine not only lasts longer, but
has an edge on fuel efficiency.

steady accelerator inputs to

avoid fuel burn spikes.

31

27

Keep belts at proper

tension. Even slight
slipping creates parasitic horsepower loss. Make sure
all belts are properly tightened
and in good condition.

Lower your average highway speed.

Every mph over 55
equals a 0.1 mpg drop in
fuel economy.

28

32

Maintain your
diesel particulate
filter. Much like a
clogged catalytic converter
on your car, a plugged
DPF hampers exhaust flow.
It can lead to compression
or combustion problems if
left untreated.

Avoid needless acceleration. For example,

dont hit the throttle
too much when approaching
the crest of a hill. Instead,
lay off the throttle and let
the trucks momentum carry
it over. Watch the boost
gauge for an exact read of
what youre doing.

Aerodynamics

33

Maintain fuel filters. Clogged filters

make the engine
run rough and work harder.
Replace according to manufacturers recommendation.

34

Maximize use of
cruise control. That
enables you to avoid
wasteful use of the throttle to
climb hills.

35

Switch to a daycab
and use motels.
If your operation
doesnt require too many
over-the-road overnight stays,
not only would you save
on the cost of a tractor by
buying a daycab instead of
a sleeper, but the reduced
weight and the reduced idling
could also save fuel costs.

The most important factor in saving fuel at speeds greater than 55 mph is aerodynamics. Individual aero
features can give impressive fuel economy savings 2 percent, 4 percent and even higher. Dont expect to
add them all up for 20 percent or more improvement, but a thorough package of them can yield a 12 percent
to 15 percent boost in fuel economy over a comparable conventional truck.

37

Add a roof fairing. If youre running a flattop tractor

or midroof in a van or reefer application, the addition of an aftermarket roof fairing can smooth the
flow of air over the top of the trailer, improving fuel efficiency. Some tests indicate that a full roof fairing, combined
with side shields/extenders, in certain applications can
deliver up to a 15 percent improvement in fuel economy.

38

Add-ons like the

trailer tail side
skirts on owneroperator Brett
Tobins van (pictured) can reduce
aerodynamic drag
and help stability in
crosswinds. The tail
reduces the drag
created by the vacuum at the back of a fast-moving tractortrailer. Some operators report a full mile-per-gallon boost
from using a trailer tail combined with side skirts.

Add
a tail.

Todd Dills

36

Choose an aero-designed model for your next truck.

Truck makers have perfected the design of the front
bumper, hood, under-hood-breather, fenders, mirrors and other features to move air as smoothly as possible
under, over and around the truck and trailer.

November 2012 | Overdrive | 4

67 tips to boost fuel economy

40

Choose a lower sleeper roof. The

stand-up sleeper with a full roof
fairing is not always the most
fuel-efficient choice when its not paired
with a dry van or reefer. In liquid bulk
operations, a midroof sleeper is going
to be your best bet for aerodynamics.
In most flatbed applications, loads are
unlikely to rise above the height of a
midroof setup as well. For some highdensity-load haulers, a flattop may even
be the best choice.

41

Use rounder mirror backs. If

youre utilizing old-style flat
West Coast mirrors for the side
views, consider moving to mirrors

IdleSmart_OVD1112_PG.indd 1

5 | Overdrive | November 2012

with a more rounded back to further

enhance airflow.

42

Dress your tanks with aero

steps. Fuel tank fairings paired
with steps that smooth airflow
over the lower side of the tractor can
improve fuel performance 2 to 3 percent, by some estimates.

43

Adjust the fifth wheel to narrow

the truck-trailer gap. The ideal
gap should be around 30 inches.
Every 10-inch increase produces 2 percent
more drag. Move the fifth wheel forward,
if possible, to get better fuel economy.

44

Use dry van gap fairings. At the

front of dry vans, gap fairings
ease airflow over the tractortrailer gap. This can boost fuel efficiency by 1 percent when paired with a
highly aerodynamic tractor with a tight
truck-trailer gap length.

45

Cover wheel hubs.

Todd Dills

39

Install side skirts. Many owners have installed these on van

and reefer trailers to minimize
the drag produced by the swirling of air
under the trailer. Side skirts can deliver
a savings of 7.4 percent, according to
EPA-verified SAE Type II testing.

Bob and Linda Caffee run with these

aerodynamic hub covers on the drives
of their Freightliner Cascadia expediting straight truck. Hub manufacturers
estimate 1.5 percent to 3 percent in fuel
savings when all outside-facing wheels
are outfitted with the devices, which
smooth airflow across the wheels.

46

Use cab side extenders. For

tractors not already optimized
for aerodynamics, installation of cab side extenders can create a
smoother airflow over the tractor-trailer
gap. Makers estimate a fuel efficiency
improvement of 1 to 3 percent.

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10/3/12 1:45 PM

67 tips to boost fuel economy

47

Add nose cone fairing. For flattop or midroof tractor owners

pulling dry vans, nose cone
fairing technology combines the vertical
fairing of more standard tractor-trailer
gap technology with an outsize fairing
at the top to direct air both over the
trailer and down and around the sides.

and at the top rear of the tractor and/

or trailer. The company says each one
creates air swirls that combine to
reduce the suction and drag at the rear
of vehicles traveling at speeds above
approximately 35 mph. Based on a
study involving Britains Institute of
Road Transport Engineers, the technology is said to produce fuel savings
of 2 to 4 percent.

