Installation Manual

Automatic TWIN Greasing System

Excavator
Volvo EW140 VA
EF1799

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 EW140 VA

1.
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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. F171812 Twin 3+3-port block, complete - - - - - - - - - - - - - - - - - - - - - - 12
2.2. F171813 Twin 12-port block, complete - - - - - - - - - - - - - - - - - - - - - - - 14
2.3. F171814 Twin 6+6-port block, complete - - - - - - - - - - - - - - - - - - - - - - 16
2.4. F171815 Twin 4+4-port block, complete - - - - - - - - - - - - - - - - - - - - - - 18

3. Grease point location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

4. Drilling and welding activities - - - - - - - - - - - - - - - - - - - - - - - - - - - 23

5. Grease pump installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

5.1. F171816 Twin Pumpkit Volvo EW140 VA - - - - - - - - - - - - - - - - - - - - - - 34

6. Electrical components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
6.1. F171817 Electronics installation kit Volvo EW140 VA - - - - - - - - - - - - - 38

7. Distribution blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41
7.1. F171818 Installation kit 3+3-port block B1 - - - - - - - - - - - - - - - - - - - - - 42
7.2. F171819 Installation kit 12-port block B2 - - - - - - - - - - - - - - - - - - - - - - 44
7.3. F171820 Installation kit 6+6-port block B3 - - - - - - - - - - - - - - - - - - - - - 48
7.4. F171821 Installation kit 4+4-port block B4 - - - - - - - - - - - - - - - - - - - - - 52

8. Installation main line - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

8.1. F171822 Twin Main line kit Volvo EW140 VA - - - - - - - - - - - - - - - - - - - 56

9. Parameter settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

10. Testing of the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63

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EF1799 Table of contents 3

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4 Table of contents EF1799

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1.

2.
PREFACE
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EF1799 Preface 5
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1.1 General information

This installation manual describes the mounting of the Twin-system on the Volvo
Excavator type EW140 VA.

Automatic Twin Grease Lubrication System

Machine type Number of Groeneveld OEM order Manual

grease points order number number
number

Volvo EW140
29 x F171371 - EF1799P0
VA

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: February 2002

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

6 Preface EF1799
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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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Notes

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2.

3.
SYSTEM LAY-OUT
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Parts list
Kitnumber F171371 of the Volvo EW140 VA comprises the following parts:

