Installation Manual

Automatic TWIN Greasing System

Excavator
Volvo EW180B
EF17166

your efficiency is our challenge

All rights reserved. No part of this manual may be copied and/or published by means of printing, photocopying,
microfilm or by any other means without prior written permission from Groeneveld. This applies also to the
drawings and diagrams appended.

Groeneveld reserves the right to change parts at any time, without prior or direct notice to the customer. The
contents of this manual may also be changed without prior notice.

This manual applies to the standard version of the product. Groeneveld cannot accept liability for any damage
arising from the use of specifications other than that supplied.

You are requested to contact Groeneveld technical service for information concerning adjustment, maintenance
work or repairs that is not described in this manual.

Whilst this manual has been prepared with the greatest possible care Groeneveld cannot accept responsibility for
any errors of the concequences of such errors.
 Excavator Volvo EW180B

1.
q^_ib=lc=`lkqbkqp
1. Preface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.1. General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.2. Use of symbols - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.3. Safety precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
1.4. General fitting instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

2. System lay-out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
2.1. F174996 Twin 4+4-port block, complete - - - - - - - - - - - - - - - - - - - - - - 12
2.2. F174997 Twin 12-port block, complete - - - - - - - - - - - - - - - - - - - - - - - 14
2.3. F174998 Twin 4+4-port block, complete - - - - - - - - - - - - - - - - - - - - - - 16
2.4. F174999 Twin 3+3-port block, complete - - - - - - - - - - - - - - - - - - - - - - 18

3. Grease point location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

4. Grease pump installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

4.1. F175000 Twin pumpkit Volvo EW180B - - - - - - - - - - - - - - - - - - - - - - - - 26

5. Electrical components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
5.1. F175001 Electronics installation kit Volvo EW180B - - - - - - - - - - - - - - - 30

6. Distribution blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
6.1. F175002 Installation kit Twin 4+4-port block / F174996 B1 - - - - - - - - - 34
6.2. F175003 Installation kit Twin 12-port block / F174997 B2 - - - - - - - - - - 38
6.3. F175004 Installation kit Twin 4+4-port block / F174998 B3 - - - - - - - - - 42
6.4. F175005 Installation kit Twin 3+3-port block / F174999 B4 - - - - - - - - - 46

7. Installation main line - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

7.1. F175006 Twin Main line kit Volvo EW180B - - - - - - - - - - - - - - - - - - - - 50

8. Parameter settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

9. Testing of the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

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EF17166 Table of contents 3

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Date of issue: January 2004

4 Table of contents EF17166

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1.

1.
PREFACE
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EF17166 Preface 5
 Excavator Volvo EW180B

1.1 General information

This installation manual describes the installation of the Twin-system on the Volvo
Excavator type EW180B.

Automatic Twin Grease Lubrication System

Machine type Number of Groeneveld OEM order Manual

grease points order number number
number

Volvo
23 x F174995 - EF17166 P0
EW180B

1.2 Use of symbols

Symbol Explanation
H High pressure hose 1/4” I/D or 3/8” I/D
1/4” S6-200-E6 1/4” = internal diameter
S6 = connector straight ø6 mm
200 = lenght (mm)
E6 = connector elbow ø6 mm
P Grease pump
PS Main line pressure switch

Distribution block

Position number on the parts list

Grease point position number

BK Black
BN Brown
BU Blue
RD Red
GY Grey
Date of issue: January 2004

YE Yellow
BR Brass
PA Polyamide
SST Stainless steel
ST-YG Yellow passivated steel
ST-G Galvanised steel

6 Preface EF17166
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1.3 Safety precautions

For starting installation, carry out the following tasks:
• Remove ignition key to prevent engine from starting while you are working.
• Block all moving parts, like lifting frames, breaking points and mast parts.
• Block the wheels.
• Follow machine manufacturer’s guidelines for general safety and precautions.

During activities that require a lifting jack:

• The machine should not rest on the lifting jack solely. Use additional support.

General:
• Always keep your work area clean.

