Installation Manual

Automatic TWIN Greasing System

Excavator
Komatsu PC210/340LC-7
EF17152

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 Komatsu PC210/340LC-7

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. F174180 Twin 9-port block, complete - - - - - - - - - - - - - - - - - - - - - - - - 14
2.2. F174181 Twin 4+4-port block, complete - - - - - - - - - - - - - - - - - - - - - - 16
2.3. F174182 Twin 4-port block, complete - - - - - - - - - - - - - - - - - - - - - - - - 18

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

4. Drilling and welding activities - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

5. Grease pump installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

5.1. F174183 Twin pumpkit Komatsu PC210/340LC-7 - - - - - - - - - - - - - - - - 30

6. Electrical components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
6.1. F174184 Electronics installation kit Komatsu PC210/340LC-7 - - - - - - - 34

7. Distribution blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
7.1. F174185 Installation kit Twin 9-port block / F174180 B1 - - - - - - - - - - - 38
7.2. F174186 Installation kit Twin 4+4-port block / F174181 B2 - - - - - - - - - 42
7.3. F174187 Installation kit Twin 4-port block / F174182 B3 - - - - - - - - - - - 46

8. Installation main line - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

8.1. F174188 Twin Main line kit exclusive bucket linkage - - - - - - - - - - - - - 50
8.2. F174189 Twin Main line kit inclusive bucket linkage - - - - - - - - - - - - - - 54

9. Parameter settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

10. Testing of the system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

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EF17152 Table of contents 3

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4 Table of contents EF17152

 Excavator Komatsu PC210/340LC-7

1.

2.
PREFACE
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EF17152 Preface 5
 Excavator Komatsu PC210/340LC-7

1.1 General information

This installation manual describes the mounting of the Twin-system on the
Komatsu Excavator type PC210LC-7, PC220LC-7, PC240LC-7, PC270LC-7, PC290LC-7,
PC300HD-7, PC300LC-7 and PC340LC-7.

Automatic Twin Grease Lubrication System

Machine type Number of Groeneveld Manual

grease points order number
number

Komatsu exclusive bucket

14 x F174178 EF17152 P0
linkage

Komatsu inclusive bucket

18 x F174179 EF17152 P0
linkage

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
Date of issue: June 2003

RD Red
GY Grey
YE Yellow
BR Brass
PA Polyamide
SST Stainless steel
ST-YG Yellow passivated steel
ST-G Galvanised steel

6 Preface EF17152
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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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EF17152 Preface 7
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Notes

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8 Preface EF17152
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2.

3.
SYSTEM LAY-OUT
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EF17152 System lay-out 9

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Parts list

The Twin-system for the Komatsu PC210/340LC-7 exclusive bucket linkage compris-
es the following parts:

Kit number Groeneveld order Description

number

F174183 Twin pumpkit Komatsu PC210/340LC-7

F174184 Electronics installation kit Komatsu PC210/340LC-7

F174180 F174185 Installation kit Twin 9-port block B1

F174181 F174186 Installation kit Twin 4+4-port block B2

F174188 Twin Main line kit Komatsu PC210/340LC-7

F174192 Manual Komatsu PC210/340LC-7

XU1701D User’s manual TWIN

F174173 High-pressure hose 3/8” S10-4000-nothing H1 2x

F173958 High-pressure hose 3/8” S10-7000-nothing H2 2x

F174174 High-pressure hose 3/8” E10-2500-nothing H3 2x

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10 System lay-out EF17152

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EF17152 System lay-out 11

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Parts list

The Twin-system for the Komatsu PC210/340LC-7 inclusive bucket linkage comprises
the following parts:

Kit number Groeneveld order Description

number

F174183 Twin pumpkit Komatsu PC210/340LC-7

F174184 Electronics installation kit Komatsu PC210/340LC-7

F174180 F174185 Installation kit Twin 9-port block B1

F174181 F174186 Installation kit Twin 4+4-port block B2

F174182 F174187 Installation kit Twin 4-port block B3

F174189 Twin Main line kit Komatsu PC210/340LC-7

F174192 Manual Komatsu PC210/340LC-7

XU1701D User’s manual TWIN

F174173 High-pressure hose 3/8” S10-4000-nothing H1 2x

F173958 High-pressure hose 3/8” S10-7000-nothing H2 2x

F174174 High-pressure hose 3/8” E10-2500-nothing H3 2x

F174175 High-pressure hose 1/4” E10-2000-nothing H4 2x

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12 System lay-out EF17152

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EF17152 System lay-out 13

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Parts list

2.1 F174180 Twin 9-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 72722 Body, T-coupling 1/4”NPT - ø10 mm ST-YG

4 2 70801 Metering unit No.1 - 0.050cc/M22/6mm/BR

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

6 2 71001 Metering unit No.3 - 0.150cc/M22/6mm/BR

7 4 71201 Metering unit No.8 - 0.400cc/M22/6mm/BR

8 1 72601 Twin 9-port block, M10 BR

9 5m 77401 Grease pipe 2 x ø6 mm x 1.5 PA per m

10 5m 77401 Grease pipe 2 x ø6 mm x 1.5 PA per m

11 1,5m 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 1,5m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

