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Description
Installation Manual
Automatic TWIN Greasing System Wheel Loader Volvo L150E / L180E ’05 EF17196P00
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.
Wheel Loader Volvo L150E / L180E ’05
1.
Preface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 1.1. 1.2. 1.3. 1.4. 1.5.
2.
4.
F173646 Electronics installation kit Volvo L150E / L180E ’05 - - - - - - - - 30
Distribution blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35 F177612 Installation kit Twin 7-port block / F170456 B1 - - - - - - - - - - F177613 Installation kit Twin 12-port block / F177611 B2 - - - - - - - - - F177614 Installation kit Twin 6-port block / F174529 B3 - - - - - - - - - - F177615 Installation kit Twin 4+4-port block / F174530 B4 - - - - - - - - -
36 40 44 50
Installation main line - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55 7.1.
8.
F170458 Twin pumpkit Volvo L150E / L180E ’05 - - - - - - - - - - - - - - - - - 26
Electrical components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
6.1. 6.2. 6.3. 6.4.
7.
12 14 16 18
Grease pump installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
5.1.
6.
F170456 Twin 7-port block, complete - - - - - - - - - - - - - - - - - - - - - - - F177611 Twin 12-port block, complete - - - - - - - - - - - - - - - - - - - - - - F174529 Twin 6-port block, complete - - - - - - - - - - - - - - - - - - - - - - - F174530 Twin 4+4-port block, complete - - - - - - - - - - - - - - - - - - - - - -
Grease point location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
4.1.
5.
6 6 7 7 8
System lay-out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 2.1. 2.2. 2.3. 2.4.
3.
General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Use of symbols - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - General fitting instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety instructions for installation of attachment points - - - - - - - - - - -
q^_ib=lc=`lkqbkqp
1.
F177616 Twin Main line kit Volvo L150E / L180E ’05 - - - - - - - - - - - - - - 56
Hydraulic attachment bracket - - - - - - - - - - - - - - - - - - - - - - - - - - - 61 8.1.
7300062 Hydraulic attachment bracket (optional) - - - - - - - - - - - - - - - 62
Parameter settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67
10.
Testing of the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
Date of issue: November 2004
9.
EF17196P00
Table of contents
3 (72)
Wheel Loader Volvo L150E / L180E ’05
Date of issue: November 2004
4 (72)
Table of contents
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
1.
1.
Date of issue: November 2004
PREFACE
your efficiency is our challenge
EF17196P00
Preface
5 (72)
Wheel Loader Volvo L150E / L180E ’05
1.1
General information This installation manual describes the installation of the Twin-system on the Volvo Wheel Loader type L150E / L180E ’05.
Automatic Twin Grease Lubrication System Machine type
1.2
Number of grease points
Groeneveld order number
Volvo order number
Manual number
Volvo L150E / L180E ’05
28 x
F177609
-
EF17196P00
Hydr. att. bracket
2x
7300062
11093615
EF17196P00
Use of symbols Symbol H 1/4” S6-200-E6
Explanation High pressure hose 1/4” I/D or 3/8” I/D 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
4.25
Position number on the parts list
Grease point position number Black
BN
Brown
BU
Blue
RD
Red
GY
Grey
YE
Yellow
BR
Brass
PA
Polyamide
SST
Stainless steel
ST-YG ST-G
6 (72)
Preface
Date of issue: November 2004
BK
Yellow passivated steel Galvanised steel
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
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.
Date of issue: November 2004
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.
EF17196P00
Preface
7 (72)
Wheel Loader Volvo L150E / L180E ’05
1.5
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
Drilling depth
Full drilling
Tap
Fill the grease point with grease
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: November 2004
Grind
Welding location
8 (72)
Preface
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
2.
2.
Date of issue: November 2004
SYSTEM LAY-OUT
your efficiency is our challenge
EF17196P00
System lay-out
9 (72)
Wheel Loader Volvo L150E / L180E ’05
Parts list The Twin-system for the Volvo L150E / L180E ’05 comprises the following parts: Groeneveld order number
Volvo order number
Description
F170458
11176458
Twin pumpkit Volvo L150E / L180E ’05
F173646
11177068
Electronics installation kit Volvo L150E / L180E ’05
F170456
11708642
Twin 7-port block, complete
F177611
-
Twin 12-port block, complete
F174529
11177553
Twin 6-port block, complete
F174530
11177558
Twin 4+4-port block, complete
F177612
-
Installation kit Twin 7-port block
B1
F177613
-
Installation kit Twin 12-port block
B2
F177614
-
Installation kit Twin 6-port block
B3
F177615
-
Installation kit Twin 4+4-port block
B4
F177616
-
Twin Main line kit Volvo L150E / L180E ’05
F177617
-
A5 manual Volvo L150E / L180E ’05
XU1701D
-
User’s manual TWIN
F173350
11177183
High-pressure hose 3/8” E10-1650-S10
H1 2x
830412
11708645
High-pressure hose 1/4” S10-2000-E10
H2 2x
830803
11708646
High-pressure hose 1/4” S8-4650-S10
H3 2x
830037
11707873
High-pressure hose 1/4” S8-0800-S8
H4 2x
Date of issue: November 2004
10
System lay-out
EF17196P00
Date of issue: November 2004
Wheel Loader Volvo L150E / L180E ’05
EF17196P00
System lay-out
11
Wheel Loader Volvo L150E / L180E ’05
Parts list 2.1
F170456 Twin 7-port block, complete
Pos.
