Volvo G940 Motor Graders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo G940 Motor Graders, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions G940 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 G940 Motor Graders Repair Service Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,322 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - GENERAL...2
00 - DESCRIPTION; COMPLETE MACHINE...3
Description; complete machine...4
Product identification plates...7
03 - SPECIFICATIONS...9
Tightening torques...10
Critical mounting torques...21
Conversion tables...24
Fuel system; tightening torques ...32
Machine dimensions...34
Cylinder liner; specifications...36
Fuel system; specifications...37
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION...38
Transporting the machine_{35-28}...39
Transporting the machine_{35-07}...41
Removing and assembly of machine from shipping container...43
07 - STANDARD TIME...53
Operation numbers for additional work...54
08 - TOOL...56
Drawings; E-tools...57
1 - STANDARD PARTS; SERVICE...60
16 - LUBRICANT; FUEL; OTHER FLUID...61
Recommended lubricants_{30-41}...62
Recommended lubricants_{30-23}...64
17 - SERVICE...66
Alternative fuels...68
Start of VCADS Pro computer and reading machine data...71
Arrival Inspection; according to Inspection Programme...72
Delivery Inspection; according to Inspection Programme...73
Maintenance of Stored Machines; according to Inspection Programme...74
Maintenance service; every 10 hours...75
Maintenance service; every 50 hours...77
Maintenance service; every 250 hours...79
Maintenance service; every 500 hours...81
Maintenance service; every 1000 hours...83
Maintenance service; every 1500 hours...85
Maintenance service; every 2000 hours...87
Engine belt tension; checking_{25-29}...89
Engine belt tension; checking_{25-11}...90
Engine oil level; checking...92
Engine oil and filter; changing...94
Water separator; checking...97
Fuel filter; replacing...99
Fuel tank breather filter; replacing...102
Engine air cleaner primary filter; replacing...104
Oil-bath air cleaner reservoir oil; checking...107
Coolant level; checking...109
Coolant; changing...111
Coolers; cleaning...114
Battery; checking...118
Transmission oil level; checking...120
Transmission oil; changing...122
Transmission breather filter; replacing...125
Rear axle oil level; checking...126
Tandem oil level; checking...128
Tandem oil; changing...130
Service brake; testing...132
Master cylinder oil level; checking...134
Master cylinder oil; changing ...136
Parking brake function; checking ...139
Front wheel bearing; repacking ...140
Tyre wear and air pressure; checking...142
Wheel nuts torque; checking...144
Cab prefilter; cleaning...145
Cab main filter; cleaning...148
Hydraulic oil level; checking...151
Hydraulic oil; changing...153
Hydraulic oil return filter; replacing...158
Hydraulic oil tank breather filter; replacing...160
Starting with booster batteries...162
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump ...164
19 - GENERAL...166
CE-marking; EMC-directive...167
Safety concerns everybody!...171
Checking function...172
Safety rules when servicing...173
Safety when handling the machine...176
Service position...181
Some simple rules regarding tyre handling...183
Safety when lifting and supporting complete machine...185
Safety when using lifting equipment...188
Safety when handling oil and fuel...189
Safety when working with batteries...190
Starting with booster batteries ...192
Check list after fire or heat exposure...194
Safety when working with air conditioning refrigerant...196
Safety when working on hydraulic systems...199
Environmental handling for the future...201
Waste handling...202
Environmentally safe handling...203
Environmentally hazardous fluids...206
Working in environmentally contaminated areas...207
Health hazards with paint; plastics and rubber...208
Decontamination...211
Fire prevention measures...213
Electric welding...216
Precaution when working on the electrical system...217
2 - ENGINE WITH MOUNTING AND EQUIPMENT...218
20 - GENERAL...219
Engine; description...220
VCADS Pro; MID 128; programming E-ECU ...222
V-ECU; replacing ...223
21 - ENGINE...225
Engine; specifications...226
Engine; volume...227
Engine; removing...228
Engine; installing...236
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope...243
Engine; tighten torques...249
Cylinder head; description...250
Cylinder head gasket; description...252
Valve cover; description and operation...253
Crankcase ventilation; changing...255
D7 cylinder block with crankcase ventilation; description and operation...257
Pistons; description...258
Cylinder liner; description...260
Cylinder liner; checking and measuring wear...262
Valve system specifications...264
Valves; adjusting...265
Valves; description...277
Internal Exhaust Gas Recirculation (IEGR); description...278
Valve cover; fitting new gasket each...283
Engine timing gear; description...285
Camshaft; description...286
Crankshaft; description...287
Connecting rod; description...289
Vibration damper; description...291
Oil sump; description...292
Engine mounting; description_47-53...293
Engine mounting; description...295
Engine mounting rear; changing...297
Engine mount front; replacing...300
22 - LUBRICATING SYSTEM...304
Lubricating system; description...305
Lubrication system D7; specifications...308
Oil pump; description...309
23 - FUEL SYSTEM...311
Fuel system; description...312
Fuel system; tightening torques...314
