Avoiding Battery and Alternator Failures Through Predictive Maintenance

A waste management company in the United States operates a large fleet of refuse trucks serving urban and suburban regions. In such operations, a stable electrical system is essential for reliable ignition, powering onboard electronics, and ensuring overall vehicle efficiency.

A waste management company in the United States operates a large fleet of refuse trucks serving urban and suburban regions. In such operations, a stable electrical system is essential for reliable ignition, powering onboard electronics, and ensuring overall vehicle efficiency.

Situation

  • Intangles’ predictive AI triggered an undervoltage alert, initially flagged as minor, which escalated to a major alert after 3 days.
  • The truck remained operational, but the voltage continued to fluctuate throughout the trip.
  • No DTCs were detected during this period, making it difficult to identify the issue through traditional diagnostics.
  • After the alert turned major, the service team conducted an electrical load test, which confirmed voltage drops at higher engine RPMs.
  • If left unresolved, this could have led to a dead battery, electrical failure, or a breakdown during service hours.

Solution

A physical inspection revealed that the ground cable connection was loose, and the battery terminal was corroded. The service team replaced the ground cable, and voltage levels returned to normal.

Thanks to Intangles’ early alerts, the fleet maintenance team was able to intervene before failure occurred. The team also checked the alternator and battery systems, confirming inconsistent voltage output and terminal corrosion as the root causes.

After cleaning the connections and replacing the cable, voltage stability was fully restored—preventing future electrical complications and avoiding on-road failures.

Success

  • Prevented vehicle breakdowns by detecting voltage irregularities early.
  • Avoided battery failure and the risk of being stranded mid-route.
  • Identified alternator inefficiency, reducing chances of power system failures.
  • Improved fleet reliability by minimizing the risk of unexpected roadside incidents.
  • Saved on potential towing costs, as the issue was resolved before any field breakdown occurred.

Outcome

By leveraging Intangles’ predictive alerts, the fleet maintenance team successfully prevented a critical electrical failure, avoided unnecessary battery replacements, and ensured smooth, uninterrupted vehicle operation.

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