EXCAVATOR GREASE AUDIT REPORT

Reported By : Andi Bau Onggong

Reported Date : Sunday, 09 June 2024

EQUIPMENT NO : EX9003 INSPECTION DATE : Wednesday, 05 June 2024

UNIT MODEL : LIEBHERR R9350 TRADES PERSON NAME : Andi Bau Onggong , Agustinus Armes Armadi , Pomo Riyanto
SERIAL NO : HOURS METER : 48453,5

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

Check grease pump & motor Condition ( check oil level , for leak , mounting bolt ,
Good N/A
ununusual noise and component fail )

Grease Pump 1 ( P1 )

Check pressure gauge condition Good N/A

Check Auto & Manual Grease Operations Inspect cycle time 10-15 Sec, grease pressure Good result ( Grease Actual
N/A
2200-3000 psi (+/- 200 Bar) Pressure : 208 Bar )

Check grease pump & motor Condition ( check oil level , for leak , mounting bolt ,
Good N/A
ununusual noise and component fail )

Grease Pump 3 ( P3 )
Check pressure gauge condition Good N/A

Check Auto & Manual Grease Operations Inspect cycle time 10-15 Sec, grease pressure Good result ( Grease Actual
N/A
120 - 150 Bar Pressure : 120 Bar )

Good result ( P1 set up on 6

Check idle timer working properly ( Spec : 4 - 10 minutes ) minutes & P3 set up on 8 minutes N/A
)

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

Check wiring system and connection Good N/A

Good N/A
 Good N/A

Check grease Injector Condition

Grease Injector

Good N/A

Check all grease nipples for manual greasing Good N/A

Check grease injector adjusment

Check grease lines on grease pump

Grease & hydraulic Lines

Check grease lines from grease pump to grease point Good N/A

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 properly Good N/A
Others

Inspect grease unloader / safety valve Good N/A

Grease Consumption Audit

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

TOP FRONT BOOM BANK 6 Minutes 5,28 5,77 52,8 57,7

TOP LOWER BOOM BANK 6 Minutes 5,28 9,90 52,8 99

LHS TOP BOOM BANK 6 Minutes 4,62 6,13 46,2 61,3

RHS TOP BOOM BANK 6 Minutes 4,62 5,23 46,2 52,3

UPPER STICK BANK 6 Minutes 13,2 129,93 132 1299,3

LOWER STICK BANK 6 Minutes 9,9 22,67 99 226,7

LH LINK BANK 6 Minutes 10,56 18,13 105,6 181,3

RH LINK BANK 6 Minutes 10,56 17,67 105,6 176,7

BUCKET BANK 6 Minutes 18,48 23,90 184,8 239

FRONT OF HOUSE BANK 6 Minutes 14,52 23,87 145,2 238,7

IN HOUSE BANK 6 Minutes 10 11,57 100 115,7

Total 107,02 274,77 1070,2 2747,7

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
Rotation ( Turn ) Length ( mm )
TOP FRONT BOOM BANK
1 LHS Boom to Stick Middle Bearing ( 12m ) LM5 2,64 2,87 Normal

2 RHS Boom to Stick Middle Bearing ( 12m ) LM5 2,64 2,90 Normal

Total 5,28 5,77

TOP LOWER BOOM BANK

1 LHS Boom Foot Middle Bearing ( 8m ) LM5 2,64 5,10 Above Normal ( Needed Grease Injector Adjustment )

2 RHS Boom Foot Middle Bearing ( 8m ) LM5 2,64 4,80 Above Normal ( Needed Grease Injector Adjustment )

Total 5,28 9,90

LHS TOP BOOM BANK

1 LHS Boom to Stick Cylinder Head End Outside & Inside Cover ( 13a-13i ) LM5 1,32 1,33 Normal

2 LHS Boom Cylinder Head End to Boom Outside Cover ( 14a ) LM5 0,66 0,87 Normal

3 LHS Boom Cylinder Head End to Boom Middle Bearing ( 14m ) LM5 1,32 1,10 Normal

4 LHS Boom Cylinder Head End to Boom Inside Cover ( 14i ) LM5 0,66 1,10 Above Normal ( Needed Grease Injector Adjustment )

5 LHS Boom to Stick Cylinder Head End Middle Bearing ( 13m ) LM5 0,66 1,73 Above Normal ( Needed Grease Injector Adjustment )