Fuel feed pump; description...315
Feed pump; replacing...316
Fuel system; bleeding...319
Fuel tank; volume...321
Fuel tank; removing...322
Fuel tank; installing...325
Ventilation filter; replacing...327
Injectors; description...329
Injectors; replacing...332
High pressure fuel pump; checking...335
Fuel control valve (FCV); checking...339
Fuel control valve (FCV); replacing...342
Pressure relief valve (PRV); inspecting...345
Pressure relief valve (PRV); replacing...348
Delivery pipe; replacing one...351
Fuel rail pressure sensor; replacing...353
25 - INLET & EXHAUST SYSTEM...355
Inlet system; description...356
Exhaust system; description...357
Silencer; removing...358
Silencer; installing...364
Turbocharger; description...370
Turbocharger; removing...371
Turbocharger; installing...372
Turbocharger; inspecting...373
Air cleaner; removing...375
Air cleaner; installing...376
Air cleaner; preheater; specifications...378
Intercooler specifications...379
Charge air cooler; replacing...380
26 - COOLING SYSTEM...382
Cooling system D7; specification...383
Cooling system; volume...384
Cooling system; description...385
Cooling system; flushing...387
Radiator; replacing...390
Coolant pump; replacing...392
Fan belt and_or alternator belt; replacing...395
Cooling fan motor; replacing...397
Fan shroud; replacing...401
Maximum fan speed; checking ...404
Low fan speed; checking ...407
Fan control valve; removing ...409
Fan control valve; seal replacing ...410
Fan control valve; installing ...412
Fan pump flow; checking ...413
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...415
30 - GENERAL...416
Electrical system; description...425
Electronic control system; description...426
Communication with data buses_{57-14}...428
Communication with data buses_{56-47}...430
Software...432
Software versions and ECUs_part number; general...433
Software versions and ECUs_part number; checking...435
Software versions and ECUs_part number; list...438
V2006.2.0; change specification...441
V2006.3.0; change specification...442
V2006.4.0; change specification...443
V2006.5.0; change specification...444
V2006.6.0; change specification...445
V2006.6.1; change specification...447
V2007.1.0; change specification...448
V2007.2.0; change specification...449
V2007.3.0; change specification...450
V2007.4.0; change specification...451
V2007.5.0; change specification...452
V2007.6.0; change specification...455
V2008.1.0; change specification...456
V2008.1.1; change specification...457
V2008.3.0; change specification...458
System voltage...460
Data links; fault tracing with Oscilloscope...461
Electrical system; specifications...471
Preheating of inlet air...472
Reduced computer communication...474
Hydraulic Oil Level...475
Description of table for software functions...476
Engine oil pressure...477
Engine Oil Level...478
Fuel Level_{38-40}...480
Fuel Level_{38-21}...482
INFO Water in fuel...484
Engine air filter restriction...485
Temperature induction air...486
Charge-air temperature...487
Charge-air pressure...488
Engine coolant level...489
Engine coolant temperature...490
Cooling fan adjustment...492
Reversible cooling fan...495
Increased fan speed for AC...498
Accelerator Pedal_{34-23}...499
Accelerator Pedal_{34-03}...501
Accelerator setting_{33-25}...503
Accelerator setting_{33-05}...505
Engine speed for V-ECU...507
Engine Protection_{32-03}...509
Engine Protection_{31-43}...511
Interruption in computer communication...513
Temperature; ambient air...514
Back-up alarm...515
Transmission oil pressure...516
Transmission oil temperature_{09-05}...518
Transmission oil temperature_{08-46}...520
Transmission oil filter bypass indicator...522
Inching_{07-58}...523
Inching_{07-39}...524
Shifting out of Neutral...525
Shifting and memory gears_{06-51}...526
Shifting and memory gears_{06-32}...528
Inching pedal and memory gears_{05-54}...530
Inching pedal and memory gears_{05-34}...532
Manual mode_{05-05}...534
Manual mode_{04-46}...536
Automatic mode_{04-17}...538
Automatic mode_{03-58}...540
Travel mode_{03-29}...541
Travel mode_{03-10}...543
Engine Over-speed Protection...545
Directional gear shifting...546
Gearshifting solenoids...547
Transmission Stall Protection...551
Inching pedal_{01-25}...552
Inching pedal_{01-06}...554
Power mode...556
VHP...558
Differential lock...560
Service brake differential pressure...562
Parking brake_{59-17}...563
Parking brake_{58-57}...565
Parking brake_{58-38}...567
Parking brake_{58-18}...569
Secondary steering...571
Hydraulic Unload...574
Hydraulic oil temperature...576
Hydraulic oil filter bypass indicator...578
VCADS Pro; Description...579
VCADS Pro; Simulator mode...581
VCADS Pro; MID187; programming V-ECU_55-49...582
VCADS Pro; MID187; programming V-ECU...584
VCADS Pro; MID 142; programming W-ECU_55-08...586
VCADS Pro; MID 142; programming W-ECU...588
VCADS Pro; MID 140; programming I-ECU_54-26...590
VCADS Pro; MID 140; programming I-ECU...592
VCADS Pro; MID 128; programming E-ECU_53-31...594
VCADS Pro; MID 128; programming E-ECU...596
VCADS Pro; 17012-3 - Error Codes...598
VCADS Pro; 17030-3 - Parameter; programming...600
VCADS Pro; 17055-3 - Central systems updating; replace control unit...602
VCADS Pro; 17095-3 Handle component...604
VCADS Pro; 17065-3 - Central systems updating; change software...606
VCADS Pro; 21006-3 - Cylinder compression; test...608
VCADS Pro; 23017-3 - Feed pressure; inspection...609
VCADS Pro; 23712-3 - Injectors shut off; manual...610
27102-3 - Accelerator pedal; test...611
