Volvo G960C Motor Graders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo G960C Motor Graders, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo G960C 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 G960C Motor Graders Repair Service Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,300 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
1 - STANDARD PARTS; SERVICE...2
16 - LUBRICANT; FUEL; OTHER FLUID...3
AdBlue®_DEF...4
Fuel; lubricant and filling capacities...10
Recommended lubricants...11
Alternative fuels...14
17 - SERVICE...17
Service and Maintenance Introduction...20
Arrival Inspection; according to Inspection Programme...21
Delivery Inspection; according to Inspection Programme...22
Maintenance of Stored Machines; according to Inspection Programme...23
Maintenance service; every 10 hours...24
Maintenance service; every 50 hours...25
Maintenance service; every 250 hours...26
Maintenance service; every 500 hours...27
Maintenance service; every 1000 hours...29
Maintenance service; every 1500 hours...30
Maintenance service; every 2000 hours...31
Maintenance service; every 4500 hours...32
Maintenance service; every 6000 hours...33
Service position 1...34
Lubrication; every 50 hours...36
Lubrication; every 250 hours...43
Lubrication; every 500 hours...45
Lubrication; every 1000 hours...47
Engine belt condition; checking...51
Valves; adjusting ...53
Engine oil level; checking...56
Engine oil and filter; changing...58
Water separator; checking...61
Fuel filter; replacing...63
Water separator filter; replacing...65
Fuel tank breather filter; replacing...67
Diesel particulate filter; regenerating...69
Diesel particulate filter; checking and cleaning...71
AdBlue®_DEF pump unit filter; replacing...88
AdBlue®_DEF tank breather filter; replacing...90
Engine air cleaner primary filter; cleaning...92
Engine air cleaner primary filter; replacing...95
Engine air cleaner secondary filter; replacing...98
Coolant level; checking...100
Coolant; changing...101
Coolant freezing point; checking...104
Coolers; cleaning...107
Software update; checking...109
Battery; checking...113
Transmission oil level; checking...115
Transmission oil; changing...116
Transmission oil filter; replacing...120
Transmission breather filter; replacing...123
All wheel drive hydraulic oil filters; replacing...125
Rear axle oil level; checking...129
Rear axle oil; changing...130
Rear axle breather; checking...132
Tandem oil level; checking...133
Tandem oil; changing...135
Tandem breather; replacing...137
Service brake; testing...139
Parking brake function; checking...140
Front wheel bearing; repacking...141
Tyre wear and air pressure; checking...144
Wheel nuts torque; checking...146
Cab prefilter; cleaning...147
Cab prefilter; replacing...149
Cab main filter; cleaning...151
Cab main filter; replacing...153
Hydraulic oil level; checking...156
Hydraulic oil; changing...158
Hydraulic oil return filter; replacing...162
Hydraulic oil tank breather filter; replacing...165
19 - GENERAL...168
CE-marking; EMC-directive...169
Safety concerns everybody!...173
Safety rules when servicing...177
Service position...180
Some simple rules regarding tyre handling...182
Safety when lifting and supporting complete machine...184
Safety when using lifting equipment...187
Safety when working with air conditioning refrigerant...188
Safety when working on hydraulic systems...191
Environmentally safe handling...193
Environmentally hazardous fluids...196
Working in environmentally contaminated areas...197
A few simple safety rules...198
Before operating...202
Before service; read...206
General...210
Cleanliness...215
Electrical system...219
Checklist after a fire or heat exposure...223
Health hazards with paint; plastics and rubber...226
Safety when handling oil and fuel...230
Safety when working with batteries...233
Charging batteries...236
Environment...240
Environmental handling for the future...245
Decontamination...248
Fire prevention measures...252
2 - ENGINE WITH MOUNTING AND EQUIPMENT...255
20 - GENERAL...256
Engine; description...257
Component locations...264
Tech Tool; operations...266
Engine control module (ECM); replacing pre-programmed...268
Engine control module (ECM); replacing non-programmed...271
21 - ENGINE...274
Engine; specifications...275
Engine; tightening torques_{06-48}...276
Engine; tightening torques_{06-26}...277
Cylinder compression; testing...282
Crankcase ventilation; description...285
Valve mechanism; specifications...289
Valves; adjusting...291
Valve cover; removing...292
Valve cover; installing...295
Valve mechanism; tightening torques...297
22 - LUBRICATING SYSTEM...298
