Proper lubrication is critical for heavy mining machinery to operate efficiently and reliably. When lubrication breakdowns occur, it can lead to increased wear on components, higher operating temperatures, loss of efficiency, and ultimately, downtime for repairs or replacement of parts.

By following lubrication best practices, mine operators can extend the service intervals on their equipment, minimize unplanned downtime, and reduce maintenance costs over the life of the asset.

Establish A Lubrication Schedule

The foundation of an effective lubrication program is establishing a schedule and checklist for lubricating all points on the equipment. This schedule should outline the lubrication tasks, frequency, specifications, procedures and responsibility. Critical components like bearings, gears and hydraulic systems typically require frequent re-lubrication, while grease fittings may only need servicing annually. Consult the OEM manuals to determine the proper lubricant types and intervals for all points and organize them on a schedule. Use software or apps to track completions and placard the equipment with labels outlining each lube point and service frequency.

Select The Right Lubricants

Choosing the right lubricant is critical based on the component and operating conditions. OEM specifications will dictate if a synthetic or mineral oil, gear oil, hydraulic fluid or grease is required. Ensure the lubricant has the proper viscosity grade, additive package and performance designations for the application. Environmental factors like moisture, dust, extreme temperatures and heavy loads require specific formulations. Consult closely with lubricant suppliers to match the appropriate product to each application based on OEM specifications and operating environment. Using the wrong lubricant can lead to damage or wear.

Utilize Lubrication Analysis

Lubricant analysis is a vital part of a preventative maintenance program. Known as oil analysis, samples are taken at scheduled intervals and analyzed at a lab to detect component wear, contamination, improper lubrication and oil condition. Key tests check viscosity, acidity, water content, soot levels and metal particles. Outliers in the results can indicate issues like excessive wear, failures, dust infiltration or wrong lubricants. This allows mine operators to take corrective action before a minor issue leads to catastrophic failure. Invest in analysis for critical components, and major systems like engines, transmissions and hydraulics.

Practice Contamination Control

Preventing contaminant ingress into lubrication systems is critical for equipment protection and uptime. Dust and dirt will quickly degrade lubricant health and performance. Utilize the best breathers, filters, caps and seals to keep systems clean during operation and maintenance. Store lubricants in closed containers in clean spaces only accessible by lubrication technicians. During oil changes, use lint-free gloves, avoid dipping into lubricant containers, and properly clean the caps, fittings and fill areas to prevent ingress. Small actions limit the contamination levels to preserve oil life and equipment reliability.

Train Maintenance Personnel

Developing skilled, competent lubrication technicians ensures proper practices are adhered to. Offer comprehensive training on lubricant classifications, schedules, procedures, analysis and contamination control. Clearly outline the importance of precision lubrication for safety, environmental compliance and production levels. Conduct hands-on training at the equipment using the lubricants, tools and methods techs will apply in the field. Emphasize that lubrication is not a check-the-box activity, but a vital maintenance function requiring attention to detail, care of equipment and quality execution. Instill a culture and mindset focused on proper lubrication.

Standardize Storage & Handling

Inefficiencies during lubricant handling, dispensing and usage leads to greater consumption and waste. Standardize methods to limit cross contamination, spills and over-application. Store lubricants based on classification in clearly labeled containers segregated by source and circulating oils. Dispense precise amounts utilizing pumps instead of opening drums. Use software to assign lubricants to equipment and track consumption which improves forecasting of volumes needed. Standardization minimizes environmental incidents, enhances inventory management and allows better evaluation by lubricant type of asset performance.

Implement Tribology Testing

Tribology is the science of interacting surfaces, friction, heat and wear on components, which provides meaningful data on asset health and lubricant effectiveness. Specialized testing identifies development of friction layers, corrosion, micro pitting, undesirable movement or lack of sufficient viscosity. This emerging technology is being applied by mine operators to detect issues in bearings, gears, bushings and other critical elements which experience surface interactions. The testing can validate that the proper lubricant formulation is protecting the equipment as intended based on OEM guidelines and operating loads.

Audit Program Execution

The first six elements only produce results if thoroughly executed at the site level. Conduct regular audits of the lubrication program covering scheduling, lubricant selection, analysis trends, contamination control, personnel competency and storage procedures. Identify gaps where practices are not being adhered to or documentation is incomplete. Enforce compliance with protocols through management oversight and supervision of activities. Well-designed programs will fail without disciplined field execution. Share success stories and corrective actions across the organization. Program audits ensure lubrication receives the requisite attention needed for heavy mining equipment reliability.

Final Words

In summary, heavy mining machinery is some of the most expensive equipment to maintain and repair. Proper lubrication programs maximize availability and protect these capital investments from unnecessary downtime.

By strategically applying lubricants, controlling contamination, validating with oil analysis, enhancing storage/handling methods and auditing program compliance, mine operators can significantly extend component life, identify failures in advance, reduce repair costs, and maximize production. The effort devoted to lubrication best practices is returned many times over through enhanced equipment reliability.