Volvo G720B Motor Graders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo G720B Motor Graders, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Volvo Constructions G720B Motor Graders 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.
Volvo G720B Motor Graders Repair Service Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,194 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
000 - Foreword......2
000 - GENERAL......3
00 - DESCRIPTION; COMPLETE MACHINE......4
Description......4
Product identification plates......7
03 - SPECIFICATIONS......10
Dimensions......10
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION......12
Grader setup instructions......12
Storage......34
Transporting the machine......36
07 - STANDARD TIME......41
Operation numbers for additional work......41
08 - TOOL......43
G700B Special tools......43
09 - MISCELLANEOUS......45
Removing corrosion protective coating......45
001 - STANDARD PARTS, SERVICE......46
16 - LUBRICANT; FUEL; OTHER FLUID......47
Alternative fuels......47
Coolant......50
Fuel system......51
Grease......52
Recommended lubricants......53
Tandem_oil disc brake oils......55
17 - SERVICE......57
Arrival Inspection, according to Inspection Programme......57
Delivery Inspection, according to Inspection Programme......58
Hydraulic oil return filter, replacing......59
Jump-start procedure......64
Maintenance of Stored Machines, according to Inspection Programme......65
Towing......66
19 - GENERAL......69
Battery, charging......69
CE marking and declaration of conformity......71
Check list after fire or heat exposure......73
Electric welding......74
Environment......76
Fire prevention measures......78
Health hazards with paint, plastics and rubber......81
Safety concerns everybody!......83
Safety concerns everybody......84
Safety when handling oil and fuel......85
Safety when handling the machine......86
Safety when handling tyres......91
Safety when lifting and supporting the machine......92
Safety when working on hydraulic systems......93
Safety when working on the electrical system......94
Safety when working with air-conditioning refrigerant......95
Safety when working with batteries......97
Service positions......99
002 - ENGINE WITH MOUNTING AND EQUIPMENT......104
20 - GENERAL......105
Description, D10B_{11-14-06}......105
Description, D7D_{11-14-34}......106
General description......107
21 - ENGINE......108
Camshaft - D10B, description......108
Connecting rod, D7D......109
Crankshaft and vibration damper, D10B......111
Crankshaft rear oil seal, replacing......113
Crankshaft, D7D......115
Cylinder block - D10B, description......117
Cylinder compression, testing......118
Cylinder head - D10B, description_{11-06-20}......123
Cylinder head - D7D, description_{11-05-52}......125
Cylinder liner; piston, D10B......127
Cylinder liner; piston, D7D description......129
Cylinder liners, D10B description......132
Engine timing gear - D10B, description......134
Engine, removing_{11-09-28}......136
Engine, removing_{11-09-57}......140
Oil trap - D10B, description......144
Specifications, D10B - capacities_{11-10-35}......145
Specifications, D10B - general_{11-12-23}......146
Specifications, D10B - tightening torques_{11-08-22}......147
Specifications, D10B - weight......148
Specifications, D7D - capacities_{11-10-59}......149
Specifications, D7D - general_{11-12-47}......150
Specifications, D7D - tightening torques_{11-08-46}......151
Specifications, D7D - weight......152
Torsional vibration damper, D7D......153
Valve mechanism - D10B, description......155
Valve mechanism - D10B, specifications......157
Valves - D7D, description......158
Valves, adjusting_{11-01-50}......160
Valves, adjusting_{11-02-26}......162
22 - LUBRICATING SYSTEM......165
General, Lubrication oil pump D7D......165
Lubrication oil circuit, D7D engine Models G710B to G730B......167
Lubrication system - D10B, description......170
Specifications, D7D......173
23 - FUEL SYSTEM......174
Fuel feed pump - D10B, description......174
Fuel flow, D10B......176
Fuel shut-off valve, D10B......178
Fuel system components, D10B......180
Fuel system, description_{10-52-53}......182
Fuel system, description_{10-53-18}......190
Injection pump - D10B, description......191
Injection pump - D10B, specifications......193
Injection system - D7D, E-ECU overview......194
Injectors - D10B, description......198
Injectors - D10B, specification......201
Injectors, replacing......202
Overflow valve, D10B......208
Water trap, D10B......209
25 - INLET & EXHAUST SYSTEM......210
Air cleaner......210
