EXCAVATOR GREASE AUDIT REPORT

Reported By : Achmad Abdul Gani

Reported Date : Sunday, 07 April 2024

EQUIPMENT NO : EX3202 INSPECTION DATE : Saturday, 06 April 2024

UNIT MODEL : HITACHI EX2500-6 TRADES PERSON NAME : Achmad Abdul Gani , Agustinus Armes Armadi & Pomo Riyanto
SERIAL NO : HCM18L00A00001058 HOURS METER : 61718.8

Item Object to Inspection Condition/Facts/Finding Picture Action Picture

Check grease pump & motor Condition ( check oil

level , for leak , mounting bolt , ununusual noise Good N/A
and component fail )

Grease Pump 1 ( Front ) Check pressure gauge condition Good N/A

Check Auto & Manual Grease Operations Inspect

Good result ( Grease Actual
cycle time 10-15 Sec, grease pressure 2200-3000 N/A
Pressure : 2300 Psi )
psi

Check grease pump & motor Condition ( check oil

level , for leak , mounting bolt , ununusual noise Good N/A
and component fail )

Grease Pump 2 ( Rear ) Check pressure gauge condition Good N/A

Check Auto & Manual Grease Operations Inspect

Good result ( Grease Actual
cycle time 10-15 Sec, grease pressure 2200-3000 N/A
Pressure : 2300 Psi )
psi

Check idle timer working properly ( Spec : 3 - 10 Good result ( Set up on 5

N/A
minutes ) minutes )

Electronic Device
Check pressure switch , pressure sensor , switch
selector , automatic & manual greasing switch Good N/A
working properly

Check wiring system and connection Good N/A

 Found cover adjuster screw
Suggest for order cover adjuster screw ( P/N : 273088 )
missing ( 13 ea )

Check grease Injector Condition

Grease Injector

Good N/A

Check all grease nipples for manual greasing Good N/A

Check grease injector adjusment Adjustment is not yet standard Need adjust all grease injector

Check grease lines on grease pump Good N/A

Grease & hydraulic Lines

Check grease lines from grease pump to grease

Good N/A
point

Check hydraulic hose pilot condition Good N/A

Check grease tank mounting bolt Good N/A

Grease Tank

Check grease Tank floating plate if available Good N/A

Grease Point Inspect autolube grease point Good N/A

Ensure hydraulic vent valve working properly Good N/A

Ensure screen condition & check valve working

Others Good N/A
properly

Inspect grease unloader / safety valve Good N/A

Grease Consumption Audit

Usage Per Hour ( Actual )

Location Gram Per Cycle ( Spec ) Gram Per Cycle ( Actual ) - Usage Per Hour ( Spec ) -
Interval Time Gram Per Cycle ( Actual ) - Before Adjustment - gr / hour - Before Usage Per Hour ( Actual ) - gr / hour - After Adjustment
After Adjustment gr / hour
Adjustment

Boom Underside 5 Minutes 22.5 24.93 270 299.16

RH Bucket Link 5 Minutes 13.75 6.17 165 74.04

LH Bucket Link 5 Minutes 13.75 6.17 165 74.04

Upper Stick 5 Minutes 20 6.67 240 80.04

Lower Stick 5 Minutes 10 15.13 120 181.56

Front of House 5 Minutes 14.5 50.37 174 604.44

Total 94.5 109.44 0 1134 1313.28 0

Saving Result

Total Saving for Grease Consumption per Hour ( gram )

Total Saving for Grease Consumption per Day ( gram )

Total Saving for Grease Consumption per Month ( gram )

Total Saving for Grease Consumption per Year ( gram )

Audit Spreadsheet ( Before Adjustment )

Grease Injector Setting ( Number of Turn )

Location Pos Application Injector Type Spec Output ( gram ) Actual Output ( gram ) Remarks
Lincoln SLV XL Lincoln SLV

Boom Underside 1 Boom Foot Centre , Left Side SLV 5 2.80 Below Normal ( Needed Grease Injector Adjustment )