VCADS Pro; 28407-3 - Sensor values; monitoring...612
VCADS Pro; 38335-3 - Displayed machine hours; correction...613
VCADS Pro; 39796-3 - MID 142 Control unit; reset...614
VCADS Pro; 41381-3 - Inching pedal; test...615
Transmission; calibrating...616
VCADS Pro; 46813-3 - Differential lock system; check...618
VCADS Pro; 55102-3 - Parking brake system test...619
General fault diagnosis information...620
Troubleshooting strategy...622
Collection of basic data...624
SAE error codes; translation to error messages; general...626
SAE J1708 (Information bus)...628
SAE J1939_ CAN-bus (control bus)...631
Conditions when checking...634
Lead and connector checks...636
Troubleshooting tools...641
Special tools for troubleshooting...642
MA2603; description and measuring...643
MA9201; description and measuring...645
MA9202; description and measuring...647
MA9203; description and measuring...649
MA9204; description and measuring...651
MA9205; description and measuring...653
MA9206; description and measuring...655
MA9207; description and measuring...657
MA9208; description and measuring...659
MA9209; description and measuring...661
MA9210; description and measuring...663
MA9220; description and measuring...665
MA9221; description and measuring...667
MA9222; description and measuring...669
MA9223; description and measuring...671
MA9224; description and measuring...673
MA9225; description and measuring...675
MA9227; description and measuring...677
MA9228; description and measuring...679
MA9229; description and measuring...681
MA9301; description and measuring...683
MA9302; description and measuring...685
MA9321; description and measuring...687
MO5201; description and measuring...689
PWM2601; description and measuring...690
PWM9101; description and measuring...692
PWM9102; description and measuring...694
PWM9103; description and measuring...696
PWM9104; description and measuring...698
PWM9105; description and measuring...700
PWM9121; description and measuring...702
PWM9122; description and measuring...704
PWM9123; description and measuring...706
PWM9124; description and measuring...708
PWM9125; description and measuring...710
RE6401; description and measuring...712
SE5201; description and measuring...714
SE5205; description and measuring...716
SE5206; description and measuring...718
Multimeter 8889 0074...720
Adapter cable 981 3194...721
Test pins 999 0008...722
Adapter cable 999 0014...723
Adapter cable 999 0020...724
Extension cable 999 0062...726
Adapter cable 999 3893...727
Template 999 3894...728
Adapter cable 999 8533...729
Multi-pin breaker box 999 8699...730
Component fault diagnosis; description...731
Test methods; description...734
SAE error codes MID 128 Engine control unit (E-ECU)...737
SAE error codes MID 187 Vehicle control unit (V-ECU)...739
SAE error codes MID 140 Instrument control unit (I-ECU)...742
MID 128 PID 84 Machine travel speed; error codes...743
MID 128 PID 91 Accelerator pedal position...745
MID 128 PID 108 Barometric pressure...746
MID 128 PID 158 Battery voltage; error codes...747
MID 128 PID 251 Clock...749
MID 128 PID 252 Date...750
MID 128 PPID 55 ECU temperature...751
MID 128 PSID 096 Common rail pressure...752
MID 128 PSID 097 Common rail valve (PRV)...754
MID 128 PPID 435 Engine torque...756
MID 128 SID 39 Engine starter motor relay...757
MID 128 SID 70 Air inlet heater driver #1...759
MID 128 SID 211 5 V feed to engine sensors 2; error codes...761
MID 128 SID 232 5 V supply...763
MID 128 SID 240 Program memory...765
MID 128 SID 253 Data set memory (EEPROM); error codes...766
MID 128 SID 254 Engine control unit; error codes...767
MID 128 PID 175 Engine oil temperature...768
MID 128 PID 100 Engine oil pressure...770
MID 128 PID 98 Engine oil level...773
MID 128 PID 94 Fuel delivery pressure...775
MID 128 PID 97 Water in fuel indicator...778
MID 128 PID 164 Injection control pressure...780
MID 128 PID 172 Air inlet temperature...783
MID 128 PID 107 Air filter pressure drop...785
MID 128 PID 105 Intake manifold temperature...787
MID 128 PID 102 Boost pressure...790
MID 128 PID 111 Coolant level...793
MID 128 PID 110 Engine coolant temperature...795
MID 128 SID 22 Timing sensor; crank...798
MID 128 SID 21 Engine position...800
MID 128 SID 1-6 Injectors...802
MID 128 PPID 19 Internal EGR status...805
MID 128 SID 42 Fuel control unit...807
MID 128 PID 45 Inlet air heater status...810
Transmission diagnosis - Gear shifting solenoids...812
Transmission diagnosis - SE4101_SE4102 Sensor; inching pedal position_{38-25}...814
Transmission diagnosis - SE4101_SE4102 Sensor; inching pedal position_{37-09}...818
Transmission diagnosis - SE4201 Sensor; gearshift selector...822
Transmission diagnosis - SE4202 Sensor; transmission oil temperature_{31-45}...825
Transmission diagnosis - SE4202 Sensor; transmission oil temperature_{30-37}...828
Transmission diagnosis - SE4214 Sensor; transmission oil pressure...831
Transmission diagnosis - SE4215 Sensor; transmission filter restriction...834
Transmission diagnosis - SE4216 Sensor; transmission internal shaft speed_{35-13}...836
Transmission diagnosis - SE4216 Sensor; transmission internal shaft speed_{34-09}...839
Transmission diagnosis - SE4217 Sensor; transmission internal shaft speed_{32-52}...842
Transmission diagnosis - SE4217 Sensor; transmission internal shaft speed_{31-50}...845
Transmission diagnosis - SE4307 Sensor; transmission output shaft speed_{30-24}...848
Transmission diagnosis - SE4307 Sensor; transmission output shaft speed_{29-21}...851
