VOLVO EW160B Ind

Installation Manual
Automatic TWIN Greasing System

Excavator
Volvo EW160B grab
EF17155
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 EW160B grab
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. F174486 Twin 4+4-port block, complete - - - - - - - - - - - - - - - - - - - - - - 12
2.2. F174487 Twin 14-port block, complete - - - - - - - - - - - - - - - - - - - - - - - 14
3. Grease point location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
4. Grease pump installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

4.1. F174488 Twin pumpkit Volvo EW160B grab - - - - - - - - - - - - - - - - - - - - 22
5. Electrical components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
5.1. F174489 Electronics installation kit Volvo EW160B grab - - - - - - - - - - - 26
6. Distribution blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
6.1. F174490 Installation kit Twin 4+4-port block / F174486 B1 - - - - - - - - - 30
6.2. F173046 Installation kit Twin 14-port block / F174487 B2 - - - - - - - - - - 34
7. Installation main line - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39

7.1. F174492 Twin Main line kit Volvo EW160B grab - - - - - - - - - - - - - - - - 40
8. Parameter settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43
9. Testing of the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

Date of issue: June 2003
EF17155 Table of contents 3

4 Table of contents EF17155

1.
1.
PREFACE
EF17155 Preface 5
1.1 General information

This installation manual describes the mounting of the Twin-system on the Volvo
Excavator type EW160B grab.
Automatic Twin Grease Lubrication System
Machine type Number of Groeneveld OEM order Manual

grease points order number number
number
Volvo
19 x F174485 - EF17155 P0
EW160B grab
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
YE Yellow
BR Brass
PA Polyamide
SST Stainless steel
ST-YG Yellow passivated steel
ST-G Galvanised steel
6 Preface EF17155
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.
EF17155 Preface 7
Notes
8 Preface EF17155
2.
2.
SYSTEM LAY-OUT
EF17155 System lay-out 9

Parts list
The Twin-system for the Volvo EW160B grab comprises the following parts:
Kit number Groeneveld order Description

number
F174488 Twin pumpkit Volvo EW160B grab
F174489 Electronics installation kit Volvo EW160B grab
F174486 F174490 Installation kit Twin 4+4-port block B1
F174487 F174491 Installation kit Twin 14-port block B2
F174492 Twin Main line kit Volvo EW160B grab
F174493 Manual Volvo EW160B grab
XU1701D User’s manual TWIN
830326 High-pressure hose 1/4” S10-1250-S10+nut H1 2x
810864 High-pressure hose 3/8” E10-4000-S10+nut H2 2x
10 System lay-out EF17155


Parts list
2.1 F174486 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 1 70701 Shut-off plug M22 x 1 BR
5 4 71101 Metering unit No.4 - 0.200cc/M22/6mm/BR
8 1 77201 Twin 4+4-port block BR
9 2 840010 H.P.H. ø4 mm S6-1000-S6
10 2.5m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m
15 7 02717 Protective cap ø6 mm


Parts list
2.2 F174487 Twin 14-port block, complete

number
1 2 32901 Threaded plug G1/4” BR
2 2 83901 Sealing ring
3 2 72322 Body, male stud elbow 1/4” - ø10 mm ST-YG
4 1 70701 Shut-off plug M22x1 BR
10 1 73701 Pressure switch complete 100 bar BR
11 1 88501 Twin 14-port block, M10 BR
12 2 72201 Grease pipe 1 x ø6 mm x 1.5 PA per 3m
15 1m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m
16 1 840002 H.P.H. ø4 mm S6-1200-S6
17 1 840007 H.P.H. ø4 mm S6-750-S6
18 1 840008 H.P.H. ø4 mm S6-950-S6
19 1 840010 H.P.H. ø4 mm S6-1000-S6
20 5 02717 Protective cap ø6 mm



Notes

3.
3.
GREASE POINT LOCATION
EF17155 Grease point location 17

18 Grease point location EF17155

EF17155 Grease point location 19

Notes
20 Grease point location EF17155

4.
4.
GREASE PUMP INSTALLATION
EF17155 Grease pump installation 21

Parts list
4.1 F174488 Twin pumpkit Volvo EW160B grab

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 10 00208 Cable tie, black 186 mm
1.5 4 108045 Bolt M8 x 45 ST-G
1.6 4 300008 Washer M8 ST-G
1.7 4 330008 Spring washer M8 ST-G
1.8 1 F174482 Cable harness pump Volvo EW-B
1.9 1 F116316 Twin Pump 12cc/24v/3L/250bar/Volvo
22 Grease pump installation EF17155

EF17155 Grease pump installation 23

Notes
24 Grease pump installation EF17155

5.
5.
ELECTRICAL COMPONENTS
EF17155 Electrical components 25

Parts list
5.1 F174489 Electronics installation kit Volvo EW160B grab

number
2.2 1 04812 Pressure switch cable 8m
2.3 1 180101 Connection kit, female 3-poles
2.4 1 180102 Connection kit, male 2-poles
2.5 1 F170671 Twin Display Unit
26 Electrical components EF17155

