Volvo G940, G940B, G940C Motor Graders Repair & Service Manual
Volvo G940, G940B, G940C Motor Graders Repair & Service Manual
Complete official service manual for Volvo G940, G940B, G940C Motor Graders, with all the workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Construction G940, G940B, G940C 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: 1,311 pages
File Format: PDF (Windows & Mac & Linux)
Language: English
0 - Foreword......2
0 - GENERAL......3
00 - DESCRIPTION; COMPLETE MACHINE......4
Product identification plates......5
03 - SPECIFICATIONS......7
Conversion tables......8
Coolant, specifications......16
Critical mounting torques......17
Hydraulic connections, tightening torques......20
Tightening torque, specifications_{04-33-13}......25
Tightening torque, specifications_{04-33-29}......28
Tightening torques......31
specifications......40
07 - STANDARD TIME......43
Operation numbers for additional work......44
08 - TOOL......46
Drawings, E-tools......47
1 - STANDARD PARTS, SERVICE......50
16 - LUBRICANT; FUEL; OTHER FLUID......51
Alternative fuels......52
Fuel, lubricant and filling capacities_{04-29-36}......55
Fuel, lubricant and filling capacities_{04-29-51}......56
Recommended lubricants_{04-28-53}......57
Recommended lubricants_{04-29-12}......62
17 - SERVICE......67
Arrival Inspection, according to Inspection Programme......69
Cab prefilter, cleaning......70
Cab prefilter, replacing......73
Coolant freezing point, checking......76
Coolant level, checking......77
Coolant, changing......79
Coolers, cleaning......81
Cooling system integrity, checking......83
Delivery Inspection, according to Inspection Programme......84
Diesel particulate filter, checking and cleaning......85
Engine air cleaner primary filter, cleaning......94
Engine air cleaner primary filter, replacing......97
Engine air cleaner secondary filter, replacing......99
Engine belt condition, checking......101
Engine oil and filter, changing......103
Engine oil level, checking......106
Front wheel bearing, repacking......108
Fuel filter, replacing......111
Fuel tank breather filter, replacing......113
Hydraulic oil level, checking......115
Hydraulic oil return filter, replacing......117
Hydraulic oil tank breather filter, replacing......120
Hydraulic oil, changing......122
Maintenance of Stored Machines, according to Inspection Programme......127
Maintenance service, every 10 hours......128
Maintenance service, every 1000 hours......129
Maintenance service, every 1500 hours......131
Maintenance service, every 2000 hours......132
Maintenance service, every 250 hours......134
Maintenance service, every 4500 hours......135
Maintenance service, every 50 hours......136
Maintenance service, every 500 hours......138
Maintenance service, every 6000 hours......140
Master cylinder oil level, checking......141
Master cylinder oil, changing......143
Rear axle oil level, checking......146
Service brake, testing......148
Spark plugs, replacing......149
Tandem breather, checking......151
Tandem oil level, checking......153
Tandem oil, changing......155
Transmission breather filter, replacing......157
Transmission oil filter, replacing......158
Transmission oil level, checking......160
Transmission oil, changing......162
Valves, adjusting......164
Water separator filter, replacing......168
Water separator, checking......170
Wheel nuts torque, checking......171
19 - GENERAL......172
A few simple safety rules......173
Before operating......177
Before service, read......181
CE-marking, EMC-directive......185
Charging batteries......189
Checklist after a fire or heat exposure......193
Cleanliness......196
Decontamination......200
Electrical system......204
Environment......208
Environmental handling for the future......213
Environmentally hazardous fluids......216
Environmentally safe handling......217
Fire prevention measures......220
General......223
Health hazards with paint, plastics and rubber......228
Safety concerns everybody!......232
Safety rules when servicing......236
Safety when handling oil and fuel......239
Safety when handling the machine......242
Safety when lifting and supporting complete machine......247
Safety when using lifting equipment......250
Safety when working on hydraulic systems......251
Safety when working with air conditioning refrigerant......253
Safety when working with batteries......256
Service position......259
Some simple rules regarding tyre handling......262
Working in environmentally contaminated areas......264
2 - ENGINE WITH MOUNTING AND EQUIPMENT......265
20 - GENERAL......266
Component locations......267
E-ECU MID 128 non-programmed, replacing......269
E-ECU MID 128 pre-programmed, replacing......271
Engine, description......273
VCADS Pro, Operations......277
21 - ENGINE......279
Crankcase ventilation separator, replacing......280
Crankcase ventilation, description......282
Cylinder compression, testing......283
Engine mounts, replacing......286
Engine rotation speed sensor (camshaft), replacing......294
Engine rotation speed sensor (crank shaft), replacing......296
Engine, installing......298
Engine, removing......306
Engine, specifications......317
Engine, tightening torques......318
