Excavator Audit Training Material

Grease Technical Training
MOST CONFIDENTIAL January 6, 2020 1

Agenda:
 We will talk about:

 Excavator Grease System
 Excavator Grease Inspection

Excavator Grease
System

DVR – Excavator Audit
Scope:
Definition: Benefit:
• Over/Under
• Excavator
system E2E
Greasing • $$$
• Injectors &
Pumps Saving
• Hoses &
Lines
DEFINITION
Excavator audit is an end to end process to observe the auto lube system in a digger.
In this auto lube system, grease was started from grease tank and ended in bearings.
VI
I II III IV V
Bearings /
Grease Tank Pump Hoses / Lines Injectors Hoses / Lines
Pins / Bushes
Controller
VI
I II III IV V
Bearings /
Grease Tank Pump Hoses / Lines Injectors Hoses / Lines
Pins / Bushes
Controller
VI
I II III IV V
Bearings /
Grease Tank Pump Hoses / Lines Injectors Hose s/ Lines
Pins / Bushes
Excavator Grease
System
Inspection & Audits

Excavator Grease System Inspection & Audits

 Report tells you:

 Grease Consumption vs
Specs
 Area of improvements
 Recommendations

PREPARATION
 Personal Protection Equipments (PPE)

 Tools
 Scope of work
 Reporting
• Actual condition of greasing system
• Specification versus actual


Personal Protective Equipments (PPE)
 Hard helmet
 Goggle
 Ear plug
 Glove
 Safety shoe
 Reflective vest
Additional
 Job Safety Analysis
 LOTO Padlock
 Falling protector

Tools
 Pen / notes / marker

 Camera
 Wrenches
 Plastic clip
 Timer
 Digital scale


SCOPE OF WORKS
1. Positioning the machine.

2. Machine walk around inspection
3. Opening injectors and install plastic clip
4. Run the engine
• Observe & record the energize pressure
• Use timer (stopwatch) to figure out the cycle
time.
• Collect 2 or 3 sample grease
5. Reconnect the injectors

SCOPE OF WORKS

4. Run the engine
time.

Scope of Work
1. Positioning the machine to allow access to all injector’s banks
Boom Under
FOH Stick Upper

Stick Lower
Crowd Link RH/LH

Scope of Work
1. Positioning the machine to allow access to all injector’s banks
Stick Upper
FOH
Stick Lower
Link & Bucket

SCOPE OF WORKS

2. Machine walk around
inspection
4. Run the engine
time.
6. Finish

Scope of Work
2.Machine walk around inspection (auto lube system)
•Service Meter Unit

•Pump
•Pressure gauge
•Cycle timer
•Injectors
•Lines
•Hoses
•Pins

Scope of Work
2. Inspecting the machine (auto lube system) - PUMP

Scope of Work
2. Inspecting the machine (auto lube system) – PRESSURE GAUGE

Scope of Work
2. Inspecting the machine (auto lube system) – CYCLE TIMER

Scope of Work
2. Inspecting the machine (auto lube system) -
INJECTORS
Injector’s Bank position
• Front of house
• Crowd link arm LH
• Crowd link arm RH
• Stick upper
• Stick lower
• Boom under

Scope of Work
2. Inspecting the machine (auto lube system) - LINES
Damage lines
• Broken lines
• Crimped lines
• Bent lines

Scope of Work
2. Inspecting the machine (auto lube system) - HOSES

Scope of Work

Scope of Work

Scope of Work

Scope of Work
2. Inspecting the machine (auto lube system) - PINS
Concerned points are:

• Dry pins
• Missing seals
• Missing bolts
• etc

SCOPE OF WORKS

3. Opening injectors and install plastic
clip
4. Run the engine
• Use timer (stopwatch) to figure out the cycle time.
6. Finish

Scope of Work
3. Opening injectors and install plastic clip – record the lubrication
points of each injectors and record the injector type and output
setting each injectors.
SL - 1 SLV SLV-XL SL-11 LM-5

Scope of Work
setting each injectors. SLV & SLV XL

Scope of Work
setting each injectors. SLV & SLV XL

Scope of Work
setting each injectors. SL-1

Scope of Work
setting each injectors. SL-11

Scope of Work
setting each injectors. LM-5

Scope of Work
setting each injectors. LM-5

Scope of Work
3. Opening injectors and install plastic clip – attach plastic clip on
each injectors.

SCOPE OF WORKS

4. Run the engine
•Observe & record the energize
pressure
•Use timer (stopwatch) to figure
out the cycle time.
•Collect 2 or 3 sample grease
6. Finish

Scope of Work
4. Run the engine

Injector Specification Comparison:

Output Range in³ (cc) Operating Pressure (psi) Max. Vent Pressure (psi)
SL-V .014 (.02) to .080 (1.31) 1,850 to 6,000 1,000

SL-1 .008 (.131) to .080 (1.31) 1,850 to 3,500 600
SL-V HO* .025 (.41) to .305 (5.0) 1,850 to 6,000 1,000
SL-11 .050 (.82) to .500 (8.2) 1,850 to 3,500 800
LM – 5 .050 (.82) to .500 (8.2) 1,000 to 3,500
* Note: (2) SLVs are required to replace one SL-11 injector

Suggested pressure

SCOPE OF WORKS

4. Run the engine
• Use timer (stopwatch) to figure out the cycle time.
6. Finish

Scope of Work


All of inspection & audit activities must be recorded on a

comprehensive report.
Full audit report consist of Inspection Report and Grease
Consumption Table




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Grease Technical Training

MOST CONFIDENTIAL January 6, 2020 1

 We will talk about:

MOST CONFIDENTIAL January 6, 2020 2

MOST CONFIDENTIAL January 6, 2020 3

MOST CONFIDENTIAL January 6, 2020 8

MOST CONFIDENTIAL January 6, 2020 9

 Report tells you:

MOST CONFIDENTIAL January 6, 2020 10

 Personal Protection Equipments (PPE)

MOST CONFIDENTIAL January 6, 2020 11

MOST CONFIDENTIAL January 6, 2020 12

MOST CONFIDENTIAL January 6, 2020 14

 Pen / notes / marker

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1. Positioning the machine.

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1. Positioning the machine.

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FOH Stick Upper

Crowd Link RH/LH

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Link & Bucket

1. Positioning the machine.

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•Service Meter Unit

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Concerned points are:

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1. Positioning the machine.

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SL - 1 SLV SLV-XL SL-11 LM-5

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1. Positioning the machine.

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Injector Specification Comparison:

SL-V .014 (.02) to .080 (1.31) 1,850 to 6,000 1,000

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1. Positioning the machine.