Installation Manual

Automatic TWIN Greasing System

Excavator
Volvo EW160B
EF17185

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

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. F174486 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. F175098 Twin 5-port block, complete - - - - - - - - - - - - - - - - - - - - - - - - 18

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

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

4.1. F175000 Twin pumpkit Volvo EW160B - - - - - - - - - - - - - - - - - - - - - - - - 26

5. Electrical components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
5.1. F175001 Electronics installation kit Volvo EW160B - - - - - - - - - - - - - - - 30

6. Distribution blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
6.1. F174490 Installation kit Twin 4+4-port block / F174486 B1 - - - - - - - - - 34
6.2. F175003 Installation kit Twin 12-port block / F174997 B2 - - - - - - - - - - 38
6.3. F175100 Installation kit Twin 4+4-port block / F174998 B3 - - - - - - - - - 42
6.4. F175101 Installation kit Twin 5-port block / F175098 B4 - - - - - - - - - - - 46

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

7.1. F175102 Twin Main line kit Volvo EW160B - - - - - - - - - - - - - - - - - - - - 50

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

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

Date of issue: April 2004

EF17185 Table of contents 3

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Date of issue: April 2004

4 Table of contents EF17185

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1.

1.
PREFACE
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EF17185 Preface 5
 Excavator Volvo EW160B

1.1 General information

This installation manual describes the installation of the Twin-system on the Volvo
Excavator type EW160B.

Automatic Twin Grease Lubrication System

Machine type Number of Groeneveld OEM order Manual

grease points order number number
number

Volvo
25 x F175988 - EF17185 P0
EW160B

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: April 2004

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

6 Preface EF17185
 Excavator Volvo EW160B

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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EF17185 Preface 7
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Notes

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8 Preface EF17185
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2.

2.
SYSTEM LAY-OUT
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Parts list

The Twin-system for the Volvo EW160B comprises the following parts:

Kit number Groeneveld order Description

number

F175000 Twin pumpkit Volvo EW160B

F175001 Electronics installation kit Volvo EW160B

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

F174997 F175003 Installation kit Twin 12-port block B2

F174998 F175100 Installation kit Twin 4+4-port block B3

F175098 F175101 Installation kit Twin 5-port block B4

F175102 Twin Main line kit Volvo EW160B

F175989 A5 manual Volvo EW160B

XU1701D User’s manual TWIN

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

F172532 High-pressure hose 3/8” E10-2450-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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10 System lay-out EF17185

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B1
F174486

H2
F172532
Date of issue: April 2004

B4
F175098

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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

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 ID 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

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EF17185 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 1 72201 Grease pipe 1 x ø6 mm x 1.5 PA per 3m

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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14 System lay-out EF17185

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EF17185 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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EF17185 System lay-out 17

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Parts list

2.4 F175098 Twin 5-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 71101 Metering unit No.4 - 0.200 cc/M22/6mm/BR

5 2 79601 Metering unit No.9 - 1.000 cc/M22/6mm/BR

6 1 06817 Twin 5-port block BR

7 1 840007 H.P.H. ø4 mm ID S6-0750-S6

8 1 02717 Protective cap ø6 mm

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18 System lay-out EF17185

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EF17185 System lay-out 19

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Notes

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20 System lay-out EF17185

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3.

3.
GREASE POINT LOCATION
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EF17185 Grease point location 21

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11
10 12 20 18 19

2 5 8 4 22 16 23 24
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2 6

22 Grease point location EF17185

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17

14
13

25 15 21 7 9
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EF17185 Grease point location 23

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Notes

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24 Grease point location EF17185

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4.

4.
GREASE PUMP INSTALLATION
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EF17185 Grease pump installation 25

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Parts list

4.1 F175000 Twin pumpkit Volvo EW160B

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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26 Grease pump installation EF17185

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ONT
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EF17185 Grease pump installation 27

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Notes

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28 Grease pump installation EF17185

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5.

5.
ELECTRICAL COMPONENTS
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EF17185 Electrical components 29

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Parts list

5.1 F175001 Electronics installation kit Volvo EW160B

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 EF17185

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EF17185 Electrical components 31

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Pressure switch in the

main lines
Fuse

Twin pump with integrated

control unit Date of issue: April 2004

32 Electrical components EF17185

 Excavator Volvo EW160B

6.