Flywheel, tightening torques......320
Oil sump, tightening torque......322
Valve system, specification......324
22 - LUBRICATING SYSTEM......325
Lubrication oil pressure, checking with pressure gauge......326
Lubrication system, component locations......328
Lubrication system, description......330
Lubrication system, specifications......334
Lubrication system, tightening torques......336
23 - FUEL SYSTEM......338
Carbon dioxide in fuel system, checking......339
Feed pump pressure, checking......341
Fuel control valve (FCV), replacing......343
Fuel pump, replacing......348
Fuel system, bleeding......352
Fuel system, component location......354
Fuel system, description......356
Fuel system, specifications......363
Fuel system, tightening torques......364
Fuel tank, installing......371
Fuel tank, removing......373
High pressure fuel pump, replacing......376
Injectors, replacing......379
Pressure relief valve (PRV), replacing......386
25 - INLET & EXHAUST SYSTEM......389
ACM (Aftertreatment control module) non-programmed, replacing......391
ACM (Aftertreatment control module) pre-programmed, replacing......394
Air cleaner, installing......397
Air cleaner, removing......399
Air pump safety valve, replacing......401
Air pump, replacing......404
Burner function, checking......407
Burner, replacing......413
Charge air cooler, inspecting......419
Charge air cooler, installing......421
Charge air cooler, removing......423
DOC (Diesel oxidation catalyst), replacing......425
DPF (Diesel particulate filter), checking and cleaning......435
Exhaust Aftertreatment System, component location......444
Exhaust Aftertreatment System, description......446
Exhaust aftertreatment system T-junction, replacing......457
Exhaust aftertreatment system, specifications......459
Exhaust aftertreatment system, tightening torques......461
Exhaust pipe flexible tube, replacing......463
Fuel metering unit A, replacing......466
Fuel metering unit B, replacing......473
Glow plug control unit, replacing......479
Glow plug, replacing......485
Inlet and exhaust system, component location......487
Inlet and exhaust system, description......489
Inlet and exhaust system, tightening torques......495
NOx sensor, replacing......496
Regeneration process, description......502
Spark plug cable, replacing......505
Spark plug control unit, replacing......508
Spark plug, inspecting......510
Spark plug, replacing......512
Throttle, replacing......514
Turbocharger, description......516
Turbocharger, replacing......518
Turbocharger, tightening torques......522
Wastegate, checking......524
26 - COOLING SYSTEM......526
Coolant pump, replacing......527
Cooling fan motor, replacing......531
Cooling fan rpm, specifications......534
Cooling system pressure, checking......535
Cooling system, component location......537
Cooling system, description......538
Expansion tank, replacing......540
Fan control valve, installing......542
Fan control valve, removing......543
Fan control valve, seal replacing......544
Fan pump flow, Checking......546
Fan pump, Installing......548
Fan pump, Removing......550
Fan shroud, replacing......552
Low fan speed, checking-[4321]......555
Low fan speed, checking......556
Maximum fan speed, checking-[4417]......558
Maximum fan speed, checking......561
Radiator, replacing......563
Thermostat, specifications......567
29 - MISCELLANEOUS......569
EGR actuator, replacing......570
EGR cooler, replacing......574
EGR reed valve, replacing......584
EGR system function, checking......587
EGR system, tightening torques......591
EGR valve, replacing......593
EGR venturi tube, replacing......595
Exhaust Gas Recirculation (EGR), description......599
Exhaust gas recirculation (EGR), component location......604
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS......606
30 - GENERAL......607
1587 Information link, description and measuring......616
27102-3 - Accelerator pedal, test......618
Accelerator Pedal......619
Accelerator setting......620
Adapter cable 981 3194......622
Adapter cable 999 0014......623
Adapter cable 999 0020......624
Adapter cable 999 0216......625
Adapter cable 999 3893......626
Adapter cable 999 8533......627
Adapter cable 999 8534......628
Automatic mode......629
Back-up alarm......630
CAN1 Control link, description and measuring......631
CAN7 Control link, description and measuring......633
CU2501, description and measuring......635
CU2503, description and measuring......637
Charge-air pressure......639
Charge-air temperature......640
Collection of basic data......641
Communication with data buses......643
Component fault diagnosis, description......645
Conditions when checking......648
Cooling fan adjustment......650
DI3801, description and measuring......652
DI5201, description and measuring......653
DI5202, description and measuring......654
DI6401, description and measuring......655
Data links, fault tracing with Oscilloscope......656
Description of table for software functions......666
Differential lock......667
Directional gear shifting......669
Electrical system, description......670
Electronic control system, description......671
Engine Oil Level......673
Engine Over-speed Protection......675
Engine Protection......676