2 To Position 1 SLV

3 Stick Cylinder Barrel End , Left Side SLV 1.25 1.30 Normal

4 Bucket Cylinder Barrel End , Left Side SLV 1.25 1.47 Above Normal ( Needed Grease Injector Adjustment )

5 Stick Cylinder Rod End , Left Side SLV 1.25 0.70 Below Normal ( Needed Grease Injector Adjustment )

6 Spare SLV

7 Boom / Stick Pin , Left Side SLV 1.25 1.33 Normal

8 Boom Cylinder Barrel End , Left Side SLV 1.25 1.30 Normal

9 Boom Cylinder Barrel End , Right Side SLV 1.25 1.10 Normal

10 Spare SLV

11 Boom / Stick Pin , Right Side SLV 1.25 6.90 Grease Injector Broken ( Needed Grease Injector Replacement )

12 Stick Cylinder Rod End , Right Side SLV 1.25 0.63 Below Normal ( Needed Grease Injector Adjustment )

13 Bucket Cylinder Barrel End , Right Side SLV 1.25 1.20 Normal

14 Stick Cylinder Barrel End , Right Side SLV 1.25 3.67 Grease Injector Broken ( Needed Grease Injector Replacement )

15 Spare SLV

16 Boom Foot Centre , Right Side SLV XL 5 2.53 Below Normal ( Needed Grease Injector Adjustment )

Total 22.5 24.93

RH Bucket Link 1 Link Arm / Crowd Ram Inner , Right Side SLV 1.25 1.10 Normal

2 Link Arm / Crowd Ram center , Right Side SLV 1.25 1.13 Normal

3 Link Arm / Bucket Centre , Right Side SLV XL 5 1.97 Below Normal ( Needed Grease Injector Adjustment )

4 Link Arm / Crowd Ram Outer , Right Side SLV 1.25 1.97 Above Normal ( Needed Grease Injector Adjustment )

5 To Position 3 SLV XL 5

Total 13.75 6.17

LH Bucket Link 1 Link Arm / Crowd Ram Outer , Left Side SLV 1.25 1.07 Below Normal ( Needed Grease Injector Adjustment )

2 Link Arm / Crowd Ram Centre , Left Side SLV 1.25 1.93 Above Normal ( Needed Grease Injector Adjustment )

3 Link Arm / Bucket Centre , Left Side SLV XL 5 2.00 Below Normal ( Needed Grease Injector Adjustment )

4 To Position 3 SLV XL 5

5 Link Arm / Crowd Ram Inner , Left Side SLV 1.25 1.17 Normal

Total 13.75 6.17

Upper Stick 1 Main Bucket / Stick Bush centre, Left Side SLV XL 5 3.30 Below Normal ( Needed Grease Injector Adjustment )

2 To Position 1 SLV XL 5

3 To Position 4 SLV XL 5

4 Main Bucket / Stick Bush Centre, Right Side SLV XL 5 3.37 Below Normal ( Needed Grease Injector Adjustment )

Total 20 6.67

Lower Stick 1 Spare SLV

2 Main Bucket / Stick Pin, Left Side SLV XL 5 6.17 Grease Injector Broken ( Needed Grease Injector Replacement )

3 Main Bucket / Stick Pin, Right Side SLV XL 5 8.97 Grease Injector Broken ( Needed Grease Injector Replacement )

4 Spare SLV XL

Total 10 15.13

Front of House 1 Boom Cylinder Rod End , Left Side SLV XL 1.25 4.07 Above Normal ( Needed Grease Injector Adjustment )

2 Boom Cylinder Rod End , Right Side SLV 1.25 1.37 Normal

3 Swing SLV 0.75 1.43 Above Normal ( Needed Grease Injector Adjustment )

4 Swing SLV 0.75 1.47 Above Normal ( Needed Grease Injector Adjustment )

5 Swing SLV 0.75 1.40 Above Normal ( Needed Grease Injector Adjustment )

6 Swing SLV 0.75 1.33 Above Normal ( Needed Grease Injector Adjustment )

7 Spare SLV

8 Spare SLV XL

9 Swing SLV XL 0.75 1.97 Above Normal ( Needed Grease Injector Adjustment )

10 Swing SLV 0.75 0.60 Normal

11 Swing SLV XL 0.75 2.83 Above Normal ( Needed Grease Injector Adjustment )

12 Swing SLV 0.75 0.87 Normal

13 Swing SLV 0.75 1.07 Above Normal ( Needed Grease Injector Adjustment )

14 Swing SLV 0.75 0.90 Normal

15 Swing SLV 0.75 1.37 Above Normal ( Needed Grease Injector Adjustment )

16 Spare SLV

17 Spare SLV

18 Swing SLV 0.75 0.73 Normal

19 Spare SLV

20 Swing SLV 0.75 1.33 Above Normal ( Needed Grease Injector Adjustment )

21 Swing SLV 0.75 1.37 Above Normal ( Needed Grease Injector Adjustment )

22 Swing SLV 0.75 6.30 Grease Injector Broken ( Needed Grease Injector Replacement )

23 Spare SLV

24 Central Slew Joint SLV 0.75 19.97 Grease Injector Broken ( Needed Grease Injector Replacement )

Total 14.5 50.37