1.4 General fitting instructions

Before
• Check if all the parts of the Twin-system are present by using the parts list.
• Check if all the grease points are open and provided with grease. Lubricate
the grease points if there is not sufficient grease. This way damage due to
insufficient grease is prevented.

During installation
• Prevent dirt from entering the system during installation.
• Use clean tools.
• Clean the machine at points, where the pump and the distribution blocks
have to be installed. Even small pollution can cause failure of the system!
• Even if stud couplings or plugs are not provided with an O-ring sealing or
sealing ring, use teflon tape or a liquid sealing agent.
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EF17166 Preface 7
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Notes

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8 Preface EF17166
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2.

2.
SYSTEM LAY-OUT
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Parts list

The Twin-system for the Volvo EW180B comprises the following parts:

Kit number Groeneveld order Description

number

F175000 Twin pumpkit Volvo EW180B

F175001 Electronics installation kit Volvo EW180B

F174996 F175002 Installation kit Twin 4+4-port block B1

F174997 F175003 Installation kit Twin 12-port block B2

F174998 F175004 Installation kit Twin 4+4-port block B3

F174999 F175005 Installation kit Twin 3+3-port block B4

F175006 Twin Main line kit Volvo EW180B

F175007 A5 manual Volvo EW180B

XU1701D User’s manual TWIN

830326 High-pressure hose 1/4” S10-1250-S10 H1 2x

F171419 High-pressure hose 3/8” E10-3500-S10 H2 2x

F174446 High-pressure hose 3/8” S10-5000-nothing H3 2x

F174447 High-pressure hose 3/8” S10-2500-nothing H4 2x

F173960 High-pressure hose 1/4” S10-3500-nothing H5 2x

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Parts list

2.1 F174996 Twin 4+4-port block, complete

Pos. Q’ty Groeneveld order Description

number

1 2 32901 Threaded plug 1/4” BR

2 2 83901 Sealing ring

3 2 72122 Body, male stud coupling 1/4” - ø10 mm ST-YG

4 3 70701 Shut-off plug M22 x 1 BR

5 2 71201 Metering unit No.8 - 0.400cc/M22/6mm/BR

6 3 72701 Metering unit No.6 - 0.300cc/M22/6mm/BR

7 1 77201 Twin 4+4-port block BR

8 2 840010 H.P.H. ø4 mm ID S6-1000-S6

9 2m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

10 0.75m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

11 2m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

12 5 02717 Protective cap ø6 mm

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EF17166 System lay-out 13

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Parts list

2.2 F174997 Twin 12-port block, complete

Pos. Q’ty Groeneveld order Description

number

1 2 32901 Threaded plug G1/4” BR

2 2 83901 Sealing ring

3 2 72722 Body, T-male stud ø10 mm - 1/4” - ø10 mm ST-YG

4 5 70701 Shut-off plug M22x1 BR

5 1 70801 Metering unit No.1 - 0.050cc/M22/6mm/BR

6 4 70901 Metering unit No.2 - 0.100cc/M22/6mm/BR

7 2 72701 Metering unit No.6 - 0.300cc/M22/6mm/BR

8 1 70601 Twin 12-port block M10 BR

9 2m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

10 2m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

11 2m 77401 Grease pipe 2 x ø6 mm x 1.5 PA per m

12 2m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

13 2m 77401 Grease pipe 2 x ø6 mm x 1.5 PA per m

14 3 02717 Protective cap ø6 mm

15 2 28401 Protective cap ø9.5 mm

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EF17166 System lay-out 15

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Parts list

2.3 F174998 Twin 4+4-port block, complete

Pos. Q’ty Groeneveld order Description

number

1 2 32901 Threaded plug G1/4” BR

2 2 83901 Sealing ring

3 2 47202 Male stud coupling 1/4” - ø10 mm ST-YG

4 1 72322 Body, male stud elbow 1/4” - ø10 mm ST-YG

5 1 80901 T-swivel coupling ø10 mm ST-YG

6 1 83801 Reduction adaptor M22 - 1/4” B.O. BR

7 1 70801 Metering unit No.1 - 0.050cc/M22/6mm/BR

