Impact of the automatic central lubrication system performance on the failure rate of electric mining excavators
V.O. Kolpakov1, D.A. Shibanov1, M.S. Seleznev2
1 Empress Catherine II Saint Petersburg Mining University, Saint Petersburg, Russian Federation
2 TECHPARTNER LLC, Saint Petersburg, Russia Federation
Russian Mining Industry №4S/ 2026 p. 33-39
Abstract: The article presents the results of studying the effects of the technical condition of automatic central lubrication systems (ACLS) on the reliability indicators of electric mining excavators operated in severe conditions of iron ore open-pit mines. Based on analyzing statistical data from 12 excavators with the bucket capacity of 20 m3 for the period 2024–2025, the following key resource-defining components were identified: the saddle bearing, bucket linkage, and slewing ring, accounting for up to 80% of emergency downtime. It was established that failures of the ACLS elements, particularly progressive distributors, lead to interruptions in the lubricant supply to the friction pairs and an increase in the failure intensity. A stable relationship between the proportion of the failed lubrication system components and the emergency repair time was proven using the Spearman’s rank correlation coefficient (ρ = 0.82). The empirical data were approximated using linear and exponential models that enable prediction of downtime increase as the ACLS operational integrity decreases. A criterion is proposed for evaluating the economic efficiency of the ACLS with account of the costs of downtime, lubricants, and maintenance labor. The study makes a conclusion on the need to shift from the run-to-failure ACLS maintenance to a predictive maintenance strategy based on differentiated schedules and implementation of IoT-based pressure and flow rate monitoring. The practical significance lies in justifying measures to reduce operational costs and extend the overhaul intervals of the mining excavators.
Keywords: electric mining excavator, automatic lubrication system, emergency failures, working equipment, lubrication system, component lubrication, saddle bearing
Acknowledgements: The study was carried out within the framework of the state assignment of the Ministry of Science and Higher Education of the Russian Federation FSRW-2026-0003 “Study of the processes of integrated development of the Earth’s interior and deep processing of geological resources”; with the support and consultations of the TECHPARTNER LLC (St. Petersburg, https://techpartner.ru).
For citation: Kolpakov V.O., Shibanov D.A., Seleznev M.S. Impact of the automatic central lubrication system performance on the failure rate of electric mining excavators. Russian Mining Industry. 2026;(4S):33–39. (In Russ.) https://doi.org/10.30686/1609-9192-2026-4S-33-39
Article info
Received: 17.06.2026
Revised: 29.07.2026
Accepted: 06.08.2026
Information about the authors
Vladimir O. Kolpakov – Postgraduate Student, Department of Mechanical Engineering, Empress Catherine II Saint Petersburg Mining University, Saint Petersburg, Russian Federation; https://orcid.org/0009-0003-3874-6633; e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.
Daniil A. Shibanov – Cand. Sci. (Eng.), Associate Professor, Department of Mechanical Engineering, Empress Catherine II Saint Petersburg Mining University, Saint Petersburg, Russian Federation; https://orcid.org/0000-0002-6203-0219
Mikhail S. Seleznev – Chief Engineer, Head of the Industrial Equipment Lubrication Systems Department, TECHPARTNER LLC, Saint Petersburg, Russia Federation; https://orcid.org/0009-0004-8225-6858
References
1. Golik V.I., Razorenov Yu.I., Valiev N.G., Gavrina O.A. Environmentally sound geotechnologies for leaching metals from polymetallic ore processing wastes and wastewater. Mining Science and Technology (Russia). 2024;9(3):271–282. https://doi.org/10.17073/2500-0632-2023-11-184
2. Shishlyannikov D., Zvonarev I., Rybin A., Zverev V., Ivanchenko A. Assessment of changes in the abrasiveness of solid particles in hydraulic mixtures pumped with ESPs. Applied Sciences. 2023;13(3):1885. https://doi.org/10.3390/app13031885
3. Vagapova E. A., Ivanova P. V. Complex of hydromechanized extraction and gasification of peat raw materials for remote and hard-to-reach regions. Mining Informational and Analytical Bulletin. 2026;(5):66–79. Available at: https://giab-online.ru/files/Data/2026/5/05_2026_66-79.pdf (accessed: 29.03.2026).
