What did the open-pit mining pilots find?

At an open-pit commodity mine in Central Asia, a pilot across five Cummins QSK60 haul trucks showed 0 OEM fault codes present, identified repairs up to 16% above the engine-approved target, a 5.2% initial repair saving, and 80% of vehicles returned to operations with minimal or no repairs. A northern Africa mine identified 5 to 12% across 14 units.

Can EBM find fuel waste with no fault code?

Yes, and the case record proves it. Every deployment identified fuel waste in engines showing zero OEM fault codes present. The fault code does not know anything is wrong, because it only fires after a problem crosses a controller threshold. Emissions-Based Maintenance reads the exhaust chemistry directly and finds the waste the dashboard never reports.

How should I read the savings figures?

Every figure in the case record is identified opportunity, reported gross, not realized, and scoped to its own deployment. Fuel recovery is framed as a 5 to 7% target band, never an average and never guaranteed. Verified entries are labeled verified; everything else is identified opportunity confirmed on the operator's actual engines.

What engines does the method cover?

Emissions-Based Maintenance is OEM-agnostic. Its baselines are calibrated against 32,000+ EPA-certified engines from 200+ manufacturers, spanning model years 1996 to 2027 across EPA Tier 2 through Tier 4. It is validated across Caterpillar, Cummins, MTU, EMD, and John Deere engines, roughly 150 HP to 3,000+ HP, so it fits the mixed fleet in the yard today.

The case record

Open-pit mining · Central Asia

Verified pilot recovery on a commodity mine

5.2% initial repair saving

What did emissions-based maintenance find on a Central Asia open-pit mining fleet?

A pilot ran across 5 Cummins QSK60 units in 244-ton MT4400 AC haul trucks, with 0 OEM fault codes present. Emissions-Based Maintenance identified repairs up to 16% above the engine-approved target and a 5.2% initial repair saving, and 80% of vehicles returned to operations with minimal or no repairs. The figures are identified opportunity, reported gross, not realized, and scoped to this deployment alone.

Verified pilot recovery on a commodity mine

An open-pit commodity mine operation in Central Asia ran a pilot across 5 Cummins QSK60 units in 244-ton MT4400 AC haul trucks. 0 OEM fault codes present. Identified repairs up to 16% above the engine-approved target. Initial repair saving of 5.2%. 80% of vehicles returned to operations with minimal or no repairs.

Method

244-ton MT4400 AC haul trucks. 0 OEM fault codes present. Identified repairs up to 16% above the engine-approved target. 80% of vehicles returned to operations with minimal or no repairs.

Figures are reported gross, not realized. Verified entries are labeled verified; all others are identified opportunity. Fuel recovery is framed as a target band of 5 to 7%, never an average and never guaranteed.

Common questions

Reading this case, answered.

What did the open-pit mining pilots find?: At an open-pit commodity mine in Central Asia, a pilot across five Cummins QSK60 haul trucks showed 0 OEM fault codes present, identified repairs up to 16% above the engine-approved target, a 5.2% initial repair saving, and 80% of vehicles returned to operations with minimal or no repairs. A northern Africa mine identified 5 to 12% across 14 units.
Can EBM find fuel waste with no fault code?: Yes, and the case record proves it. Every deployment identified fuel waste in engines showing zero OEM fault codes present. The fault code does not know anything is wrong, because it only fires after a problem crosses a controller threshold. Emissions-Based Maintenance reads the exhaust chemistry directly and finds the waste the dashboard never reports.
How should I read the savings figures?: Every figure in the case record is identified opportunity, reported gross, not realized, and scoped to its own deployment. Fuel recovery is framed as a 5 to 7% target band, never an average and never guaranteed. Verified entries are labeled verified; everything else is identified opportunity confirmed on the operator's actual engines.
What engines does the method cover?: Emissions-Based Maintenance is OEM-agnostic. Its baselines are calibrated against 32,000+ EPA-certified engines from 200+ manufacturers, spanning model years 1996 to 2027 across EPA Tier 2 through Tier 4. It is validated across Caterpillar, Cummins, MTU, EMD, and John Deere engines, roughly 150 HP to 3,000+ HP, so it fits the mixed fleet in the yard today.

Next in the record

Identified opportunity across a working fleet

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