Lubricating system; description...299
Lubrication system; specifications...304
Lubrication system; component locations...306
Lubrication system; tightening torques...308
Lubrication oil pressure; checking with pressure gauge...311
23 - FUEL SYSTEM...313
Fuel system; description...314
Fuel system; specifications...321
Fuel system; tightening torques...323
Carbon dioxide in fuel system; checking...330
Fuel system; component location...332
Feed pump pressure; checking...334
Fuel system; bleeding...336
Fuel tank; removing...338
Fuel tank; installing...344
Injectors; replacing...348
Injector sleeves; replacing...353
Fuel rail; replacing...363
Fuel rail pressure sensor; replacing...366
High pressure fuel pump; replacing...368
High pressure fuel pipes; replacing...371
Fuel control valve (FCV); replacing...374
Pressure relief valve (PRV); replacing...379
25 - INLET & EXHAUST SYSTEM...381
Inlet and exhaust system; description...383
Inlet and exhaust system; specification...389
Inlet and exhaust system; component location...391
Inlet and exhaust system; tightening torques...393
Exhaust pipe flexible tube; replacing...398
Exhaust Aftertreatment System; description...401
Exhaust Aftertreatment System; component location...415
Regeneration process; description...418
AdBlue®_DEF dosing injector; replacing...425
AdBlue®_DEF mixing tube; replacing...428
AdBlue®_DEF tank; replacing...437
AdBlue®_DEF; draining...439
Coolant valve; replacing...441
SCR (Selective catalytic reduction) muffler; replacing...443
SCR (Selective catalytic reduction) dosing system; checking...446
AdBlue®_DEF pump unit diagnostics; description...448
ACM (Aftertreatment control module) non-programmed; replacing...452
ACM (Aftertreatment control module) pre-programmed; replacing...455
Inlet throttle; replacing...458
DOC (Diesel oxidation catalyst); replacing...460
AdBlue®_DEF pump unit; replacing...477
AdBlue®_DEF tank armature; replacing...481
AdBlue®_DEF tank armature; cleaning...490
AdBlue®_DEF tank armature suction filter; replacing...493
AdBlue®_DEF...495
AdBlue®_DEF pump unit; flushing...501
AdBlue®_DEF pump unit; inlet nipple; replacing...505
Turbocharger; replacing...508
Wastegate; checking...512
Air cleaner; removing...514
Air cleaner; installing...516
Charge air cooler; removing...518
Charge air cooler; installing...521
26 - COOLING SYSTEM...524
Cooling system; description...525
Cooling system; specifications...529
Carbon dioxide in coolant system; checking...530
Cooling system; component location...536
Cooling system; tightening torques...539
Cooling fan; tightening torques...542
Fan motor; specifications...543
Fan pump; specifications...544
Radiator; replacing...545
Expansion tank; replacing...547
Thermostat; replacing...555
Coolant pump; replacing...561
Cooling fan; description...565
Cooling fan motor; replacing...569
Fan shroud; replacing...582
Maximum fan speed; checking...590
Low fan speed; checking...592
Fan control valve; removing...594
Fan control valve; installing...598
Fan pump; removing...601
Fan pump; installing...604
29 - MISCELLANEOUS...608
Exhaust Gas Recirculation (EGR); description...609
Exhaust gas recirculation (EGR); component location...616
EGR system; tightening torques...618
EGR reed valve; replacing...620
EGR cooler; replacing...624
EGR valve; replacing...640
EGR venturi tube; replacing...646
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...649
30 - GENERAL...650
Transmission oil pressure...653
Transmission oil filter bypass indicator...655
VCADS Pro; 23712-3 - Injectors shut off; manual...656
27102-3 - Accelerator pedal; test...657
VCADS Pro; 41381-3 - Inching pedal; test...658
FX1005; description and measuring...659
FX1006; description and measuring...661
FX1007; description and measuring...664
FX1008; description and measuring...667
FX1074; description and measuring...670
FX1079; description and measuring...672
HE2501; description and measuring...675
HE2511; description and measuring...677
HE2512; description and measuring...679
HE2513; description and measuring...681
MA2301-MA2306; description and measuring...683
MA2517; description and measuring...685
MA2519; description and measuring...687
MA2602; description and measuring...689
MA2603; description and measuring...691
MA4601; description and measuring...693
MA5501; description and measuring...695
MA9133; description and measuring...697
MO2503; description and measuring...699
MO3301; description and measuring...701
PWM2303; description and measuring...702
PWM2601; description and measuring...704
PWM4205 - PWM4212; description and measuring...706
RE2501; description and measuring...708
SAE J1939_CAN1 Control link; description and measuring...710