Exhaust system - D10B engine......212
Exhaust system - D7D engine......214
General-[4333]......216
Intercooler D10B, specifications......218
Intercooler, D10B......219
Preheating coil, D10B......221
26 - COOLING SYSTEM......223
Cooling system - D10B engine, description......223
Cooling system - D7D engine, description......226
27 - ENGINE CONTROL......229
Accelerator_decelerator pedal......229
Hand Throttle......231
VHP (Variable Horsepower)......233
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS......234
30 - GENERAL......235
Description-......235
General......237
Operation......249
31 - BATTERY......250
Battery box......250
Description......251
Explosion hazard......252
Non-maintenance batteries, testing......253
Specifications......254
32 - ALTERNATOR; CHARGE REGULATOR......255
Alternator, description......255
Specifications......256
Voltage regulator......257
33 - STARTING SYSTEM......258
Electric air - preheater......258
Neutral start relay......259
Specifications......260
Starting system, general description......261
35 - LIGHTING......262
General......262
Lighting, front......263
Lighting, interior......264
Lighting, rear......265
Lighting, side......266
36 - OTHER ELECTRICAL EQUIPMENT......267
Automatic control_blocking function......267
Description......269
Direction indicator; turn signal......270
External warning system......271
Ignition switch......272
37 - CABLE; FUSE; RELAY......274
Cable; Battery isolation switch......274
Data link port......275
Description-......276
Electrical component list......277
Electrical distribution box fuses, relays......284
Electrical symbols and designations......286
Ground stud - locations......288
Wiring diagram 1 Main diagram_Positive feeds_Chassis connections_{10-21-03}......296
Wiring diagram 1 Main diagram_Positive feeds_Chassis connections_{10-21-31}......299
Wiring diagram 10 EEC Headlights and flashers_{10-10-14}......302
Wiring diagram 10 EEC Headlights and flashers_{10-10-43}......305
Wiring diagram 11 Work lights_{10-09-03}......308
Wiring diagram 11 Work lights_{10-09-32}......311
Wiring diagram 12 EEC Worklights_{10-07-53}......314
Wiring diagram 12 EEC Worklights_{10-08-21}......317
Wiring diagram 13 Windshield wiper systems_{10-06-43}......320
Wiring diagram 13 Windshield wiper systems_{10-07-11}......324
Wiring diagram 14 25 amp_60 amp converter_equalizer_{10-06-01}......327
Wiring diagram 14 Rotating beacons_ Differential lock_MBCS_Articulation sensor_{10-05-32}......330
Wiring diagram 15 Rotating beacons_differential lock_MBCS_{10-04-22}......333
Wiring diagram 15 Transmission ECU_{10-04-51}......336
Wiring diagram 16 AWD ECU_{10-03-24}......339
Wiring diagram 16 Transmission ECU_{10-02-56}......342
Wiring diagram 17 AWD ECU_{10-01-43}......346
Wiring diagram 17 AWD ECU_{10-02-12}......350
Wiring diagram 18 AWD ECU_{10-01-00}......354
Wiring diagram 18 Sensors_{10-00-30}......359
Wiring diagram 19 Brake circuit, lights_{09-59-19}......362
Wiring diagram 19 Sensors_{09-59-48}......365
Wiring diagram 2 Positive feed_Chassis connection I-ECU_E-ECU_{10-19-52}......368
Wiring diagram 2 Positive feed_Chassis connection I-ECU_E-ECU_{10-20-19}......370
Wiring diagram 20 Brake circuit, lights_{09-58-37}......372
Wiring diagram 20 Secondary steering_{09-58-08}......375
Wiring diagram 21 Climate control unit_{09-57-26}......378
Wiring diagram 21 Secondary steering_{09-56-58}......382
Wiring diagram 22 Climate control unit_{09-55-46}......385
Wiring diagram 22 Front and rear defroster fans_{09-56-14}......389
Wiring diagram 23 Front defroster fans_{09-55-03}......392
Wiring diagram 23 Radio_Heated mirrors_{09-54-35}......395
Wiring diagram 24 Blade float module_{09-53-53}......397
Wiring diagram 24 Radio_Dome light_Heated mirrors_{09-53-25}......400
Wiring diagram 25 Blade float module_{09-52-15}......403
Wiring diagram 25 Front float module_{09-52-43}......406
Wiring diagram 26 Front float module_{09-51-05}......409
Wiring diagram 26 Tire pump_{09-51-33}......412
Wiring diagram 27 Communication, E-ECU_I-ECU_{09-49-55}......414
Wiring diagram 27 Rear float module_{09-50-23}......417
Wiring diagram 28 Keyboard_{09-48-45}......419
Wiring diagram 28 Tire pump_Power outlet_{09-49-13}......421
Wiring diagram 29 Communication, E-ECU_I-ECU......424
Wiring diagram 3 Engine_{10-18-41}......427
Wiring diagram 3 Engine_{10-19-09}......430
Wiring diagram 30 Keyboard......433
Wiring diagram 4 D7 Engine ECU_{10-17-23}......435
Wiring diagram 4 D7 Engine ECU_{10-17-51}......438
Wiring diagram 5 D10 Engine ECU_{10-16-13}......440