4. Ermakov B.S., Shvetsov О.V., Ermakov S.B., Vologzhanina S.А. Investigation of the influence of cast microstructure on the operability of the crown of a quarry excavator. News of the National Academy of Sciences of the Republic of Kazakhstan. Series of Geology and Technical Sciences. 2025;1(469):59–71. https://doi.org/10.32014/2025.2518-170X.476
5. Mikhailov A.V., Kazakov Y.A., Soloviev I.V. Analysis of block technology elements for surface excavation of organogenic material. Russian Mining Industry. 2025;(1):129–136. https://doi.org/10.30686/1609-9192-2025-1-129-136
6. Zhuravlev A.G., Glebov I.A., Cherepanov V.A. On the issue of development of productivity and technical readiness of powerful domestic excavators. Problems of Subsoil Use. 2023;(4):76–88. https://doi.org/10.25635/2313-1586.2023.04.076
7. Keksin A.I., Filipenko I.A., Sorokopud N.I., Ovsyannikov D.A. Effect of process parameters of magnetic abrasive finishing on productivity while ensuring surface quality of electrical engineering products. International Journal of Engineering, Transactions B: Applications. 2026;39(11):2815–2823. https://doi.org/10.5829/ije.2026.39.11b.13
8. Agaguena A., Repkina K.S., Mikhailov A.V. Adjusting the maintenance schedule of the hydraulic excavator at the open-pit Boukhadra mine. Transport, Mining and Construction Engineering: Science and Production. 2024;(24):146–151. https://doi.org/10.26160/2658-3305-2024-24-146-151
9. Ivanov S.L., Safronchuk K.A., Olt Y. Justification and selection of design parameters of the eccentric gear mechanism of the piston lubrication and filling unit for the mining machines maintenance. Journal of Mining Institute. 2021;248:290–299. https://doi.org/10.31897/PMI.2021.2.13
10. Ivanov S.L., Dudko P.P., Dmitriev G.Y., Podkhalyuzin S.P. Automatic centralized lubrication systems. Experience of application, problems and prospects of use. Journal of Mining Institute. 2008;178:22–26. Available at: https://pmi.spmi.ru/pmi/article/view/7188 (accessed: 29.03.2026).
11. Vinogradov Y.I., Khokhlov S.V., Zigangirov R.R., Miftakhov A.A., Suvorov Y.I. Optimization of specific energy consumption for rock crushing by explosion at deposits with complex geological structure. Journal of Mining Institute. 2024;266:231–245. Available at: https://pmi.spmi.ru/pmi/article/view/16223 (accessed: 23.01.2025).
12. Anikin K.V. The perspectives of application of excavators with bucket capacities of 20 cub. m and higher. Mining Informational and Analytical Bulletin. 2009;(12):365–369. Available at: https://giab-online.ru/files/Data/2009/12/Anikin_12_2009.pdf (accessed: 29.03.2026).
13. Kolpakov V.O., Shibanov D.A., Seleznev M.S., Khamidov O.U. Analysis of the functioning of centralized lubrication systems for quarry excavator’s parts. Transport, Mining and Construction Engineering: Science and Production. 2025;(34):122–128. https://doi.org/10.26160/2658-3305-2025-34-122-128
14. Khamidov O.U., Shibanov D.A. Regulated maintenance and repair of quarry excavators considering real-world conditions and operating modes. Mining Informational and Analytical Bulletin. 2025;(12-3):152–167. https://doi.org/10.25018/0236_1493_2025_123_0_152
15. Kovalev M.A., Moskvichev V.V. Reliability of quarry excavators in Kuzbass coal open pits. In: Lebedev M.P. (ed.) Integrity and Resource in Extreme Conditions: Proceedings of the All-Russian Conference dedicated to the 75th anniversary of YSC SB RAS, Yakutsk, 19–23 September 2024. Yakutsk: Interregional Center for Innovative Technologies in Education; 2024. P. 300–303. https://doi.org/10.24412/cl-37269-2024-1-300-303
16. Kurganov V.M., Gryaznov M.V., Kolobanov S.V. Assessment of operational reliability of quarry excavator-dump truck complexes. Journal of Mining Institute. 2020;241:10–21. https://doi.org/10.31897/pmi.2020.1.10
17. Grabsky A.A., Sergeev V.Yu., Grabskaya E.P. Rationale for choosing a strategy for maintenance and repair of quarry excavators. Ugol’. 2021;(2):14–17. https://doi.org/10.18796/0041-5790-2021-2-14-17
18. Surina N.V., Mnatsakanyan V.U. Automated process design system for mining equipment repair. Gornyi Zhurnal. 2019;(7):90–95. https://doi.org/10.17580/gzh.2019.07.08
19. Litvin O.I., Khoreshok A.A., Dubinkin D.M., Markov S.O., Stenin D.V., Tyulenev M.A. Analysis of methods for calculating the productivity of open-pit hydraulic shovels and backhoes. Russian Mining Industry. 2022;(5):112–120. https://doi.org/10.30686/1609-9192-2022-5-112-120
20. Berdnikov I.E., Ozornin S.P. Mathematical models for determining the transport-technological machines failure rate depending on the factors of operating conditions. Modern Technologies. System Analysis. Modeling. 2017;(2):134–141.
