November 5, 2026
A single cylinder running hot can point to an injector problem that, left unchecked, may damage the piston, valves or turbocharger of a large haul truck engine. DataMind AI continuously monitors exhaust temperatures cylinder by cylinder alongside air system parameters, enabling early detection of combustion issues before they escalate into failure.
In this case, DataMind AI detected isolated exhaust temperature peaks of around 750-850°C on a single exhaust channel of a Komatsu HD1500 haul truck, against an operating range of about 150-500°C for its other channels and for comparable trucks in the fleet. OEM cylinder exhaust high temperature alarms appeared at the same time, while charge pressure, charge air temperature and turbo speed remained comparable to the fleet.
By ruling out a system-wide air supply problem through fleet comparison, DataMind AI isolated the issue to one cylinder, pointing to either a temperature sensor or connection fault or an injector malfunction.
A cylinder cutout test under load confirmed a faulty injector. After replacement at a planned stop, the channel returned to the 150-500°C range of the other cylinders, with no further alarms. Early, targeted diagnosis helped avoid an estimated 2 days of unplanned downtime and approximately $40,000 in engine repair costs.
Results at a Glance
$40,000
saved2 Days of unplanned downtime prevented
Conclusion
Isolated 750-850°C exhaust peaks on one cylinder
Sensor fault or injector malfunction, air system ruled out
Injector replaced, exhaust temperature back to normal
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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.