Wiring diagram 5 D10 Engine ECU_{10-16-41}......442
Wiring diagram 6 D7, D10 Engine ECU_{10-15-02}......446
Wiring diagram 6 D7, D10 Engine ECU_{10-15-31}......448
Wiring diagram 7 Accelerator pedal_Fuel level_{10-13-52}......451
Wiring diagram 7 Accelerator pedal_Fuel level_{10-14-20}......454
Wiring diagram 8 Fan ECU_{10-12-39}......457
Wiring diagram 8 Fan ECU_{10-13-10}......460
Wiring diagram 9 Headlights_Turn signals_Horn_{10-11-26}......463
Wiring diagram 9 Headlights_Turn signals_Horn_{10-11-54}......466
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM......470
Description of tests......470
Description-......471
Diagnostic software......487
004 - POWER TRANSMISSION......488
41 - CLUTCH; TORQUE CONVERTER......489
Bearing support housing, installing......489
Clutch Slave Cylinder and Pedal Free Play, adjusting-[3903]......491
Clutch Slave Cylinder and Pedal Free Play, adjusting......494
Clutch assembly, installing......496
Clutch assembly, removing......498
Clutch housing, installing......500
Clutch housing, removing......502
Description and operation, engine clutch......505
Description, clutch master cylinder and booster......509
Specifications, clutch master cylinder and booster circuit......513
Specifications, engine clutch......514
42 - TRANSMISSION; HYDRAULIC CONTROL......516
Description, 8400 transmission......516
Error codes......519
Hydraulic system troubleshooting......522
Specifications-......528
Transmission ECU and shifter assembly......530
Transmission components......533
Transmission hydraulic circuit and operation......535
Transmission oil circuit and operation......537
Transmission troubleshooting......542
Transmission, installing......546
Transmission, removing......550
44 - HYDROSTATIC DRIVE......554
AWD electrical system......554
AWD error codes and troubleshooting......562
AWD hydraulic system......576
AWD test procedure and test port locations......585
All Wheel Drive Operational Checks......590
All Wheel Drive Pump and Motor Priming Procedure......592
Description, AWD system......595
Specifications, All Weel Drive system......604
46 - FRONT AXLE; REAR AXLE......605
Description, G780B - DR final drive......605
Description, SR final drives......606
Differential Lock, G710B - G746B......607
Differential Lock, G780B......609
Final drive assembly, installing-......611
Final drive assembly, installing......613
Final drive assembly, removing-......618
Final drive assembly, removing......620
Lock_unlock function-......625
Lock_unlock function......626
Lubrication circuit......627
Operation, G780B DR final drive......628
Operation, SR final drive......630
Specifications, G780B - DR final drive......632
Specifications, SR final drive......633
Specifications, tandems......634
Tandem assembly......635
Tandem, removing-......637
Tandem, removing......638
005 - BRAKE......644
50 - GENERAL......645
Overview......645
51 - WHEEL BRAKE......649
Brake circuit hydraulic schematic......649
Brake housing, pre-assembling......651
Description......653
Electric motor_pump troubleshooting......657
Electrical schematic......660
General......663
Oil Disc Brake - Cleaning and Inspection......664
Oil Disc Brakes - Bench Adjustment......666
Oil disc brake assembly, removing-......668
Oil disc brake assembly, removing......671
Oil disc brake, installing......674
Oil disc brakes , assembling......678
Oil disc brakes, disassembling......683
Tandem axle oil seal installation......689
Tandem axle seal, installing......691
52 - HYDRAULIC BRAKE SYSTEM......697
Adjustment checks......697
Brake master cylinder and power booster, installing......699
Brake master cylinder and power booster, removing-......701
Brake master cylinder and power booster, removing......702
Brake master cylinder, assembling......703
Brake master cylinder, disassembling......706
Description......709
Power booster, assembling......719
Power booster, disassembling......721
Specifications-......723
Specifications......724
Specifications......725
55 - PARKING BRAKE......726
Description......726
Electrical schematic......728
Hydraulic diagram......730
Parking brake assembly, removing......733
Parking brake intensifier......734
Parking brake overhaul procedure......736
Parking brake troubleshooting......739
Parking brake valve assembly......740
Parking brake, adjusting......742
Parking brake, assembling......744
Parking brake, disassembling......746
Parking brake, installing......748
Parking brake, manually releasing......750
Parking brake, pre-assembling......752
Specifications......753
006 - STEERING......755
