Preventing High-Cost Engine Failures with Real-Time Insights

A leading East Coast waste management company faced frequent engine overheating and costly failures due to radiator clogging in its heavy-duty truck fleet. Intangles’ predictive AI solution helped the fleet team detect anomalies early, preventing unplanned downtime and expensive repairs.

A leading East Coast waste management company faced frequent engine overheating and costly failures due to radiator clogging in its heavy-duty truck fleet. Intangles’ predictive AI solution helped the fleet team detect anomalies early, preventing unplanned downtime and expensive repairs.

Situation

  • October 29: Intangles’ AI detected abnormal temperature fluctuations in a refuse truck.
  • October 31: A major overheating event occurred, triggering multiple DTCs.
  • Key Insight: No DTCs were active; traditional systems would have missed the issue.
  • Risk: Impending engine seizure, estimated $85k+ repair costs, and disrupted waste collection schedules.

Solution

With Intangles’ predictive AI system, fleet managers received an early overheating alert—before any DTCs were triggered. The real-time monitoring system identified temperature inconsistencies, prompting the maintenance team to inspect the vehicle before the issue escalated.

Initially, a minor overheating alert was raised. Shortly after, an AI-driven major overheating alert was triggered, prompting the supervisor to pull the truck in for inspection. Upon investigation, the radiator was found to be completely clogged due to dust and debris buildup – a common issue in refuse trucks.

With a simple pressure cleanup of the radiator, the maintenance team was able to restore normal engine temperatures, preventing a major engine breakdown.

Success

  • Failure Prevention: Avoided over two engine overheating incidents per month across similar vehicles.
  • Cost Savings: Saved approximately $2,000 per incident by reducing towing and downtime costs.
  • Operational Continuity: Achieved zero missed waste collection routes due to engine overheating issues after implementing AI solutions.
  • Maintenance Shift: Reduced reactive radiator-related repairs by 90%, transitioning toward more proactive maintenance.

Outcome

With Intangles’ predictive AI, the company successfully prevented a major overheating-related breakdown, reinforcing the value of real-time monitoring, early detection, and proactive fleet maintenance.

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