PREVENTING ENGINE FAILURE THROUGH SMARTFLEET^DX CONDITION MONITORING

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1. DETECTING AN ABNORMAL TREND DURING ROUTINE MONITORING

During a condition monitoring report for a mining site, the SmartFleet^DX Condition Monitoring Engineer identified a sudden and unusual drop in engine oil pressure in one of the HD785 dump trucks.

This observation was highlighted in the report and supported by general recommendations for on-site verification.

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2. THE ISSUE BEHIND THE PRESSURE DROP‍

Once the site team had received the report, they quickly escalated the matter to the client and called for an inspection of the machine.
Further review revealed that the pressure drop had occurred immediately after the machine had returned from its preventive maintenance (PM) service.

A PM timeline chart confirmed that the low oil pressure began directly after the service period.
In order to determine the cause, the site team collected an engine oil sample for analysis.

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3. OIL ANALYSIS REVEALS THE ROOT CAUSE‍

The oil sample results showed that the viscosity was far below normal engine oil standards. This led to the discovery that:

• Hydraulic oil had been mistakenly filled into the engine compartment during PM servicing.

As hydraulic oil has a significantly lower viscosity than engine oil, the pressure dropped.

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4. RISKS OF OPERATING WITH LOW‑VISCOSITY OIL‍

Running an engine with incorrect or low-viscosity oil can cause the following issues:

• Insufficient lubrication
• Severe wear on internal sliding components
• Increased friction
• Risk of complete engine failure

Had the issue gone unnoticed, the machine would likely have suffered major damage.

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5. SMARTFLEET^DX IMPACT‍

Thanks to timely condition monitoring and clear reporting:

• The abnormal pressure trend was detected early
• The machine was immediately withdrawn from operation
• The incorrect oil was replaced before damage could escalate
• The engine was saved from a potentially catastrophic failure

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This case study demonstrates how SmartFleet^DX delivers real value through continuous monitoring, rapid insights and proactive maintenance support.