Volvo G740, G740 VHP, G740B Motor Graders Repair & Service Manual
Complete repair service manual with electrical wiring diagrams for Volvo G740, G740 VHP, G740B Motor Graders, with workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions G740, G740 VHP, G740B workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,263 pages
File Format: PDF (Windows & Mac & Linux)
Language: English
TABLE OF CONTENTS
0 - Foreword................2
0 - GENERAL................3
00 - DESCRIPTION; COMPLETE MACHINE................4
Description................5
Product identification plates................8
03 - SPECIFICATIONS................11
Dimensions................12
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION................14
Transporting the machine................15
Storage................20
Grader setup instructions................22
07 - STANDARD TIME................44
Operation numbers for additional work................45
08 - TOOL................47
G700B Special tools................48
09 - MISCELLANEOUS................50
Removing corrosion protective coating................51
1 - STANDARD PARTS; SERVICE................52
16 - LUBRICANT; FUEL; OTHER FLUID................53
Fuel system................54
Recommended lubricants................55
Grease................57
Coolant................58
Tandem_oil disc brake oils................59
Alternative fuels................61
17 - SERVICE................64
Maintenance of Stored Machines; according to Inspection Programme................65
Delivery Inspection; according to Inspection Programme................66
Arrival Inspection; according to Inspection Programme................67
Hydraulic oil return filter; replacing................68
Towing................73
Jump-start procedure................76
19 - GENERAL................77
Safety concerns everybody................78
CE marking and declaration of conformity................79
Environment................81
Safety when handling the machine................83
Service positions................88
Fire prevention measures................93
Health hazards with paint; plastics and rubber................96
Check list after fire or heat exposure................98
Safety when handling tyres................99
Safety when lifting and supporting the machine................100
Safety when handling oil and fuel................101
Safety when working on the electrical system................102
Safety when working with batteries................103
Battery; charging................105
Safety when working with air-conditioning refrigerant................107
Safety when working on hydraulic systems................109
Safety concerns everybody!................110
Electric welding................111
2 - ENGINE WITH MOUNTING AND EQUIPMENT................113
20 - GENERAL................114
Description; D7D_{01-06-37}................115
Description; D10B_{01-06-13}................116
General description ................117
21 - ENGINE................118
Specifications; D7D - general_{01-04-17}................120
Specifications; D10B - general_{01-03-56}................121
Specifications; D7D - weight................122
Specifications; D10B - weight................123
Specifications; D7D - capacities_{01-02-41}................124
Specifications; D10B - capacities_{01-02-19}................125
Engine; removing_{01-01-46}................126
Engine; removing_{01-01-19}................130
Specifications; D7D - tightening torques_{01-00-41}................134
Specifications; D10B - tightening torques_{01-00-19}................135
Cylinder compression; testing................136
Cylinder head - D10B; description_{12-58-54}................141
Cylinder head - D7D; description_{12-58-28}................143
Cylinder block - D10B; description................145
Oil trap - D10B; description................146
Cylinder liner; piston; D7D description................147
Cylinder liners; D10B description................150
Cylinder liner; piston; D10B................152
Valves; adjusting_{12-52-27}................154
Valves; adjusting_{12-51-59}................157
Valves - D7D; description................159
Valve mechanism - D10B; description................161
Valve mechanism - D10B; specifications................163
Engine timing gear - D10B; description................164
Camshaft - D10B; description................166
Connecting rod; D7D................167
Crankshaft; D7D................169
Torsional vibration damper; D7D................171
Crankshaft rear oil seal; replacing................173
Crankshaft and vibration damper; D10B................175
General; Lubrication oil pump D7D................177
22 - LUBRICATING SYSTEM................179
Specifications; D7D................180
Lubrication oil circuit; D7D engine– Models G710B to G730B................181
Lubrication system - D10B; description................184
23 - FUEL SYSTEM................187
