Maintenance Matters

Regular daily maintenance and scheduled complete maintenance of roll-off boxes and hoist trucks will save money—avoiding downtime, damaged equipment and extending the useful life of this valuable equipment.

THE BASICS

The list of “gotchas” in roll-off maintenance is long, but near the top is the danger of insufficient lubrication of grease fittings, which can cause hoist failure and possibly cause injury to the operator.

If hydraulic oil is not checked and changed frequently, it can cause pump failure. When the hydraulic pressure is set too low, or the hydraulic cylinder has a leak, the unit may not lift a loaded container, sources say.

Low oil or air leaks can cause control problems. Staff should be alert to a faltering or noisy pump—it could be the result damage, according to contacts. The truck air system must be equipped with a proper air dryer to prevent dirt and moisture from getting into the air valves. If the air dryer and valves are not checked often, damage to the air valves could occur resulting in various problems.

“Preventive maintenance is an enormous issue. Equipment maintenance is the No. 3 cost center for recyclers,” says Greg Brown, president of Benlee, Romulus, Mich. To give you an idea of what that means for an operation, No. 1 is materials, No. 2 is payroll, he adds.

“The key is grease. If you grease roll-offs, they will last forever,” Brown says.

On top of a good dose of quality grease, “Include giving the unit a once-over every day to make sure that you don't have any leaks, loose bolts, cotter pins, cracked components or any damaged hydraulic cylinders,” says Curtis Dorwart, vocational products marketing manager for truck maker Mack, Greensboro, N.C.

“Don't forget to look for problems before they become bigger than they are, including electrical wiring that is dangling or stands the chance of rubbing, chaffing or getting pinched,” he adds.

Follow the hoist manufacturer’s specific recommendations and the maintenance manual for the truck chassis. Inspect cable hoists for fraying and worn sheaves. Keep batteries clean and charged, Dorwart says.

“Preventive maintenance is incredibly essential to the performance of roll-off and hoist trucks,” agrees Rich Hood, president of Mid-Atlantic Waste Systems, Easton, Md. As part of the daily visual check, he recommends inspecting lights, bolts, pins and brackets as well as checking the oil reservoir for sufficient hydraulic oil and replacing dirty or harsh smelling oil.

Service grease fittings every 40 hours or once a week, according to sources. Every 30 days, oil metal pivot points. The hydraulic oil filter element should be removed and cleaned after 30 days of service and regularly once a year after that. After the first 30 service days, make sure to inspect the oil often, suppliers suggest.

“A lack of adequate and proper lubrication results in premature wear of components due to increased abrasion and excessive heat,” Hood says.

“Even the best hoist on the market will not last as long as it should if you don't keep on top of the simple things,” Dorwart cautions.

Service technicians recommend a daily inspection of all hoist cables with a thorough inspection for any breakage or unraveling every 40 hours. They also suggest checking the cable ends, clamps and pins. “If these things are overlooked, the hoisting or roll-off system will function improperly and can cause damage to other parts of the system,” Hood says.

Mack has various schedules based upon the type of service that the truck sees. “For heavy service, which is pretty much what a typical roll-off will see, we have a straightforward 25,000-miles engine oil change interval [and] 15,000-miles chassis lubrication interval,” Dorwart says. Coolant replacement, belts and other items have much longer term service intervals of up to 150,000 miles or 24 months, he adds.

“Regardless of the service intervals, the daily inspection is still key to staying on top of things,” Dorwart emphasizes.

HANDLING HYDRAULICS

If there is one key system to any roll-off or hoist system, it is the hydraulic system. Hydraulic oil is in constant contact with precision-machined surfaces. All of the sources contacted for this feature agree that hydraulic oil must be kept as clean as possible to prevent unnecessary wear. Dirt particles in the hydraulic oil can cause pump failure. If this happens, the entire hydraulic system must be drained and flushed clean, the filter changed and the entire system filled with new oil.