8 1 71001 Metering unit No.3 - 0.150cc/M22/6mm/BR

9 2 72701 Metering unit No.6 - 0.300cc/M22/6mm/BR

10 1 79601 Metering unit No.9 - 1.000cc/M22/6mm/BR

11 1 91001 Metering unit No.10 - 2.000cc/M22/6mm/BR

12 1 73701 Pressure switch 100 bar, complete

13 1 77201 Twin 4+4-port block BR

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EF17166 System lay-out 17

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Parts list

2.4 F174999 Twin 3+3-port block, complete

Pos. Q’ty Groeneveld order Description

number

1 2 32901 Threaded plug 1/4” BR

2 2 83901 Sealing ring

3 1 72122 Body, male stud coupling 1/4” - ø10 mm ST-YG

4 1 72322 Body, male stud elbow 1/4” - ø10 mm ST-YG

5 1 80801 Elbow swivel coupling ø10 mm ST-YG

6 1 70701 Shut-off plug M22x1 BR

7 3 71101 Metering unit No.4 - 0.200 cc/M22/6mm/BR

8 2 79601 Metering unit No.9 - 1.000 cc/M22/6mm/BR

9 1 76701 Twin 3+3-port block BR

10 0.2m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

11 0.2m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

12 1 840003 H.P.H. ø4 mm ID S6-0400-S6

13 3 02717 Protective cap ø6 mm

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EF17166 System lay-out 19

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Notes

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3.

3.
GREASE POINT LOCATION
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EF17166 Grease point location 21

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EF17166 Grease point location 23

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Notes

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24 Grease point location EF17166

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4.

4.
GREASE PUMP INSTALLATION
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Parts list

4.1 F175000 Twin pumpkit Volvo EW180B

Pos. Q’ty Groeneveld order Description

number

1.1 1 01901 Quick connector female

1.2 1 02001 Quick connector male

1.3 1 03501 Dust cap, quick connector male

1.4 4 128030 Allen bolt M8 x 30 ST-G

1.5 4 220008 Nut, self-locking M8 ST-G

1.6 4 300008 Washer M8 ST-G

1.8 1 F174482 Cable harness, pump

1.12 1 F175008 Bracket, pump

1.13 1 F116316 Pump 12cc/24V/3L/250bar/VCE

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Notes

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5.

5.
ELECTRICAL COMPONENTS
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Parts list

5.1 F175001 Electronics installation kit Volvo EW180B

Pos. Q’ty Groeneveld order Description

number

2.1 100 00208 Cable tie, black 186 mm

2.2 1 04912 Cable harness, pressure switch 15m

2.3 1 180101 Connector 3-pole female

2.4 1 180102 Connector 2-pole male

2.5 1 F170671 Twin Display Unit

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30 Electrical components EF17166

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EF17166 Electrical components 31

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Pressure switch in the

main lines
Fuse

Twin pump with integrated

control unit Date of issue: January 2004

32 Electrical components EF17166

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6.

6.
DISTRIBUTION BLOCKS
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Parts list

6.1 F175002 Installation kit Twin 4+4-port block / F174996 B1

Pos. Q’ty Groeneveld order Description

number

3.1 2 09202 Spring washer 6.4

3.2 25 00208 Cable tie, black 186 mm

3.3 2 126010 Allen bolt M6 x 10 ST-G

3.4 2 126030 Allen bolt M6 x 30 ST-G

3.5 1 F174481 Bracket 4+4-port block

3.6 1 F174996 Twin 4+4-port block, complete

3.7 2 08608 Reduction connector 1/4” - 1/8” BR

3.8 2 43402 Male stud coupling 1/8” - ø6 mm ST-YG

3.9 3 43802 Male stud elbow 1/8” - ø6 mm ST-YG

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EF17166 Distribution blocks 35

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36 Distribution blocks EF17166

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4 5
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Parts list