Fuel system; description_{12-41-39}................188
Fuel system; description_{12-41-17}................189
Fuel system components; D10B................197
Fuel flow; D10B................199
Fuel feed pump - D10B; description................201
Water trap; D10B................203
Injection pump - D10B; specifications................204
Injection pump - D10B; description................205
Fuel shut-off valve; D10B................207
Overflow valve; D10B................209
Injectors - D10B; specification................210
Injectors - D10B; description................211
Injectors; replacing................214
Injection system - D7D; E-ECU overview................220
25 - INLET & EXHAUST SYSTEM................224
Exhaust system - D7D engine................225
Exhaust system - D10B engine................227
General ................229
Air cleaner................231
Preheating coil; D10B................233
Intercooler D10B; specifications................235
Intercooler; D10B................236
26 - COOLING SYSTEM................238
Cooling system - D7D engine; description................239
Cooling system - D10B engine; description................242
27 - ENGINE CONTROL................245
Accelerator_decelerator pedal................246
Hand Throttle................248
VHP (Variable Horsepower)................250
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS................251
30 - GENERAL................252
Description ................253
Operation................255
General ................256
31 - BATTERY................268
Description ................269
Specifications ................270
Non-maintenance batteries; testing................271
Explosion hazard................272
Battery box................273
32 - ALTERNATOR; CHARGE REGULATOR................274
Voltage regulator................275
Specifications ................276
Alternator; description................277
33 - STARTING SYSTEM................278
Specifications-................279
Starting system; general description................280
Neutral start relay................281
Electric air - preheater................282
35 - LIGHTING................283
General ................284
Lighting; front................285
Lighting; rear................286
Lighting; interior................287
Lighting; side................288
36 - OTHER ELECTRICAL EQUIPMENT................289
Description ................290
Direction indicator; turn signal................291
External warning system................292
Ignition switch................293
Automatic control_blocking function................295
37 - CABLE; FUSE; RELAY................297
Electrical symbols and designations................300
Description ................302
Cable; Battery isolation switch................303
Electrical component list................304
Wiring diagram 1 – Main diagram_Positive feeds_Chassis connections_{11-56-27}................311
Wiring diagram 1 – Main diagram_Positive feeds_Chassis connections_{11-56-03}................314
Wiring diagram 2 – Positive feed_Chassis connection I-ECU_E-ECU_{11-55-26}................317
Wiring diagram 2 – Positive feed_Chassis connection I-ECU_E-ECU_{11-55-02}................319
Wiring diagram 3 – Engine_{11-54-25}................321
Wiring diagram 3 – Engine_{11-54-00}................324
Wiring diagram 4 – D7 Engine ECU_{11-53-12}................327
Wiring diagram 4 – D7 Engine ECU_{11-52-49}................329
Wiring diagram 5 – D10 Engine ECU_{11-52-12}................332
Wiring diagram 5 – D10 Engine ECU_{11-51-48}................336
Wiring diagram 6 – D7; D10 Engine ECU_{11-51-12}................338
Wiring diagram 6 – D7; D10 Engine ECU_{11-50-47}................341
Wiring diagram 7 – Accelerator pedal_Fuel level_{11-50-12}................343
Wiring diagram 7 – Accelerator pedal_Fuel level_{11-49-47}................346
Wiring diagram 8 – Fan ECU_{11-49-11}................349
Wiring diagram 8 – Fan ECU_{11-48-43}................352
Wiring diagram 9 – Headlights_Turn signals_Horn_{11-48-05}................355
Wiring diagram 9 – Headlights_Turn signals_Horn_{11-47-40}................359
Wiring diagram 10 – EEC Headlights and flashers_{11-47-03}................362
Wiring diagram 10 – EEC Headlights and flashers_{11-46-38}................365
Wiring diagram 11 – Work lights_{11-46-02}................368
Wiring diagram 11 – Work lights_{11-45-38}................371
Wiring diagram 12 – EEC Worklights_{11-45-02}................374
Wiring diagram 12 – EEC Worklights_{11-44-37}................377
Wiring diagram 13 – Windshield wiper systems_{11-44-01}................380
Wiring diagram 13 – Windshield wiper systems_{11-43-36}................383
Wiring diagram 14 – 25 amp_60 amp converter_equalizer_{11-43-00}................387
Wiring diagram 14 – Rotating beacons_ Differential lock_MBCS_Articulation sensor_{11-42-35}................390
Wiring diagram 15 – Transmission ECU_{11-41-53}................393