SE2203; description and measuring...712
SE2301; description and measuring...715
SE2303; description and measuring...718
SE2309; description and measuring...720
SE2512; description and measuring...724
SE2513; description and measuring...726
SE2515; description and measuring...729
SE2516; description and measuring...734
SE2519; description and measuring...737
SE2521; description and measuring...739
SE2522; description and measuring...741
SE2533; description and measuring...743
SE2543; description and measuring...746
SE2544; description and measuring...748
SE2603; description and measuring...750
SE2606; description and measuring_34-26...752
SE2606; description and measuring...754
SE2607; description and measuring_33-03...756
SE2607; description and measuring...758
SE2702; description and measuring_31-36...760
SE2702; description and measuring...762
SE2703; description and measuring_30-09...764
SE2703; description and measuring...766
SE2704; description and measuring...768
SE2707; description and measuring...770
SE3802; description and measuring...772
SE4101; description and measuring...774
SE4102; description and measuring...776
SE4201; description and measuring...778
SE4202; description and measuring...780
SE4214; description and measuring...782
SE4215; description and measuring...784
SE4216; description and measuring...786
SE4217; description and measuring...788
SE4307; description and measuring...790
SE4308; description and measuring...792
SE4601; description and measuring...794
SE5201; description and measuring...796
SE5205; description and measuring...798
SE5206; description and measuring...800
SE5501; description and measuring...802
SE6402; description and measuring...804
SE9102; description and measuring...806
SE9104; description and measuring...808
SE9105; description and measuring...810
SE9107; description and measuring...812
Multimeter 8889 0074...814
Adapter cable 999 0014...815
Extension cable 999 0062...816
Adapter cable 999 3893...817
Multi-pin breaker box 999 8699...818
31 - BATTERY...819
Battery box; removing...820
Battery box; installing...822
32 - ALTERNATOR; CHARGE REGULATOR...824
Alternator; removing...825
Alternator; installing...828
33 - STARTING SYSTEM...831
Starter motor; tightening torques...832
36 - OTHER ELECTRICAL EQUIPMENT...835
Engine Gateway MID 165 non-programmed; replacing...836
Engine Gateway MID 165 pre-programmed; replacing...839
I-ECU MID 140 non-programmed; replacing...842
I-ECU MID 140 pre-programmed; replacing...845
V-ECU MID 187 pre-programmed; replacing...848
V-ECU MID 187 non-programmed; replacing...851
37 - CABLE; FUSE; RELAY...854
Electrical symbols and designations...856
Explanation of wiring diagrams...860
Component list; Diodes...864
Component list; fuses...865
Component list; PWM valves...868
Component list; relays...870
Component list; resistors...872
Component list; sensors...873
Component list; Solenoid valves...876
Component list; Switches...878
Wiring diagram index...881
Wiring diagram 1...883
Wiring diagram 2...885
Wiring diagram 3...887
Wiring diagram 4...889
Wiring diagram 5...891
Wiring diagram 6...893
Wiring diagram 7...895
Wiring diagram 8...897
Wiring diagram 9...899
Wiring diagram 10...901
Wiring diagram 11...903
Wiring diagram 12...905
Wiring diagram 13...907
Wiring diagram 14...909
Wiring diagram 15...911
Wiring diagram 16...913
Wiring diagram 17...915
Wiring diagram 18...917
Wiring diagram 19...919
Wiring diagram 20...921
Wiring diagram 21...923
Wiring diagram 22...925
Wiring diagram 23...927
Wiring diagram 24...929
Wiring diagram 25...931
Wiring diagram 26...933
Wiring diagram 27...935
Wiring diagram 28...937
Wiring diagram 29...939
Wiring diagram 30...941
Wiring diagram 31...943
Wiring diagram 32...945
Wiring diagram 33...948
Wiring diagram 34...950
Wiring diagram 35...952
Wiring diagram 36...954
Wiring diagram 37...956
Wiring diagram 38...958
Wiring diagram 39...960
Wiring diagram 40...962
Wiring diagram 41...964
Grounding points; frame connections...966
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...968
Transmission; revolution sensor; replacing...969
4 - POWER TRANSMISSION...972
41 - CLUTCH; TORQUE CONVERTER...973
Inching pedal; replacing...974
42 - TRANSMISSION; HYDRAULIC CONTROL...977
Transmission; tightening torques...978
Transmission; description_{58-45}...979
Transmission; description_{58-20}...986
Transmission; specifications_{57-44}...993
Transmission; specifications_{57-22}...994
Transmission oil pressure; checking_{55-57}...995
Transmission oil pressure; checking_{55-32}...997
Transmission; removing...999
Transmission; installing...1005
Transmission pump; removing...1012