Transmission diagnosis - SE4308 Sensor; transmission output shaft speed_{28-12}...854
Transmission diagnosis - SE4308 Sensor; transmission output shaft speed_{27-13}...857
MID 187 PID 96 Fuel level_{26-03}...860
MID 187 PID 96 Fuel level_{25-05}...863
V-ECU diagnosis - SE2702_SE2704 Sensor; accelerator pedal position_{23-57}...866
V-ECU diagnosis - SE2702_SE2704 Sensor; accelerator pedal position_{22-47}...869
V-ECU diagnosis - SE3802 Sensor; ambient air temperature...872
V-ECU diagnosis - SE4601 Sensor; differential lock pressure...874
V-ECU diagnosis - SE5201 Sensor; brake booster pressure...877
V-ECU diagnosis - SE5215 Sensor; brake pressure differential...879
V-ECU diagnosis - SE5501 Sensor; park brake pressure...881
V-ECU diagnosis - SE6401 Sensor; steering pressure...884
V-ECU diagnosis - SE8701 Sensor; A_C pressure...887
V-ECU diagnosis - SE9104 Sensor; hydraulic oil level...890
V-ECU diagnosis - SE9105 Sensor; hydraulic oil temperature...892
V-ECU diagnosis - SE9107 Sensor; hydraulic filter restriction...895
V-ECU diagnosis - MA2602 Solenoid; Fan control - direction...897
V-ECU diagnosis - MA2603 Solenoid; Fan control - shutoff...899
V-ECU diagnosis - PWM 2601 Solenoid; fan speed control...901
V-ECU diagnosis - MA4601 Solenoid; Differential lock...903
V-ECU diagnosis - MA5501 Solenoid; Park brake...905
V-ECU diagnosis - MA9111 Solenoid; hydraulic unload_{58-00}...907
V-ECU diagnosis - MA9111 Solenoid; hydraulic unload_{57-01}...909
I-ECU diagnosis - SW3301 Ignition switch...911
I-ECU diagnosis - SW3801 switch_keypad...913
Auxiliary hydraulic system...915
V-ECU diagnosis - SE2607 Sensor; cooling fan speed_{50-57}...918
V-ECU diagnosis - SE2607 Sensor; cooling fan speed_{50-05}...921
31 - BATTERY...924
Starting with booster batteries...925
Battery storage...927
Battery; specifications_{47-12}...928
Battery; specifications_{46-53}...929
Battery charging capacity; checking...930
Battery; charging...932
Batteries; replacing...934
Battery box; removing...936
Battery box; installing...938
32 - ALTERNATOR; CHARGE REGULATOR...940
Alternator; specifications_{43-21}...941
Alternator; specifications_{43-02}...942
Alternator; tightening torques...943
Alternator; description...944
Alternator; removing...945
Alternator; installing...948
33 - STARTING SYSTEM...949
Starter motor D7; specifications...950
Starting system; general description...951
Starter motor; removing...952
Starter motor; installing...953
Cold-start device; specifications...954
Electric air pre-heater; description...955
Start switch; description...956
Starter switch (engine start switch); replacing...958
35 - LIGHTING...961
Lighting; specifications...962
Headlights; adjusting...963
36 - OTHER ELECTRICAL EQUIPMENT...965
Direction indicator; turn signal description...966
Direction indicator switch; replacing...967
Horn; description...968
Reverse alarm; replacing...969
Wiper; specifications...970
Front upper window wiper; description...972
Rear window wiper; description...973
Lower front window wiper; description...974
Lower window wiper; replacing...975
Windscreen wiper rear; replacing motor...977
Windscreen wiper front motor; replacing...979
Windscreen wiper; replacing pivot linkage...981
Windscreen wiper; install and adjust...983
Connectors; overview...985
Connectors; configuration_{23-13}...993
Connectors; configuration_{22-51}...995
Connectors; position...998
Instrument control unit I-ECU; description...1008
Vehicle control unit V-ECU; description...1010
Engine control unit E-ECU; description...1012
I-ECU; replacing...1014
V-ECU; replacing...1015
37 - CABLE; FUSE; RELAY...1017
Electrical symbols and designations...1021
Explanation of wiring diagrams...1025
Additional component list...1028
Component list; motors...1030
Component list; PWM valves...1032
Component list; sensors...1035
Component list 1 alternator; batteries; capacitors; electronic units...1044
Component list 2 diodes...1045
Component list 3 fuses_{09-18}...1046
Component list 3 fuses_{08-56}...1050
Component list 4 heating coils; instruments; service connections...1054
Component list 5 lights...1055
Component list 6 control-; warning lights...1058
Component list 7 solenoid valves...1060
Component list 9 relays_{06-45}...1062
Component list 9 relays_{06-24}...1066
Component list 9 relays_{06-01}...1070
Component list 11 sensors...1074
Component list 12 switches...1077
Wiring diagram 1_{04-30}...1080
Wiring diagram 1 – Main diagram_Positive feeds_Chassis connections_{04-09}...1082
Wiring diagram 2_{03-38}...1084
Wiring diagram 2 Feeds V-ECU; I-ECU_{03-16}...1086
Wiring diagram 2 Feeds V-ECU; I-ECU_{02-55}...1088
Wiring diagram 3_{02-25}...1090
Wiring diagram 3_{02-03}...1092
Wiring diagram 3_{01-42}...1094
Wiring diagram 4_{01-12}...1096
Wiring diagram 4 – D7 Engine ECU_{00-50}...1098
Wiring diagram 5...1100
Wiring diagram 6_{59-48}...1102
Wiring diagram 6_{59-27}...1104
Wiring diagram 7_{58-57}...1105
Wiring diagram 7_{58-35}...1107
Wiring diagram 8_{58-04}...1109
Wiring diagram 8_{57-43}...1111
Wiring diagram 8_{57-22}...1113
Wiring diagram 9_{56-47}...1115
Wiring diagram 9_{56-26}...1117
Wiring diagram 10_{55-55}...1119
Wiring diagram 10_{55-34}...1121
Wiring diagram 11_{55-03}...1123
Wiring diagram 11 – Work lights_{54-41}...1125
Wiring diagram 12_{54-02}...1127
Wiring diagram 12_{53-40}...1129
Wiring diagram 13_{53-09}...1131
Wiring diagram 13_{52-48}...1133
Wiring diagram 14_{52-17}...1135
Wiring diagram 14_{51-56}...1137
Wiring diagram 15_{51-16}...1139