Wiring diagram 15 – Rotating beacons_differential lock_MBCS_{11-41-29}................396
Wiring diagram 16 – AWD ECU_{11-40-53}................399
Wiring diagram 16 – Transmission ECU_{11-40-28}................402
Wiring diagram 17 – AWD ECU_{11-39-52}................406
Wiring diagram 17 – AWD ECU_{11-39-27}................410
Wiring diagram 18 – AWD ECU_{11-38-39}................414
Wiring diagram 18 – Sensors_{11-38-15}................419
Wiring diagram 19 – Sensors_{11-37-39}................422
Wiring diagram 19 – Brake circuit; lights_{11-37-15}................425
Wiring diagram 20 – Brake circuit; lights_{11-36-38}................428
Wiring diagram 20 – Secondary steering_{11-36-13}................431
Wiring diagram 21 – Climate control unit_{11-35-38}................434
Wiring diagram 21 – Secondary steering_{11-35-13}................438
Wiring diagram 22 – Front and rear defroster fans_{11-34-36}................441
Wiring diagram 22 – Climate control unit_{11-34-12}................444
Wiring diagram 23 – Front defroster fans_{11-33-36}................448
Wiring diagram 23 – Radio_Heated mirrors_{11-33-11}................451
Wiring diagram 24 – Blade float module_{11-32-35}................453
Wiring diagram 24 – Radio_Dome light_Heated mirrors_{11-32-10}................456
Wiring diagram 25 – Front float module_{11-31-34}................459
Wiring diagram 25 – Blade float module_{11-31-10}................462
Wiring diagram 26 – Tire pump_{11-30-34}................465
Wiring diagram 26 – Front float module_{11-30-10}................467
Wiring diagram 27 – Rear float module_{11-29-34}................470
Wiring diagram 27 – Communication; E-ECU_I-ECU_{11-29-10}................472
Wiring diagram 28 – Tire pump_Power outlet_{11-28-34}................475
Wiring diagram 28 – Keyboard_{11-28-09}................478
Wiring diagram 29 – Communication; E-ECU_I-ECU................480
Wiring diagram 30 – Keyboard................483
Electrical distribution box fuses; relays................485
Data link port................487
Ground stud - locations................488
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM................496
Description ................497
Diagnostic software................513
Description of tests................514
4 - POWER TRANSMISSION................515
41 - CLUTCH; TORQUE CONVERTER................516
Specifications; engine clutch................517
Description and operation; engine clutch................519
Clutch housing; removing................523
Clutch assembly; removing................526
Clutch assembly; installing................528
Clutch housing; installing................530
Bearing support housing; installing................532
Clutch Slave Cylinder and Pedal Free Play; adjusting ................534
Clutch Slave Cylinder and Pedal Free Play; adjusting................537
Specifications; clutch master cylinder and booster circuit................539
Description; clutch master cylinder and booster................540
42 - TRANSMISSION; HYDRAULIC CONTROL................544
Specifications ................545
Description; 8400 transmission................547
Transmission components................550
Transmission ECU and shifter assembly................552
Transmission oil circuit and operation................555
Transmission hydraulic circuit and operation................560
Transmission troubleshooting................562
Error codes................566
Hydraulic system troubleshooting................569
Transmission; removing................575
Transmission; installing................579
44 - HYDROSTATIC DRIVE................583
Specifications; All Weel Drive system................584
Description; AWD system................585
AWD electrical system................594
AWD hydraulic system................602
All Wheel Drive Operational Checks................611
AWD test procedure and test port locations................613
AWD error codes and troubleshooting................618
All Wheel Drive Pump and Motor Priming Procedure................632
46 - FRONT AXLE; REAR AXLE................635
Specifications; SR final drive................636
Description; SR final drives................637
Operation; SR final drive................638
Lock_unlock function ................640
Final drive assembly; removing ................641
Tandem; removing ................643
Final drive assembly; installing ................644
Specifications; G780B - DR final drive................646
Description; G780B - DR final drive................647
Operation; G780B DR final drive................648
Lock_unlock function................650
Lubrication circuit................651
Final drive assembly; removing................652
Final drive assembly; installing................657
Specifications; tandems................662
Tandem assembly................663
Tandem; removing................665