49

48

Install Airtabs.

Some owner-operators swear by

Airtabs, such as these installed on
owner-operator James McCarters
Freightliner. Recommended installation is on the hood, along the sides

Choose aero mudflaps. Years

ago, some owner-operators
running wide-single tires in
drive and trailer positions began custom-cutting mudflaps and brackets to
eliminate the overhang of conventional
mudflaps to reduce drag. Other options
exist today, such as porous mudflaps.

50

Use aluminum wheels. The

weight reduction relative to
steel brings better fuel economy.
It can also mean a payload increase.

Toug
h
M er.
conn ore
ected
.

51

Choose a 13-liter engine over a

15-liter. Unless your application
absolutely needs the extra muscle, there is a considerable fuel savings
with the smaller engine.

52
53

Choose trucks with lighter

specs. Having 2,000 extra
pounds results in a tenth of a
mile per gallon hit.
Use a hybrid in city operation.
They can cut fuel consumption as much as 50 percent
in pickup and delivery applications.
Return on investment is around 12
to 13 years, but federal and state
incentive programs can reduce that.
California, for example, offers a
$25,000 incentive for the first hybrid
purchased and $20,000 for each
hybrid thereafter.

Done

LARGE
7"Screen

Weather

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Untitled-13 1

November 2012 | Overdrive

| AM
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10/4/12 10:06

67 tips to boost fuel economy

WINTER CHILLS FUEL ECONOMY. You get fewer

miles per gallon during winter months because cold
air is thicker and harder for trucks to move through.
Every 10 degrees of extra warmth equates to a 2 percent improvement in fuel economy.

WINTER FUEL BLENDS.

Because fuel sold in northern
climates for winter has a lower
BTU content than summer blend
fuels, fuel economy is poorer.

54
55

Choose a truck with smaller fuel

tanks. Fuel weighs 7 pounds to
the gallon, so a smaller tank
can cut weight significantly.
Spec the optimal gear ratio.
Gear ratios can be optimized
for a variety of applications.
For a highly efficient highway ratio,
3:08 is a good choice for most trucks,
says the Technology and Maintenance
Council of the American Trucking
Associations.

56

Use an automated manual

transmission. Dont let acquisition costs scare you off.
These transmissions have been proven
to deliver vastly better fuel economy
than manual transmissions.

Tires
After diesel, an
owner-operators biggest variable expense is tires. Maintaining
them well not only extends their
lifespan but also can save hundreds of dollars a year in fuel.

57

Use tires with low rolling resistance. Deeper lug tires usually
last longer, but the extended
treads very slight movement is enough
to decrease fuel economy. Shallower
lugs decrease rolling resistance and
give improved fuel economy.

58
59

Run wide-based tires. They

have been proven to deliver
better fuel economy than duals.

Monitor tire pressure. Each 10

psi of underinflation reduces
fuel economy by 1 percent.
Check pressure during pretrip. Tire
pressure monitoring systems can
monitor the pressure of each tire and,
through wireless communications, provide instant alerts through a display
in the cab the instant a tire is underinflated.

60

Check wheel alignment. Make

alignment testing both on
the tractor and trailer part
of your periodic maintenance. Its
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7 | Overdrive | November 2012

67 tips to boost fuel economy

essential for optimum fuel economy and
maximum tire life.

61

Match tires well to your application.

If youre running long-haul and
using tires designed for any other
application, your fuel economy will suffer.

Analyze data
Todays electronic control modules
capture and display a lot of information on fuel performance. Dealers
and fleets can extract this informa-

tion, much of which relates to fuel

economy. You may need up to six
months of data before the numbers
stabilize and yield useful trends.

62

Analyze your fuel consumption

trends. When miles-per-gallon
falls, try to determine why. Did
you encounter much more urban driving? Did your length of haul change? As
a general rule, drops of more than 0.5
mpg are due to maintenance problems.
ECMs can be wildly optimistic, so your
actual mileage may be lower than indicated. Validate ECM readings with your
own calculations based on the odometer
and gallons purchased at fill-up.

63

Isolate data and look for correlations. The ECM records

many things that can affect fuel
economy. Look for noticeable changes
in average speed, top gear time, idle
time, DPF regenerations, shifting and
idling. Compare those trends with fuel
economy during the same period. You
might be surprised at the potential for
saving fuel by changing the way you
operate.

64

Check your fuel consumption by

route. If you have dedicated
runs that can be made via
interstate or a shorter route with a lot
of stop-and-go traffic, run trials for fuel
usage and time to see which is the most
efficient.

65

Get an extra set of eyes. Some

technology companies offer
services tailored to owner-operators to maximize fuel savings. These
companies can monitor engine data
and fuel purchases and provide realtime feedback and consulting.

66

Use reefer monitoring systems.

An often overlooked expense
is burning excess fuel to cool
trailers. Trailer monitoring systems capture the vital information needed to use
no more fuel than necessary.

67
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Get oil analysis. The main value

of routine analysis is identifying engine problems before they
become serious, but some of those problems can affect fuel usage as well.
November 2012 | Overdrive | 8