6.2 F175003 Installation kit Twin 12-port block / F174997 B2

Pos. Q’ty Groeneveld order Description

number

4.1 10 00208 Cable tie, black 186 mm

4.2 2 126016 Bolt M6 x 16 ST-G

4.3 2 300006 Washer M6 ST-G

4.4 2 330006 Spring washer M6 ST-G

4.5 1 F174993 Bracket, distribution block

4.6 1 F174997 Twin 12-port block, complete

4.7 1 78401 Tube clamp, double ø6 mm

4.8 7 43802 Male stud elbow 1/8” - ø6 mm ST-YG

4.9 15 11107 Cable tie, black 338 mm

4.11 2 08508 Reduction adaptor 1/8” BR

4.12 1 13312 Cover plate, tube clamp double 6-12 mm

4.13 1 126035 Allen bolt M6 x 35 ST-G

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38 Distribution blocks EF17166

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EF17166 Distribution blocks 39

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10
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EF17166 Distribution blocks 41

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Parts list

6.3 F175004 Installation kit Twin 4+4-port block / F174998 B3

Pos. Q’ty Groeneveld order Description

number

5.1 4 02701 Screw, self-tapping M5 x 10 ST-G

5.2 2 15001 Stud elbow 1/8” ST-YG

5.3 3 29901 Straight connecting coupling ø6 mm ST-YG

5.4 3 78401 Tube clamp, double ø6 mm

5.5 3 78801 Welding plate, tube clamp double 6-12 mm

5.6 1 81701 Welding plate, 4+4-port block

5.7 2 09202 Spring washer 6.4

5.8 1.5m 23702 Protection steel square 10 mm

5.9 14m 31902 Grease pipe ø6 mm x 1 mm ST-YG

5.10 7 43402 Male stud coupling 1/8” - ø6 mm ST-YG

5.11 1 43802 Male stud elbow 1/8” - ø6 mm ST-YG

5.12 1 81502 Tube clamp, single ø6 mm

5.13 1 82002 Welding plate, tube clamp single 6-12 mm

5.14 1 87402 Welding block 1/8”

5.15 4 01208 Clamp ø10 mm

5.16 3 13312 Cover plate, tube clamp double 6-12 mm

5.17 1 16012 Cover plate, tube clamp single 6-12 mm

5.18 4 126030 Allen bolt M6 x 30 ST-G

5.19 3 126035 Allen bolt M6 x 35 ST-G

5.20 1 F172019 H.P.H. 1/4” S6-0400-E6

5.21 1 F174483 H.P.H. 1/4” S6-0800-E6

5.22 1 F174998 Twin 4+4-port block, complete

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42 Distribution blocks EF17166

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EF17166 Distribution blocks 43

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16
13

14

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44 Distribution blocks EF17166

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15

18
17
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EF17166 Distribution blocks 45

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Parts list

6.4 F175005 Installation kit Twin 3+3-port block / F174999 B4

Pos. Q’ty Groeneveld order Description

number

6.1 1 02701 Screw, self-tapping M5 x 10 ST-G

6.2 4 15001 Stud elbow 1/8” ST-YG

6.3 2 09202 Spring washer 6.4

6.4 1m 31902 Grease pipe ø6 mm x 1 mm ST-YG

6.5 1 39302 Protection plate

6.6 4 43402 Male stud coupling 1/8” - ø6 mm ST-YG

6.7 1 43802 Male stud elbow 1/8” - ø6 mm ST-YG

6.8 1 01208 Clamp ø10 mm

6.9 2 126030 Allen bolt M6 x 30 ST-G

6.10 1 F174999 Twin 3+3-port block, complete

19 20
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21

22
23

46 Distribution blocks EF17166

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EF17166 Distribution blocks 47

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Notes

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48 Distribution blocks EF17166

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7.