21. Gericke P.B., Gericke B.L. Creation of a unified diagnostic criterion for assessing the technical condition of mining equipment. Mining Equipment and Electromechanics. 2021;(2):17–22. https://doi.org/10.26730/1816-4528-2021-2-17-22
22. Yusov D.S., Ivanova P.V., Ivanov S.L. Systematization of end effectors of deep milling machines for peat extraction. Russian Mining Industry. 2024;(3):85–89. https://doi.org/10.30686/1609-9192-2024-3-85-89
23. Mikhailov А.V., Smirnov A.I. Digging method analyzing organogenic materials mining by in-pit method. Mining Informational and Analytical Bulletin. 2026;(2-1):197–209. Available at: https://giab-online.ru/files/Data/2026/2-1/2-1_2026_197-209.pdf (accessed: 23.01.2026).
24. Babyr N.V., Kuziev D.A., Sazankova E.S., Dobler M.O. Influence of cyclic impacts of powered roof support on weakening of immediate roof rocks. Eurasian Mining. 2026;(1):14–19. Available at: https://www.rudmet.ru/journal/2523/article/41017/ (accessed: 17.04.2026).
25. Komissarov A.P., Lagunova Yu.A., Nabiullin R.Sh., Khoroshavin S.A. Digital model of shovel work process. Mining Informational and Analytical Bulletin. 2022;(4):156–168. https://doi.org/10.25018/0236_1493_2022_4_0_156
26. Muminov R.O., Ruzibaev A.N., Juraev N.N., Ravshanov J.R., Kuziev D.A. Development of measures to enhance the rotation and feed mechanism of a drill rig. Ugol’. 2024;(1):94–99. https://doi.org/10.18796/0041-5790-2024-1-94-99
27. Sosnina E.N., Asabin A.A., Bedretdinov R.S., Kryukov E.V., Gusev D.A. Thyristor booster device for voltage fluctuation reduction in power supply systems of ore mining enterprises. Journal of Mining Institute. 2025;272:159–170. Available at: https://pmi.spmi.ru/pmi/article/view/16450 (accessed: 25.03.2026).
28. Kantovich L.I., Litvin O.I., Khoreshok A.A., Tyuleneva E.A. Hydraulic excavators in coal-rich zones of open pit mines in Kuzbass: experience and prospects. Mining Informational and Analytical Bulletin. 2019;(4):152–160. https://doi.org/10.25018/0236-1493-2019-04-0-152-160
29. Dombrovsky N.G. Excavators: General Issues of Theory, Design, Research and Application. Moscow: Mashinostroenie; 1969. 319 p. (In Russ.)
30. Klementieva I.N., Kuziev D.A. Maximal stiffness of elastically damping device in traction of draglines. Gornyi Zhurnal. 2021;(5):79–83. https://doi.org/10.17580/gzh.2021.05.09
31. Malafeev S.I., Malafeeva A.A., Konyashin V.I., Novgorodov A.A. Mechatronic system for running-in and testing of mechanical transmissions in mining shovels. Mining Science and Technology (Russia). 2025;10(1):75–83. https://doi.org/10.17073/2500-0632-2024-05-262
32. Reshetnyak S.N., Zotov V.V., Kuziev D.A., Kozlova O.Yu. Enhancing performance efficiency of electric consumers within surface infrastructure of coal mines. Eurasian Mining. 2025;(1):100–104. https://doi.org/10.17580/em.2025.01.20
33. Khalimonenko A.D., Shmakova Yu.R., Admakina O.N., Kufaev V.G. High-speed face milling features of deformable aluminum alloys. Tsvetnye Metally. 2024;(6):81–88. https://doi.org/10.17580/tsm.2024.06.10
34. Khakulov V.A., Shapovalov V.A., Ignatov V.N., Karpova Zh.V., Ignatov M.V., Nogerov I.A. Justification of the rational scope and technology for the use of hydraulic excavators in surface mining. Mining Science and Technology (Russia). 2025;10(4):338–345. https://doi.org/10.17073/2500-0632-2025-09-460
35. Kuvshinkin S., Ivanova P. Impact analysis of bucket capacity and boom length of mining excavators on hoisting mechanism life. E3S Web of Conferences. 2021;326:00032. https://doi.org/10.1051/e3sconf/202132600032
