Graco EC140 Manuale di istruzioni

Mobile Lubrication Library

Volvo Excavator Centralized

Lubrication System Installation

Instructions for installing a Graco automatic lubrication system on the

Volvo Excavator Models EC140 to EC480

Maximum System Working Pressure: 3000 psi (20.68 MPa, 206.8 bar)

The lubrication system design described in this manual is based upon representative equipment models. Models may

vary slightly depending on series and year. Additional hoses, fittings, and valve outlet doubling plugs are supplied with

the kits to modify the system based on your model’s specific configuration.

The installation instructions contained in this manual are only a recommendation for an automatic lubrication system.

They are not intended to replace any instructions provided in the OEM manuals. Always refer to the OEM’s manuals for

details on lubrication intervals.

Important Safety Information

Before beginning any installation, read all warnings and instructions in all related Graco component

manuals (page 25) and all related Original Equipment Manufacturer (OEM) manuals, including the vehi-

cle’s Operation and Maintenance Manual (OMM). Save all instructions.

WARNING

FLUID INJECTION HAZARD

Fluid leaks from incorrectly installed or ruptured compo-

nents, and/or failure to verify the components are prop-

erly installed and tested, can result in serious injury

such as fluid spraying in the eyes or on skin and fluid

injection, or equipment damage.

NOTICE

Welding can damage electronics and the equipment’s

structure. To help prevent equipment damage caused

by welding:

•Disconnect the vehicle battery before welding.

•Follow all welding guidelines in the OEM manuals,

including the OEM service manuals.

•Only weld in locations specifically approved by the

OEM. Consult OEM dealership for information and

recommendations.

•Perform all welding in accordance with American

Welding Standard (AWS) standards.

333546B

Table of Contents

2333546B

NOTE: Images may include optional equipment.

Table of Contents

Recommended Tools and Supplies . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Zerks and Grease Point Fittings . . . . . . . . . . . . . 4

System Layout and Lubrication Points . . . . . . . . . 5

Volvo 21 Point Excavator

Models EC140 to EC480 . . . . . . . . . . . . . . . 5

Volvo 21 Point Excavator

Models EC140 to EC480 with Primary Valve 6

G3 Pump Mounting Bracket and Pressure Relief

Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7

Assemble CSP Valves . . . . . . . . . . . . . . . . . . . . . . . 7

Assemble Hose Fittings . . . . . . . . . . . . . . . . . . . . . 9

Install Power Cable . . . . . . . . . . . . . . . . . . . . . . . . 11

Assemble Bracket and Install the GLC2200

Controller (if equipped) . . . . . . . . . . . . . . . . . 12

Hose Routing Guidelines . . . . . . . . . . . . . . . . . . . 13

Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . 18

G3 SP Pumps with Internal Controller, Feedback

and Manual Run Button Wiring Schematic . 18

G3 Pro Pumps with Internal Controller and Manual

Run Button Wiring Schematic . . . . . . . . . . . 18

G3 Standard Pumps with GLC2200 External

Controller, With and Without Feedback Wiring

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fill Pump, Valves, and Hoses with Grease

to Purge Air . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fill Valves and Hoses with Grease to Purge Air 21

Test the System . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Train the Operator . . . . . . . . . . . . . . . . . . . . . . . . . 22

Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Valve Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Pump Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 26

Recommended Tools and Supplies

333546B 3

NOTE: Images may include optional equipment.

Recommended Tools and Supplies

*Both US and Metric sizes of these tools are recommended.

Loctite®is a registered trademark of the Henkel Corporation.

All trademarks and registered trademarks used in this manual are for identification purposes only. All trademarks and

registered trademarks are the property of their respective owners.

NOTE: When any of the following images are shown in the instructions it means that these components should be

used during the installation to secure or protect parts.

Tool

Size/Description

US Metric

Combination wrench* 1/4 in. - 3/4 in. 6 mm - 20 mm

Socket, standard and deep well with ratchet* 3/8 in. - 3/4 in. 9.5 mm - 20 mm

Screwdrivers: standard and Phillips 1 short; 1 long

Adjustable wrench 1 small; 1 medium

High speed drill (corded or cordless)

Drill bit - steel, high quality 5/16 in., 11/16 in.

Center punch fine point

Pipe taper tap 1/8 in. NPT

Hammer

Angle grinder

Grinding disc Heavy grade grinding disc

Flap disc 60 - 80 grit

Cutoff disc High quality disc

Cutting blade / knife Razor blade cutting tool

Standard pliers Rubber handle

Needle nose pliers Rubber handle

Side cut pliers (diagonal cutters) Rubber handle

Slip joint pliers Rubber handle

Locking pliers Small or medium

Wire stripper / crimper General duty wire striper / crimper

Soldering iron 30 watt minimum

Electrical solder

Soldering flux

Shrink tubing Various sizes

Electrical tape Black, small roll

Thread sealant Liquid thread sealant such as Loctite®656

Multimeter / voltmeter Must test DC/AC/Ohms

Electrical connectors Ring connectors (14 -18 gauge)

Tape measure Standard / metric

Primer and paint Color should match the equipment

Documentation / writing implements Small note pad, pen, pencil, marker

P-Clamp Anchor Block Zip Tie

and Bolts

Weld Block

Installation

4333546B

NOTE: Images may include optional equipment.

Installation

Disconnect battery before installing the lubrication system. Inspect the machine and verify that the system design

includes all lubrication points and meets the manufacturer’s requirements.