Kit number Groeneveld order Description

number

F171816 Twin pumpkit Volvo EW140 VA

F171817 Electronics installation kit Volvo EW140 VA

F171812 F171818 Installation kit Twin 3+3-port block B1

F171813 F171819 Installation kit Twin 12-port block B2

F171814 F171820 Installation kit Twin 6+6-port block B3

F171815 F171821 Installation kit Twin 4+4-port block B4

F171822 Twin Main line kit Volvo EW140 VA

XU1701D User’s Manual Twin

F171823 High pressure hose 3/8” E10-1800-S10 H1

F170897 High pressure hose 1/4” S10-1100-S10 H2

F171824 High pressure hose 3/8” S10-1500-S10 H3

F171825 High pressure hose 3/8” S10-1500-S12 H4

F171826 High pressure hose 1/4” S12-2350-S8 H5

F171827 High pressure hose 1/4” E8-500-S8 H6

F171828 High pressure hose 1/4” E8-550-S8 H6a

F171829 High pressure hose 1/4” S8-700-S8 H7

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Parts list

2.1 F171812 Twin 3+3-port block, complete

Pos. Q’ty Groeneveld order Description
number

0 0 AF171812 Assembly Instruction F171812 R.0

1 2 32901 Threaded plug 1/4 BR

2 2 83901 Sealing ring

3 2 72322 Body, connector elbow 1/4NPT - ø10 mm ST-YG

4 1 70701 Shut-off plug M22 x 1 BR

5 2 70801 Metering unit no.1 - 0.050cc/M22/6mm/BR

6 1 71201 Metering unit no.8 - 0.400cc/M22/6mm/BR

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

8 1 76701 Twin 3+3-port block BR

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Parts list

2.2 F171813 Twin 12-port block, complete

Pos. Q’ty Groeneveld order Description
number

0 0 AF171813 Assembly Instruction F171813 R.0

1 2 28912 Adaptor M10x1 - ø6 mm ST-YG

2 4 72122 Body, connector straight 1/4NPT - ø10 mm ST-YG

3 1 70701 Shut-off plug M22 x 1 BR

4 2 70801 Metering unit no.1 - 0.050cc/M22/6mm/BR

5 5 70901 Metering unit no.2 - 0.100cc/M22/6mm/BR

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

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

8 1 70601 Twin 12-port block BR

9 1 72201 Grease pipe 1 x ø6 mm x 1.5 per 3m PA

10 3 72301 Grease pipe 2 x ø6 mm x 1.5 per 3m PA

11 1 02717 Protective cap ø6 mm

12 3 28401 Protective cap ø9.5 mm

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Parts list

2.3 F171814 Twin 6+6-port block, complete

Pos. Q’ty Groeneveld order Description

number

0 0 AF171814 Assembly Instruction F171814 R.0

1 2 32901 Threaded plug 1/4” BR

2 2 83901 Sealing washer

3 1 45502 Connector, straight 1/4NPT - ø8 mm ST-YG

4 1 80701 Connector, elbow ø8 mm ST-YG

5 1 72222 Body, connector elbow 1/4NPT - ø8 mm ST-YG

6 3 70701 Shut-off plug M22 x 1 BR

7 1 73701 Pressure switch, 100 bar complete BR

8 1 70801 Metering unit no.1 - 0.050cc/M22/6mm/BR

9 1 71001 Metering unit no.3 - 0.150cc/M22/6mm/BR

10 2 72701 Metering unit no.6 - 0.300cc/M22/6mm/BR

11 4 79601 Metering unit no.9 - 1.000cc/M22/6mm/BR

12 1 79301 Twin 6+6-port block BR

13 2m 77301 Grease pipe 1 x ø6 mm x 1.5 per m PA

14 2.5m 77401 Grease pipe 2 x ø6 mm x 1.5 per m PA

15 1 02717 Protective cap ø6 mm

16 1 28401 Protective cap ø9.5 mm

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Parts list

2.4 F171815 Twin 4+4-port block, complete

Pos. Q’ty Groeneveld order Description

number

0 0 AF171815 Assembly Instruction F171815 R.0

1 4 32901 Threaded plug G1/4 BR

2 4 83901 Sealing ring

3 2 72022 Body, connector straight 1/4NPT - ø8 mm ST-YG

4 1 70701 Shut-off plug M22 x 1 BR

5 3 71001 Metering unit no.3 - 0.150 cc/M22/6mm/BR

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

7 1 83701 Adapter, screw thread M22 - 1/4” BR

8 1 83801 Adapter, screw thread M22 - 1/4” BR

9 1 77201 Twin 4+4-port block BR

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3.

4.
GREASE POINT LOCATION
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EF1799 Grease point location 19

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Notes

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4.

5.
DRILLING AND WELDING ACTIVITIES
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Safety instructions for installation of attachment points:

When drilling:
• Wear safety goggles.
• Make sure there are no vital parts behind the hole to be drilled.

Drilling

10mm
Drilling depth

Full drilling

M8x1.25
Tapping

Fill the grease point with grease

1 Drilling location

In case of welding:
• Ask the workshop manager whether welding is allowed in this room.
• Disconnect the earthing cable from the battery or remove the earthing key.
• Disconnect any computers present. In case of doubt, always refer to the
supplier of the machine.
• Wear welding goggles and overalls.

Welding
Date of issue: February 2002

Grind

1 Welding location

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Notes

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5.

6.
GREASE PUMP INSTALLATION
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Parts list

5.1 F171816 Twin Pumpkit Volvo EW140 VA

Pos. Q’ty Groeneveld order Description

number

1.1 1 F116317 Twin pump 12cc/24V/4L/250 bar

1.2 1 82301 Cable harness, pump 7m

1.3 1 43402 Connector, straight 1/8” - ø6 mm ST-YG

1.4 1 47202 Connector, straight 1/4” - ø10 mm ST-YG

1.5 2 39008 Clamp ø14 mm, for M10 bolt

1.6 1 81522 Bracket, pump

1.7 1 F171830 High pressure hose 1/4” E10-600-S6

1.8 4 108050 Bolt M8 x 50 ST-G

1.9 4 101030 Bolt M10 x 30 ST-G

1.10 4 220008 Nut self-locking M8 ST-G

1.11 4 220010 Nut self-locking M10 ST-G

1.12 4 300008 Washer M8 ST-G

1.13 8 300010 Washer M10 ST-G

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Notes

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6.