Q’ty
Groeneveld order number
Volvo order number
Description
1
2
31801
11702148
Sealing ring
2
2
32901
11702149
Threaded plug 1/4” BR
3
2
50802
11997270
T-male stud 1/4” - ø10mm ST-YG
4
4
71101
11702153
Metering unit No.4 - 0.200cc/M22/6mm/BR
5
3
79601
11702154
Metering unit No.9 - 1.000cc/M22/6mm/BR
6
1
70401
11708193
Twin 7-port block M10 BR
7
1.5m
77301
11701833
Grease pipe 1 x ø6mm x 1.5 PA per m
8
2m
77301
11701833
Grease pipe 1 x ø6mm x 1.5 PA per m
9
1.5m
77301
11701833
Grease pipe 1 x ø6mm x 1.5 PA per m
10
1m
77301
11701833
Grease pipe 1 x ø6mm x 1.5 PA per m
11
1m
77501
11701835
Grease pipe 3 x ø6mm x 1.5 PA per m
12
4
02717
-
Protective cap ø6mm
13
1
03217
-
Protective cap ø12mm
Date of issue: November 2004
12
System lay-out
EF17196P00
Date of issue: November 2004
Wheel Loader Volvo L150E / L180E ’05
EF17196P00
System lay-out
13
Wheel Loader Volvo L150E / L180E ’05
Parts list 2.2 Pos.
F177611 Twin 12-port block, complete Q’ty
Groeneveld order number
Volvo order number
Description
1
2
31801
11702148
Sealing ring
2
2
32901
11702149
Threaded plug G1/4” BR
3
2
72722
-
Body, T-male stud 1/4” - ø10mm ST-YG
4
2
70801
11702371
Metering unit No.1 - 0.050cc/M22/6mm/BR
5
7
71001
11702152
Metering unit No.3 - 0.150cc/M22/6mm/BR
6
1
71201
11702155
Metering unit No.8 - 0.400cc/M22/6mm/BR
7
1
91001
11702375
Metering unit No.10 - 2.000cc/M22/6mm/BR
8
1
F115874
-
Pressure switch 150 bar, complete BR
9
1
70601
11708191
Twin 12-port block M10 BR
10
2m
77401
11701834
Grease pipe 2 x ø6mm x 1.5 PA per m
11
2m
77401
11701834
Grease pipe 2 x ø6mm x 1.5 PA per m
12
2m
77401
11701834
Grease pipe 2 x ø6mm x 1.5 PA per m
13
1.25m
77301
11701833
Grease pipe 1 x ø6mm x 1.5 PA per m
14
2m
77401
11701834
Grease pipe 2 x ø6mm x 1.5 PA per m
15
1
830545
11707875
HPH 1/4” S6-4600-S6
16
1
F174651
11177548
HPH 1/4” S6-4700-S10
17
1
15417
11707861
Pressure switch cable
18
2
02717
-
Protective cap ø6mm
19
5
28401
-
Protective cap ø9.5mm
Date of issue: November 2004
14
System lay-out
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
18
16
17 10
15
11
13 12 14 19
8
Date of issue: November 2004
2
4
5
5
6
7
1
3
5
EF17196P00
4
5
5
5
5
9
System lay-out
15
Wheel Loader Volvo L150E / L180E ’05
Parts list 2.3
F174529 Twin 6-port block, complete
Pos.
Q’ty
Groeneveld order number
Volvo order number
Description
1
1
45502
11700972
Male stud coupling 1/4” - ø8mm ST-YG
2
1
80701
11702476
Elbow swivel coupling ø8mm ST-YG
3
2
72022
11713081
Body, male stud coupling 1/4” - ø8mm ST-YG
4
1
72222
11713082
Body, male stud elbow 1/4” - ø8mm ST-YG
5
2
70701
11702150
Shut-off plug M22 x 1 BR
6
2
71201
11702155
Metering unit No.8 - 0.400cc/M22/6mm/BR
7
1
79601
11702154
Metering unit No.9 - 1.000cc/M22/6mm/BR
8
1
91001
11702375
Metering unit No.10 - 2.000cc/M22/6mm/BR
9
1
75601
11705430
Twin 6-port block, flat BR
10
1
F174654
-
H.P.H. 1/4” S6-0900-S10
11
1
830061
11708064
H.P.H. 1/4” S6-0900-S6
12
1
830273
11708065
H.P.H. 1/4” S6-1200-S6
13
1
F174538
11713084
H.P.H. 1/4” S6-0350-E6
14
3
02717
-
Protective cap ø6mm
Date of issue: November 2004
16
System lay-out
EF17196P00
Date of issue: November 2004
Wheel Loader Volvo L150E / L180E ’05
EF17196P00
System lay-out
17
Wheel Loader Volvo L150E / L180E ’05
Parts list 2.4
F174530 Twin 4+4-port block, complete
Pos.