7.
INSTALLATION MAIN LINE
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EF17166 Installation main line 49

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Parts list

7.1 F175006 Twin Main line kit Volvo EW180B

Pos. Q’ty Groeneveld order Description

number

7.1 6 78701 Tube clamp, double ø12 mm

7.2 5 78801 Welding plate, tube clamp double 6-12 mm

7.3 0.5m 23702 Protection steel square 10 mm

7.4 4 35802 Hose end fitting ø10 mm - 3/8 ID ST-YG

7.5 4 35902 Screw nut 3/8” ID ST-YG

7.6 2 48102 Bulkhead coupling straight ø10 mm ST-YG

7.7 2 48302 L-swivel coupling ø10 mm ST-YG

7.8 100 11107 Cable tie, black 338 mm

7.9 6 13312 Cover plate twin tube clamp

7.10 2 06417 Hose end fitting ø10 mm - 1/4” ID ST-YG

7.11 5 126035 Allen bolt M6 x 35 ST-G

7.12 1 126040 Allen bolt M6 x 40 ST-G

7.13 1 F173846 Bracket with two holes ø16.5 mm ST-YG

7.14 2 830326 H.P.H. 1/4” S10-1250-S10 H1

7.15 2 F171419 H.P.H. 3/8” E10-3500-S10 H2

7.16 2 F174446 H.P.H. 3/8” S10-5000-nothing H3

7.17 2 F174447 H.P.H. 3/8” S10-2500-nothing H4

7.18 2 F173960 H.P.H. 1/4” S10-3500-nothing H5

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50 Installation main line EF17166

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EF17166 Installation main line 51

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EF17166 Installation main line 53

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B1 Date of issue: January 2004

54 Installation main line EF17166

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8.

8.
PARAMETER SETTINGS
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EF17166 Parameter settings 55

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Parameter settings

Code Description Setting

HDCY Heavy duty cycle 30 minutes

NDCY Normal duty cycle 45 minutes

LDCY Low duty cycle 60 minutes

CMS Cycle mode select 2

MPT Maximum pumping time 10 minutes

VMF Venting multiply factor 5 (/10) x

Number of attempts before pump

NOA 10 x
holds

BCDC Blink code duty cycle 4x

CSI Command signal 'inverted' 1 (GINA) / YES (PC)

Consumption metering units each cycle : 9,15 cc

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56 Parameter settings EF17166

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9.

9.
TESTING OF THE SYSTEM
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EF17166 Testing of the system 57

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Testing of the system

Warning

Only operate machine when fully familiar with the controls and permission
of the person in charge at the working place.

• Remove the end-plugs out of the distributions blocks.

De-aerate pipe A
• Start the pump manually with the Gina; leave the 5/2 magnet valve non-
excited (exit A).
• Close the distribution blocks with an end-plug as soon as main pipe (A) is
completely clear of air and dirt.
• Stop the pump.
• Remove main pipe A.

De-aerate pipe B
• Mount main pipe (B) on exit A of the pump.
• Start the pump manually with the Gina; leave the 5/2 magnet valve non-
excited (exit A).
• Close the distribution blocks with an end-plug as soon as main pipe (B) is
completely clear of air and dirt.
• Stop the pump.
• Connect main pipe (B) to exit B and main pipe (A) to exit A.

Accelerated test
• Start an accelerated test by means of the test button on the pump or with the
GINA.
• Check the main pipe for leakage.
• Check if all the grease points are provided with grease.
• Terminate the accelerated test by switching off the ignition.

• Switch the machine back on.

• Operate the machine in all positions and check if all the parts of the Twin-
lubrication have enough tolerance and do not jam or scrape.
• Check the timer settings by means of the GINA (if available).
• Shut the machine down. Date of issue: January 2004