Engine air filter restriction......679
Engine coolant level......680
Engine coolant temperature......681
Engine oil pressure......682
Extension cable 999 0062......683
FX1006, description and measuring......684
FX1007, description and measuring......687
FX1008, description and measuring......690
FX1031, description and measuring......693
Fuel Level......696
Gearshifting solenoids......697
General fault diagnosis information......701
HE2501, description and measuring......702
Harness 8889 0016......704
Hydraulic Oil Level......705
Hydraulic Unload......706
Hydraulic oil filter bypass indicator......707
Hydraulic oil temperature......708
INFO Water in fuel......709
Inching pedal and memory gears......710
Inching pedal......712
Inching......713
Increased fan speed for AC......714
Interruption in computer communication......715
Lead and connector checks......716
MA2301-MA2306, description and measuring......720
MA2508, description and measuring......722
MA2509, description and measuring......724
MA2510, description and measuring......726
MA2512, description and measuring......728
MA2602, description and measuring......730
MA2603, description and measuring......732
MA4601, description and measuring......734
MA5501, description and measuring......736
MA8501, description and measuring......738
MA8701, description and measuring......739
MA9111, description and measuring......741
MA9201, description and measuring......743
MA9202, description and measuring......745
MA9203, description and measuring......747
MA9204, description and measuring......749
MA9205, description and measuring......751
MA9206, description and measuring......753
MA9207, description and measuring......755
MA9208, description and measuring......757
MA9209, description and measuring......759
MA9210, description and measuring......761
MA9220, description and measuring......763
MA9221, description and measuring......765
MA9222, description and measuring......767
MA9223, description and measuring......769
MA9224, description and measuring......771
MA9225, description and measuring......773
MA9226, description and measuring......775
MA9227, description and measuring......777
MA9228, description and measuring......779
MA9229, description and measuring......781
MA9301, description and measuring......783
MA9302, description and measuring......785
MA9321, description and measuring......787
MA9801, description and measuring......789
MO2502, description and measuring......791
MO2503, description and measuring......793
MO3301, description and measuring......795
MO5201, description and measuring......797
Manual mode......798
Multi-pin breaker box 999 8699......799
Multimeter 8889 0074......800
PWM2303, description and measuring......801
PWM2601, description and measuring......803
PWM4205 - PWM4212, description and measuring......805
PWM9101, description and measuring......807
PWM9102, description and measuring......809
PWM9103, description and measuring......811
PWM9104, description and measuring......813
PWM9105, description and measuring......815
PWM9121, description and measuring......817
PWM9122, description and measuring......819
PWM9123, description and measuring......821
PWM9124, description and measuring......823
PWM9125, description and measuring......825
Parking brake......827
Power mode......829
Power supply E-ECU, description and measuring......831
Preheating of inlet air......832
RE2501, description and measuring......834
RE3301, description and measuring......836
RE3302, description and measuring......838
RE3501, description and measuring......840
RE3502, description and measuring......842
RE3503, description and measuring......844
RE3505, description and measuring......846
RE3506, description and measuring......848
RE3507, description and measuring......850
RE3510, description and measuring......852
RE3512, description and measuring......854
RE3602, description and measuring......856
RE3701, description and measuring......858
RE3702, description and measuring......860
RE3703, description and measuring......862
RE3705, description and measuring......864
RE4201, description and measuring......866
RE5201, description and measuring......868
RE5501, description and measuring......870
RE5502, description and measuring......872
RE6401, description and measuring......874
RE8501, description and measuring......876
RE8701, description and measuring......878
RE8704, description and measuring......880
RE9101, description and measuring......882
RE9111, description and measuring......884
Reduced computer communication......886
Reversible cooling fan......887
SAE error codes, translation to error messages, general......890
SE2203, description and measuring......893
SE2301, description and measuring......896
SE2302, description and measuring......898
SE2303, description and measuring......903
SE2309, description and measuring......905
SE2507, description and measuring......907
SE2512, description and measuring......909
SE2515, description and measuring......913
SE2516, description and measuring......915
SE2518, description and measuring......917
SE2519, description and measuring......922
SE2520, description and measuring......924
SE2521, description and measuring......926
