The radiator fan keeps engine, brake and oil temperatures under control in articulated dump trucks, and repeated overspeed can harm the fan motor and eventually the fan itself. DataMind AI continuously monitors cooling system behavior, comparing actual fan performance with control commands and fleet behavior, enabling early detection of developing faults.
In this case, DataMind AI detected radiator fan speed spikes of up to 1,625 rpm on a Komatsu HM400, above the 1,550 rpm threshold and higher than other trucks in the fleet, with no OEM alarm raised. At the peak, the fan speed command was only around 1,040 rpm and the fan pump EPC solenoid current was 400 mA, showing the fan was not following its command.
By correlating actual fan speed, commanded speed and solenoid current against fleet behavior, DataMind AI pointed to incorrect calibration settings, a solenoid malfunction, a speed sensor fault or operating practices as the likely causes.
Maintenance recalibrated the fan pump solenoid settings, and fan speed again followed its command, staying below the 1,550 rpm threshold like the rest of the fleet. Early detection helped avoid an estimated 1 day of unplanned downtime and approximately $15,000 in fan system repair costs.
Published by Razor Labs