Wiring diagram 15_{50-55}...1141
Wiring diagram 16_{50-24}...1143
Wiring diagram 16_{50-03}...1145
Wiring diagram 17_{49-31}...1147
Wiring diagram 17_{49-11}...1149
Wiring diagram 18_{48-35}...1151
Wiring diagram 18_{48-14}...1153
Wiring diagram 19_{47-43}...1155
Wiring diagram 19_{47-22}...1157
Wiring diagram 20...1159
Wiring diagram 21_{46-25}...1161
Wiring diagram 21_{46-04}...1163
Wiring diagram 21_{45-43}...1165
Wiring diagram 22_{45-12}...1167
Wiring diagram 22_{44-51}...1170
Wiring diagram 22_{44-29}...1172
Wiring diagram 23_{43-58}...1174
Wiring diagram 23_{43-38}...1176
Wiring diagram 24_{43-07}...1178
Wiring diagram 24_{42-46}...1180
Wiring diagram 25_{42-11}...1182
Wiring diagram 25_{41-50}...1184
Wiring diagram 25_{41-29}...1186
Wiring diagram 26_{40-58}...1188
Wiring diagram 26_{40-37}...1190
Wiring diagram 26_{40-16}...1192
Wiring diagram 27_{39-45}...1194
Wiring diagram 27_{39-24}...1196
Wiring diagram 28_{38-48}...1198
Wiring diagram 28_{38-27}...1200
Wiring diagram 28_{38-06}...1202
Wiring diagram 28_{37-45}...1204
Wiring diagram 29_{37-05}...1206
Wiring diagram 29_{36-43}...1208
Wiring diagram 29_{36-22}...1210
Wiring diagram 29_{36-01}...1212
Wiring diagram 30_{35-30}...1214
Wiring diagram 30_{35-10}...1216
Wiring diagram 30_{34-49}...1218
Wiring diagram 31_{34-18}...1220
Wiring diagram 31_{33-57}...1222
Wiring diagram 31_{33-36}...1224
Wiring diagram 32_{32-51}...1226
Wiring diagram 32_{32-30}...1228
Wiring diagram 33...1230
Wiring diagram 34...1232
Wiring diagram 35...1235
Wiring diagram 36...1238
Wiring diagram 37...1240
Wiring diagram 38...1243
Positive feed...1245
Battery disconnect switch ...1246
Battery main switch; checking...1248
Battery disconnect switch...1250
Grounding points; frame connections...1252
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...1254
Revolution sensor (hydraulic cooling fan); replacing...1255
Transmission; revolution sensor; replacing...1256
Transmission sensor and connection; checking...1259
Fuel level sender; replacing...1261
39 - MISCELLANEOUS...1263
CareTrack system; description...1264
CareTrack W-ECU; description...1265
Radio; removing...1267
Radio; installing...1268
Speaker; replacing...1269
Antenna; replacing...1270
Voltage converter; replacing...1272
4 - POWER TRANSMISSION...1273
41 - CLUTCH; TORQUE CONVERTER...1274
Inching pedal; function check...1275
Inching pedal; replacing...1276
42 - TRANSMISSION; HYDRAULIC CONTROL...1278
Transmission; component locations_{19-28}...1279
Transmission; component locations_{19-07}...1282
Transmission; specifications_{18-37}...1284
Transmission; specifications_{18-18}...1285
Hydraulic transmission; volume...1286
Transmission; tightening torques...1287
Type HTE840 transmission; description and operation...1288
Type HTE1160 transmission; description and operation...1290
Transmission; changing oil and filter...1292
Transmission control HTE840_HTE1160; description and operation...1295
Transmission hydraulic system; description and operation...1298
Transmission circuit hydraulic schematic...1299
Transmission; component locations...1301
Transmission oil pressure; checking...1305
Transmission; removing...1308
Transmission; installing...1313
Transmission pump; removing...1315
Transmission pump; installing...1319
Transmission temperature sensor; replacing...1321
Transmission pressure sensor; replacing...1323
Transmission solenoid; replacing...1325
Transmission oil filter restriction sensor; replacing...1327
Gear selector; replacing...1328
Transmission mounting; description and operation...1330
Rubber cushion; changing...1331
44 - HYDROSTATIC DRIVE...1333
Charge pump; replacing...1334
Pump drive; tighten torques...1337
Pump drive; description and operation...1338
Pump drive; removing...1345
Pump Drive; reconditioning...1348
Spring coupling; changing...1361
Pump drive; installing...1363
Control neutral adjustment for EDC controls...1365
Filter description...1367
45 - PROPELLER SHAFT...1368
Driveshaft - upper; description and operation...1369
Driveshaft - lower and midship; description and operation...1371
Drive shaft; removing ...1373
Drive shaft; installing ...1375
Drive shaft; removing...1376
Drive shaft; installing...1378
Drive shaft; repair...1379
Universal joint; replacing...1382
49 - MISCELLANEOUS...1385
Transmission oil cooler; description and operation...1386
Hydraulic oil cooler; removing ...1388
Hydraulic oil cooler; installing ...1390
5 - BRAKE...1391
50 - GENERAL...1392
Brake system; overview...1393
51 - WHEEL BRAKE...1396
Service brakes; specifications...1397
Service brakes; tightening torques...1398
Service brakes function; checking...1399
Wheel brake; description...1400
Brake circuit hydraulic schematic...1404
Service brakes warning system; checking...1406
Oil disc brake assembly; removing...1408
Oil disc brakes; disassembling...1411
Oil Disc Brake - Cleaning and Inspection...1417
Brake housing; pre-assembling...1419
Tandem axle oil seal installation...1421
Tandem axle seal; installing...1424
Oil disc brakes ; assembling...1431
Oil Disc Brakes - Bench Adjustment...1435
Oil disc brake; installing...1437
52 - HYDRAULIC BRAKE SYSTEM...1440
Hydraulic brake system; specifications...1441
Hydraulic brake system; tightening torques...1442
Brake system; specifications...1443
Brake system hydraulic function; checking...1444
Brake master cylinder and power booster; description...1447
Brake circuit; operation...1457
Brake pedal switch; replacing...1459
Brake system; bleeding...1461
Hydraulic brake system; description...1463