7.
ELECTRICAL COMPONENTS
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Parts list

6.1 F171817 Electronics installation kit Volvo EW140 VA

Pos. Q’ty Groeneveld order Description

number

2.1 3m 57806 Electrical wire 1mm2 YE+BU

2.2 5 61416 Flat plug, not insulated 0.75mm²

2.3 9 67806 Flat plug sleeve, not insulated 0.75mm²

2.4 2 68606 Flat plug sleeve, not insulated 1.5mm²

2.5 2 68706 Flat plug, not insulated 1.5mm²

2.6 1 04912 Cable wire pressure switch 15m

2.7 1 10912 Connector housing, 11 pole female

2.8 1 11012 Connector housing, 11 pole male

2.9 0.5m 02808 Electrical wire 1.5mm2 RD+YE+BU

2.10 1 12817 Switch + integrated control lamp

2.11 1 17417 Connector housing, 8 pole female

2.12 1 16422 Yellow lens for switch

2.13 1 20022 Connector housing, 2 pole female

2.14 1 890004 Ring 0,5 - 1 QMM

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Pressureswitch in
Selectorswitch with

main lines
control lamp

Switch of the hydraulic

safety handle

Twin pump with

integrated control unit
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EF1799 Electrical components 39

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40 Electrical components EF1799

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7.

8.
DISTRIBUTION BLOCKS
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Parts list

7.1 F171818 Installation kit 3+3-port block B1

Pos. Q’ty Groeneveld order Description

number

3.1 1 81601 Welding plate, 3+3-port block

3.2 2 09202 Spring washer 6.4

3.3 2 126030 Allen bolt M6 x 30 ST-G

3.4 1 F171812 Twin 3+3-port block, complete

B1

Date of issue: February 2002

1 2

42 Distribution blocks EF1799

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Connect the centralisated hoses to the distribution block, according to the

drawings of the grease point location (chapter 3).
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EF1799 Distribution blocks 43

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Parts list

7.2 F171819 Installation kit 12-port block B2

Pos. Q’ty Groeneveld order Description

number

4.1 1 13901 Adaptor, elbow 45° 1/8”- 27NPT BR

4.2 4 15001 Adaptor, elbow 1/8”NPT ST-YG

4.3 1 16301 Allen plug 1/8”NPT BR

4.4 1 78701 Double tube clamp ø12 mm

4.5 5 43402 Connector, straight 1/8”NPT - ø6 mm ST-YG

4.6 4 43802 Connector, elbow 1/8”NPT - ø6 mm ST-YG

4.7 2m 01908 Spi-wrap ø5 mm

4.8 1 08508 Adaptor, straight 1/8”NPT BR

4.9 1.5m 14008 Flexible protection hose 9.9 I/D - 12.9 O/D

4.10 1 13312 Cover plate, double tube clamp

4.11 1 12712 Bracket 170 x 30 x 6 mm

4.12 4m 05716 H.P.H. ø4 mm I/D / ø9 mm

4.13 2 05816 Stand pipe ø6 mm, straight H.P.H. ø4 mm I/D

4.14 4 09516 Stand pipe ø6 mm, elbow H.P.H. ø4 mm I/D

4.15 1 126035 Allen bolt M6 x 35 ST-G

4.16 1 F171813 Twin 12-port block, complete

B2
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Connect the two centra-

lised hoses of the Volvo
excavator with part num-
ber 4.14 to the distribu-
tion block
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EF1799 Distribution blocks 45

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16 6 7 9 8 15

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11

13 4.3 14

10
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12

EF1799 Distribution blocks 47

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Parts list

7.3 F171820 Installation kit 6+6-port block B3

Pos. Q’ty Groeneveld order Description

number

5.1 9 02701 Screw, self-tapping M5 x 10

5.2 4 15001 Adaptor, elbow 1/8NPT ST-YG

5.3 1 29901 Connector, straight ø6 mm ST-YG

5.4 2 78401 Double tube clamp ø6 mm

5.5 2 78801 Welding plate, double tube clamp

5.6 1 81801 Welding plate, 6+6-port block

5.7 2 09202 Spring washer 6.4

5.8 4m 23702 Protection steel, square 10 mm

5.9 9m 31902 Tube ø6 mm x 1 mm ST-YG

5.10 2 43202 Connector, straight M6x1 - ø6 mm ST-YG

5.11 4 43402 Connector, straight 1/8”NPT - ø6 mm ST-YG

5.12 2 43802 Connector, elbow 1/8”NPT - ø6 mm ST-YG

5.13 2 81502 Single tube clamp ø6 mm

5.14 2 81802 Single tube clamp ø12 mm

5.15 4 82002 Welding plate, single tube clamp

5.16 2 87502 Welding block, G1/8”, 16 mm

5.17 9 01008 Clamp ø6 mm

5.18 2 13312 Coverplate, double tube clamp

5.19 4 16012 Coverplate, single tube clamp

5.20 4 26712 Welding block, 2 x M8x1.25

5.21 4 26812 Bracket, angle for pipe ø10 mm

5.22 2 24622 Pipe G1/8 x ø10 x 800 mm

5.23 8 108016 Bolt M8 x 16 ST-G

Date of issue: February 2002

5.24 10 126030 Allen bolt M6 x 30 ST-G

5.25 2 126035 Allen bolt M6 x 35 ST-G

5.26 8 300008 Washer M8 ST-G

5.27 1 830066 H.P.H. 1/4” S6-950-S6

5.28 1 F171814 Twin 6+6-port block, complete

48 Distribution blocks EF1799

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EF1799 Distribution blocks 49

