Volvo G940C Motor Graders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo G940C Motor Graders, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions G940C 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 G940C Motor Graders Repair Service Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,312 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - GENERAL...2
03 - SPECIFICATIONS...3
Tightening torque; specifications_{20-10}...4
Tightening torque; specifications_{19-51}...7
Thread locking compound; application_specifications...10
Hydraulic connections; tightening torques...12
07 - STANDARD TIME...15
Operation numbers for additional work...16
08 - TOOL...18
E-6000...19
E-6001...22
1 - STANDARD PARTS; SERVICE...24
16 - LUBRICANT; FUEL; OTHER FLUID...25
AdBlue®_DEF ...26
Fuel; lubricant and filling capacities...32
Recommended lubricants...33
Alternative fuels...36
17 - SERVICE...39
Service and Maintenance Introduction...42
Arrival Inspection; according to Inspection Programme...43
Delivery Inspection; according to Inspection Programme...44
Maintenance of Stored Machines; according to Inspection Programme...45
Maintenance service; every 10 hours...46
Maintenance service; every 50 hours...47
Maintenance service; every 250 hours...48
Maintenance service; every 500 hours...49
Maintenance service; every 1000 hours...51
Maintenance service; every 1500 hours...52
Maintenance service; every 2000 hours...53
Maintenance service; every 4500 hours...54
Maintenance service; every 6000 hours...55
Service position 1...56
Lubrication; every 50 hours...58
Lubrication; every 250 hours...65
Lubrication; every 500 hours...67
Lubrication; every 1000 hours...69
Engine belt condition; checking...73
Valves; adjusting ...75
Engine oil level; checking...78
Engine oil and filter; changing...80
Water separator; checking...83
Fuel filter; replacing...85
Water separator filter; replacing...87
Fuel tank breather filter; replacing...89
Diesel particulate filter; regenerating...91
Diesel particulate filter; checking and cleaning...93
AdBlue®_DEF pump unit filter; replacing...110
AdBlue®_DEF tank breather filter; replacing...112
Engine air cleaner primary filter; cleaning...114
Engine air cleaner primary filter; replacing...117
Engine air cleaner secondary filter; replacing...120
Coolant level; checking...122
Coolant; changing...123
Coolant freezing point; checking...126
Coolers; cleaning...129
Software update; checking...131
Battery; checking...135
Transmission oil level; checking...137
Transmission oil; changing...138
Transmission oil filter; replacing...142
Transmission breather filter; replacing...145
All wheel drive hydraulic oil filters; replacing...147
Rear axle oil level; checking...151
Rear axle oil; changing...152
Rear axle breather; checking...154
Tandem oil level; checking...155
Tandem oil; changing...157
Tandem breather; replacing...159
Service brake; testing...161
Parking brake function; checking...162
Front wheel bearing; repacking...163
Tyre wear and air pressure; checking...166
Wheel nuts torque; checking...168
Cab prefilter; cleaning...169
Cab prefilter; replacing...171
Cab main filter; cleaning...173
Cab main filter; replacing...175
Hydraulic oil level; checking...178
Hydraulic oil; changing...180
Hydraulic oil return filter; replacing...184
Hydraulic oil tank breather filter; replacing...187
19 - GENERAL...190
CE-marking; EMC-directive...191
Safety concerns everybody!...195
Safety rules when servicing...199
Service position...202
Some simple rules regarding tyre handling...204
Safety when lifting and supporting complete machine...206
Safety when using lifting equipment...209
Safety when working with air conditioning refrigerant...210
Safety when working on hydraulic systems...213
Environmentally safe handling...215
Environmentally hazardous fluids...218
Working in environmentally contaminated areas...219
A few simple safety rules...220
Before operating...224
Before service; read...228
General...232
Cleanliness...237
Electrical system...241
Checklist after a fire or heat exposure...245
Health hazards with paint; plastics and rubber...248
Safety when handling oil and fuel...252
Safety when working with batteries...255
Charging batteries...258
Environment...262
Environmental handling for the future...267
Decontamination...270
Fire prevention measures...274
2 - ENGINE WITH MOUNTING AND EQUIPMENT...277
20 - GENERAL...278
Engine; description...279
Component locations...286
Tech Tool; operations...288
Engine control module (ECM); replacing pre-programmed...290
Engine control module (ECM); replacing non-programmed...293
21 - ENGINE...296
Engine; specifications...297
Engine; tightening torques_{31-37}...298