SE2522, description and measuring......928
SE2523, description and measuring......930
SE2524, description and measuring......932
SE2525, description and measuring......934
SE2526, description and measuring......936
SE2603, description and measuring......938
SE2606, description and measuring......940
SE2701, description and measuring......942
SE2702, description and measuring......944
SE2703, description and measuring......946
SE2704, description and measuring......948
SE3802, description and measuring......950
SE4101, description and measuring......952
SE4102, description and measuring......954
SE4201, description and measuring......956
SE4202, description and measuring......958
SE4214, description and measuring......960
SE4215, description and measuring......962
SE4216, description and measuring......964
SE4217, description and measuring......966
SE4307, description and measuring......968
SE4308, description and measuring......970
SE4601, description and measuring......972
SE5201, description and measuring_{06-35-36}......974
SE5201, description and measuring_{06-36-44}......976
SE5205, description and measuring......978
SE5206, description and measuring......980
SE5215, description and measuring......982
SE5501, description and measuring......984
SE6401, description and measuring......986
SE6402, description and measuring......988
SE8701, description and measuring......990
SE9104, description and measuring......992
SE9105, description and measuring......994
SE9107, description and measuring......996
SE9801, description and measuring......998
SW3301, description and measuring......999
Secondary steering......1001
Service brake differential pressure......1003
Shifting and memory gears......1004
Shifting out of Neutral......1006
Software......1007
Special tools for troubleshooting......1008
System voltage......1009
Temperature induction air......1010
Temperature, ambient air......1011
Template 8889 0019......1012
Template 999 3894......1013
Test methods, description......1014
Test pins 999 0008......1017
Transmission Stall Protection......1018
Transmission oil filter bypass indicator......1019
Transmission oil pressure......1020
Transmission oil temperature......1022
Travel mode......1023
Troubleshooting strategy......1024
Troubleshooting tools......1026
VCADS Pro service Tool......1027
VCADS Pro service tool-[1012]......1031
VCADS Pro service tool......1035
VCADS Pro, 17012-3 - Error Codes......1039
VCADS Pro, 17030-3 - Parameter, programming......1042
VCADS Pro, 17034-3 - Vehicle information, test......1044
VCADS Pro, 17055-3 - Central systems updating, replace control unit......1045
VCADS Pro, 17056-3 - Central systems updating, change software......1047
VCADS Pro, 17095-3 Handle component......1049
VCADS Pro, 21006-3 - Cylinder compression, test......1051
VCADS Pro, 23017-3 - Feed pressure, inspection......1052
VCADS Pro, 23712-3 - Injectors shut off, manual......1053
VCADS Pro, 28407-3 - Sensor values, monitoring......1054
VCADS Pro, 38335-3 - Displayed machine hours, correction......1055
VCADS Pro, 39796-3 - MID 142 Control unit, reset......1056
VCADS Pro, 41381-3 - Inching pedal, test......1057
VCADS Pro, 46813-3 - Differential lock system, check......1058
VCADS Pro, 55102-3 - Parking brake system test......1059
VCADS Pro, Description......1060
VCADS Pro, Simulator mode......1062
VHP......1063
part number, checking......1065
part number, general......1068
31 - BATTERY......1070
Batteries, replacing......1071
Battery box, installing......1073
Battery box, removing......1074
Battery charging capacity, checking......1075
Battery description......1077
Battery specification......1078
Battery storage......1079
Battery, charging......1080
32 - ALTERNATOR; CHARGE REGULATOR......1082
Alternator connections and expected readings......1083
Alternator, description......1084
Alternator, specifications......1085
33 - STARTING SYSTEM......1086
Electric air pre-heater, description......1087
Ignition switch, replacing......1088
Start switch, description......1090
Starter motor, tightening torques......1092
Starting system, general description......1095
35 - LIGHTING......1096
Headlights, adjusting......1097
Lighting, specifications......1099
36 - OTHER ELECTRICAL EQUIPMENT......1100
Connectors, configuration_{05-57-08}......1101
Connectors, configuration_{05-57-27}......1104
Connectors, configuration_{05-57-47}......1106
Connectors, configuration_{05-58-05}......1110
Connectors, overview......1113
Connectors, position......1127
Direction indicator switch, replacing......1137
Direction indicator; turn signal description......1139
Engine control unit E-ECU, description......1140
Front upper window wiper, description......1142
Horn, description......1143
I-ECU MID 140 non-programmed, replacing......1144
I-ECU MID 140 pre-programmed, replacing......1146
Instrument control unit I-ECU, description......1148
Lower front window wiper, description......1150
Lower window wiper, replacing......1151
Rear window wiper, description......1153
Reverse alarm, replacing......1154
V-ECU MID 187 non-programmed, replacing......1155
V-ECU MID 187 pre-programmed, replacing......1157
Vehicle control unit V-ECU, description......1159