Differential Lock; G710B - G746B................671
Differential Lock; G780B................673
5 - BRAKE................675
50 - GENERAL................676
Overview................677
51 - WHEEL BRAKE................681
Electrical schematic - Image................682
Brake circuit hydraulic schematic - Image................684
General ................685
Description ................686
Brake circuit hydraulic schematic................690
Electrical schematic ................692
Electric motor_pump troubleshooting................695
Oil disc brake assembly; removing................698
Oil disc brakes; disassembling................701
Oil Disc Brake - Cleaning and Inspection................707
Brake housing; pre-assembling................709
Tandem axle oil seal installation................711
Tandem axle seal; installing................713
Oil disc brakes ; assembling................719
Oil Disc Brakes - Bench Adjustment................724
Oil disc brake; installing................726
52 - HYDRAULIC BRAKE SYSTEM................730
Specifications ................731
Description ................732
Brake master cylinder and power booster; removing................742
Power booster; disassembling................743
Power booster; assembling................745
Brake master cylinder; disassembling................747
Brake master cylinder; assembling................750
Brake master cylinder and power booster; installing................753
Adjustment checks................755
55 - PARKING BRAKE................757
Electrical schematic - Image................758
Hydraulic diagram - Image................759
Specifications ................760
Description ................762
Parking brake; manually releasing................764
Hydraulic diagram................766
Electrical schematic................769
Parking brake troubleshooting................771
Parking brake overhaul procedure................772
Parking brake assembly; removing................775
Parking brake; disassembling................776
Parking brake; pre-assembling................778
Parking brake; assembling................779
Parking brake; installing................781
Parking brake; adjusting................783
Parking brake intensifier................785
Parking brake valve assembly................787
6 - STEERING................789
60 - GENERAL................790
Steering system; description................791
Tightening torques ................794
Front axle toe-in ................795
Description ................796
Tightening torque.................801
Front axle toe-in................802
Front axle pivot (G710B to G746B)................803
62 - STEERING AXLE................804
Wheel hub; removing................806
Wheel hub; installing................808
Steering axle – Disassembly................810
Preparation and wheel; removing................811
Tie bar; removing................813
Tie bar; installing................814
Steering cylinder; removing................815
Steering cylinder; installing................817
Knuckle; removing................818
Knuckle; installing................819
Drag link; removing................820
Drag link; installing................822
Pivot block; removing and disassembling................823
Pivot block; assembling and installing................824
Wheel lean cylinder; removing................825
Wheel lean cylinder; installing................827
Front axle frame; removing................828
Front axle frame; installing................830
Wheel; installing................832
Axle disassembly and assembly - G780B................833
Front Axle Pivot Pin Bearings; disassembling................834
Front Axle Pivot Pin Bearings; assembling................836
King Pin Bearings and Spindle Thrust Bearing; disassembling................839
King Pin Bearings and Spindle Thrust Bearing; assembling................841
Wheel bearings; disassembling................843
Wheel bearings; assembling................845
Pivot Block Adjustments................847
Wheel Bearing; cleaning and inspecting................848
Spindle; removing and disassembling................850
Spindle; assembling and installing................852
Toe - in; adjustment_{10-04-17}................854
Toe - in; adjustment_{10-03-57}................855
64 - STEERING................857
Wheel lean hydraulic schematic - Image................859
Secondary steering hydraulic schematic - Image................860
Steering hydraulic schematics - Image................861
Specifications ................862
Description ................863
Steering column; disassembling................865
Steering column; assembling................867
Steering Column - Cleaning and Inspection................868
Steering control unit; removing................869
Steering control unit; installing................870
Specifications.................871
Description.................872
Steering hydraulic schematics................873