Engine; tightening torques_{31-19}...299
Cylinder compression; testing...304
Crankcase ventilation; description...307
Valve mechanism; specifications...311
Valves; adjusting...313
Valve cover; removing...314
Valve cover; installing...317
Valve mechanism; tightening torques...319
22 - LUBRICATING SYSTEM...320
Lubricating system; description...321
Lubrication system; specifications...326
Lubrication system; component locations...328
Lubrication system; tightening torques...330
Lubrication oil pressure; checking with pressure gauge...333
23 - FUEL SYSTEM...335
Fuel system; description...336
Fuel system; specifications...343
Fuel system; tightening torques...345
Carbon dioxide in fuel system; checking...352
Fuel system; component location...354
Feed pump pressure; checking...356
Fuel system; bleeding...358
Fuel tank; removing...360
Fuel tank; installing...366
Injectors; replacing...370
Injector sleeves; replacing...375
Fuel rail; replacing...385
Fuel rail pressure sensor; replacing...388
High pressure fuel pump; replacing...390
High pressure fuel pipes; replacing...393
Fuel control valve (FCV); replacing...396
Pressure relief valve (PRV); replacing...401
25 - INLET & EXHAUST SYSTEM...403
Inlet and exhaust system; description...405
Inlet and exhaust system; specification...411
Inlet and exhaust system; component location...413
Inlet and exhaust system; tightening torques...415
Exhaust pipe flexible tube; replacing...420
Exhaust Aftertreatment System; description...423
Exhaust Aftertreatment System; component location...437
Regeneration process; description...440
AdBlue®_DEF dosing injector; replacing...447
AdBlue®_DEF mixing tube; replacing...450
AdBlue®_DEF tank; replacing...459
AdBlue®_DEF; draining...461
Coolant valve; replacing...463
SCR (Selective catalytic reduction) muffler; replacing...465
SCR (Selective catalytic reduction) dosing system; checking...468
AdBlue®_DEF pump unit diagnostics; description...470
ACM (Aftertreatment control module) non-programmed; replacing...474
ACM (Aftertreatment control module) pre-programmed; replacing...477
Inlet throttle; replacing...480
DOC (Diesel oxidation catalyst); replacing...482
AdBlue®_DEF pump unit; replacing...499
AdBlue®_DEF tank armature; replacing...503
AdBlue®_DEF tank armature; cleaning...512
AdBlue®_DEF tank armature suction filter; replacing...515
AdBlue®_DEF...517
AdBlue®_DEF pump unit; flushing...523
AdBlue®_DEF pump unit; inlet nipple; replacing...527
Turbocharger; replacing...530
Wastegate; checking...534
Air cleaner; removing...536
Air cleaner; installing...538
Charge air cooler; removing...540
Charge air cooler; installing...543
26 - COOLING SYSTEM...546
Cooling system; description...547
Cooling system; specifications...551
Carbon dioxide in coolant system; checking...552
Cooling system; component location...558
Cooling system; tightening torques...561
Cooling fan; tightening torques...564
Fan motor; specifications...565
Fan pump; specifications...566
Radiator; replacing...567
Expansion tank; replacing...569
Thermostat; replacing...577
Coolant pump; replacing...583
Cooling fan; description...587
Cooling fan motor; replacing...591
Fan shroud; replacing...604
Maximum fan speed; checking...612
Low fan speed; checking...614
Fan control valve; removing...616
Fan control valve; installing...620
Fan pump; removing...623
Fan pump; installing...626
29 - MISCELLANEOUS...630
Exhaust Gas Recirculation (EGR); description...631
Exhaust gas recirculation (EGR); component location...638
EGR system; tightening torques...640
EGR reed valve; replacing...642
EGR cooler; replacing...646
EGR valve; replacing...662
EGR venturi tube; replacing...668
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...671
30 - GENERAL...672
Transmission oil pressure...675
Transmission oil filter bypass indicator...677
VCADS Pro; 23712-3 - Injectors shut off; manual...678
27102-3 - Accelerator pedal; test...679
VCADS Pro; 41381-3 - Inching pedal; test...680
FX1005; description and measuring...681
FX1006; description and measuring...683
FX1007; description and measuring...686
FX1008; description and measuring...689
FX1074; description and measuring...692
FX1079; description and measuring...694
HE2501; description and measuring...697
HE2511; description and measuring...699
HE2512; description and measuring...701
HE2513; description and measuring...703
MA2301-MA2306; description and measuring...705
MA2517; description and measuring...707
MA2519; description and measuring...709
MA2602; description and measuring...711
MA2603; description and measuring...713
MA4601; description and measuring...715
MA5501; description and measuring...717
MA9133; description and measuring...719
MO2503; description and measuring...721