14 1,5m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

15 1,5m 77301 Grease pipe 1 x ø6 mm x 1.5 PA per m

16 5 02717 Protective cap ø6 mm

17 2 28401 Protective cap ø9.5 mm

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14 System lay-out EF17152

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EF17152 System lay-out 15

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Parts list

2.2 F174181 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 1 47202 Male stud coupling 1/4”NPT - ø10 mm ST-YG

4 1 47402 Male stud elbow 1/4”NPT - ø10 mm ST-YG

5 1 80801 Elbow swivel coupling ø10 mm ST-YG

6 2 70701 Shut-off plug M22x1 BR

7 1 70901 Metering unit No.2 - 0.100cc/M22/6mm/BR

8 1 71101 Metering unit No.4 - 0.200cc/M22/6mm/BR

9 1 79501 Metering unit No.8,5 - 0.600cc/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, complete BR

13 1 77201 Twin 4+4-port block, flat BR

14 1 F173956 H.P.H. 1/4” S6-3000-nothing

15 1 F174176 H.P.H. 1/4” S6-1000-nothing

16 2 F173969 H.P.H. 1/4” S6-2000-nothing

17 1 F174177 H.P.H. 1/4” E6-1000-nothing

18 5 03217 Protective cap ø12 mm

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16 System lay-out EF17152

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EF17152 System lay-out 17

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Parts list

2.3 F174182 Twin 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 72022 Male stud coupling 1/4”NPT - ø8 mm ST-YG

4 3 71101 Metering unit No.4 - 0.200cc/M22/6mm/BR

5 1 91001 Metering unit No.10 - 2.000cc/M22/6mm/BR

6 1 77101 Twin 4-port block, flat BR

7 1 F174191 H.P.H. ø4 mm S6-600-E6

8 1 02717 Protective cap ø6 mm

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18 System lay-out EF17152

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EF17152 System lay-out 19

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Notes

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20 System lay-out EF17152

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3.

4.
GREASE POINT LOCATION
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EF17152 Grease point location 21

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22 Grease point location EF17152

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EF17152 Grease point location 23

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Notes

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24 Grease point location EF17152

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4.

5.
DRILLING AND WELDING ACTIVITIES
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EF17152 Drilling and welding activities 25

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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

Safety instructions for installation of attachment points:

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
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Grind

Welding location

26 Drilling and welding activities EF17152

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Grease point 13
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EF17152 Drilling and welding activities 27

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Grease point 14

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28 Drilling and welding activities EF17152

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5.

6.
GREASE PUMP INSTALLATION
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EF17152 Grease pump installation 29

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Parts list

5.1 F174183 Twin pumpkit Komatsu PC210/340LC-7

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 1 89801 Cable harness, pump 3m

1.5 10 00208 Cable tie, black 186 mm

1.6 1 81522 Pump bracket with bottom plate

1.7 4 101025 Bolt M10 x 25 ST-G

1.8 4 108050 Bolt M8 x 50 ST-G

1.9 4 220008 Selflocking nut M8 ST-G

1.10 4 220010 Selflocking nut M10 ST-G

1.11 4 300008 Washer M8 ST-G

1.12 4 300010 Washer M10 ST-G

1.13 1 F111842 Twin Pump 12cc/24v/3L/250 bar

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30 Grease pump installation EF17152

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EF17152 Grease pump installation 31

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Notes

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32 Grease pump installation EF17152

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6.