58 Testing of the system EF17166

Groeneveld Australia Pty. Ltd.
18 - 20 Mc Dougall Road
P.O.Box 787
Sunbury, Vic 3429, AUSTRALIA
Tel.: +61 397 4099943
Fax: +61 397 4099665
Groeneveld Belgium NV/SA
Industriezone Hogenakkerhoek
Heirbaan 3, B-9150 Kruibeke, BELGIUM
Tel.: +32 3 8979860
Fax: +32 3 8979861
CPL Systems Canada Inc.
7053 Twiss Road R.R.3.
LoP 1Bo Oakville, Ontario, CANADA
Tel: + 1 905 875 1017
Fax: + 1 905 875 2125
Groeneveld Québec Canada Inc.
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H9P1H2 Quebec, CANADA
Tel: + 1 514 631 4277
Fax: + 1 514 631 4377
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Bullermanshof 2B
47441 Moers-Hülsdonk, DEUTSCHLAND
Tel.: +49 2841 793520
Fax: +49 2841 7935222
Groeneveld France
53, rue Antoine Condorcet
38090 Vaulx Milieu, FRANCE
Tel.: +33 4 74999333
Fax: +33 4 74999350
Groeneveld France IT
53, rue Antoine Condorcet
38090 Vaulx Milieu, FRANCE
Tel.: +33 4 74999333
Fax: +33 4 74999350
GINTEC
Active Safety Ltd.,
49, Hasharoshet 1st
Karmiel, 20101, ISRAËL
Tel.: +972 4 9882220
Fax: +972 4 9883179
Groeneveld L’Efficienza nel Trasporto
S.r.l. (GENT)
Via Chiari 100
23868 Valmadrera (Lecco), ITALIA
Tel.: +39 3 41200536
Fax: +39 3 41201539
Groeneveld Italia (GRIT)
Via Chiari 100
23868 Valmadrera (Lecco), ITALIA
Tel.: +39 3 41201133
Fax: +39 3 41201158
Groeneveld Transport Efficiency B.V.
Postbus 777, 4200 AT Gorinchem
THE NETHERLANDS
Tel.: +31 183 641400
Fax: +31 183 624993
Groeneveld Information Technology B.V.
Stephensonweg 12, 4207 HB Gorinchem
THE NETHERLANDS
Tel.: +31 183 641400
Fax: +31 183 641690
Groeneveld New Zealand Ltd.
58 Newton Road
P.O.Box 4509
Mt Maunganui, NEW ZEALAND
Tel.: +64 7 5720684
Fax: +64 7 5724587
Groeneveld Polska Sp. Z.o.o.
Ul. Ostrowska 476
61 - 342 Poznan, POLAND
Tel.: +48 61 8726207/08/09
Fax: +48 61 8798166
Groeneveld South Africa
Unit 65, Sunny Rock Park
Sun Rock Close, Germiston
1401 SOUTH AFRICA
Tel.: +27 11 4503977
Fax.: +27 11 4503980
Groeneveld Ibérica S.A.
Pol. Ind. Mercederias,
C/. Font de Sant Llorenç 36
08720 Vilafranca del Penedès (Barcelona), SPAIN
Tel.: +34 93 8171822
Fax: +34 93 8172061
Groeneveld Transport Efficiency U.K. Ltd.
The Greentec Centre
Gelders Hall Road, Shepshed
Loughborough, Leicestershire, LE12 9NH
UNITED KINGDOM
Tel.: +44 1509 600033
Fax: +44 1509 602000
Groeneveld Transport Efficiency, Inc.
1130 Industrial Parkway North
Brunswick, Ohio 44212, U.S.A.
Tel.: +1 330 2254949
Toll free: +1 800 5867283
Fax: +1 330 2255213
Mobile: +1 800 5867283
Groeneveld Pacific West L.L.C.
1089 Valentine Avenue SE
Pacific, WA 98047, U.S.A.
Tel.: +1 253 8633700
Fax: +1 253 8633131
Mobile: +1 253 6061838
Groeneveld Atlantic South, Inc.
9633 Palm River Road
Tampa, FL 33619, U.S.A.
Tel.: +1 813 6265600
Fax: +1 813 6265540
Mobile: +1 813 7650928
Groeneveld Transport Efficiency B.V., Stephensonweg 12, 4207 HB Gorinchem, Postbus 777, 4200 AT Gorinchem,
the Netherlands. Tel. +31 183 64 14 00, Fax +31 183 62 34 05, http:// www.groeneveld-groep.com