Wiper, specifications......1161
37 - CABLE; FUSE; RELAY......1163
Battery disconnect switch......1167
Battery main switch, checking......1168
Component list, Diodes......1170
Component list, Miscellaneous......1171
Component list, PWM valves......1174
Component list, Solenoid valves......1178
Component list, Sounders......1181
Component list, Switches......1182
Component list, fuses......1185
Component list, instruments......1188
Component list, lamps......1190
Component list, lights......1192
Component list, relays......1195
Component list, resistors......1197
Component list, sensors......1198
Electrical symbols and designations......1201
Explanation of wiring diagrams......1205
Grounding points, frame connections......1209
Wiring diagram 10_{05-36-55}......1211
Wiring diagram 10_{05-37-14}......1213
Wiring diagram 11_{05-36-00}......1215
Wiring diagram 11_{05-36-18}......1217
Wiring diagram 12_{05-35-14}......1219
Wiring diagram 12_{05-35-33}......1221
Wiring diagram 13_{05-34-27}......1223
Wiring diagram 13_{05-34-46}......1225
Wiring diagram 14_{05-33-40}......1227
Wiring diagram 14_{05-33-59}......1229
Wiring diagram 15_{05-32-41}......1231
Wiring diagram 15_{05-32-59}......1233
Wiring diagram 16_{05-31-54}......1235
Wiring diagram 16_{05-32-13}......1237
Wiring diagram 17_{05-31-07}......1239
Wiring diagram 17_{05-31-26}......1241
Wiring diagram 18_{05-30-20}......1243
Wiring diagram 18_{05-30-39}......1245
Wiring diagram 19_{05-29-34}......1247
Wiring diagram 19_{05-29-52}......1249
Wiring diagram 1_{05-44-17}......1251
Wiring diagram 1_{05-44-36}......1253
Wiring diagram 20_{05-28-47}......1255
Wiring diagram 20_{05-29-06}......1257
Wiring diagram 21_{05-28-01}......1259
Wiring diagram 21_{05-28-19}......1261
Wiring diagram 22_{05-27-10}......1263
Wiring diagram 22_{05-27-29}......1265
Wiring diagram 23_{05-26-24}......1267
Wiring diagram 23_{05-26-42}......1269
Wiring diagram 24_{05-25-37}......1271
Wiring diagram 24_{05-25-56}......1273
Wiring diagram 25_{05-24-45}......1275
Wiring diagram 25_{05-25-04}......1277
Wiring diagram 26_{05-23-55}......1279
Wiring diagram 26_{05-24-13}......1281
Wiring diagram 27_{05-23-08}......1283
Wiring diagram 27_{05-23-27}......1285
Wiring diagram 28_{05-22-22}......1287
Wiring diagram 28_{05-22-40}......1289
Wiring diagram 29_{05-21-35}......1291
Wiring diagram 29_{05-21-54}......1293
Wiring diagram 2_{05-43-30}......1295
Wiring diagram 2_{05-43-49}......1297
Wiring diagram 30_{05-20-44}......1299
Wiring diagram 30_{05-21-03}......1301
Wiring diagram 31_{05-19-58}......1303
Wiring diagram 31_{05-20-17}......1305
Wiring diagram 32_{05-19-12}......1307
Wiring diagram 32_{05-19-30}......1309
Wiring diagram 33_{05-18-25}......1312
Wiring diagram 33_{05-18-44}......1314
Wiring diagram 34_{05-17-30}......1316
Wiring diagram 34_{05-17-48}......1319
Wiring diagram 35_{05-16-43}......1321
Wiring diagram 35_{05-17-02}......1324
Wiring diagram 36_{05-15-57}......1326
Wiring diagram 36_{05-16-15}......1328
Wiring diagram 37_{05-15-11}......1330
Wiring diagram 37_{05-15-29}......1333
Wiring diagram 38......1335
Wiring diagram 3_{05-42-39}......1337
Wiring diagram 3_{05-42-57}......1339
Wiring diagram 4_{05-41-48}......1341
Wiring diagram 4_{05-42-07}......1343
Wiring diagram 5_{05-41-01}......1345
Wiring diagram 5_{05-41-20}......1347
Wiring diagram 6_{05-40-15}......1349
Wiring diagram 6_{05-40-33}......1351
Wiring diagram 7_{05-39-28}......1353
Wiring diagram 7_{05-39-47}......1355
Wiring diagram 8_{05-38-28}......1357
Wiring diagram 8_{05-38-47}......1359
Wiring diagram 9_{05-37-42}......1361
Wiring diagram 9_{05-38-00}......1363
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM......1365
Fuel level sender, replacing......1366
Revolution sensor (hydraulic cooling fan), replacing......1368
Transmission, revolution sensor, replacing......1369
39 - MISCELLANEOUS......1372
CareTrack W-ECU, description......1373
CareTrack system, description......1375
Radio, installing......1376
Radio, removing......1377
4 - POWER TRANSMISSION......1378
41 - CLUTCH; TORQUE CONVERTER......1379
Inching pedal, replacing......1380
42 - TRANSMISSION; HYDRAULIC CONTROL......1382
Gear selector, replacing......1383
HTE1160, description and operation......1385
Hydraulic transmission, volume......1388
Transmission hydraulic system, description and operation......1389
Transmission mounting, description and operation......1390
Transmission oil filter restriction sensor, replacing......1391
Transmission oil pressure, checking......1392
Transmission pressure sensor, replacing......1395
Transmission pump, installing......1398
Transmission pump, removing......1400
Transmission solenoid, replacing......1404
Transmission temperature sensor, replacing......1406
Transmission, component locations-[0733]......1408
Transmission, component locations......1412
Transmission, installing......1416
Transmission, removing......1420
Transmission, specifications_{05-09-45}......1425
Transmission, specifications_{05-10-01}......1426
Transmission, tightening torques......1427
Type HTE1160 transmission, description and operation......1428
Type HTE840 transmission, description and operation......1430