“Be sure to inspect the valves, pumps, cylinders and any other hydraulic components for leaks and damage,” Hood suggests.

Inspect the hydraulic hose assembly for hose cover abrasions, cracks or cuts; leaks of any kind; and for hoses that are twisted, close to a heat source or rubbing against each other.

“Hydraulic fluid under pressure is dangerous and can cause serious injury,” Hood warns. “Never touch a pressurized hydraulic hose assembly with any part of your body,” he adds. Rather, he suggests using a piece of cardboard to localize the pressurized leak.

“If hydraulic fluid punctures the skin, seek immediate medical attention or you could risk losing the injured body part,” he cautions. Additionally, hot fluid can cause severe burns.

When working with hydraulic fluids, Hood cautions recyclers to be careful around electricity. “Electricity can create the spark that causes a fire, explosion or electrocution,” he says. “Make sure the electric systems are all shut down before performing any service or maintenance.”

Brown says too many recyclers miss the maintenance points on the rear hinge pins and bushings and the shivs/pulleys. The latter is a real safety hazard, he adds.

“When cables fail, it is catastrophic,” Brown says. Boxes fall. Cables whip through the air and hit people. It takes a couple of years for such a failure; but, when it hits, there are massive repercussions, he adds.

WHAT YOU MAY BE MISSING

Cleanliness is often overlooked, Dorwart says. “It is difficult to spot a problem if you can't see it,” he says. “The cost, at the end of the day, is lost productivity and downtime. If the truck is not running, you are not making money—you are losing money,” he says.

Brown recommends painting roll-offs to prevent rust. “Paint them and paint them again,” he says. “Painting is nice for the company image but it also will stop boxes from rusting.” Dorwart notes that it usually is the simple things that can cause problems. “A cracked spring or leaky air bag can take a unit out of service pretty quickly,” he says. “So can a pinched wire that blows a fuse. It’s very frustrating.”

He recommends greasing pivot points. “Don't forget your brake cams, driveline, springs and steering knuckles,” he adds. “Nothing is worse than losing a driveshaft.”

Brown agrees. Hidden spots like the rear hitch pins and bushings are dollar items, not safety items. Failure to maintain them will cut their life from 10 years to three, he notes.

Recyclers have the option of performing preventive maintenance on their own hoist and roll-off trucks.

Maintenance can be done at home. “Many recyclers have their own service in house, and much of it can be done without a lot of special tools...just some elbow grease,” Dorwart says.

“Preferably, the customers should have service technicians perform the work, though, since they are specifically trained in the procedures and operations,” Hood says.

However, most companies offer preventive maintenance service. “We are proud that our technicians have the ability and the knowledge to service any and all equipment we sell, including hoist and roll-off trucks,” Hood says. In addition, vendors stock thousands of parts.

If you do in-house maintenance, be thorough about the job, sources suggest.

“Inspecting the sheave is something that is often overlooked,” Hood says. The grease fitting of the sheave is not as obvious as those on other parts of a truck. “They are somewhat hidden and easy to forget,” he says.

Proper inspection of the sheave should include checking for excessive wear or damage and correct wire rope placement. If either of these inspection points are overlooked, the sheave can break and cause a variety of problems.

If nothing else, Brown says, stay on top of preventive maintenance to avoid Department of Transportation fines. Dorwart emphasizes cleanliness, changing the oil and filter at the recommended intervals and addressing leaks or damage to components at once.

“Above all, one of the most important things about performing service and preventive maintenance is the knowledge of the equipment,” Hood says. “Knowing about your hoist or roll-off truck is the key to safety.” Dorward concludes, “Oil and grease are cheap insurance and a daily once-over and periodic maintenance make things go so much smoother and make life a lot easier in the long run.”

The author is a freelance writer based in Cleveland. He can be contacted at a href="mailto:curt@curtharler.com">curt@curtharler.com.