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19
17

B3

18

24 Date of issue: February 2002

20

50 Distribution blocks EF1799

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22

21

23
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Parts list

7.4 F171821 Installation kit 4+4-port block B4

Pos. Q’ty Groeneveld order Description

number

6.1 1 02701 Screw, self-tapping M5 x 10

6.2 1m 77301 Grease pipe 1 x ø6 mm x 1.5 per m PA

6.3 2 09202 Spring washer 6.4

6.4 1 43802 Connector, straight 1/8”NPT - ø6 mm ST-YG

6.5 1 01208 Clamp ø10 mm

6.6 8 07908 Connector, straight 1/8”NPT - ø6 mm BR

6.7 4 08008 Connector, elbow 1/8”NPT - ø6 mm BR

6.8 4 10612 Welding block M10x1.5, 20 mm

6.9 1m 05716 H.P.H. ø4 mm I/D - ø9 mm O/D

6.10 1 05816 Stand pipe, straight ø6 mm, H.P.H. ø4 mm I/D

6.11 1 09516 Stand pipe, elbow ø6 mm, H.P.H. ø4 mm I/D

6.12 1 25122 Protection plate 250 x 200 x 8 mm

6.13 2 126030 Allen bolt M6 x 30 ST-G

6.14 3 101090 Bolt M10 x 90 ST-G

6.15 3 300010 Washer M10 ST-G

6.16 3 F171301 Spacer 60 x 20 x 10 mm

6.17 1 F171815 Twin 4+4-port block, complete

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B4

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26 29 27 25

28

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8.

9.
INSTALLATION MAIN LINE
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Parts list

8.1 F171822 Twin Main line kit Volvo EW140 VA

Pos. Q’ty Groeneveld order Description

number

7.1 2 F171823 H.P.H. 3/8” E10-1800-S10 + nut H1

7.2 2 F170897 H.P.H. 1/4” S10-1100-S10 + nut H2

7.3 2 F171824 H.P.H. 3/8” S10-1500-S10 + nut H3

7.4 2 F171825 H.P.H. 3/8” S12-1500-S10 + nut H4

7.5 2 F171826 H.P.H. 1/4” S12-2350-S8 + nut H5

7.6 1 F171827 H.P.H. 1/4” E8-500-S8 + nut H6

7.7 1 F171828 H.P.H. 1/4” E8-550-S8 + nut H6a

7.8 2 F171829 H.P.H. 1/4” S8-700-S8 + nut H7

7.9 3 78501 Double tube clamp ø8 mm

7.10 5 78701 Double tube clamp ø12 mm

7.11 4 78801 Welding plate, double tube clamp

7.12 4m 32002 Grease pipe ø8 mm x 1 mm ST-G

7.13 6m 32202 Grease pipe ø12 mm x 1 mm ST-G

7.14 2 45702 Connector, straight ø8 mm ST-YG

7.15 2 45902 T-connector ø8 mm ST-YG

7.16 2 47802 T-connector ø10 mm ST-YG

7.17 6 49402 Connector, straight ø12 mm ST-YG

7.18 100 11107 Cable tie, black (L= 338 mm)

7.19 200 00208 Cable tie, black (L= 186 mm)

7.20 3m 02008 Spi-wrap ø8 mm

7.21 8 13312 Cover plate, double tube clamp

7.22 3 28412 Bracket, several tube clamps

Date of issue: February 2002

7.23 4 126035 Allen bolt M6 x 35 ST-G

7.24 4 126040 Allen bolt M6 x 40 ST-G

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B2

B1
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B3
B3

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9.

10.
PARAMETER SETTINGS
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Parameter settings

Code Description Setting

HDCY Heavy duty cycle 15 minutes

NDCY Normal duty cycle 30 minutes

LDCY Low duty cycle 40 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' 0 (GINA)/NO(PC)

Consumption metering units each cycle : 10,35 cc

Date of issue: February 2002

62 Parameter settings EF1799

 Excavator Volvo EW140 VA

10.

11.
TESTING OF THE SYSTEM
Date of issue: February 2002

your efficiency is our challenge

EF1799 Testing of the system 63

 Excavator Volvo EW140 VA

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: February 2002

64 Testing of the system EF1799

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