Volvo G940 Motor Graders Repair Service Manual

Make: 
Model: 
Price: US$ 69.00

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

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