Q’ty
Groeneveld order number
Volvo order number
Description
1
2
32901
11702148
Threaded plug 1/4” BR
2
2
83901
11702149
Sealing ring
3
1
45502
11700972
Male stud coupling 1/4” - ø8mm ST-YG
4
1
72222
11713082
Body, male stud elbow 1/4” - ø8mm ST-YG
5
1
80701
11702476
Elbow swivel coupling ø8mm ST-YG
6
2
70701
11702150
Shut-off plug M22 x 1 BR
7
2
71001
11702152
Metering unit No.3 - 0.150 cc/M22/6mm/BR
8
1
71101
11702153
Metering unit No.4 - 0.200 cc/M22/6mm/BR
9
1
72701
11702370
Metering unit No.6 - 0.300 cc/M22/6mm/BR
10
2
79601
11702154
Metering unit No.9 - 1.000 cc/M22/6mm/BR
11
1
77201
11713962
Twin 4+4-port block, flat BR
12
1
830276
11708426
H.P.H. 1/4” S6-2200-S6
13
1
F173538
11713085
H.P.H. 1/4” S6-2300-S10
14
2
830482
11713086
H.P.H. 1/4” S6-2800-S6
15
2
830667
11713087
H.P.H. 1/4” S6-0200-S6
16
5
02717
-
Protective cap ø6mm
Date of issue: November 2004
18
System lay-out
EF17196P00
Date of issue: November 2004
Wheel Loader Volvo L150E / L180E ’05
EF17196P00
System lay-out
19
Wheel Loader Volvo L150E / L180E ’05
Notes
Date of issue: November 2004
20
System lay-out
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
3.
3.
Date of issue: November 2004
GREASE POINT LOCATION
your efficiency is our challenge
EF17196P00
Grease point location
21
Wheel Loader Volvo L150E / L180E ’05
Date of issue: November 2004
22
Grease point location
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
28
30 13
16 11 10
12
8
18
7
4
3
2
1
Date of issue: November 2004
9
EF17196P00
Grease point location
23
Wheel Loader Volvo L150E / L180E ’05
Notes
Date of issue: November 2004
24
Grease point location
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
4.
4.
Date of issue: November 2004
GREASE PUMP INSTALLATION
your efficiency is our challenge
EF17196P00
Grease pump installation
25
Wheel Loader Volvo L150E / L180E ’05
Parts list 4.1
F170458 Twin pumpkit Volvo L150E / L180E ’05
Pos.
Q’ty
Groeneveld order number
Volvo order number
Description
1.1
1
15517
11176708
Cable harness, pump
1.2
10
00208
4881439
Cable tie, black 186mm
1.3
1
F173347
11177137
Mounting bracket, pump 270 x 270mm
1.5
3
101110
969313
Hexagonal bolt M10 x 110 ST-G
1.6
4
108050
965179
Hexagonal bolt M8 x 40 ST-G
1.7
4
220008
948645
Nut, self-locking M8 ST-G
1.8
3
220010
971098
Nut, self-locking M10 ST-G
1.9
4
300008
960141
Plain washer M8 ST-G
1.10
3
300010
960143
Plain washer M10 ST-G
1.11
1
F116316
11708641
Twin pump 24V/12cc/3L/250bar
1.12
3
16512
11708538
Distance spacer 80mm ST-YG
Date of issue: November 2004
26
Grease pump installation
EF17196P00
Date of issue: November 2004
Wheel Loader Volvo L150E / L180E ’05
EF17196P00
Grease pump installation
27
Wheel Loader Volvo L150E / L180E ’05
Notes
Date of issue: November 2004
28
Grease pump installation
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
5.
5.
Date of issue: November 2004
ELECTRICAL COMPONENTS
your efficiency is our challenge
EF17196P00
Electrical components
29
Wheel Loader Volvo L150E / L180E ’05
Parts list 5.1
F173646 Electronics installation kit Volvo L150E / L180E ’05
Pos.
