November 5, 2026
Low fuel rail pressure reduces engine power and, if left unresolved, can shorten engine life on large hydraulic excavators that set the pace for the whole loading operation. DataMind AI continuously monitors fuel system pressure and its electrical signals in critical assets, enabling early detection of fuel delivery problems before they escalate.
In this case, DataMind AI identified 14 low and very low fuel common rail pressure OEM alarms within a few days on a Komatsu PC850 excavator. Each alarm lined up with a clear drop in measured rail pressure, and the rail pressure sensor voltage dropped at the same moments.
Because sensor pressure and voltage moved together, DataMind AI concluded the alarms most likely reflected a real loss of rail pressure rather than a simple sensor glitch, pointing to fuel rail leaks, a fuel control valve malfunction or a weakening high-pressure fuel pump, with the sensor itself still to be verified.
Targeted checks located a fuel rail leak, while the high-pressure pump tested within specification. After the repair at a planned stop, rail pressure stabilized and the alarms stopped. Early detection helped avoid an estimated 1 day of unplanned downtime and approximately $25,000 in fuel system repair and lost production costs.
Results at a Glance
$25,000
saved1 Day of unplanned downtime prevented
Conclusion
14 low rail pressure alarms with matching pressure drops
Likely real fuel rail pressure loss, not a sensor glitch
Fuel rail leak repaired, pressure alarms stopped
Don’t let the next failure go undetected.
Explore 50+ real-world case studies showing how DataMind AI saves mining operations millions — or book a live demo to see it in action.
Fill in the form to download the case study
Don’t let the next failure go undetected.
Explore 50+ real-world case studies showing how DataMind AI saves mining operations millions — or book a live demo to see it in action.