Total 4,62 6,13

RHS TOP BOOM BANK

1 RHS Boom to Stick Cylinder Head End Outside & Inside Cover ( 13a-13i ) LM5 1,32 0,90 Normal

2 RHS Boom Cylinder Head End to Boom Outside Cover ( 14a ) LM5 0,66 0,83 Normal

3 RHS Boom Cylinder Head End to Boom Middle Bearing ( 14m ) LM5 1,32 1,23 Normal

4 RHS Boom Cylinder Head End to Boom Inside Cover ( 14i ) LM5 0,66 0,80 Normal

5 RHS Boom to Stick Cylinder Head End Middle Bearing ( 13m ) LM5 0,66 1,47 Above Normal ( Needed Grease Injector Adjustment )

Total 4,62 5,23

UPPER STICK BANK

Injector grease bypass (Broken) HAS BEEN REPLACE AFTER
1 LHS Stick Cylinder Rod End to Stick Middle Bearing ( 19m ) LM5 0,66 32,27
GREASE AUDIT

Injector grease bypass (Broken) HAS BEEN REPLACE AFTER

2 Stick Cylinder Rod End t to Stick Outside & Inside Cover ( 19a-19i ) LM5 2,64 11,90
GREASE AUDIT

Injector grease bypass (Broken) HAS BEEN REPLACE AFTER

3 RHS Stick Cylinder Rod End t to Stick Middle Bearing ( 19m ) LM5 0,66 11,37
GREASE AUDIT

Injector grease bypass (Broken) HAS BEEN REPLACE AFTER

4 LHS Stick to Bucket Cylinder Head End Outside & Inside Cover ( 18a-18i ) LM5 1,32 21,53
GREASE AUDIT

Injector grease bypass (Broken) HAS BEEN REPLACE AFTER

5 LHS Stick to Bucket Cylinder Head End Middle Bearing ( 18m ) LM5 0,66 21,47
GREASE AUDIT

6 LHS Boom to Stick Outside Cover ( 12a) LM5 1,32 1,43 Normal

7 N/A LM5

8 N/A LM5

9 LHS Boom to Stick Inside Cover ( 12i ) LM5 1,32 1,60 Normal

Injector grease bypass (Broken) HAS BEEN REPLACE AFTER

10 RHS Stick to Bucket Cylinder Head End Outside & Inside Cover ( 18a-18i ) LM5 1,32 11,37
GREASE AUDIT

Injector grease bypass (Broken) HAS BEEN REPLACE AFTER

11 RHS Stick to Bucket Cylinder Head End Middle Bearing ( 18m ) LM5 0,66 0,00
GREASE AUDIT

Injector grease bypass (Broken) HAS BEEN REPLACE AFTER

12 RHS Boom to Stick Outside Cover ( 12a) LM5 1,32 0,00
GREASE AUDIT

13 N/A LM5

14 N/A LM5

Injector grease bypass (Broken) HAS BEEN REPLACE AFTER

15 RHS Boom to Stick Inside Cover ( 12i ) LM5 1,32 17,00
GREASE AUDIT

Total 13,2 129,93

LOWER STICK BANK

1 LHS Stick to Shift Lever Middle Bearing ( 20m ) LM5 1,98 2,77 Above Normal ( Needed Grease Injector Adjustment )

2 LHS Stick to Bucket Middle Bearing / LHS Main Bucket Pin ( 17m ) LM5 2,97 8,63 Above Normal ( Needed Grease Injector Adjustment )

3 Jumper to Grease Injector No.2 LM5

4 Jumper to Grease Injector No.5 LM5

5 RHS Stick to Bucket Middle Bearing / RHS Main Bucket Pin ( 17m ) LM5 2,97 8,47 Above Normal ( Needed Grease Injector Adjustment )

6 RHS Stick to Shift Lever Middle Bearing ( 20m ) LM5 1,98 2,80 Below Normal ( Needed Grease Injector Adjustment )

Total 9,9 22,67

LH LINK BANK
1 Bucket Cylinder Rod End to Shift Lever Middle Bearing ( 24m ) LM5 1,98 5,00 Below Normal ( Needed Grease Injector Adjustment )

2 Stick to Shift Lever Outside & Inside Cover ( 20a-20i ) LM5 2,64 4,90 Below Normal ( Needed Grease Injector Adjustment )
 LH LINK BANK

3 Bucket Cylinder Rod End to Shift Lever Inside Cover ( 24i ) LM5 0,33 1,13 Above Normal ( Needed Grease Injector Adjustment )