6.
DISTRIBUTION BLOCKS
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EF17185 Distribution blocks 33

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Parts list

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

Pos. Q’ty Groeneveld order Description

number

3.1 1 15001 Stud elbow 1/8” ST-YG

3.2 2 09202 Spring washer 6.4

3.3 1 43402 Male stud coupling 1/8” - ø6 mm ST-YG

3.4 6 43802 Male stud elbow 1/8” - ø6 mm ST-YG

3.5 10 11107 Cable tie, black 338 mm

3.6 25 00208 Cable tie, black 186 mm

3.7 4 08508 Reduction connector 1/8” BR

3.8 2 126010 Allen 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

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FRO
NT
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EF17185 Distribution blocks 35

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2 3

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36 Distribution blocks EF17185

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4 7
5 6
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EF17185 Distribution blocks 37

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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

Date of issue: April 2004

38 Distribution blocks EF17185

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13 14

11

12
10
11 13
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10 12 14

EF17185 Distribution blocks 39

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11 10

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40 Distribution blocks EF17185

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13 14

12
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EF17185 Distribution blocks 41

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Parts list

6.3 F175100 Installation kit Twin 4+4-port block / F174998 B3

Pos. Q’ty Groeneveld order Description

number

5.1 3 02701 Screw, self-tapping M5 x 10 ST-G

5.2 4 15001 Stud elbow 1/8” ST-YG

5.3 1 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 1m 23702 Protection steel square 10 mm

5.9 12m 31902 Grease pipe ø6 mm x 1 mm ST-YG

5.10 6 43402 Male stud coupling 1/8” - ø6 mm ST-YG

5.11 2 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 3 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 830059 H.P.H. 1/4” S6-0450-S6

5.21 1 830060 H.P.H. 1/4” S6-0550-S6

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

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42 Distribution blocks EF17185

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ONT
FR

18

19

20

17

16 15
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EF17185 Distribution blocks 43

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17

19

18

20

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44 Distribution blocks EF17185

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15
16
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EF17185 Distribution blocks 45

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Parts list

6.4 F175101 Installation kit Twin 5-port block / F175098 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 2m 31902 Grease pipe ø6 mm x 1 mm ST-YG

6.4 4 43402 Male stud coupling 1/8” - ø6 mm ST-YG

6.5 1 43802 Male stud elbow 1/8” - ø6 mm ST-YG

6.6 1 01208 Clamp ø10 mm

6.7 2 126040 Allen bolt M6 x 40 ST-G

6.8 2 230006 Nut, self-locking M6 SST

6.9 2 300006 Washer M6 ST-G

6.10 1 F175098 Twin 5-port block, complete

23
25
24

21 22
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46 Distribution blocks EF17185

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ONT
FR

23

24

25

22

21
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EF17185 Distribution blocks 47

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Notes

Date of issue: April 2004

48 Distribution blocks EF17185

 Excavator Volvo EW160B

7.

7.
INSTALLATION MAIN LINE
Date of issue: April 2004

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EF17185 Installation main line 49

 Excavator Volvo EW160B

Parts list

7.1 F175102 Twin Main line kit Volvo EW160B

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 2 80901 T-swivel coupling ø10 mm ST-YG

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

7.7 100 11107 Cable tie, black 338 mm

7.8 4m 02008 Spiral protective wrap ø12 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 F172532 H.P.H. 3/8” E10-2450-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

Date of issue: April 2004

50 Installation main line EF17185

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EF17185 Installation main line 51

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FRO
NT

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52 Installation main line EF17185

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ONT
FR
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EF17185 Installation main line 53

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B1 Date of issue: April 2004

54 Installation main line EF17185

 Excavator Volvo EW160B

8.

8.
PARAMETER SETTINGS
Date of issue: April 2004

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EF17185 Parameter settings 55

 Excavator Volvo EW160B

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 : 10,05 cc

Date of issue: April 2004

56 Parameter settings EF17185

 Excavator Volvo EW160B

9.

9.
TESTING OF THE SYSTEM
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EF17185 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: April 2004

58 Testing of the system EF17185

Groeneveld Australia Pty. Ltd. Groeneveld Information Technology B.V.
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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