Q’ty
Groeneveld order number
Volvo order number
Description
2.1
3
02701
11176861
Self-tapping screw M5 x 10
2.2
1
97101
-
Relais housing with cable harness
2.3
1
97201
11701821
Cable harnes, cycle mode switch
2.4
1
97301
4786690
Relais + diode
2.5
1
97401
-
Fuse box, 6 fuses
2.6
35
00208
4881439
Cable tie, black 186 mm
2.7
1
19508
13967545
Fuse 10A, plug-in
2.8
1
12817
11705936
Cycle mode switch 24V
2.9
1
16422
11997279
Illuminated lamp cover, yellow
2.10
1
F173645
Cable harness, cabine
Date of issue: November 2004
30
Electrical components
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
2.6
1.11
2.9 2.3
2.8
1.6
Date of issue: November 2004
2.10
2.4
2.2
2.5
EF17196P00
Electrical components
31
Wheel Loader Volvo L150E / L180E ’05
Position number
Description
1
+ 30
2
Fuse box (optional)
3
Relais
4
Circuit board Volvo
5
Fuse box (standard)
6
Cycle mode switch with integrated control lamp
7
Gear box connector housing CL
8
- 31 Central earth connection
9
Cabine
10
Grease pump with integrated timer
11
Main line pressure switch
Date of issue: November 2004
32
Electrical components
EF17196P00
Date of issue: November 2004
Wheel Loader Volvo L150E / L180E ’05
EF17196P00
Electrical components
33
Wheel Loader Volvo L150E / L180E ’05
2.2
2.4
2.7
2.5
34
Electrical components
Date of issue: November 2004
2.3
2.10
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
6.
6.
Date of issue: November 2004
DISTRIBUTION BLOCKS
your efficiency is our challenge
EF17196P00
Distribution blocks
35
Wheel Loader Volvo L150E / L180E ’05
Parts list 6.1
F177612 Installation kit Twin 7-port block / F170456 B1
Pos.
Q’ty
Groeneveld order number
Volvo order number
Description
3.1
2
02701
11176861
Self-tapping screw M5 x 10
3.2
1
97701
11701842
Extend adaptor 1/8”NPTF - 70mm ST-YG
3.3
1
97901
11701845
Elbow red. adaptor 1/8”NPTF ST-YG
3.4
1
98101
11701843
Male stud coupling 1/8”NPTF - ø6mm BR
3.5
6
98201
11701837
Male stud elbow 1/8”NPTF - ø6mm BR
3.6
10
11107
4881440
Cable tie, black 338mm
3.7
25
00208
4881439
Cable tie, black 186mm
3.8
2
01108
11176860
Clamp ø8mm
3.9
5m
36608
941451
Protection hose ø7mm ID per m
3.10
1
F170756
11177147
Clamp ø6mm for a M10 bolt
3.11
1
220010
971098
Nut, self-locking M10 ST-G
3.12
1
300010
960143
Plain washer M10 ST-G
3.13
1
F170456
11708642
Twin 7-port block, complete
Date of issue: November 2004
36
Distribution blocks
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
NT O R F
6
5 3.2
4
3
2
1
3.5
3.13 3.10 3.12 3.11
3.1 3.8
7 3.3
Date of issue: November 2004
3.4
BK
BK
BU
BK
7
5
3
1
6
4
2
BK
BK
RD
EF17196P00
Distribution blocks
37
Wheel Loader Volvo L150E / L180E ’05
6 5
7 4
3
2
1
Date of issue: November 2004
38
Distribution blocks
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
6 5
7 3
2
1
Date of issue: November 2004
4
EF17196P00
Distribution blocks
39
Wheel Loader Volvo L150E / L180E ’05
Parts list 6.2 Pos.