Volvo connector for grease

system, MO9901
EF17155 Electrical components 27

Pressure switch in the

main lines
Fuse
Volvo connector for grease
system, MO9901
Twin pump with integrated

control unit
28 Electrical components EF17155

6.
6.
DISTRIBUTION BLOCKS
EF17155 Distribution blocks 29

Parts list
6.1 F174490 Installation kit Twin 4+4-port block / F174486 B1

number
3.1 1 15001 Stud elbow R1/8”- G1/8” ST-YG
3.2 2 09202 Spring washer M6
3.3 3 43402 Male stud coupling 1/8” - ø6 mm ST-YG
3.4 4 43802 Male stud elbow 1/8” - ø6 mm ST-YG
3.7 4 08508 Reduction connector R1/8” - G1/8” BR
3.8 2 126010 Countersunk bolt M6 x 10 ST-G
3.9 2 126030 Allen bolt M6 x 30 ST-G
3.10 1 F174481 Bracket 4+4-port block
3.11 1 F174486 Twin 4+4-port block, complete
30 Distribution blocks EF17155


5
1
2 3

6 7

Parts list
6.2 F173046 Installation kit Twin 14-port block / F174487 B2

number
4.1 2 02701 Self-tapping screw M5 x 10
4.2 1 15001 Stud elbow R1/8” - G1/8” ST-YG
4.3 1 20901 Connecting block G1/8” 1-hole
4.4 2 21001 Connecting block G1/8” 2-holes
4.5 1 78401 Tube clamp, double ø6 mm
4.6 7 43402 Male stud coupling 1/8” - ø6 mm ST-YG
4.7 5 43802 Male stud elbow 1/8” - ø6 mm ST-YG
4.8 2 47602 Straight connecting coupling ø10 mm ST-YG
4.11 2 01308 Clamp ø12 mm
4.12 4 02008 Spiral protective wrap 8 mm
4.13 6 07908 Male stud coupling 1/8” - ø6 mm BR
4.14 2 08008 Male stud elbow 1/8” - ø6 mm BR
4.15 2 08508 Reduction connector R1/8” - G1/8”BR
4.16 1 06612 Bracket, distribution block
4.17 1 13312 Cover plate, tube clamp double 6-12 mm
4.18 2 24622 Tube ø10 x 8 mm, 800 mm
4.19 1 126035 Allen bolt M6 x 35 ST-G
4.20 1 830789 H.P.H. 1/4” E6-1500-S6
4.21 2 F174483 H.P.H. 1/4” S6-800-S6
4.22 2 F174484 H.P.H. 1/4” S6-3000-S10
4.23 1 F174487 Twin 14-port block, complete


9 13
8 12
10 11

16
10 12
13
11
14

19
18
15
17
19

Notes

7.
7.
INSTALLATION MAIN LINE
EF17155 Installation main line 39

Parts list
7.1 F174492 Twin Main line kit Volvo EW160B grab

number
5.1 2 80901 T-male stud 1/4” - ø10 mm ST-YG
5.4 2 830326 High-pressure hose 1/4” S10-1250-S10+nut H1
5.5 2 810864 High-pressure hose 3/8” E10-4000-S10+nut H2
40 Installation main line EF17155

EF17155 Installation main line 41

42 Installation main line EF17155

8.
8.
PARAMETER SETTINGS
EF17155 Parameter settings 43

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 6 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 : 5,7 cc
44 Parameter settings EF17155

9.
9.
TESTING OF THE SYSTEM
EF17155 Testing of the system 45

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: June 2003
46 Testing of the system EF17155

Groeneveld Australia Pty. Ltd. Groeneveld Information Technology B.V.
18 - 20 Mc Dougall Road Stephensonweg 12, 4207 HB Gorinchem
P.O.Box 787 THE NETHERLANDS
Sunbury, Vic 3429, AUSTRALIA Tel.: +31 183 641400
Tel.: +61 397 4099943 Fax: +31 183 641690
Fax: +61 397 4099665
Groeneveld New Zealand Ltd.
Groeneveld Belgium NV/SA 58 Newton Road
Industriezone Hogenakkerhoek P.O.Box 4509
Heirbaan 3, B-9150 Kruibeke, BELGIUM Mt Maunganui, NEW ZEALAND
Tel.: +32 3 8979860 Tel.: +64 7 5720684
Fax: +32 3 8979861 Fax: +64 7 5724587
CPL Systems Canada Inc. Groeneveld Polska Sp. Z.o.o.