Zerks and Grease Point Fittings

1. Grease all zerk fittings (FIG. 1).

2. Remove all grease zerks (FIG. 2).

3. The kit includes a variety of extenders, elbows,

straight compression fittings, and elbow compres-

sion fittings (FIG. 3). Mix and match fittings and com-

ponents supplied in the kit to replace the zerks.

4. Apply pipe sealant to fittings. To avoid contamina-

tion do not use PTFE tape on the fitting threads. If

you must use PTFE tape, always ensure the first

thread on the fitting is not taped and the tape is

applied precisely.

FIG. 1

FIG. 2

FIG. 3

System Layout and Lubrication Points

333546B 5

NOTE: Images may include optional equipment.

System Layout and Lubrication Points

Volvo 21 Point Excavator Models EC140 to EC480

FIG. 4

Lube

Point Description

A Swing Gear

B Boom Foot Pin

C Boom Cylinder Foot Pin

D Boom Cylinder Rod Pin

E Stick Cylinder Foot Pin

F Boom/Stick Pin

G Stick Cylinder Rod Pin

H Bucket Cylinder Foot Pin

I Bucket Link Pin

JBucketPin

KHLink

No Shim

Double

Shim

System Layout and Lubrication Points

6333546B

NOTE: Images may include optional equipment.

Volvo 21 Point Excavator Models EC140 to EC480 with Primary

Valve

FIG. 5

Lube

Point Description

A Swing Gear

B Boom Foot Pin

C Boom Cylinder Foot Pin

D Boom Cylinder Rod Pin

E Stick Cylinder Foot Pin

F Boom/Stick Pin

G Stick Cylinder Rod Pin

H Bucket Cylinder Foot Pin

I Bucket Link Pin

JBucketPin

KHLink

G3 Pump Mounting Bracket and Pressure Relief Valve Assembly

333546B 7

NOTE: Images may include optional equipment.

G3 Pump Mounting Bracket and Pressure Relief Valve

Assembly

Assemble and install pressure relief valve and pump mounting bracket on the pump (FIG. 6). See the Graco G3 pump

instruction manual for additional instructions. A complete list of related Graco instruction manuals is provided on

page 25.

Assemble CSP Valves

The CSP primary valve assembly shown in FIG. 7 is provided as a guide. Assemble the parts as needed to best

accommodate your installation. See the Graco CSP Valve instruction manual for instructions. A complete list of

related Graco instruction manuals is provided on page 25.

FIG. 6

Pressure

Relief

Valve

FIG. 7

Torque to 12 to 14 ft-lbs (16 to 19 N•m)

Torque to 10 to 12 ft-lbs (13.5 to 16 N•m)

Install CSP Valves

8333546B

NOTE: Images may include optional equipment.

Install CSP Valves

Use supplied weld block and bolts to install the CSP valves on the equipment. Refer to FIG. 8 and FIG. 10 for recom-

mended installation locations for the valves.

NOTE: If using a proximity switch to monitor the system:

• Route the proximity cable to the G3 SP pump mounting location.

• Route the proximity cable under the cab of the Excavator when using a GLC2200 Controller.

FIG. 8

FIG. 9: Optional valve mounting if using primary

valve

Recommended Installation

Components

Recommended Installation

Components

FIG. 10

FIG. 11: Optional valve mounting

Recommended Installation

Components

Recommended Installation

Components

Assemble Hose Fittings

333546B 9

NOTE: Images may include optional equipment.

Assemble Hose Fittings

The hoses included in the kit require assembly prior to installation. The two piece connection fittings must be installed

to the end of the hose. For detailed instructions see manual 3A3159.

NOTE: Steps 1-7 refer to FIG. 12.

1. Wrap or slide the hose wrap over the end of the cut-to-length hose until the entire length of the hose is encased

in the hose wrap.

2. Trim the hose wrap, leaving approximately 1 inch of the hose end unwrapped.

3. Remove the stud and sleeve from their package and disassemble the two pieces.

4. Lubricate the sleeve threads and hose inside diameter.

5. Install the sleeve onto the end of the hose by rotating it counter-clockwise until its seated.

6. Back off 1/4 turn. This will allow enough space for the stud to be connected.

7. Thread the stud clockwise into the sleeve until the sleeve nearly bottoms out against the stud shoulder.

8. Repeat Steps 1-7 for all hose assemblies.

FIG. 12

sleeve

hose wrap

hose

stud

NOTICE

Do not over-tighten the fittings during the final assembly. After the two fittings are securely connected, stop tighten-

ing. Over-tightening can damage the fittings and a new hose assembly will need to be made.

The sleeve should be firm when tightening but not difficult to install. If the sleeve is difficult to install, check the hose

for proper lubrication. Reapply lubricant as needed. Installation without proper lubrication can cause damage to the

core tube.

Install G3 Pump

10 333546B

NOTE: Images may include optional equipment.

Install G3 Pump

Install the pump in a protected area near the cab. The installation location should have ample space around the

pump to allow for the hoses, cables and a relief valve.

• The deck plate that surrounds the cab is the preferred installation location (FIG. 13). The deck plate is a non-crit-

ical component and therefore drilling through the deck plate is generally acceptable by most manufacturers.

However, if this location is not acceptable due to durability or space constraints, identify an alternate location

around the cab such as below the ladder, in the engine compartment or on the frame.

• A custom pump mounting bracket may be required if the preferred or alternative locations (referenced above) are

not acceptable for mounting the pump.

NOTICE

Never install pump directly to the cab. Do not drill holes or weld on any part of the cab. Drilling or welding on the

cab will likely void the cab certification for Roll Over Protective Structures (ROPS) and Falling Object Protective

Structures (FOPS).

FIG. 13

Recommended Installation

Components

Option 2

Option 1

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