HAUL TRUCK – CAT 796AC KINGPINS​

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This pilot saved our client around $6,000,000 a year. The GreaseBoss system immediately identified severe under-greasing across all monitored injectors, allowing targeted maintenance and significantly improved truck performance.

  • Immediate identification of injector issues – all four injectors were severely under-greasing these critical components.
  • Reveal root cause of greasing issue – many injectors were mistuned.
  • Detected autolubricator system failure – this finding triggered a full fleet refit.

$250k

Cost per kingpin component failure

2 / month

failure frequency across the fleet

4/4

injectors were found undergreased

$6m/year

estimated savings across the fleet

The Challenge

A large Australian coal mine had experienced repeated kingpin failures on their fleet of CAT 796AC trucks, with no clear understanding of the root cause. The failure frequency across the fleet was approximately one a fortnight with each failure incurring costs of approximately $250,000.

The maintenance team suspected it was related to grease, but couldn’t pinpoint the exact issue. This uncertainty led to significant operational challenges and continued asset downtime.

Each Kingpin failure costs approximately $250,000.

Haul Trucks in a workshop
The Solution

critical point monitoring

To address this, our client implemented GreaseBoss’ Critical Point Monitoring solution by installing two Endpoint Low Flow units on each kingpin. The Endpoints were installed in minutes, mounted on brackets using high-strength magnets.

A gateway was installed in the electrical cabinet of the truck, using SIM card data connectivity. This setup has been very successful in providing accurate monitoring and ensuring proper lubrication.

1

2x Endpoint lf per kingpin

Mounted on brackets using high-strength magnets, installed in minutes.

2

precise grease flow tracking per point

Volume delivered to each kingpin, measured against a target daily volume.

Key findings

Detected all four injectors to be undergreased

Endpoints, CAT 796AC

All 4 points under-greased

Every monitored injector sat below its target daily volume.

Kingpin LHS top (SLV) Kingpin LHS bottom (SLVxl) Kingpin RHS top (SLV) Kingpin RHS bottom (SLVxl)

Daily grease volume vs target
Daily grease volume delivered to the CAT 796AC kingpin LHS top point, sitting below the target daily volume of 106.00 cc shown as a red dashed line Daily grease volume delivered to the CAT 796AC kingpin LHS bottom point, sitting below the target daily volume of 171.00 cc shown as a red dashed line Daily grease volume delivered to the CAT 796AC kingpin RHS top point, sitting below the target daily volume of 105.00 cc shown as a red dashed line Daily grease volume delivered to the CAT 796AC kingpin RHS bottom point, sitting below the target daily volume of 171.00 cc shown as a red dashed line
Daily grease volume delivered at the selected point. The red dashed line is the target daily volume. Bars below the line are under-greasing events.

The Result

The data from GreaseBoss enabled the mine to understand the root cause of greasing issues and prevent fortnightly kingpin failures.

Before GreaseBoss
failure 2x/month

Kingpin failures at approximately $250,000 each, root cause unknown.

After GreaseBoss
Reveal root cause of greasing issue

GreaseBoss data highlighted mistuned injectors across the asset.

estimated savings

$6m/year

Forecasted savings from eliminating fortnightly kingpin failures.

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