Q’ty
Groeneveld order number
4.1
2
33301
11701850
Extend adaptor 1/8”NPTF - 42mm ST-YG
4.2
2
50301
11701827
Allen plug 1/8”NPTF BR
4.3
5
78701
11701854
Tube clamp, double ø12mm
4.4
3
97701
11701842
Extend adaptor 1/8”NPTF - 70mm ST-YG
4.5
10
98201
11701837
Male stud elbow 1/8”NPTF - ø6mm BR
4.6
10
11107
4881440
Cable tie, black 338mm
4.7
25
00208
4881439
Cable tie, black 186mm
4.8
1
36208
11707383
Bracket 5 x 30 x 90mm
4.9
5m
36608
941451
Protection hose ø7mm ID per m
4.10
2
39008
980614
Clamp ø14mm for M10 bolt
4.11
1
39308
11708539
Mounting bracket
4.12
1
02112
11707384
Mounting bracket
4.13
5
13312
11707381
Cover plate, tube clamp double 6-12mm
4.14
1
18312
11707877
Flange bolt M12 x 35 with grease channel
4.15
2
101016
946471
Hexagonal bolt M10 x 16 ST-G
4.16
2
101040
965185
Hexagonal bolt M10 x 40 ST-G
4.17
2
108016
955294
Hexagonal bolt M8 x 16 ST-G
4.18
3
126035
959208
Allen bolt M6 x 35 ST-G
4.19
2
126040
959209
Allen bolt M6 x 40 ST-G
4.20
2
300008
960141
Plain washer M8 ST-G
4.21
4
300010
960143
Plain washer M10 ST-G
4.22
0,5m
F117437
11176983
Spiral protective wrap ø22mm
4.23
1
F118881
11177488
Male stud coupling 1/8”NPTF - ø10mm (L150E)
4.24
1
F171197
11177136
Clamp ø12 for M10 bolt
4.25
2
F173293
-
Bracket bucketpin tube ø10mm ST-YG
4.26
1
F173414
11177103
Male stud coupling 1/8”NPTF - ø10mm (L180E)
4.27
1
F173417
11177105
Straight connecting coupling ø10mm ST-YG
4.28
1
F174531
11177549
Tube lower bucket pin left ø10 mm ST-YG
4.29
2
F176943
-
Welding block M8x1.25 / 35 / 20 / 10mm
4.30
1
F177610
-
Protection bracket bucket pin
4.31
1
F177611
-
Twin 12-port block, complete
Distribution blocks
Volvo order number
Description
EF17196P00
Date of issue: November 2004
40
F177613 Installation kit Twin 12-port block / F177611 B2
Wheel Loader Volvo L150E / L180E ’05
NT O R F
4.13
4.15 4.21 4.12
15 4.3 4.8 4.18 4.19
14
17
4.5
4.28
18 4.4
4.27 4.24
16 4.14 4.1
4.16
4.17
4.11
12 4.10
11
4.25 4.20
10 4.30 4.29
13
4.31
4.23
8
4.26
9
Date of issue: November 2004
BK RD BK RD 8 9 10 11 12 13
14 15 16 17 18 BK RD BK RD BK
EF17196P00
Distribution blocks
41
Wheel Loader Volvo L150E / L180E ’05
4.21 4.16
Date of issue: November 2004
4.10 4.31 4.11
42
Distribution blocks
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
ø5mm
FULL
ø5mm
1.
2.
1. Remove the bushing. 2. Drill a hole of 5mm to the inside of the lift frame. 3. Assemble the bushing again. This bushing needs to be provided with a grease channel around the outside, with on one spot a hole to the pin. If such a bushing is not available, the old one needs to be adapted.
3.
A-A
FULL
B-B 4.19 4.21 4.16 4.13
4.18
4.12
4.13
4.3
4.29
4.3
4.21
4.25
4.15
4.20
4.27 4.10
4.17
4.28
4.30
B A
B A Date of issue: November 2004
4.3 4.8 4.13 4.19
EF17196P00
4.5
4.23
4.14
4.26
Distribution blocks
43
Wheel Loader Volvo L150E / L180E ’05
Parts list 6.3 Pos.
Q’ty
Groeneveld order number
5.1
2
50301
11701827
Allen plug 1/8”NPTF BR
5.2
1
78701
11701854
Tube clamp, double ø12mm
5.3
2
97701
11701842
Extend adaptor 1/8”NPTF - 70mm ST-YG
5.4
3
98201
11701837
Male stud elbow 1/8”NPTF - ø6mm BR
5.5
2
09202
11176859
Spring washer 6.4
5.6
1
39702
11706046
Protection ring ø60 x 40mm
5.7
2
81802
11701117
Tube clamp, single ø12mm
5.8
1
35808
11707389
Distance spacer 20 x 20 x 10mm
5.9
1
36008
11176596
Mounting bracket 6/8 port block
5.10
1
36208
11707383
Mounting bracket
5.11
1
01712
11707879
Clamping bracket ø390mm
5.12
1
13312
11707381
Cover plate, tube clamp double 6-12mm
5.13
2
16012
11707377
Cover plate, tube clamp single 6-12mm
5.14
1
18312
11707877
Flange bolt M12 x 35 with grease channel
5.15
1
101016
949471
Hexagonal bolt M10 x 16 ST-G
5.16
1
101040
965185
Hexagonal bolt M10 x 40 ST-G
5.17
1
101070
965188
Hexagonal bolt M10 x 70 ST-G
5.18
2
108016
946440
Hexagonal bolt M8 x 16 ST-G
5.19
1
108080
965182
Hexagonal bolt M8 x 80 ST-G
5.20
4
126030
959207
Allen bolt M6 x 30 ST-G
5.21
3
126035
959208
Allen bolt M6 x 35 ST-G
5.22
1
220008
948645
Nut, self-locking M8 ST-G
5.23
2
220010
971098
Nut, self-locking M10 ST-G
5.24
3
300008
960141
Plain washer M8 ST-G
5.25
2
300010
960143
Plain washer M10 ST-G
Distribution blocks
Volvo order number
Description
Date of issue: November 2004
44
F177614 Installation kit Twin 6-port block / F174529 B3
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
NT O R F
5.15 5.20
5.27 5.30 5.34
22
5.19 5.14
8
5.5
10
89
5.22
20 5.31
5.11
5.28
5.2
5.24 5.18
19
5.17 5.16 5.25
5.32
5.7
5.26 5.29
5.9
5.12
5.33
5.21
5.8 5.23
5.13
5.6
5.10
5.4
21
Date of issue: November 2004
5.3
EF17196P00
Distribution blocks
45
Wheel Loader Volvo L150E / L180E ’05
Parts list F177614 Installation kit Twin 6-port block / F174529 B3 (continue) Pos.