MO3301; description and measuring...723
PWM2303; description and measuring...724
PWM2601; description and measuring...726
PWM4205 - PWM4212; description and measuring...728
RE2501; description and measuring...730
SAE J1939_CAN1 Control link; description and measuring...732
SE2203; description and measuring...734
SE2301; description and measuring...737
SE2303; description and measuring...740
SE2309; description and measuring...742
SE2512; description and measuring...746
SE2513; description and measuring...748
SE2515; description and measuring...751
SE2516; description and measuring...756
SE2519; description and measuring...759
SE2521; description and measuring...761
SE2522; description and measuring...763
SE2533; description and measuring...765
SE2543; description and measuring...768
SE2544; description and measuring...770
SE2603; description and measuring...772
SE2606; description and measuring...774
SE2607; description and measuring...776
SE2702; description and measuring...778
SE2703; description and measuring...780
SE2704; description and measuring...782
SE2707; description and measuring...784
SE3802; description and measuring...786
SE4101; description and measuring...788
SE4102; description and measuring...790
SE4201; description and measuring...792
SE4202; description and measuring...794
SE4214; description and measuring...796
SE4215; description and measuring...798
SE4216; description and measuring...800
SE4217; description and measuring...802
SE4307; description and measuring...804
SE4308; description and measuring...806
SE4601; description and measuring...808
SE5201; description and measuring...810
SE5205; description and measuring...812
SE5206; description and measuring...814
SE5501; description and measuring...816
SE6402; description and measuring...818
SE9102; description and measuring...820
SE9104; description and measuring...822
SE9105; description and measuring...824
SE9107; description and measuring...826
Multimeter 8889 0074...828
Adapter cable 999 0014...829
Extension cable 999 0062...830
Adapter cable 999 3893...831
Multi-pin breaker box 999 8699...832
31 - BATTERY...833
Battery box; removing...834
Battery box; installing...836
32 - ALTERNATOR; CHARGE REGULATOR...838
Alternator; removing...839
Alternator; installing...842
33 - STARTING SYSTEM...845
Starter motor; tightening torques...846
36 - OTHER ELECTRICAL EQUIPMENT...849
Engine Gateway MID 165 non-programmed; replacing...850
Engine Gateway MID 165 pre-programmed; replacing...853
I-ECU MID 140 non-programmed; replacing...856
I-ECU MID 140 pre-programmed; replacing...859
V-ECU MID 187 pre-programmed; replacing...862
V-ECU MID 187 non-programmed; replacing...865
37 - CABLE; FUSE; RELAY...868
Electrical symbols and designations...870
Explanation of wiring diagrams...874
Component list; Diodes...878
Component list; fuses...879
Component list; PWM valves...882
Component list; relays...884
Component list; resistors...886
Component list; sensors...887
Component list; Solenoid valves...890
Component list; Switches...892
Wiring diagram index...895
Wiring diagram 1...897
Wiring diagram 2...899
Wiring diagram 3...901
Wiring diagram 4...903
Wiring diagram 5...905
Wiring diagram 6...907
Wiring diagram 7...909
Wiring diagram 8...911
Wiring diagram 9...913
Wiring diagram 10...915
Wiring diagram 11...917
Wiring diagram 12...919
Wiring diagram 13...921
Wiring diagram 14...923
Wiring diagram 15...925
Wiring diagram 16...927
Wiring diagram 17...929
Wiring diagram 18...931
Wiring diagram 19...933
Wiring diagram 20...935
Wiring diagram 21...937
Wiring diagram 22...939
Wiring diagram 23...941
Wiring diagram 24...943
Wiring diagram 25...945
Wiring diagram 26...947
Wiring diagram 27...949
Wiring diagram 28...951
Wiring diagram 29...953
Wiring diagram 30...955
Wiring diagram 31...957
Wiring diagram 32...959
Wiring diagram 33...962
Wiring diagram 34...964
Wiring diagram 35...966
Wiring diagram 36...968
Wiring diagram 37...970
Wiring diagram 38...972
Wiring diagram 39...974
Wiring diagram 40...976
Wiring diagram 41...978
Grounding points; frame connections...980
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...982
Transmission; revolution sensor; replacing...983
4 - POWER TRANSMISSION...986
41 - CLUTCH; TORQUE CONVERTER...987
Inching pedal; replacing...988
42 - TRANSMISSION; HYDRAULIC CONTROL...991
Transmission; tightening torques...992
Transmission; description_{28-22}...993
Transmission; description_{28-02}...1000
Transmission; specifications_{27-32}...1007
Transmission; specifications_{27-14}...1008
Transmission oil pressure; checking_{25-57}...1009
Transmission oil pressure; checking_{25-39}...1011
Transmission; removing...1013