44 - HYDROSTATIC DRIVE......1432
Charge pump, replacing......1433
Pump drive, description and operation......1438
Pump drive, installing......1445
Pump drive, removing......1447
Pump drive, tighten torques......1449
45 - PROPELLER SHAFT......1450
Drive shaft, installing ......1451
Drive shaft, installing......1452
Drive shaft, removing ......1457
Drive shaft, removing......1459
Driveshaft - lower and midship, description and operation......1463
Driveshaft - upper, description and operation......1465
Intermediate bearing, replacing......1467
Universal joint, replacing......1473
46 - FRONT AXLE; REAR AXLE......1476
Axle, installing......1477
Axle, removing......1479
Axle, tightening torques......1481
Differential lock and control, description and operation......1483
Final drive axle (APR70 and APR90), description and operation......1485
Final drive, specifications......1486
Final drive, tightening torques......1487
Final drive, volume......1488
Four point bearing, replacing......1489
Front axle, specification......1493
Sensor unit (differential lock), replacing......1494
Tandem drive chain, installing_{04-55-17}......1496
Tandem drive chain, installing_{04-55-35}......1498
Tandem drive chain, removing_{04-56-02}......1500
Tandem drive chain, removing_{04-56-21}......1503
Tandem drive sprocket, installing......1507
Tandem drive sprocket, removing......1509
Tandem, installing......1511
Tandem, removing......1514
49 - MISCELLANEOUS......1518
Transmission oil cooler, description and operation......1519
Transmission oil cooler, installing......1521
Transmission oil cooler, removing......1523
5 - BRAKE......1525
50 - GENERAL......1526
Brake system, overview......1527
51 - WHEEL BRAKE......1530
Brake circuit hydraulic schematic......1531
Brake housing, pre-assembling......1533
Oil Disc Brake - Cleaning and Inspection......1535
Oil Disc Brakes - Bench Adjustment......1537
Oil disc brake assembly, removing......1539
Oil disc brake, installing......1542
Oil disc brakes , assembling......1545
Oil disc brakes, disassembling......1549
Service brakes function, checking......1555
Service brakes warning system, checking......1556
Service brakes, specifications......1558
Service brakes, tightening torques......1559
Tandem axle oil seal installation......1560
Tandem axle seal, installing......1563
Wheel brake, description......1570
52 - HYDRAULIC BRAKE SYSTEM......1574
Accumulator (removed) charging pressure, checking......1575
Accumulator, installing......1577
Accumulator, removing......1580
Adjustment checks......1584
Brake accumulator, description......1586
Brake accumulator, specifications......1588
Brake circuit, operation......1589
Brake master cylinder and power booster, description......1590
Brake master cylinder, assembling......1600
Brake master cylinder, disassembling......1603
Brake master cylinder, installing......1607
Brake master cylinder, removing......1609
Brake pedal angle, adjusting......1610
Brake pedal stop, adjusting......1612
Brake pedal switch, replacing......1615
Brake system hydraulic function, checking......1617
Brake system, bleeding_{03-12-51}......1620
Brake system, bleeding_{03-13-08}......1622
Brake system, specifications......1624
Foot brake valve, description......1625
Foot brake valve, installing......1628
Foot brake valve, removing......1632
Hydraulic brake system, description......1637
Hydraulic brake system, specifications......1641
Hydraulic brake system, tightening torques......1642
Power booster, assembling......1643
Power booster, disassembling......1645
55 - PARKING BRAKE......1647
Parking brake assembly, installing......1648
Parking brake assembly, removing......1651
Parking brake function, checking......1654
Parking brake, description and operation......1655
Parking brake, manually releasing......1656
6 - STEERING......1659
60 - GENERAL......1660
Steering system function, checking......1661
Steering, description......1662
Steering, specification......1663
62 - STEERING AXLE......1664
Drag link, installing......1665
Drag link, removing......1666
Front axle frame, installing......1667
Front axle frame, removing......1669
Front wheel bearing preload, adjusting......1671
Steering axle, description and operation......1673
Tie bar, installing......1675
Tie bar, removing......1677
Toe-in, adjusting......1679
64 - STEERING......1681
Electric unload of main implement and steering pump-[3945]......1682
Main implement and steering hydraulic pump, description and Operation......1684
Pedestal gas shock, replacing......1686
Pressure and flow compensator, Description......1688
Secondary steering function, checking......1689
Secondary steering motor, specifications......1690
Secondary steering pump, specifications......1691
Secondary steering relief valve, adjusting......1692
Secondary steering, description and general information......1695
Steering and implement pump controller, installing......1697
Steering and implement pump controller, removing......1700
Steering column, installing......1703
Steering column, removing......1706
Steering control unit, description and operation......1710
Steering control unit, installing......1714
Steering control unit, removing......1716
Steering cylinder, description......1719