Q’ty
Groeneveld order number
Volvo order number
Description
5.26
1
F118881
11177488
Male stud coupling 1/8”NPTF - ø10mm (L150E)
5.27
1
F171197
11177136
Clamp ø12 mm for M10 bolt
5.28
2
F173293
-
Bracket bucketpin tube ø10mm ST-YG
5.29
1
F173414
11177103
Male stud coupling 1/8”NPTF - ø10mm (L180E)
5.30
1
F173417
11177105
Straight connecting coupling ø10mm ST-YG
5.31
1
F174532
11177552
Tube lower bucket pin right ø10mm ST-YG
5.32
2
F176943
-
Welding block M8x1.25 / 35 / 20 / 10mm
5.33
1
F177610
-
Protection bracket bucket pin
5.34
1
F174529
11177553
Twin 6-port block, complete
Date of issue: November 2004
46
Distribution blocks
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
NT O R F
5.15 5.20
5.27 5.30 5.34
22
5.19 5.14
8
5.5
10
89
5.22
20 5.31
5.11
5.28
5.2
5.24 5.18
19
5.17 5.16 5.25
5.32
5.7
5.26 5.29
5.9
5.12
5.33
5.21
5.8 5.23
5.13
5.6
5.10
5.4
21
Date of issue: November 2004
5.3
EF17196P00
Distribution blocks
47
Wheel Loader Volvo L150E / L180E ’05
5.23
5.17
5.25
5.9
5.8
5.25
5.23
5.13
5.7
5.10
5.21
48
Distribution blocks
EF17196P00
Date of issue: November 2004
5.16
Wheel Loader Volvo L150E / L180E ’05
ø5mm
FULL
ø5mm
1.
2.
1. Remove the bushing. 2. Drill a hole of 5mm to the inside of the lift frame. 3. Assemble the bushing again. This bushing needs to be provided with a grease channel around the outside, with on one spot a hole to the pin. If such a bushing is not available, the old one needs to be adapted.
3.
A-A
B-B
5.32 5.28 5.24 5.33
5.31
FULL
5.27 5.25 5.15
5.30
5.18
B A
Date of issue: November 2004
B 5.26
A
5.29 5.4 5.14
EF17196P00
Distribution blocks
49
Wheel Loader Volvo L150E / L180E ’05
Parts list 6.4 Pos.
Q’ty
Groeneveld order number
6.1
1
50301
11701827
Allen plug 1/8”NPTF BR
6.2
1
61801
11706053
Extend adaptor 1/8”NPTF - 1/4”G - 70mm ST-YG
6.3
6
78701
11701854
Tube clamp, double ø12mm
6.4
1
97701
11701842
Extend adaptor 1/8”NPTF - 70mm ST-YG
6.5
6
97901
11701845
Elbow red. adaptor 1/8”NPTF ST-YG
6.6
1
98001
11701838
Extend adaptor 1/8”NPTF - 22mm BR
6.7
4
98101
11701843
Male stud coupling 1/8”NPTF - ø6mm BR
6.8
1
98201
11701837
Male stud elbow 1/8”NPTF - ø6mm BR
6.9
2
09202
11176859
Spring washer 6.4
6.10
1
39702
11706046
Protection ring ø60 x 40mm
6.11
1
47402
11997271
Male stud elbow 1/4” - ø10mm ST-YG
6.12
5
11107
4881440
Cable tie, black 338mm
6.13
0,5m
02008
11176982
Spiral protective wrap
6.14
2
39008
980614
Clamp ø14 mm for M10 bolt
6.15
6
13312
11707381
Cover plate, tube clamp double 6-12mm
6.16
2
18212
11707868
Hose support bracket
6.17
1
23612
-
Protection ring ø60 x 20mm
6.18
3
108030
946671
Hexagonal bolt M8 x 30 ST-G
6.19
1
108050
965179
Hexagonal bolt M8 x 50 ST-G
6.20
2
126030
959207
Allen bolt M6 x 30 ST-G
6.21
4
126035
959208
Allen bolt M6 x 35 ST-G
6.22
2
126040
959209
Allen bolt M6 x 40 ST-G
6.23
4
220008
948645
Nut, self-locking M8 ST-G
6.24
1
220010
971098
Nut, self-locking M10 ST-G
6.25
4
300008
960141
Plain washer M8 ST-G
Distribution blocks
Volvo order number
Description
Date of issue: November 2004
50
F177615 Installation kit Twin 4+4-port block / F174530 B4
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
NT O R F
6.22 6.15 6.3 6.32
6.23 6.16 6.19
6.28
6.25
6.29 6.17
6.31
6.20
6.27
6.8
6.10 6.11
6.20 6.4
6.2
26
6.14
25
63 99
6.9 6.33
43
6.18 6.30 6.26 6.24
27
24
28
23
6.7 6.6
Date of issue: November 2004
6.5
EF17196P00
Distribution blocks
51
Wheel Loader Volvo L150E / L180E ’05
Parts list F177615 Installation kit Twin 4+4-port block / F174530 B4 (continue) Pos.