Transmission pump; installing...1017
Transmission temperature sensor; replacing...1022
Transmission pressure sensor; replacing...1024
Transmission solenoid; replacing...1026
Transmission oil filter restriction sensor; replacing...1028
44 - HYDROSTATIC DRIVE...1030
Pump drive; tightening torques...1031
46 - FRONT AXLE; REAR AXLE...1032
Axle; tightening torques...1033
Differential lock; description...1035
Tandem drive chain; removing...1039
Tandem drive chain; installing...1042
Tandem drive sprocket; removing...1045
Tandem drive sprocket; installing...1046
Four point bearing; replacing...1048
Tandem; removing...1050
Tandem; installing...1053
Axle; removing...1056
Axle; installing...1059
49 - MISCELLANEOUS...1062
Transmission oil cooler; removing...1063
Transmission oil cooler; installing...1066
5 - BRAKE...1068
50 - GENERAL...1069
Brake system; specifications ...1070
Brake system; tightening torques...1071
52 - HYDRAULIC BRAKE SYSTEM...1072
Brake system; specifications...1073
Brake system hydraulic function; checking...1074
Brake system; bleeding...1077
Hydraulic brake system; description...1079
Brake pedal stop; adjusting...1086
Brake accumulator; specifications...1089
Accumulator; removing...1090
55 - PARKING BRAKE...1094
Parking brake; manually releasing...1095
6 - STEERING...1098
60 - GENERAL...1099
Steering system; specifications...1100
Steering; tightening torques...1101
Steering valve; specifications...1102
Secondary steering pump; specifications...1103
62 - STEERING AXLE...1104
Toe-in; adjusting...1105
64 - STEERING...1107
Secondary steering; description...1108
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...1111
71 - FRAME...1112
Transmission guard; removing...1113
Transmission guard; installing...1115
74 - FRAME LINK...1117
Articulation; tightening torques...1118
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...1119
Wheels; specifications...1120
Wheels; tightening torques...1121
Wheel; removing...1122
Wheel; installing...1124
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...1126
81 - CAB; NAKED; CANOPY...1127
Cab; removing...1128
Cab; installing...1138
Cab; tightening torques...1148
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING...1149
Windows; general...1150
85 - CAB INTERIOR; UPHOLSTERY...1152
Front headliner; removing...1153
Front headliner; installing...1156
Side console covers; replacing...1159
Operator's seat; removing...1163
Operator's seat; installing...1166
Operator seat; tightening torques...1169
87 - AIR CONDITIONING UNIT...1170
Air conditioning; specifications...1171
Air conditioning; tightening torques...1172
Air distribution; specifications...1173
Defroster fan; replacing...1174
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...1177
90 - GENERAL...1178
Hydraulic diagram 2 - Image...1179
Hydraulic diagram 1 - Image...1180
Hydraulic diagram; component locations...1181
Hydraulic diagram 1...1198
Hydraulic diagram 2...1199
Hydraulic pressure; testing...1200
Hydraulic system; tightening torques...1205
Accumulator; discarding...1206
91 - WORKING HYDRAULIC; SERVO HYDRAULICS...1208
Hydraulic oil tank; removing...1209
Hydraulic oil tank; installing...1216
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump...1223
Main implement and steering hydraulic pump; specifications...1225
Steering and implement pump; removing...1227
Steering and implement pump; installing...1230
Steering and implement pump controller; removing...1233
Steering and implement pump controller; installing...1237
Joystick control system; description...1240
Joystick control; component locations...1244
Left side controller; replacing...1248
Joystick control; replacing...1250
Display unit; replacing...1253
Rear option controller; replacing...1255
Front option controller; replacing...1257
Directional control valve solenoid; replacing...1259
Counter balance steering valve; replacing...1262
Power supply unit; replacing...1264
Relay; replacing...1266
Steering valve solenoid; replacing...1268
Articulation sensor; replacing...1270
Articulation sensor; calibrating...1272
Joysticks; calibrating...1280
J-ECU controller; replacing...1285
Rear auxiliary valve solenoid; replacing...1287
Steering pressure sensor; replacing...1289
92 - MECHANICAL EQUIPMENT_ATTACHMENT...1291
Attachment; tightening torques...1292
98 - FUNCTION FOR ROAD CONSTRUCTION...1293
Mouldboard cutting edge; replacing...1294
Circle and drawbar; specifications...1296
Circle and drawbar; tightening torques...1297
Blade lift system lock pin cylinder solenoid valve; specifications...1298
Blade lift system; tighten torques...1299
Accumulator; specifications...1300
Volvo G960C Motor Graders Repair Service Manual