7053 Twiss Road R.R.3. Ul. Ostrowska 476
LoP 1Bo Oakville, Ontario, CANADA 61 - 342 Poznan, POLAND
Tel: + 1 905 875 1017 Tel.: +48 61 8726207/08/09
Fax: + 1 905 875 2125 Fax: +48 61 8798166
Groeneveld Québec Canada Inc. Groeneveld South Africa

2068 Chartier Street Dorval Unit 65, Sunny Rock Park
H9P1H2 Quebec, CANADA Sun Rock Close, Germiston
Tel: + 1 514 631 4277 1401 SOUTH AFRICA
Fax: + 1 514 631 4377 Tel.: +27 11 4503977
Fax.: +27 11 4503980
Groeneveld Deutschland GMBH
Bullermanshof 2B Groeneveld Ibérica S.A.
47441 Moers-Hülsdonk, DEUTSCHLAND Pol. Ind. Mercederias,
Tel.: +49 2841 793520 C/. Font de Sant Llorenç 36
Fax: +49 2841 7935222 08720 Vilafranca del Penedès (Barcelona), SPAIN
Tel.: +34 93 8171822
Groeneveld France Fax: +34 93 8172061
53, rue Antoine Condorcet
38090 Vaulx Milieu, FRANCE Groeneveld Transport Efficiency U.K. Ltd.
Tel.: +33 4 74999333 The Greentec Centre
Fax: +33 4 74999350 Gelders Hall Road, Shepshed
Loughborough, Leicestershire, LE12 9NH
Groeneveld France IT UNITED KINGDOM
53, rue Antoine Condorcet Tel.: +44 1509 600033
38090 Vaulx Milieu, FRANCE Fax: +44 1509 602000
Tel.: +33 4 74999333
Fax: +33 4 74999350 Groeneveld Transport Efficiency, Inc.
1130 Industrial Parkway North
GINTEC Brunswick, Ohio 44212, U.S.A.
Active Safety Ltd., Tel.: +1 330 2254949
49, Hasharoshet 1st Toll free: +1 800 5867283
Karmiel, 20101, ISRAËL Fax: +1 330 2255213
Tel.: +972 4 9882220 Mobile: +1 800 5867283
Fax: +972 4 9883179
Groeneveld Pacific West L.L.C.
Groeneveld L’Efficienza nel Trasporto 1089 Valentine Avenue SE
S.r.l. (GENT) Pacific, WA 98047, U.S.A.
Via Chiari 100 Tel.: +1 253 8633700
23868 Valmadrera (Lecco), ITALIA Fax: +1 253 8633131
Tel.: +39 3 41200536 Mobile: +1 253 6061838
Fax: +39 3 41201539
Groeneveld Atlantic South, Inc.
Groeneveld Italia (GRIT) 9633 Palm River Road
Via Chiari 100 Tampa, FL 33619, U.S.A.
23868 Valmadrera (Lecco), ITALIA Tel.: +1 813 6265600
Tel.: +39 3 41201133 Fax: +1 813 6265540
Fax: +39 3 41201158 Mobile: +1 813 7650928
Groeneveld Transport Efficiency B.V.

Postbus 777, 4200 AT Gorinchem
THE NETHERLANDS
Tel.: +31 183 641400
Fax: +31 183 624993
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

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Installation Manual

Automatic TWIN Greasing System

your efficiency is our challenge

3. Grease point location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

4. Grease pump installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

7. Installation main line - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39

9. Testing of the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

EF17155 Table of contents 3

Date of issue: June 2003

4 Table of contents EF17155

your efficiency is our challenge

1.1 General information

Automatic Twin Grease Lubrication System

Machine type Number of Groeneveld OEM order Manual

1.2 Use of symbols

Position number on the parts list

Grease point position number

1.3 Safety precautions

During activities that require a lifting jack:

1.4 General fitting instructions

Date of issue: June 2003

your efficiency is our challenge

EF17155 System lay-out 9

Kit number Groeneveld order Description

F174488 Twin pumpkit Volvo EW160B grab

F174489 Electronics installation kit Volvo EW160B grab

F174486 F174490 Installation kit Twin 4+4-port block B1

F174487 F174491 Installation kit Twin 14-port block B2

F174492 Twin Main line kit Volvo EW160B grab

F174493 Manual Volvo EW160B grab

XU1701D User’s manual TWIN

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

810864 High-pressure hose 3/8” E10-4000-S10+nut H2 2x

Date of issue: June 2003

10 System lay-out EF17155

EF17155 System lay-out 11

2.1 F174486 Twin 4+4-port block, complete

Pos. Q’ty Groeneveld order Description

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 1 70701 Shut-off plug M22 x 1 BR

5 4 71101 Metering unit No.4 - 0.200cc/M22/6mm/BR

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

7 1 79601 Metering unit No.9 - 1.000cc/M22/6mm/BR

8 1 77201 Twin 4+4-port block BR

9 2 840010 H.P.H. ø4 mm S6-1000-S6

10 2.5m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

11 2.5m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

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

13 0.5m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

14 0.5m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

15 7 02717 Protective cap ø6 mm

Date of issue: June 2003

12 System lay-out EF17155

EF17155 System lay-out 13

2.2 F174487 Twin 14-port block, complete

Pos. Q’ty Groeneveld order Description

1 2 32901 Threaded plug G1/4” BR

2 2 83901 Sealing ring

3 2 72322 Body, male stud elbow 1/4” - ø10 mm ST-YG

4 1 70701 Shut-off plug M22x1 BR

5 1 70901 Metering unit No.2 - 0.100cc/M22/6mm/BR