Q’ty
Groeneveld order number
Volvo order number
Description
6.26
1
300010
960143
Plain washer M10 ST-G
6.27
1
F173292
-
Block for bracket bucketpin
6.28
1
F173293
-
Bracket bucketpin tube ø10mm ST-YG
6.29
1
F173417
11177105
Straight connecting coupling ø10mm ST-YG
6.30
1
F174534
11177555
Bracket, 4+4-port block
6.31
1
F174535
11177556
Tube ø10 mm ST-YG
6.32
1
F174536
11177557
Bracket for tube clamps
6.33
1
F174530
11177558
Twin 4+4-port block, complete
Date of issue: November 2004
52
Distribution blocks
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
NT O R F
6.22 6.15 6.3 6.32
6.23 6.16 6.19
6.28
6.25
6.29 6.17
6.31
6.20
6.27
6.8
6.10 6.11
6.20 6.4
6.2
26
6.14
25
63 99
6.9 6.33
43
6.18 6.30 6.26 6.24
27
24
28
23
6.7 6.6
Date of issue: November 2004
6.5
EF17196P00
Distribution blocks
53
Wheel Loader Volvo L150E / L180E ’05
ø5mm
1.
FULL
2.
1. Remove the bushing. 2. Drill a hole of 5mm to the inside of the lift frame. 3. Assemble the bushing again. This bushing needs to be provided with a grease channel around the outside, with on one spot a hole to the pin. If such a bushing is not available, the old one needs to be adapted.
3.
A-A
A 6.13
A
INSIDE VIEW Date of issue: November 2004
6.14
54
Distribution blocks
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
7.
7.
Date of issue: November 2004
INSTALLATION MAIN LINE
your efficiency is our challenge
EF17196P00
Installation main line
55
Wheel Loader Volvo L150E / L180E ’05
Parts list 7.1
F177616 Twin Main line kit Volvo L150E / L180E ’05
Pos.
Q’ty
Groeneveld order number
Volvo order number
Description
7.1
6
78701
11701854
Tube clamp, double ø12mm
7.2
25
11107
4881440
Cable tie, black 338mm
7.3
2
39008
980614
Clamp ø14mm for M10 bolt
7.4
2
02112
11707384
Mounting bracket
7.5
6
13312
11707381
Cover plate, tube clamp double 6-12mm
7.6
1
101016
946471
Hexagonal bolt M10 x 16 ST-G
7.7
1
101020
946441
Hexagonal bolt M10 x 20 ST-G
7.8
4
126035
959208
Allen bolt M6 x 35 ST-G
7.9
2
126040
959209
Allen bolt M6 x 40 ST-G
7.10
2
300010
960143
Plain washer M10 ST-G
7.11
0,5m
F117437
11176983
Spiral protective wrap ø22mm
7.12
2
F173350
11177183
High-pressure hose 3/8” E10-1650-S10
H1
7.13
2
830412
11708645
High-pressure hose 1/4” S10-2000-E10
H2
7.14
2
830803
11708646
High-pressure hose 1/4” S8-4650-S10
H3
7.15
2
830037
11707873
High-pressure hose 1/4” S8-0800-S8
H4
Date of issue: November 2004
56
Installation main line
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
5.34
7.14 7.15
6.33
4.31
7.13
3.13
1.11
Date of issue: November 2004
7.12
EF17196P00
Installation main line
57
Wheel Loader Volvo L150E / L180E ’05
NT O R F
7.12 3.13 7.13
7.8
1.11
7.10 7.6
7.14 7.1
7.3
5.34
7.7
6.33
4.31
Date of issue: November 2004
5.11
7.15
7.9 7.5
7.4
58
Installation main line
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
7.14
7.3
7.11
6.33
5.34
7.14
Date of issue: November 2004
7.15
EF17196P00
Installation main line
59
Wheel Loader Volvo L150E / L180E ’05
Notes
Date of issue: November 2004
60
Installation main line
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
8.
8.
Date of issue: November 2004
HYDRAULIC ATTACHMENT BRACKET
your efficiency is our challenge
EF17196P00
Hydraulic attachment bracket
61
Wheel Loader Volvo L150E / L180E ’05
Parts list 8.1
7300062 Hydraulic attachment bracket (optional)
Pos.
