Brake System Pressure Degradation Detected in Epiroc LHD

Brake system faults in underground loaders operating on ramps and grades represent both a safety risk and a maintenance challenge. Gradual pressure degradation is difficult to detect through operator feedback alone until the failure becomes acute. DataMind AI continuously monitors brake system pressures and hydraulic circuit health, enabling early identification of developing faults before they affect operational safety.

In this case, DataMind AI detected a progressive decline in brake pressure on a Epiroc LHD Loader, correlating with an increase in brake temperature readings. The pressure trend showed a consistent downward drift across multiple operating shifts, a pattern that would not have triggered a conventional threshold alarm but that DataMind AI identified as statistically anomalous against the unit’s historical baseline. Brake temperature elevation during normal operations confirmed the brakes were partially engaging during travel.

By analyzing the simultaneous pressure decline and temperature rise, DataMind AI identified the root cause as a degraded brake circuit, most likely a worn slack adjuster or a restriction in the hydraulic line causing incomplete brake disengagement. Partial brake drag generates heat and accelerates lining wear, eventually leading to full brake failure or lining damage.

Following the DataMind AI alert, the maintenance team inspected the brake circuit, found and replaced a worn slack adjuster, and flushed the hydraulic line. This resolved the partial drag condition, restored full brake, and prevented brake lining damage. Early intervention saved approximately $22,000 and avoided 16 hours of unplanned downtime.