Steering system troubleshooting guide................875
Steering control unit troubleshooting................877
Specifications-................880
Components-................881
Steering control unit overhaul procedure................883
Steering control unit; disassembling................884
Steering control unit; assembling................889
Steering Control Unit - Bleeding Procedure................895
Specifications- ................896
Description- ................897
Function ................899
Specifications .................901
General description................903
Secondary steering; specifications................904
Secondary steering; description................905
Secondary steering; component location................907
Secondary steering hydraulic schematic................910
Secondary steering troubleshooting................912
Hydraulic cylinder specifications................913
Description-. ................915
Wheel lean hydraulic schematic................917
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT................919
71 - FRAME................920
Description ................921
74 - FRAME LINK................923
Articulation Indicator - Setup and Adjustment - Image................924
Articulation Indicator - Setup and Adjustment................925
Tightening torques................931
Articulation hinge................932
Articulation hinge – Preparation for disassembly................935
Articulation hinge; disassembling................937
Cleaning and inspection................941
Articulation Hinge; assembling................942
Articulation hydraulics................946
77 - WHEELS; TRACKS; TYRE; HUB; DRUM................949
Wheels; specifications................950
General description – Wheels................951
Tire troubleshooting guide................953
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE................955
87 - AIR CONDITIONING UNIT................956
Climate control unit electrical schematic - Image................957
Specifications ................958
Description ................960
Operating principle................961
HVAC system components................963
Cab air distribution_{09-37-51}................968
Cab air distribution_{09-37-27}................970
Basic operational checks................972
Air conditioning system................973
Climate control unit electrical schematic................974
Troubleshooting guide Low pressure gauge shown on left; high pressure gauge shown on right.................976
HVAC routine maintenance................979
Air conditioner service................981
Air Conditioning System Repairs................982
88 - INTERIOR EQUIPMENT................984
Description ................985
Control levers; disassembling................989
Control Levers - Cleaning and Inspection................992
Control levers; assembling................993
Pedestal Locking Strut - Setup................995
Locking Strut - Troubleshooting................996
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS................997
90 - GENERAL................998
Main hydraulic schematic; EEC float valves – Sheet 4 - Image................999
Main hydraulic schematic; EEC – Sheet 3 - Image................1000
Main hydraulic schematic; float valves – Sheet 2 - Image................1001
Main hydraulic schematic - sheet 1 - Image................1002
Main hydraulic schematic - sheet 1................1003
Main hydraulic schematic; float valves – Sheet 2................1007
Main hydraulic schematic; EEC – Sheet 3................1010
Main hydraulic schematic; EEC float valves – Sheet 4................1013
Specifications ................1016
Description ................1017
Hydraulic components; location................1019
Hydraulic system troubleshooting guide................1022
91 - WORKING HYDRAULIC; SERVO HYDRAULICS................1026
Auxiliary control valves – Sheet 5 - Image................1029
Auxiliary load sense shuttle valve - Image................1030
Counterbalance valve for attachments - Image................1031
Single attachment valve with relief (EEC) - Image................1035
Auxiliary control valves – Sheet 5................1036
Hydraulic Oil Filler Cap - Prevention of Contaminants................1038
Hydraulic oil cleanliness................1040
Specifications ................1046
Description ................1048
Main control valve spool flow rates................1049
Main control valve section................1051
Main control valve troubleshooting................1055
Main control valve overhaul procedure................1057
Main control valve; removing................1058
Main control valve; disassembling................1059
Valve section; disassembling................1061
Valve section; assembling................1064
Main control valve; assembling................1066
Main control valve; installing................1069