60 - GENERAL......756
Description-......756
Description......761
Front axle pivot (G710B to G746B)......764
Front axle toe-in-......765
Front axle toe-in......766
Tightening torques......767
Tightening torques......768
62 - STEERING AXLE......769
Axle disassembly and assembly - G780B......769
Drag link, installing......770
Drag link, removing......771
Front Axle Pivot Pin Bearings, assembling......773
Front Axle Pivot Pin Bearings, disassembling......776
Front axle frame, installing......778
Front axle frame, removing......780
King Pin Bearings and Spindle Thrust Bearing, assembling......782
King Pin Bearings and Spindle Thrust Bearing, disassembling......784
Knuckle, installing......786
Knuckle, removing......787
Pivot Block Adjustments......788
Pivot block, assembling and installing......789
Pivot block, removing and disassembling......790
Preparation and wheel, removing......791
Spindle, assembling and installing......793
Spindle, removing and disassembling......795
Steering axle Assembly......797
Steering axle Disassembly......798
Steering cylinder, installing......799
Steering cylinder, removing......800
Tie bar, installing......802
Tie bar, removing......803
Toe - in, adjustment-[0157]......804
Toe - in, adjustment......805
Wheel Bearing, cleaning and inspecting......807
Wheel bearings, assembling......809
Wheel bearings, disassembling......811
Wheel hub, installing......813
Wheel hub, removing......815
Wheel lean cylinder, installing......817
Wheel lean cylinder, removing......818
Wheel, installing......820
64 - STEERING......821
Components-......821
Description ......823
Description- ......824
Description-......826
Description......828
Description......830
Function ......832
General description......834
Hydraulic cylinder specifications......835
Secondary steering hydraulic schematic......837
Secondary steering system components......839
Secondary steering troubleshooting......842
Specifications- ......843
Specifications-......844
Specifications-[......845
Specifications-[]......846
Specifications......847
Specifications......848
Steering Column - Cleaning and Inspection......850
Steering Control Unit - Bleeding Procedure......851
Steering column, assembling......852
Steering column, disassembling......853
Steering control unit overhaul procedure......855
Steering control unit troubleshooting......856
Steering control unit, assembling......859
Steering control unit, disassembling......865
Steering control unit, installing......870
Steering control unit, removing......871
Steering hydraulic schematics......872
Steering system troubleshooting guide......874
Wheel lean hydraulic schematic......876
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT......878
71 - FRAME......879
Description-......879
74 - FRAME LINK......881
Articulation Hinge, assembling......881
Articulation Indicator - Setup and Adjustment......885
Articulation Indicator - Setup and Adjustment......887
Articulation hinge Preparation for disassembly......891
Articulation hinge, disassembling......893
Articulation hinge......897
Articulation hydraulics......900
Cleaning and inspection......903
Tightening torques......904
77 - WHEELS; TRACKS; TYRE; HUB; DRUM......905
General description Wheels......905
Specifications......907
Tire troubleshooting guide......908
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE......910
87 - AIR CONDITIONING UNIT......911
Air Conditioning System Repairs......911
Air conditioner service......913
Air conditioning system......914
Basic operational checks......915
Cab air distribution_{08-29-45}......916
Cab air distribution_{08-30-12}......918
Climate control unit electrical schematic......920
Description......922
HVAC routine maintenance......923
HVAC system components......925
Operating principle......930
Specifications......932
88 - INTERIOR EQUIPMENT......934
Control Levers - Cleaning and Inspection......934
Control levers, assembling......935
Control levers, disassembling......937
Description......940
Locking Strut - Troubleshooting......944
Pedestal Locking Strut - Setup......945
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS......946
90 - GENERAL......947
Description......947
Hydraulic components, location......949
Hydraulic system troubleshooting guide......952
Specifications......956
91 - WORKING HYDRAULIC; SERVO HYDRAULICS......957
Accumulator -Charging......957
Accumulator precharge adjustment chart......959
Accumulator precharge pressure, checking......960
Auxiliary control valves Sheet 5......962
Auxiliary load sense shuttle valve......964
