Success Story: Wayne Engineering

Location: Cedar Falls, Iowa

Segment:Refuse collection

Challenge: Obtaining customer’s interest in a hydraulic work system that would improve refuse truck productivity.

Solution: Eaton® Power On Demand (POD) Advanced Technology.

Results: In addition to reducing fuel consumption, the Eaton POD system coordinates dumping and packing functions for time savings of up to 20 percent.

Contact Information: John Wagner Eaton’s Hydraulics Group (651) 905-9205johnmwagner@eaton.com

“Anyone can build a truck body. Eaton helped us create one with a better brain and circulatory system, and we now have the most intelligent machine on the market.” Scott Kanne, Wayne Engineering Vice President of Sales and Marketing

Background In 2009, households and institutions in the United States generated 243 million tons of municipal solid waste (MSW). The average American threw away 4.34 pounds of trash each day. Although recycling rates have increased and more facilities are available for converting MSW into energy, all that material has to be collected. To move MSW quickly, quietly, and economically, many public and private waste collectors turn to Wayne Engineering.

Based in Cedar Falls, Iowa, Wayne Engineering designs and builds MSW collection vehicles that are used nationwide. Its Curbtender Auto Side Loader, first offered in the 1970s, set new standards for productivity. More recently, the company introduced a commercial-class front loader and full-size rear loader, along with a one-man

commercial container handling system that can be included on new machines or adapted to fit existing equipment.

Wayne Engineering continues to pursue new technologies, both in its products and its processes. The company added 38,000 square feet of manufacturing space in 2007, and invested in robotic welders and laser cutters for maximum capacity and precision. Its design engineers constantly look for opportunities to improve machine performance, and collaborate with trusted partners.

Challenge Managers from Wayne Engineering met with Phil Dybing and John Wagner of the Eaton Commercial Vehicle Market Development Team to discuss Eaton’s development of time and fuel saving advancements for refuse collection. The Eaton team

Eaton technologies help improve refuse collection productivity

Market Served:Vehicle/Transportation

Eaton Corporation is a diversified power management company ranked among the largest Fortune 500 companies. Eaton is a global leader in electrical components and systems for power quality, distribution and control; hydraulics components, systems and services for industrial and mobile equipment; aerospace fuel, hydraulics and pneumatic systems for commercial and military use; and truck and automotive drivetrain and powertrain systems for performance, fuel economy and safety. Eaton has approximately 73,000 employees and sells products to customers in more than 150 countries. www.eaton.com.

presented the newest set of hydraulic work system solutions, Power On Demand (POD) Advanced Technology.

“Eaton was already working with our people on Eaton Hydraulic Launch Assist™ technology,” said Scott Kanne, vice president of sales and marketing, Wayne Engineering. “Large refuse collection trucks benefit from the HLA® system; it significantly reduces fuel consumption and increases brake life. Clearly, they will also benefit from POD technology.”

Eaton POD system technology improves productivity while reducing costs. Kanne understood immediately how a POD system could help operations and fleet managers meet the challenges of waste collection and disposal. “We also saw opportunities for improvement in the compaction cycle using Eaton POD,” he said.

SolutionTraditional vane or gear pumps operate continuously, resulting in unnecessary fuel consumption. The Eaton POD load-sensing hydraulic system features a variable displacement piston pump that uses energy only when it is required.

Eaton POD systems are built for trouble-free operation. They incorporate durable

components such as Eaton 420 Series piston pumps, Vickers® CMX electro-hydraulic load-sense valves and Vickers MCD manifolds, along with Aeroquip® GH493 and GH781 hose assemblies.

By itself, Eaton POD technology increases the productivity of waste collection vehicles; combined with the HLA system, it can reduce fuel consumption by up to 40 percent. In field tests, Eaton POD systems have saved 4 to 7 gallons per truck each day; at $3 per gallon of diesel fuel, that translates to annual savings of $4,000 to $6,000 per truck.

“For years, fleet managers paid little attention to fuel efficiency,” said Kanne. “But with diesel at record high prices, operating costs have become as important as capital expenses.” ResultsFuel economy is not the only benefit of using the Eaton POD system in a refuse truck; it also reduces cycle time significantly for greater productivity. Equipped with two 80cc Eaton 420 Series pumps operating in tandem, the system coordinates dumping and packing functions for time savings of up to 20 percent. Optimized hose routings and installations using Eaton Aeroquip Triple Crown Advantage hose styles and O-ring face seal fitting connections reduce or

eliminate leakage problems that are common to conventional hoses and SAE 37° flare fittings.

The advantages for municipalities and private fleet owners are clear: Wayne Engineering refuse trucks with Eaton POD technology offer higher performance in daily operation, reducing labor expenses immediately and reducing total cost of ownership over time.

Even though Wayne Engineering is a relatively new customer for Eaton, the two companies work well together. Technical experts at Wayne Engineering constantly look for ways to improve the performance of their equipment; the company built its reputation on quality and innovation. And Eaton Hydraulics technical and sales specialists are proud to answer new challenges with industry-leading components and systems.

If the success of this collaboration is any indication, Wayne Engineering and Eaton will continue to develop products that deliver increased value—and drive their industries forward.

“Anyone can build a truck body,” Kanne said. “Eaton helped us create one with a better brain and circulatory system, and we now have the most intelligent machine on the market.”

EatonHydraulics Group USA14615 Lone Oak RoadEden Prairie, MN 55344USATel: 952-937-9800Fax: 952-294-7722www.eaton.com/hydraulics

EatonHydraulics Group EuropeRoute de la Longeraie 71110 MorgesSwitzerlandTel: +41 (0) 21 811 4600Fax: +41 (0) 21 811 4601

EatonHydraulics Group Asia PacificEaton Building4th Floor, No. 3 Lane 280 Linhong Rd.Changning DistrictShanghai 200335ChinaTel: (+86 21) 5200 0099Fax: (+86 21) 5200 0400

© 2011 Eaton CorporationAll Rights ReservedPrinted in USADocument No. E-HYOV-MS064-EDecember 2011

Wayne Engineering’s automated side loader features tandem Eaton 420 pumps.

Aeroquip Triple Crown Advantage hose assemblies are plumbed on the truck’s main load sense valve.