7.
ELECTRICAL COMPONENTS
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EF17152 Electrical components 33

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Parts list

6.1 F174184 Electronics installation kit Komatsu PC210/340LC-7

Pos. Q’ty Groeneveld order Description

number

2.1 1 13103 Connector housing, 4 pole male

2.2 1 61006 Connector housing, 2 pole male

2.3 1 61106 Connector housing, 2 pole female

2.4 1 67506 Connector housing, 4 pole female

2.5 4 67806 Flat plug sleeve, not insulated 0.75mm²

2.6 2 68606 Flat plug sleeve, not insulated 1.5mm²

2.7 2 68706 Flat plug, not insulated 1.5mm²

2.8 1 15608 Fuse, 5A plug-in

2.9 2 17408 Fuse holder

2.10 1 17508 Bracket for fuse holder

2.11 1 17608 Screw for 17508

2.12 1 19508 Fuse, 10 plug-in

2.13 1 25812 Pressure switch cable 25m

2.14 4 61416 Flat plug, not insulated 0.75mm²

2.15 2 023595 Screw 3.5 x 9

2.16 1 800003 Ring 4-6 QMM M8

2.17 4 03203 AMP Plug

2.18 1 F170671 Twin Display Unit

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34 Electrical components EF17152

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EF17152 Electrical components 35

 Excavator Komatsu PC210/340LC-7

Pressure switch in the

main lines
Fuses

Twin pump with integrated

control unit
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36 Electrical components EF17152

 Excavator Komatsu PC210/340LC-7

7.

8.
DISTRIBUTION BLOCKS
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EF17152 Distribution blocks 37

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Parts list

7.1 F174185 Installation kit Twin 9-port block / F174180 B1

Pos. Q’ty Groeneveld order Description

number

3.1 1 02701 Self-tapping screw M5 x 10 ST-G

3.2 5 15001 Stud elbow R1/8” x G1/8” ST-YG

3.3 1 33301 Extend adaptor 1/8”NPTF - 42 mm ST-YG

3.4 25 00208 Cable tie, black 186 mm

3.5 1 01308 Clamp ø12 mm

3.6 5 07908 Male stud coupling 1/8” - ø6 mm BR

3.7 4 08008 Male stud elbow 1/8” - ø6 mm BR

3.8 2m 11912 Flexible protective hose

3.9 1 F173845 Bracket, distribution block

3.10 3m 17012 Flexible protective hose 8.4 / 11.7 mm

3.11 1 F174180 Twin 9-port block, complete

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38 Distribution blocks EF17152

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EF17152 Distribution blocks 39

 Excavator Komatsu PC210/340LC-7

1 2 3 4 5

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40 Distribution blocks EF17152

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7 6 8 9
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EF17152 Distribution blocks 41

 Excavator Komatsu PC210/340LC-7

Parts list

7.2 F174186 Installation kit Twin 4+4-port block / F174181 B2

Pos. Q’ty Groeneveld order Description

number

4.1 2 16301 Allen plug R1/8” BR

4.2 5 78701 Tube clamp, double ø12 mm

4.3 5 78801 Welding plate, double tube clamp 6-12 mm

4.4 1 81701 Welding plate 4+4-port block

4.5 2 09202 Spring washer toothed 6.4

4.6 1 22502 Welding block G1/8”, 16 mm

4.7 3 43802 Male stud elbow 1/8” - ø6 mm ST-YG

4.8 2 47602 Straight connecting coupling ø10 mm ST-YG

4.9 1 65102 Extension spindle M10x1.25

4.10 3 81802 Tube clamp, single ø12 mm

4.11 3 82002 Welding plate, single tube clamp 6-12 mm

4.12 10 11107 Cable tie, black 338 mm

4.13 1 10312 Tube ø10x8, 1750 mm, 1/8”G

4.14 5 13312 Cover plate, double tube clamp 6-12 mm

4.15 3 16012 Cover plate, single tube clamp 6-12 mm

4.16 3 05817 Hose end fitting ø6 mm straight ST-YG

4.17 2 06417 Hose end fitting ø10 mm straight ST-YG

4.18 1 24622 Tube ø10x8, 800 mm, 1/8”G

4.19 8 126030 Allen bolt M6 x 30 ST-G

4.20 5 126035 Allen bolt M6 x 35 ST-G

4.21 1 F174181 Twin 4+4-port block, complete

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42 Distribution blocks EF17152

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Note: The number of clamps 78701 and 81802, which must be used, de-
pends on the lenght of the dipper stick!