Brake pedal stop; adjusting...1467
Brake master cylinder and power booster; removing...1470
Power booster; disassembling...1472
Power booster; assembling...1474
Master cylinder oil; changing...1476
Brake master cylinder; disassembling...1479
Brake master cylinder; assembling...1483
Brake master cylinder; installing...1486
Adjustment checks...1488
Foot brake valve; removing...1490
Foot brake valve; installing...1495
Brake pedal angle; adjusting...1499
Foot brake valve; description...1501
Brake accumulator; specifications...1504
Accumulator (removed) charging pressure; checking...1505
Accumulator; removing...1507
Accumulator; installing...1511
Brake accumulator; description...1514
55 - PARKING BRAKE...1516
Parking brake assembly; installing...1517
Parking brake; description and operation...1520
Parking brake function; checking...1521
Parking brake hydraulic schematic...1522
Parking brake; manually releasing...1525
Parking brake assembly; removing...1528
Parking brake; installing...1531
6 - STEERING...1533
60 - GENERAL...1534
Steering system; specifications...1535
Steering system; description...1536
Steering system function; checking...1537
62 - STEERING AXLE...1538
Steering axle; description and operation...1539
Steering axle; components...1541
Wheel hub; removing...1545
Wheel hub; installing...1546
Front wheel bearing; repacking...1547
Front axle wheel bearing preload; checking and adjusting...1549
Front axle frame; removing...1551
Front axle frame; installing...1553
Drag link; removing...1555
Drag link; installing...1556
Front axle; overhaul...1558
Tie bar; removing...1567
Tie bar; installing...1569
Knuckle; removing...1570
Knuckle; installing...1575
Toe - in; adjustment...1577
64 - STEERING...1579
Steering wheel; tightening torques...1581
Steering wheel; description...1582
Steering column; disassembling...1585
Steering column; assembling...1587
Control lever; adjusting...1589
Pedestal gas shock; replacing...1591
Steering control unit; removing...1593
Steering control unit; installing...1596
Steering cylinders; specification (G930 - G976)...1598
Steering cylinders; specification...1599
Steering cylinders; tightening torques...1600
Steering hydraulic cylinders; description...1601
Steering hydraulic circuit; specifications...1603
Steering hydraulic circuit; description...1604
Steering hydraulic schematics...1605
Steering system working pressure; checking and adjusting...1609
Shock valve; testing...1610
Main implement and steering hydraulic pump; description and operation ...1612
Pressure and flow compensator; description ...1614
Electric unload of main implement and steering pump ...1615
Steering and implement pump controller; removing ...1617
Steering control unit; description and operation...1619
Secondary steering pump; specifications...1623
Secondary steering; description and general information...1624
Secondary steering function; checking...1626
Secondary steering relief valve; adjusting...1627
Secondary steering circuit hydraulic diagram...1630
Secondary steering motor; specifications...1632
Secondary steering hydraulic schematic; relief valve opened...1633
Secondary steering hydraulic schematic; relief valve closed...1636
Wheel lean system; description and operation...1639
Wheel lean hydraulic schematic...1642
Wheel lean cylinders; specification...1645
Wheel lean cylinders; tightening torques...1646
Wheel lean hydraulic cylinder; description...1647
Wheel lean cylinder; removing...1649
Wheel lean cylinder; installing...1650
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...1651
71 - FRAME...1652
Frame; tightening torque...1653
Frame; description...1654
Transmission guard; removing...1656
Transmission guard; installing...1658
Neck and nose cover; removing...1660
Neck and nose cover; installing...1661
74 - FRAME LINK...1662
Frame joint; separating machine...1663
Frame joint; assembly of separated machine...1668
Articulation hydraulics; description...1670
Frame link_articulation; specifications...1672
Articulation cylinders; specifications (Models G930 - G960)...1673
Articulation cylinders; tightening torque (Models G930 - G960)...1674
Articulation cylinder; removing...1675
Articulation cylinder; installing...1678
Articulation hydraulic schematic...1680
Articulation circuit hydraulic diagram...1683
Articulation Indicator - Setup and Adjustment...1685
Articulation indicator cable; removing...1687
Articulation indicator cable; installing...1689
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...1692
Wheels; specifications...1693
Wheels; tightening torques...1694
Wheels; general description...1695
Troubleshooting...1697
Wheel; removing and fitting one...1699
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...1702
80 - GENERAL...1703
Cab description...1704
81 - CAB; NAKED; CANOPY...1706
Cab; specifications...1707
Cab mounts; tightening torques...1708
Cab; removing...1709
Cab; installing...1714
82 - ENGINE HOOD; MUDGUARD; FOOT STEP...1716
Engine hood; removing...1717
Engine hood; installing...1725
Cab ladder; replacing...1730
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING...1732
Reflectors and Decals...1733
Mirrors; tightening torques...1734
Cover; installing...1735
Windows; general...1737
85 - CAB INTERIOR; UPHOLSTERY...1739
Rear headliner; removing...1740
Rear headliner; installing...1741
Front headliner; removing...1742
Front headliner; installing...1743
Floor mats; replacing...1744
Cab interior covers; replacing...1746
Side console covers; replacing...1749