Steering cylinders, specifications......1720
Steering cylinders, tightening torques......1721
Steering hydraulic circuit, description......1722
Steering hydraulic circuit, specifications......1723
Steering hydraulic schematics......1724
Steering system working pressure, checking and adjusting......1728
Steering wheel, tightening torques......1729
Wheel lean cylinder, installing......1730
Wheel lean cylinder, removing......1731
Wheel lean cylinders, specification......1732
Wheel lean cylinders, tightening torques......1733
Wheel lean hydraulic cylinder, description......1734
Wheel lean system, description and operation......1735
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT......1737
71 - FRAME......1738
Frame, description......1739
Frame, tightening torque......1741
Neck and nose cover, installing......1742
Neck and nose cover, removing......1743
Transmission guard, installing......1744
Transmission guard, removing......1746
74 - FRAME LINK......1748
Articulation cylinder, installing......1749
Articulation cylinder, removing......1751
Articulation cylinders, specifications......1754
Articulation cylinders, tightening torque......1755
Articulation hydraulics, description......1756
Articulation indicator cable, installing......1758
Articulation indicator cable, removing......1761
Frame joint, separating machine......1765
articulation, specifications......1770
77 - WHEELS; TRACKS; TYRE; HUB; DRUM......1771
Wheel, removing and fitting one......1772
Wheels, general description......1775
Wheels, specifications......1777
Wheels, tightening torques......1778
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE......1779
80 - GENERAL......1780
Cab description......1781
81 - CAB, NAKED; CANOPY......1783
Cab mounts, tightening torques......1784
Cab, installing......1785
Cab, removing......1790
Cab, specifications......1795
82 - ENGINE HOOD; MUDGUARD; FOOT STEP......1796
Cab ladder, replacing......1797
Engine hood, installing......1799
Engine hood, removing......1805
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING......1812
Reflectors and Decals......1813
Windows, general......1814
85 - CAB INTERIOR; UPHOLSTERY......1816
Cab interior covers, replacing......1817
Front headliner, installing......1820
Front headliner, removing......1821
Operator seat, tightening torques......1822
Operator's seat, installing......1823
Operator's seat, removing......1824
Rear headliner, installing......1825
Rear headliner, removing......1826
Side console covers, replacing......1827
87 - AIR CONDITIONING UNIT......1830
Air conditioning unit, operation......1831
Air conditioning, specifications......1834
Air conditioning, tightening torques......1835
Air distribution, description......1836
Air distribution, specifications......1838
Air mix door actuator, replacing......1839
Cooler and Heater assembly, installing......1841
Cooler and Heater assembly, removing......1846
Defroster fan, replacing......1851
Evaporator, replacing incl draining and filling......1853
Fan motor, replacing......1856
HVAC control switch, replacing......1858
HVAC system components......1859
HVAC system......1862
Heat control valve, replacing......1864
Heater core, replacing......1866
Heater unit relays, replacing......1868
Receiver, replacing incl draining and filling......1870
Stepless motor drive, replacing......1872
Thermostat, replacing......1874
Troubleshooting, air conditioning unit (AC)......1876
88 - INTERIOR EQUIPMENT......1878
Lap Seat Belts......1879
Pedestal controls, tilt function......1880
Seat safety belt, replacing......1882
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS......1883
90 - GENERAL......1884
Accumulator, discarding......1885
Hydraulic components, storing and transporting......1887
Hydraulic oil, description......1888
Hydraulic oil, storing and handling......1889
Hydraulic system, description......1890
Oil and filtration......1891
91 - WORKING HYDRAULIC; SERVO HYDRAULICS......1893
Accumulator precharge pressure, checking-[5345]......1896
Articulation sensor, calibrating......1898
Articulation sensor, replacing......1907
Auxiliary hydraulic system control, description......1910
Auxiliary load sense shuttle valve, tightening torques......1913
Auxiliary load sense shuttle valve......1914
Blade lift section assembly - with float, specifications......1915
Blade lift section assembly - without float, specifications......1917
Blade lift system lock pin cylinder solenoid valve, tightening torques......1919
Circle turn valve, installing......1920
Circle turn valve, removing......1922
Circle turn valve, tightening torques......1925
Control lever, adjusting......1926
Control levers, replacing......1928
Counter balance steering valve, replacing......1930
Directional control valve - 10 bank, description and operation......1932
Directional control valve solenoid, replacing......1934
Directional control valve, installing......1937
Directional control valve, removing......1941
Display unit, replacing......1946
Electric unload of main implement and steering pump......1948
Fan motor, specifications......1950
Fan pump flow, checking......1951
Fan pump specification......1953
Fan pump, installing......1955