EF17152 Distribution blocks 43

 Excavator Komatsu PC210/340LC-7

10

11

12

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44 Distribution blocks EF17152

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13

14
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EF17152 Distribution blocks 45

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Parts list

7.3 F174187 Installation kit Twin 4-port block / F174182 B3

Pos. Q’ty Groeneveld order Description

number

5.1 1 15001 Stud elbow R1/8” - G1/8” ST-YG

5.2 1 16301 Allen plug R1/8” BR

5.3 1 81201 Welding plate, Twin 4-port block

5.4 2 09202 Spring washer toothed 6.4

5.5 2m 31902 Grease pipe ø6 mm x 1 mm ST-YG

5.6 3 43402 Male stud coupling ø6 mm - 1/8" ST-YG

5.7 1 43802 Male stud elbow ø6 mm - 1/8" ST-YG

5.8 10 00208 Cabkle tie, black 186 mm

5.9 0.09m 45822 Flat iron 40 x 5 mm

5.10 6 126030 Allen bolt M6 x 30 ST-G

5.11 1 F174182 Twin 4-port block, complete

18
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18

17 15 16

46 Distribution blocks EF17152

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EF17152 Distribution blocks 47

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48 Distribution blocks EF17152

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8.

9.
INSTALLATION MAIN LINE
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your efficiency is our challenge

EF17152 Installation main line 49

 Excavator Komatsu PC210/340LC-7

Parts list

8.1 F174188 Twin Main line kit exclusive bucket linkage

Pos. Q’ty Groeneveld order Description

number

6.1 2 80801 Elbow swivel coupling ø10 mm ST-YG

6.2 6 35802 Hose end fitting ø10 mm straight ST-YG

6.3 6 35902 Crimp nut hose 3/8” i/d ST-YG

6.4 2 47602 Straight connecting coupling ø10 mm ST-YG

6.5 2 48802 Coupling nut ø10 mm - M16x1,5 ST-YG

6.6 2 48902 Olive ø10 mm ST-YG

6.7 100 11107 Cable tie, black 338 mm

6.8 200 00208 Cable tie, black 186 mm

6.9 2 F174173 High-pressure hose 3/8” S10-4000-nothing H1

6.10 2 F173958 High-pressure hose 3/8” S10-7000-nothing H2

6.11 2 F174174 High-pressure hose 3/8” E10-2500-nothing H3

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50 Installation main line EF17152

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EF17152 Installation main line 51

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52 Installation main line EF17152

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H1

B1
Date of issue: June 2003

H3

EF17152 Installation main line 53

 Excavator Komatsu PC210/340LC-7

Parts list

8.2 F174189 Twin Main line kit inclusive bucket linkage

Pos. Q’ty Groeneveld order Description

number

7.1 4 78601 Tube clamp, double ø10 mm

7.2 5 78701 Tube clamp, double ø12 mm

7.3 9 78801 Welding plate, double tube clamp 6-12 mm

7.4 4m 32102 Grease pipe ø10 mm x 1 mm ST-YG

7.5 6 35802 Hose end fitting ø10 mm straight ST-YG

7.6 6 35902 Crimp nut hose 3/8” i/d ST-YG

7.7 4 47602 Straight connecting coupling ø10 mm ST-YG

7.8 2 48302 L-swivel coupling ø10 mm ST-YG

7.9 100 11107 Cable tie, black 338 mm

7.10 200 00208 Cable tie, black 186 mm

7.11 9 13312 Cover plate, double tube clamp 6-12 mm

7.12 2 06217 Hose end fitting ø8 mm ST-YG

7.13 9 126035 Allen bolt M6 x 35 ST-G

7.14 2 F174173 High-pressure hose 3/8” S10-4000-nothing H1

7.15 2 F173958 High-pressure hose 3/8” S10-7000-nothing H2

7.16 2 F174174 High-pressure hose 3/8” E10-2500-nothing H3

7.17 2 F174175 High-pressure hose 1/4” S10-2000-nothing H4

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54 Installation main line EF17152

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EF17152 Installation main line 55

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Date of issue: June 2003

Note: The number of clamps 78601 and 78701, which must be used, de-
pends on the lenght of the dipper stick!

56 Installation main line EF17152

 Excavator Komatsu PC210/340LC-7

9.

10.
PARAMETER SETTINGS
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EF17152 Parameter settings 57

 Excavator Komatsu PC210/340LC-7

Parameter settings

Code Description Setting

HDCY Heavy duty cycle 20 minutes

NDCY Normal duty cycle 30 minutes

LDCY Low duty cycle 45 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 exclusive bucket linkage: 6,0 cc

Consumption metering units each cycle inclusive bucket linkage: 8,6 cc

Date of issue: June 2003

58 Parameter settings EF17152

 Excavator Komatsu PC210/340LC-7

10.

11.
TESTING OF THE SYSTEM
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EF17152 Testing of the system 59

 Excavator Komatsu PC210/340LC-7

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

60 Testing of the system EF17152

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