Q’ty
Groeneveld order number
Volvo order number
Description
8.1
2
02701
946501
Self-tapping screw M5 x 10
8.2
2
50301
11701827
Allen plug 1/8”NPTF BR
8.3
2
71201
11702155
Metering unit No.8 - 0.400cc/M22/6mm/BR
8.4
2m
77301
11701833
Grease pipe 1 x ø6mm x 1,5 PA per m
8.5
1
78701
11701854
Tube clamp, double ø12mm
8.6
2
97901
11701845
Elbow red. adaptor 1/8”NPTF ST-YG
8.7
2
98101
11701843
Male stud coupling 1/8”NPTF - ø6mm BR
8.8
4
98201
11701837
Male stud elbow 1/8”NPTF - ø6mm BR
8.9
5
11107
4881440
Cable tie, black 338mm
8.10
2
01108
952624
Clamp ø8mm
8.11
1,5m
36608
11176651
Protection hose ø7mm ID per m
8.12
1
13312
11707381
Cover plate, tube clamp double 6-12mm
8.13
1
126035
959208
Allen bolt M6 x 35 ST-G
8.14
2
830368
11176847
High pressure hose 1/4” S6-2300-S6
Date of issue: November 2004
62
Hydraulic attachment bracket
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
NT O R F
5.19 5.24
8.3 8.13
5.22
88
8.12
8.14 8.5
8.6
5.11
8.8
29
8.10 8.7
8.1
Date of issue: November 2004
30
EF17196P00
Hydraulic attachment bracket
63
Wheel Loader Volvo L150E / L180E ’05
Date of issue: November 2004
64
Hydraulic attachment bracket
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
8.9
8.14
8.7 8.6
8.8
8.1
Date of issue: November 2004
8.10
EF17196P00
Hydraulic attachment bracket
65
Wheel Loader Volvo L150E / L180E ’05
Notes
Date of issue: November 2004
66
Hydraulic attachment bracket
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
9.
9.
Date of issue: November 2004
PARAMETER SETTINGS
your efficiency is our challenge
EF17196P00
Parameter settings
67
Wheel Loader Volvo L150E / L180E ’05
Parameter settings Code
Description
Setting
HDCY
Heavy duty cycle
15 minutes
NDCY
Normal duty cycle
20 minutes
LDCY
Low duty cycle
30 minutes
CMS
Cycle mode select
2
MPT
Maximum pumping time
15 minutes
VMF
Venting multiply factor
10 (/10) x
NOA
Number of attempts before pump holds
10 x
BCDC
Blink code duty cycle
4x
CSI
Command signal 'inverted'
1 (GINA) / YES (PC)
Consumption metering units each cycle : 14,75 cc
Date of issue: November 2004
68
Parameter settings
EF17196P00
Wheel Loader Volvo L150E / L180E ’05
10.
10.
Date of issue: November 2004
TESTING OF THE SYSTEM
your efficiency is our challenge
EF17196P00
Testing of the system
69
Wheel Loader Volvo L150E / L180E ’05
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 nonexcited (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 nonexcited (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 Twinlubrication 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: November 2004
70
Testing of the system
EF17196P00
Groeneveld Australia Pty. Ltd.
Groeneveld Information Technology B.V.
18 - 20 Mc Dougall Road P.O.Box 787 Sunbury, Vic 3429, AUSTRALIA Tel.: +61 397 4099943 Fax: +61 397 4099665
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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. Groeneveld CPL Systems Canada Inc. 7065 Twiss Road R.R.#3. LOP 1BO Campbellville, Ontario, CANADA Tel: + 1 905 875 1017 Fax: + 1 905 875 2125
Ul. Ostrowska 476 61 - 342 Poznan, POLAND Tel.: +48 61 8726207/08/09 Fax: +48 61 8798166
Groeneveld South Africa Groeneveld Deutschland GMBH Bullermanshof 2B 47441 Moers-Hülsdonk, DEUTSCHLAND Tel.: +49 2841 793520 Fax: +49 2841 7935222
Unit 65, Sunny Rock Park Sun Rock Close, Germiston 1401 SOUTH AFRICA Tel.: +27 11 4503977 Fax.: +27 11 4503980
Groeneveld France
Groeneveld Ibérica S.A.
53, rue Antoine Condorcet 38090 Vaulx Milieu, FRANCE Tel.: +33 4 74999333 Fax: +33 4 74999350
Pol. Ind. Mercederias, C/. Font de Sant Llorenç 36 08720 Vilafranca del Penedès (Barcelona), SPAIN Tel.: +34 93 8171822 Fax: +34 93 8172061
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 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. 7820 Professional Place, suite #6 Tampa, FL 333637, U.S.A. Tel.: +1 883 983 1883 Fax: +1 813 983 1873 Toll free: +1 877 977 7772
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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