Main Control Valve Bleeding Procedure................1070
Specifications - ................1072
Description - ................1073
Hydraulic swivel joint; removing................1075
Hydraulic swivel joint; disassembling................1078
Hydraulic swivel joint; assembling................1081
Hydraulic swivel joint; installing................1084
Specifications................1087
Description................1088
Components................1089
Circle Turn Valve Overhaul Procedure................1092
Circle turn valve; removing................1093
Circle turn valve; disassembling................1095
Circle turn valve; assembling................1099
Circle turn valve; installing................1102
Circle Timing................1104
Specifications_................1107
Description_................1109
Specifications_ ................1110
Test procedures ................1111
Description_ ................1113
Function ................1114
Specifications ................1115
Test procedures................1116
Description ................1118
Function-................1119
Specifications -................1121
Description ................1123
Preventive maintenance................1124
Accumulator precharge pressure; checking................1125
Accumulator -Charging................1127
Accumulator precharge adjustment chart................1129
Specifications ................1130
Hydraulic Cylinder Overhaul Procedure................1132
Hydraulic cylinder; disassembling................1134
Hydraulic cylinder; assembling................1140
Special tools................1145
Specifications ................1146
General ................1147
Specifications ................1148
Function ................1149
Specifications.................1150
Description ................1151
Function................1152
Auxiliary load sense shuttle valve................1154
Counterbalance valve for attachments................1155
Single attachment valve with relief (EEC)................1157
General ................1158
General................1159
Specifications-................1160
Specifications- ................1162
Specifications- ................1164
Specifications- ................1165
Description ................1166
Principle of operation; main hydraulic pump................1169
Principle of operation; pressure compensator control................1172
Hydraulic system; bleeding air................1176
Main hydraulic pump troubleshooting guide................1178
LS (load sense) pressure; checking................1180
Compensator Valve Pressure Setting - Checking................1182
LS (load sense) Differential Pressure - Checking................1183
92 - MECHANICAL EQUIPMENT_ATTACHMENT................1186
Specifications - ripper................1187
Description................1188
Specifications - A-frame................1189
Description ................1190
Specifications - front mounted scarifier................1191
Specifications - mid mount scarifier................1192
Description ................1193
Specifications - windrow eliminator................1194
Specifications - utility dozer blade................1196
Description ................1197
Specifications - one way plow................1198
Description_................1199
Specifications - V-plow................1200
Description_ ................1201
Specifications - hydraulic snow wing................1202
Description_ ................1204
Specifications - push block................1206
Description_ ................1207
98 - FUNCTION FOR ROAD CONSTRUCTION................1208
Circle adjustment................1209
Pinion wear................1212
Specifications ................1213
Description ................1214
Circle operation................1217
Troubleshooting guide................1220
G710B to G746B circle and drawbar................1221
Circle and drawbar; removing and disassembling ................1222
Circle and drawbar; assembling and installing ................1225
Mouldboard; shimming ................1231
G780B circle and drawbar................1233
Circle and drawbar; removing and disassembling................1234
Circle and drawbar; assembling and installing................1236
Mouldboard; shimming................1240
Circle turn mechanism; disassembling................1241
Circle turn mechanism; assembling................1243
Drawbar ball stud; disassembling................1246
Drawbar ball stud; assembling................1247
Circle Setup and Timing................1248
Specifications................1250
Description................1251
Blade lift cylinder; removing................1255
Blade lift stirrup; removing................1257
Blade lift arm; removing................1258
Blade lift arm; installing................1260
Blade lift stirrup; installing................1261
Blade lift cylinder; installing................1262
Volvo G740, G740 VHP, G740B Motor Graders Repair & Service Manual