Operator's seat; removing...1752
Operator's seat; installing...1753
Operator seat; tightening torques...1754
87 - AIR CONDITIONING UNIT...1755
Air conditioning; specifications...1756
Air conditioning; tightening torques...1757
Air distribution; specifications...1758
Cooler and Heater assembly; removing...1759
Cooler and Heater assembly; installing...1764
Air distribution; description...1769
Defroster fan; replacing...1771
Fan motor; replacing...1773
Heater core; replacing...1775
Air mix door actuator; replacing...1777
Stepless motor drive; replacing...1779
Heater unit relays; replacing...1781
Heat control valve; replacing...1783
HVAC system...1786
HVAC system components...1788
Air conditioning unit; operation...1791
Air Conditioning System Repairs...1794
Cooling unit; performance test...1796
Cooling unit; leak detection...1798
Troubleshooting; air conditioning unit (AC)...1800
Thermostat; replacing...1803
Evaporator; replacing incl draining and filling...1805
Receiver; replacing incl draining and filling...1808
Condenser; replacing incl draining and filling...1810
HVAC control switch; replacing...1812
88 - INTERIOR EQUIPMENT...1814
Pedestal controls; tilt function...1815
Lap Seat Belts...1818
Seat safety belt; replacing...1819
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...1820
90 - GENERAL...1821
Main hydraulic schematic - sheet 1 - Image...1822
Hydraulic diagram 2 - Image...1824
Hydraulic diagram 1 - Image...1826
Explanations to hydraulic diagram...1827
Hydraulic components; cleanliness when handling...1836
Hydraulic diagram 1...1837
Hydraulic diagram 2_{14-40}...1841
Hydraulic diagram 2_{14-20}...1843
Main hydraulic schematic - sheet 1...1845
Hydraulic oil cooling system hydraulic schematics...1849
Fan pump hydraulic schematic...1859
Hydraulic circuits; travel_{11-49}...1860
Hydraulic circuits; travel_{11-29}...1862
Scarifier circuit hydraulic schematic...1865
Blade tilt circuit hydraulic schematic...1868
Blade lift system; hydraulic schematics...1871
Blade slide shift circuit hydraulic schematic...1875
Circle turn circuit hydraulic schematic...1878
Circle side shift circuit hydraulic schematic...1881
Hydraulic system; volume...1884
Hydraulic system; description...1885
Oil and filtration...1886
Hydraulic oil; description...1888
Hydraulic oil; storing and handling...1889
Hydraulic components; repairing in workshop...1890
Hydraulic components; storing and transporting...1891
Accumulator; discarding...1892
91 - WORKING HYDRAULIC; SERVO HYDRAULICS...1894
Hydraulic pump; standby pressure; checking and adjusting...1898
Hydraulic return line filter; specification ...1901
Hydraulic couplings; description...1902
Hydraulic couplings; installation instructions...1903
Hydraulic oil tank; changing oil and filter incl.cleaning tank...1905
Hydraulic oil tank - description and operation...1908
Hydraulic oil tank; removing...1911
Hydraulic oil tank; replacing...1917
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump ...1920
Hydraulic oil cooling system...1922
Maximum fan speed; checking...1928
Low fan speed; checking...1932
Fan motor; specifications...1934
Fan pump specification...1935
Fan pump flow; checking ...1937
Unloading valve; description and operation...1939
Oil cooler line bypass valve (check valve); replacing...1942
Hydraulic return line filter; specification...1944
Return line filter - description and operation...1945
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump...1946
Hydraulic oil cooler; removing...1948
Hydraulic oil cooler; installing...1950
Fan pump flow; checking_{55-26}...1951
Low fan speed; checking_{55-05}...1953
Low fan speed; checking_{54-45}...1955
Fan pump flow; checking...1957
Blade lift system lock pin cylinder solenoid valve; tightening torques...1959
Load sense shuttle valve; description and operation...1960
Load sense shuttle valve; tightening torques...1961
Auxiliary load sense shuttle valve; tightening torques...1962
Auxiliary load sense shuttle valve...1963
Load sense relief valve; specifications...1964
Load sense relief valve; description and operation...1965
Test procedure for external load sense relief valve...1967
Hydraulic cylinder; description...1969
Hydraulic Cylinder Overhaul Procedure...1971
Hydraulic cylinder; disassembling...1973
Hydraulic cylinder; assembling...1979
Special tools...1981
Fan control valve; removing...1982
Fan control valve; seal replacing...1983
Fan control valve; installing...1985
Directional control valve; specifications...1986
Directional control valve - 10 bank; description and operation...1987
Blade lift section assembly - with float; specifications...1989
Blade lift section assembly - without float; specifications...1992
Directional control valve troubleshooting...1994
Directional control valve; removing...1996
Directional control valve; reconditioning...2001
Directional control valve; reconditioning (1 valve section)...2007
Directional control valve; installing...2015
Priority flow valve; specifications...2020
Priority flow valve - description and operation...2022
Priority flow valve; removing...2026
Priority flow valve; disassembling and inspection...2027
Priority flow valve; assembling...2029
Priority flow valve; installing...2031
Main implement and steering hydraulic pump; specifications...2032
Main implement and steering hydraulic pump; description and operation...2034
Pressure and flow compensator; description...2036
Electric unload of main implement and steering pump...2037
