Express diagnostics of power transmission systems of mine excavators

In conditions of intensified mining operations, the EKG-20K open-pit excavators in Uzbekistan and Russia demonstrate high levels of unscheduled downtime for their pressure and lift drives, accounting for 36–44% of the total equipment downtime. Traditional preventive and predictive maintenance methods fail to provide the required level of availability. This paper proposes a Conscientious Maintenance and Repair concept that integrates an adapted Fine-Kinney method with express field diagnostics of oil and an algorithm for a comprehensive assessment of the technical condition. The integrated algorithm automates the Diagnostic Trouble Codes (DTC) and the Equipment Health Index (EHI). A key indicator of the technical condition is the content of iron, zinc, and phosphorus in the oil, which enables prediction of failures with a high degree of probability. The system includes a five-stage analysis procedure, a unified DTС system, and a risk assessment matrix in accordance with GOST. Implementation of the Conscientious Maintenance and Repair System ensures an increase in the fleet availability up to 0.9 and a reduction in unscheduled downtime by 20–30% without increasing costs, as well as a 19.7% increase in the service life of the lift and thrust gearboxes