Graco EC140 Instruction Manual

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)
1
Torque to 10 to 12 ft-lbs (13.5 to 16 N•m)
2
1
2

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

Install Power Cable
333546B 11
NOTE: Images may include optional equipment.
Install Power Cable
1. Route the power cable from the pump through the body of the machine and under the cab to protect it from the
environment and to aid in wiring into the cab. For installations utilizing a proximity switch and a GLC2200 control-
ler, route the prox cable along the same path as the power cable (FIG. 14).
NOTE: If using a G3 SP pump, route the prox cable directly to the pump and connect it to the supplied M12 con-
nector.
2. Route the power cable into the cab through the rubber grommet located under the floor mat (FIG. 14).
NOTE:
• If your pump uses a remote manual run button with a 5-wire CPC cable, route the cable to the manual run
button. See Wiring Guidelines, page 18.
• If your pump uses a GLC2200 Controller, route the pump power cable into the cab, toward the fuse panel
(FIG. 15). See Wiring Guidelines, page 18.
FIG. 14
FIG. 15
Recommended Installation
Components
Grommet
Recommended Installation
Components
Fuse
Panel

Assemble Bracket and Install the GLC2200 Controller (if equipped)
12 333546B
NOTE: Images may include optional equipment.
Assemble Bracket and Install the GLC2200 Controller
(if equipped)
NOTE: All parts included in the mounting bracket kit may not be required for your installation. The bracket assembly
shown in FIG. 16 is provided as a guide. The bracket is designed to be assembled in several configurations. Assem-
ble the parts as needed to best accommodate your installation.
1. Assemble the GLC2200 mounting bracket.
NOTE: FIG. 16 is only provided as a guide. Parts
can be rotated to best suit your installation location
and to provide optimal orientation for operator
access inside the cab.
2. Attach the controller to the bracket using the hard-
ware provided in the kit.
3. Install the bracket inside the cab using existing
holes in the cab using the hardware provided in the
kit (FIG. 17).
FIG. 16
NOTICE
Never install controller directly to the cab. Do not drill
holes or weld on any part of the cab. Drilling or weld-
ing on the cab will likely void the cab certification for
Roll Over Protective Structures (ROPS) and Falling
Object Protective Structures (FOPS).
FIG. 17

Hose Routing Guidelines
333546B 13
NOTE: Images may include optional equipment.
Hose Routing Guidelines
• Identify the internal and external pivot points to ensure proper hose lengths are used. If hoses are too short they
will bind and eventually break. If hoses are too long, they can easily get snagged on external debris or pinched in
the machine.
• Follow the existing hydraulic and electrical routing. This will ensure the lines are protected and routing is consis-
tent with the OEM’s existing hydraulic hose routing.
• Utilize existing grommets, supports or cut outs in the equipment’s frame for access points. Routing hoses
through these areas keeps the hoses inside the machine and provides protection. It also provides a cleaner and
more professional looking installation.
• Install hoses to ensure they move with the machine. Consider pivot, oscillation, extension, and pinch point areas
on the equipment. Before cutting and securing hoses, have a qualified technician move the various parts of the
machine to ensure proper routing is achieved.
• Connect hoses to divider valves.
• Use weld studs and p-clamps to secure hoses to the equipment. Use zip ties to the secure hoses together and to
the equipment’s existing hydraulic hoses.
• If possible, fill hoses with grease prior to installing on the equipment.
•SeeF
IG. 18 through FIG. 25 for hose routing examples.
NOTICE
Never install valves 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. 18
Recommended Installation
Components

Hose Routing Guidelines
14 333546B
NOTE: Images may include optional equipment.
FIG. 19
FIG. 20
Recommended Installation
Components
Recommended Installation
Components

Hose Routing Guidelines
333546B 15
NOTE: Images may include optional equipment.
FIG. 21
FIG. 22
Recommended Installation
Components
Stick/Arm
Feed Hose
Anchor Block
Anchor Block
Recommended Installation
Components

Hose Routing Guidelines
16 333546B
NOTE: Images may include optional equipment.
FIG. 23
FIG. 24: Top View
Recommended Installation
Components
Recommended Installation
Components

Hose Routing Guidelines
333546B 17
NOTE: Images may include optional equipment.
FIG. 25: Bottom View
Recommended Installation
Components

Wiring Guidelines
18 333546B
NOTE: Images may include optional equipment.
Wiring Guidelines
G3 SP Pumps with Internal Controller, Feedback and Manual Run
Button Wiring Schematic (FIG. 26)
G3 Pro Pumps with Internal Controller and Manual Run Button
Wiring Schematic (FIG. 27)
FIG. 26
FIG. 27

Wiring Guidelines
333546B 19
NOTE: Images may include optional equipment.
G3 Standard Pumps with GLC2200 External Controller, With and
Without Feedback Wiring Schematic (FIG. 28)
FIG. 28

Programming (FIG. 30, FIG. 29, FIG. 31)
20 333546B
NOTE: Images may include optional equipment.
Programming (FIG. 30, FIG. 29, FIG. 31)
FIG. 29
FIG. 30
FIG. 31