Macmahon | 66% Fewer Low Power Incidents
Proven results
The Challenge
At a gold mine in Sumatra, Indonesia, Macmahon’s Volvo A60H articulated dump trucks were plagued with excessive Low Power Incidents (LPIs). The combination of wet, dusty site conditions and widespread use of B30 biodiesel was driving equipment downtime, fuel inefficiency, and injector failures.
Macmahon needed proven, comparative data to justify adopting new technology. As a conservative industry, mining contractors demand evidence of consistent performance and a measurable return on investment before committing to change.
The Solution
In April 2021, three Volvo A60H ADTs with 4,500 operating hours were fitted with FuelActive FA16 units and benchmarked against three new ADTs of the same specification at the same site. This high bar test ensured a rigorous comparison.
Over 25 weeks, Volvo OEM telematics tracked fuel consumption and service records. The trial demonstrated that despite being older, the FuelActive-fitted trucks outperformed the new control group in both efficiency and reliability.
“Low Power Incidents have been reduced by 66% on these trucks, boosting reliability and availability. We also recorded consistent fuel savings of 3.4%, equating to nearly 18 tonnes of CO₂ saved per year, per truck. I would recommend FuelActive on all mining equipment for the repairs and maintenance savings, increased uptime, fuel savings and sustainability benefits.”
Nigel Wixon, PT Macmahon Maintenance Manager
The Benefit
The FuelActive trial reduced LPIs by 66% (9 vs. 27) compared with standard units, directly improving truck reliability and availability. Fuel consumption improved by an average of 3.4%, saving 1.25 litres per hour — equivalent to nearly 18 tonnes of CO₂ saved per truck annually.
Maintenance costs also fell: injector replacements were required on one control truck during the trial (and two further trucks outside the control group), while none were needed on FuelActive-equipped units. With an ROI of 251% in year one, Macmahon moved quickly to expand FuelActive across more equipment.
The Outcome
Fuel economy
3.4% improvement across ADTs.
Cost saving
251% ROI in year one.
Sustainability
17.9 tonnes CO₂ saved annually per truck.
Reliability
LPIs reduced by 66%, injector failures eliminated on trial units.
Proven data, proven results
FuelActive delivers measurable savings, reliability, and sustainability in mining. See the data and results from leading contractors.