Circle Timing......965
Circle Turn Valve Overhaul Procedure......968
Circle turn valve, assembling......969
Circle turn valve, disassembling......972
Circle turn valve, installing......976
Circle turn valve, removing......978
Compensator Valve Pressure Setting - Checking......980
Components......981
Counterbalance valve for attachments-[4705]......984
Counterbalance valve for attachments......985
Description-......987
Description-......988
Description-[4317]......990
Description-[4836]......993
Description-[5620]......994
Description-[5759]......995
Description-[5948]......996
Description......997
Description......998
Function-[4929]......999
Function-[5733]......1000
Function-[5922]......1002
Function......1003
General-[4523]......1005
General-[5022]......1006
Hydraulic Cylinder Overhaul Procedure......1007
Hydraulic Oil Filler Cap - Prevention of Contaminants......1009
Hydraulic cylinder, assembling......1011
Hydraulic cylinder, disassembling......1016
Hydraulic oil cleanliness......1022
Hydraulic swivel joint, assembling......1028
Hydraulic swivel joint, disassembling......1031
Hydraulic swivel joint, installing......1034
Hydraulic swivel joint, removing......1037
Hydraulic system, bleeding air......1040
LS (load sense) Differential Pressure - Checking......1042
LS (load sense) pressure, checking......1045
Main Control Valve Bleeding Procedure......1047
Main control valve overhaul procedure......1049
Main control valve section......1050
Main control valve spool flow rates......1054
Main control valve troubleshooting......1056
Main control valve, assembling......1058
Main control valve, disassembling......1061
Main control valve, installing......1063
Main control valve, removing......1064
Main hydraulic pump troubleshooting guide......1065
Main hydraulic schematic - sheet 1......1067
Main hydraulic schematic, EEC float valves Sheet 4......1071
Main hydraulic schematic, EEC Sheet 3......1074
Main hydraulic schematic, float valves Sheet 2......1077
Preventive maintenance......1080
Principle of operation, main hydraulic pump......1081
Principle of operation, pressure compensator control......1084
Single attachment valve with relief (EEC)......1088
Special tools......1089
Specifications-......1090
Specifications-......1092
Specifications-[0046]......1093
Specifications-[4344]......1094
Specifications-[4422]......1095
Specifications-[4449]......1097
Specifications-[4903]......1099
Specifications-[4955]......1100
Specifications-[5048]......1101
Specifications-[5351]......1102
Specifications-[5653]......1104
Specifications-[5857]......1106
Specifications......1107
Specifications......1108
Test procedures-[0020]......1110
Test procedures......1112
Valve section, assembling......1114
Valve section, disassembling......1116
92 - MECHANICAL EQUIPMENT_ATTACHMENT......1119
Description-[3130]......1119
Description-[3223]......1120
Description-[3327]......1122
Description-[3416]......1123
Description-[3508]......1124
Description-[3635]......1125
Description-[3750]......1126
Description-[3839]......1127
Specifications - A-frame......1128
Specifications - V-plow......1129
Specifications - front mounted scarifier......1130
Specifications - hydraulic snow wing......1131
Specifications - mid mount scarifier......1133
Specifications - one way plow......1134
Specifications - push block......1135
Specifications - ripper......1136
Specifications - utility dozer blade......1137
Specifications - windrow eliminator......1138
98 - FUNCTION FOR ROAD CONSTRUCTION......1140
Blade lift arm, installing......1140
Blade lift arm, removing......1141
Blade lift cylinder, installing......1143
Blade lift cylinder, removing......1145
Blade lift stirrup, installing......1147
Blade lift stirrup, removing......1148
Circle Setup and Timing......1149
Circle adjustment......1151
Circle and drawbar, assembling and installing-[2726]......1154
Circle and drawbar, assembling and installing......1160
Circle and drawbar, removing and disassembling-[2759]......1164
Circle and drawbar, removing and disassembling......1167
Circle operation......1169
Circle turn mechanism, assembling......1172
Circle turn mechanism, disassembling......1175
Description-[2151]......1177
Description-[2936]......1181
Drawbar ball stud, assembling......1184
Drawbar ball stud, disassembling......1185
G710B to G746B circle and drawbar......1186
G780B circle and drawbar......1187
Mouldboard, shimming-[2651]......1188
Mouldboard, shimming......1190
Pinion wear......1191
Specifications-[2217]......1192
Specifications-[3002]......1193
Troubleshooting guide......1194