Fan pump, removing......1957
Hydraulic couplings, description......1959
Hydraulic cylinder, description......1960
Hydraulic diagram 1_{04-07-57}......1961
Hydraulic diagram 1_{04-08-16}......1965
Hydraulic diagram 2_{04-06-53}......1969
Hydraulic diagram 2_{04-07-12}......1971
Hydraulic diagram 2_{04-07-30}......1973
Hydraulic oil cooler, installing......1975
Hydraulic oil cooler, removing......1977
Hydraulic oil cooling system hydraulic schematics......1980
Hydraulic oil cooling system......1990
Hydraulic oil tank - description and operation......1996
Hydraulic oil tank, cleaning......1999
Hydraulic oil tank, installing......2002
Hydraulic oil tank, removing......2007
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump......2013
Hydraulic return line filter, specification......2015
Hydraulic swivel joint, installing......2016
Hydraulic swivel joint, removing......2020
J-ECU controller, replacing......2024
Joystick control system, description......2026
Joystick control, component locations......2031
Joystick control, hydraulic diagram1......2036
Joystick control, replacing......2040
Joystick control, wiring diagram 1......2043
Joystick control, wiring diagram 2......2044
Joystick control, wiring diagram 3......2046
Joystick control, wiring diagram 4......2047
Joystick control, wiring diagram 5......2048
Joystick control, wiring diagram 6......2049
Joystick control, wiring diagram 7......2050
Left side controller, replacing......2051
Load sense relief valve, description and operation......2054
Load sense relief valve, specifications......2056
Load sense shuttle valve, description and operation......2057
Load sense shuttle valve, tightening torques......2058
Main implement and steering hydraulic pump, description and operation......2059
Main implement and steering hydraulic pump, specifications......2061
Power supply unit, replacing......2063
Pressure and flow compensator, description......2066
Priority flow valve - description and operation......2067
Priority flow valve, disassembling and inspection......2071
Priority flow valve, installing......2073
Priority flow valve, removing......2075
Priority flow valve, specifications......2077
Rear auxiliary valve solenoid, replacing......2079
Rear option controller, replacing......2082
Relay, replacing......2084
Return line filter - description and operation......2086
Steering and implement pump, installing......2087
Steering and implement pump, removing......2090
Steering pressure sensor, replacing......2093
Steering valve solenoid, replacing......2095
Unloading valve, description and operation......2098
92 - MECHANICAL EQUIPMENT_ATTACHMENT......2101
Front mounted scarifier, specifications......2102
Parallel lift cylinder, specifications......2103
Parallel lift cylinder, tightening torque......2104
Push block, specifications......2105
Ripper cylinders, specifications......2106
Ripper cylinders, tightening torque......2107
Ripper, specifications......2108
Scarifier cylinder, specifications......2109
Scarifier cylinder, tightening torque......2110
Support arch, installing......2111
Support arch, removing......2113
Utility dozer blade, specifications......2115
98 - FUNCTION FOR ROAD CONSTRUCTION......2116
Accumulator -Charging......2118
Accumulator precharge adjustment chart......2120
Accumulator precharge pressure, checking......2121
Accumulator, description......2124
Accumulator, replacing......2126
Accumulator, specifications......2132
Blade lift arm, installing......2133
Blade lift arm, removing......2134
Blade lift cylinder, installing......2136
Blade lift cylinder, removing......2139
Blade lift cylinders, specifications......2142
Blade lift cylinders, tightening torques......2143
Blade lift stirrup, installing......2144
Blade lift stirrup, removing......2146
Blade lift system lock cylinder, installing......2148
Blade lift system lock cylinder, removing......2149
Blade lift system lock pin cylinder solenoid valve, specifications......2151
Blade lift system, description......2152
Blade lift system, tighten torques......2155
Blade lift, description and operation......2156
Blade slide cylinder, replacing......2158
Blade slide cylinders, specifications......2162
Blade slide cylinders, tightening torques......2163
Circle Setup and Timing......2164
Circle and drawbar, description and operation......2168
Circle and drawbar, installing......2171
Circle and drawbar, overview......2176
Circle and drawbar, removing......2177
Circle and drawbar, specifications......2181
Circle and drawbar, tightening torques......2182
Circle crank arm, installing......2183
Circle crank arm, removing......2186
Circle operation......2189
Circle side shift cylinders, specifications......2192
Circle side shift cylinders, tightening torques......2193
Circle turn cylinders, specifications......2194
Circle turn cylinders, tightening torques......2195
Circle, checking......2196
Mouldboard cutting edge, replacing......2201
Mouldboard lower slide tube bearing, replacing......2203
Mouldboard upper slide wear plate, replacing......2206
Mouldboard, shimming......2209
Power tilt cylinders, specifications (Models G940B - G960B)......2211
Power tilt cylinders, tightening torques (Models G940B - G960B)......2212