Transmission; installing...1019
Transmission pump; removing...1026
Transmission pump; installing...1031
Transmission temperature sensor; replacing...1036
Transmission pressure sensor; replacing...1038
Transmission solenoid; replacing...1040
Transmission oil filter restriction sensor; replacing...1042
44 - HYDROSTATIC DRIVE...1044
Pump drive; tightening torques...1045
49 - MISCELLANEOUS...1046
Axle; tightening torques...1047
Differential lock; description...1049
Tandem drive chain; removing...1053
Tandem drive chain; installing...1056
Tandem drive sprocket; removing...1059
Tandem drive sprocket; installing...1060
Four point bearing; replacing...1062
Tandem; removing...1064
Tandem; installing...1067
Axle; removing...1070
Axle; installing...1073
Transmission oil cooler; removing...1076
Transmission oil cooler; installing...1079
5 - BRAKE...1081
50 - GENERAL...1082
Brake system; specifications ...1083
Brake system; tightening torques...1084
52 - HYDRAULIC BRAKE SYSTEM...1085
Brake system; specifications...1086
Brake system hydraulic function; checking...1087
Brake system; bleeding...1090
Hydraulic brake system; description...1092
Brake pedal stop; adjusting...1099
Brake accumulator; specifications...1102
Accumulator; removing...1103
55 - PARKING BRAKE...1107
Parking brake; manually releasing...1108
6 - STEERING...1111
60 - GENERAL...1112
Steering system; specifications...1113
Steering; tightening torques...1114
Steering valve; specifications...1115
Secondary steering pump; specifications...1116
62 - STEERING AXLE...1117
Toe-in; adjusting...1118
64 - STEERING...1120
Secondary steering; description...1121
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...1124
71 - FRAME...1125
Transmission guard; removing...1126
Transmission guard; installing...1128
74 - FRAME LINK...1130
Articulation; tightening torques...1131
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...1132
Wheels; specifications...1133
Wheels; tightening torques...1134
Wheel; removing...1135
Wheel; installing...1137
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...1139
81 - CAB; NAKED; CANOPY...1140
Cab; removing...1141
Cab; installing...1151
Cab; tightening torques...1161
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING...1162
Windows; general...1163
85 - CAB INTERIOR; UPHOLSTERY...1165
Front headliner; removing...1166
Front headliner; installing...1169
Side console covers; replacing...1172
Operator's seat; removing...1176
Operator's seat; installing...1179
Operator seat; tightening torques...1182
87 - AIR CONDITIONING UNIT...1183
Air conditioning; specifications...1184
Air conditioning; tightening torques...1185
Air distribution; specifications...1186
Defroster fan; replacing...1187
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...1190
90 - GENERAL...1191
Hydraulic diagram 2 - Image...1192
Hydraulic diagram 1 - Image...1193
Hydraulic diagram; component locations...1194
Hydraulic diagram 1...1211
Hydraulic diagram 2...1212
Hydraulic pressure; testing...1213
Hydraulic system; tightening torques...1218
Accumulator; discarding...1219
91 - WORKING HYDRAULIC; SERVO HYDRAULICS...1221
Hydraulic oil tank; removing...1222
Hydraulic oil tank; installing...1229
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump...1236
Main implement and steering hydraulic pump; specifications...1238
Steering and implement pump; removing...1240
Steering and implement pump; installing...1243
Steering and implement pump controller; removing...1246
Steering and implement pump controller; installing...1250
Joystick control system; description...1253
Joystick control; component locations...1257
Left side controller; replacing...1261
Joystick control; replacing...1263
Display unit; replacing...1266
Rear option controller; replacing...1268
Front option controller; replacing...1270
Directional control valve solenoid; replacing...1272
Counter balance steering valve; replacing...1275
Power supply unit; replacing...1277
Relay; replacing...1279
Steering valve solenoid; replacing...1281
Articulation sensor; replacing...1283
Articulation sensor; calibrating...1285
Joysticks; calibrating...1293
J-ECU controller; replacing...1298
Rear auxiliary valve solenoid; replacing...1300
Steering pressure sensor; replacing...1302
92 - MECHANICAL EQUIPMENT_ATTACHMENT...1304
Attachment; tightening torques...1305
98 - FUNCTION FOR ROAD CONSTRUCTION...1306
Mouldboard cutting edge; replacing...1307
Circle and drawbar; specifications...1309
Circle and drawbar; tightening torques...1310
Blade lift system lock pin cylinder solenoid valve; specifications...1311
Blade lift system; tighten torques...1312
Accumulator; specifications...1313
Volvo G940C Motor Graders Repair Service Manual