Hydraulic pump; standby pressure and working pressure; checking and adjusting...2039
Pump; removing ...2043
Pump; installing ...2046
Pump; removing...2049
Pump; installing...2052
Steering and implement pump; performance test...2055
Steering and implement pump controller; removing...2057
Steering and implement pump controller; inspection and cleaning...2059
Steering and implement pump controller; installing...2062
Control lever; overhaul and adjustment...2063
Auxiliary hydraulic system control; description_{35-07}...2065
Auxiliary hydraulic system control; description_{34-46}...2069
Joystick control system; description...2073
Joystick control; component locations...2078
Joystick control; wiring diagram 1...2083
Joystick control; wiring diagram 2...2084
Joystick control; wiring diagram 3...2086
Joystick control; wiring diagram 4...2087
Joystick control; wiring diagram 5...2088
Joystick control; wiring diagram 6...2089
Joystick control; wiring diagram 7...2090
Left side controller; replacing...2091
Joystick control; replacing...2094
Display unit; replacing...2097
Rear option controller; replacing...2099
Directional control valve solenoid; replacing...2101
Counter balance steering valve; replacing...2104
Power supply unit; replacing...2106
Relay; replacing...2109
Steering valve solenoid; replacing...2111
Articulation sensor; replacing...2114
Articulation sensor; calibrating...2117
J-ECU controller; replacing...2126
Rear auxiliary valve solenoid; replacing...2128
Steering pressure sensor; replacing...2131
92 - MECHANICAL EQUIPMENT_ATTACHMENT...2133
Push block; specifications...2134
Push block; description and operation...2135
Dozer blade; description...2137
Specifications - utility dozer blade...2139
Front mount scarifier; description and operation...2140
Specifications - front mounted scarifier...2142
Scarifier cylinder; specifications...2144
Scarifier cylinder; tightening torque...2145
Ripper; description and operation...2146
Specifications - ripper...2148
Ripper cylinders; specifications...2149
Ripper cylinders; tightening torque...2150
Support arch; removing...2151
Support arch; installing...2153
Ripper; removing...2155
Ripper; installing...2157
Parallel lift assembly; description and operation...2160
Parallel lift cylinder; specifications...2163
Parallel lift cylinder; tightening torque...2164
98 - FUNCTION FOR ROAD CONSTRUCTION...2165
Mouldboard cutting edge; replacing...2168
Blade lift system lock pin cylinder solenoid valve; specifications...2171
Mouldboard upper slide wear plate; replacing...2172
Mouldboard lower slide tube bearing; replacing...2174
Blade lift; description and operation...2176
Blade lift cylinders; specifications (Models G930 - G960)...2178
Blade lift cylinders; tightening torques...2179
Blade lift circuit hydraulic diagram...2180
Blade lift cylinder; removing...2182
Blade lift cylinder; installing...2184
Blade lift stirrup; removing...2186
Blade lift stirrup bearing; replacing...2188
Blade lift stirrup; installing...2190
Accumulator; specification...2192
Accumulator; description...2193
Accumulators; preventive maintenance...2195
Accumulator precharge pressure; checking...2196
Accumulator -Charging...2199
Accumulator precharge adjustment chart...2201
Accumulator; replacing...2202
Blade slide cylinders; specifications (Models G930 - G960)...2208
Blade slide cylinders; tightening torque (Models G930 - G990)...2209
Blade slide cylinder; replacing...2210
Hydraulic swivel joint; removing...2212
Hydraulic swivel joint; disassembling...2216
Hydraulic swivel joint; assembling...2220
Hydraulic swivel joint; installing...2227
Circle turn cylinders; specifications (Models G930 - G976)...2231
Circle turn cylinders; tightening torque...2232
Circle Turn Valve Overhaul Procedure...2233
Circle turn circuit hydraulic diagram...2234
Circle turn valve; removing...2236
Circle turn valve; disassembling...2238
Circle turn valve; assembling...2242
Circle turn valve; installing...2245
Circle Timing...2247
Circle crank arm; removing...2250
Circle crank arm; installing...2253
Circle; checking...2256
Circle side shift cylinders; specifications (Models G930 - G960)...2261
Circle side shift cylinders; tightening torque (Models G930 - G990)...2262
Circle side shift circuit hydraulic diagram_{00-58}...2263
Circle side shift circuit hydraulic diagram_{00-38}...2265
Circle and drawbar; specifications...2267
Circle and drawbar; tighten torques...2268
Circle and drawbar; description and operation...2269
Circle and drawbar; overview...2272
Circle operation...2273
Circle and drawbar troubleshooting guide...2276
G930 to G976 circle and drawbar...2278
Circle and drawbar; removing and disassembling...2279
Circle and drawbar; assembling and installing...2282
Mouldboard; shimming...2287
Circle turn mechanism; disassembling...2289
Circle turn mechanism; assembling...2291
Drawbar ball stud; disassembling...2294
Drawbar ball stud; assembling...2297
Drawbar Ball Stud – Adjusting...2301
Circle Setup and Timing...2305
Power tilt cylinders; specifications (Models G940 - G976)...2309
Power tilt cylinders; tightening torque (Models G940 - G990)...2310
Blade lift system; tighten torques...2311
Blade lift system; description...2312
Blade lift arm; removing...2315
Blade lift arm; installing...2317
Blade lift system lock cylinder; removing...2318
Blade lift system lock cylinder; disassembling...2320
Blade lift cylinder lock cylinder seal; replacing...2321
Blade lift system lock cylinder; installing...2322
Volvo G940 Motor Graders Repair Service Manual