4 Bucket Cylinder Rod End to Shift Lever Outside Cover ( 24a ) LM5 0,33 1,77 Above Normal ( Needed Grease Injector Adjustment )

5 Bucket Cylinder Rod End to Shift Lever Outside & Inside Cover ( 24a-24i ) LM5 2,64 2,70 Normal

6 Shift Lever to Connecting Link Outside & Inside Cover ( 23a-23i ) LM5 2,64 2,63 Normal

Total 10,56 18,13

RH LINK BANK
1 Bucket Cylinder Rod End to Shift Lever Middle Bearing ( 24m ) LM5 1,98 3,63 Above Normal ( Needed Grease Injector Adjustment )

2 Stick to Shift Lever Outside & Inside Cover ( 20a-20i ) LM5 2,64 3,20 Above Normal ( Needed Grease Injector Adjustment )

3 Bucket Cylinder Rod End to Shift Lever Inside Cover ( 24i ) LM5 0,33 2,20 Above Normal ( Needed Grease Injector Adjustment )

4 Bucket Cylinder Rod End to Shift Lever Outside Cover ( 24a ) LM5 0,33 1,87 Above Normal ( Needed Grease Injector Adjustment )

5 Bucket Cylinder Rod End to Shift Lever Outside & Inside Cover ( 24a-24i ) LM5 2,64 3,17 Above Normal ( Needed Grease Injector Adjustment )

6 Shift Lever to Connecting Link Outside & Inside Cover ( 23a-23i ) LM5 2,64 3,60 Above Normal ( Needed Grease Injector Adjustment )

Total 10,56 17,67

BUCKET BANK
1 RHS Connecting Link to Bucket Outside & Inside Cover ( 28a-28i ) LM5 2,64 3,67 Above Normal ( Needed Grease Injector Adjustment )

2 RHS Connecting Link to Bucket Middle Bearing ( 28m ) LM5 1,98 3,27 Above Normal ( Needed Grease Injector Adjustment )

3 RHS Shift Lever to Connecting Link Middle Bearing ( 23m ) LM5 1,98 2,63 Above Normal ( Needed Grease Injector Adjustment )

4 Spare LM5

5 RHS Stick to Bucket Inside Cover ( 17i ) LM5 2,64 3,97 Above Normal ( Needed Grease Injector Adjustment )

6 Spare LM5

7 Spare LM5

8 LHS Stick to Bucket Inside Cover ( 17i ) LM5 2,64 3,23 Above Normal ( Needed Grease Injector Adjustment )

9 LHS Shift Lever to Connecting Link Middle Bearing ( 23m ) LM5 1,98 2,13 Normal

10 LHS Connecting Link to Bucket Middle Bearing ( 28m ) LM5 1,98 2,03 Normal

11 LHS Connecting Link to Bucket Outside & Inside Cover ( 28a-28i ) LM5 2,64 2,97 Normal

12 Spare LM5

Total 18,48 23,90

FRONT OF HOUSE BANK

1 LHS Boom Cylinder Rod End Inside Cover ( 9i ) LM5 1,32 3,73 Above Normal ( Needed Grease Injector Adjustment )

2 LHS Boom Cylinder Rod End Outside Cover ( 9a) LM5 1,32 4,37 Below Normal ( Needed Grease Injector Adjustment )

3 LHS Boom Cylinder Rod End Middle Bearing ( 9m ) LM5 2,64 2,97 Normal

4 LH Boom Foot Outside Cover ( 8a) LM5 1,32 2,63 Above Normal ( Needed Grease Injector Adjustment )

5 Boom Foot Inside Cover ( 8i ) LM5 1,32 2,53 Above Normal ( Needed Grease Injector Adjustment )

6 RH Boom Foot Outside Cover ( 8a) LM5 1,32 1,77 Normal

7 RHS Boom Cylinder Rod End Middle Bearing ( 9m ) LM5 2,64 2,57 Normal

8 RHS Boom Cylinder Rod End Outside Cover ( 9a) LM5 1,32 1,53 Above Normal ( Needed Grease Injector Adjustment )

9 RHS Boom Cylinder Rod End Inside Cover ( 9i ) LM5 1,32 1,77 Normal

10 Spare LM5

11 Spare LM5

Total 14,52 23,87

IN HOUSE BANK
1 Slew Ring Top of The Bearing ( DK Top ) LM5 5 5,23 Normal

2 Slew Ring Bottom of The Bearing ( DK Bottom ) LM5 5 5,13 Normal

Total 10 10,37