Volvo G960B Motor Graders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo G960B Motor Graders, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions G960B 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 G960B Motor Graders Repair Service Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,231 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
Product identification plates....4
03 - SPECIFICATIONS....6
Tightening torques....7
Critical mounting torques....18
Tightening torque; specifications_{43-20}....21
Tightening torque; specifications_{42-58}....24
Conversion tables....27
Thread locking compound; application_specifications....35
Coolant; specifications....38
Hydraulic connections; tightening torques....39
07 - STANDARD TIME....46
Operation numbers for additional work....47
08 - TOOL....49
Drawings; E-tools....50
1 - STANDARD PARTS; SERVICE....53
16 - LUBRICANT; FUEL; OTHER FLUID....54
Fuel; lubricant and filling capacities_{35-27}....55
Fuel; lubricant and filling capacities_{35-04}....56
Recommended lubricants_{05-28}....57
Recommended lubricants_{05-27}....62
Alternative fuels....67
17 - SERVICE....70
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....76
Maintenance service; every 250 hours....78
Maintenance service; every 500 hours....79
Maintenance service; every 1000 hours....81
Maintenance service; every 1500 hours....83
Maintenance service; every 2000 hours....84
Maintenance service; every 4500 hours....86
Maintenance service; every 6000 hours....87
Engine belt condition; checking....88
Valves; Adjusting....90
Engine oil level; checking....94
Engine oil and filter; changing....96
Water separator; checking....99
Fuel filter; replacing....100
Water separator filter; replacing....102
Fuel tank breather filter; replacing....104
Spark plugs; replacing....106
Diesel particulate filter; checking and cleaning....108
Engine air cleaner primary filter; cleaning....117
Engine air cleaner primary filter; replacing....120
Engine air cleaner secondary filter; replacing....122
Coolant level; checking....124
Coolant; changing....126
Coolant freezing point; checking....128
Cooling system integrity; checking....129
Coolers; cleaning....130
Transmission oil level; checking....133
Transmission oil; changing....135
Transmission oil filter; replacing....137
Transmission breather filter; replacing....139
Rear axle oil level; checking....140
Tandem oil level; checking....142
Tandem oil; changing....144
Tandem breather; checking....146
Service brake; testing....148
Master cylinder oil level; checking....149
Master cylinder oil; changing....151
Parking brake function; checking....154
Front wheel bearing; repacking....155
Wheel nuts torque; checking....158
Cab prefilter; cleaning....159
Cab prefilter; replacing....162
Hydraulic oil level; checking....165
Hydraulic oil; changing....167
Hydraulic oil return filter; replacing....172
Hydraulic oil tank breather filter; replacing....175
19 - GENERAL....177
CE-marking; EMC-directive....178
Safety concerns everybody!....182
Safety when handling the machine....186
Safety rules when servicing....191
Service position....194
Some simple rules regarding tyre handling....197
Safety when lifting and supporting complete machine....199
Safety when using lifting equipment....202
Safety when working with air conditioning refrigerant....203
Safety when working on hydraulic systems....206
Environmentally safe handling....208
Environmentally hazardous fluids....211
Working in environmentally contaminated areas....212
A few simple safety rules....213
Before operating....217
Before service; read....221
General....225
Cleanliness....230
Electrical system....234
Checklist after a fire or heat exposure....238
Health hazards with paint; plastics and rubber....241
Safety when handling oil and fuel....245
Safety when working with batteries....248
Charging batteries....251
Environment....255
Environmental handling for the future....260
Decontamination....263
Fire prevention measures....267
2 - ENGINE WITH MOUNTING AND EQUIPMENT....270
20 - GENERAL....271
Engine; description....272
VCADS Pro; Operations....276
Component locations....278
E-ECU MID 128 pre-programmed; replacing....280
E-ECU MID 128 non-programmed; replacing....282
21 - ENGINE....284
Engine; specifications....285
Engine rotation speed sensor (crank shaft); replacing....286
Engine rotation speed sensor (camshaft); replacing....288
Engine; removing....290
Engine; installing....301
Engine; tightening torques....309
Cylinder compression; testing....311
Crankcase ventilation; description....314
Crankcase ventilation separator; replacing....315
Valve system; specification....317
Valves; adjusting....318
Flywheel; tightening torques....322
Oil sump; tightening torque....324
Engine mounts; replacing....326
22 - LUBRICATING SYSTEM....334
Lubrication system; description....335
Lubrication system; specifications....339
Lubrication system; tightening torques....341
Lubrication system; component locations....343
Lubrication oil pressure; checking with pressure gauge....345
23 - FUEL SYSTEM....347
Fuel system; description....348
Fuel system; specifications....355
Fuel system; tightening torques....356
Fuel system; bleeding....363
Carbon dioxide in fuel system; checking....365
Fuel system; component location....367
Feed pump pressure; checking....369
Fuel pump; replacing....371
Fuel tank; removing....375
Fuel tank; installing....378
Injectors; replacing....380
High pressure fuel pump; replacing....387
Fuel control valve (FCV); replacing....390
Pressure relief valve (PRV); replacing....395
25 - INLET & EXHAUST SYSTEM....398
Inlet and exhaust system; description....400
Inlet and exhaust system; component location....406
Inlet and exhaust system; tightening torques....408
Exhaust pipe flexible tube; replacing....409
Exhaust Aftertreatment System; description....412
Exhaust Aftertreatment System; component location....423
Regeneration process; description....425
Exhaust aftertreatment system; specifications....428
DPF (Diesel particulate filter); checking and cleaning....430
Exhaust aftertreatment system; tightening torques....439
Spark plug control unit; replacing....441
Glow plug; replacing....443
Glow plug control unit; replacing....445
Fuel metering unit A; replacing....451
Fuel metering unit B; replacing....458
Air pump safety valve; replacing....464
ACM (Aftertreatment control module) non-programmed; replacing....467
ACM (Aftertreatment control module) pre-programmed; replacing....470
Spark plug; inspecting....473
Spark plug; replacing....475
Spark plug cable; replacing....477
Air pump; replacing....480
Throttle; replacing....483
Burner function; checking....485
Burner; replacing....491
NOx sensor; replacing....497
Exhaust aftertreatment system T-junction; replacing....503
DOC (Diesel oxidation catalyst); replacing....505
Turbocharger; description....515
Turbocharger; replacing....517
Turbocharger; tightening torques....521
Wastegate; checking....523
Air cleaner; removing....525
Air cleaner; installing....527
Charge air cooler; inspecting....529
Charge air cooler; removing....531
Charge air cooler; installing....533
26 - COOLING SYSTEM....535
Cooling system; description....536
Cooling system; component location....538
Cooling system pressure; checking....539
Radiator; replacing....541
Expansion tank; replacing....545
Thermostat; specifications....547
Coolant pump; replacing....549
Cooling fan rpm; specifications....553
Cooling fan motor; replacing....554
Fan shroud; replacing....557
Maximum fan speed; checking....560
Low fan speed; checking....562
Fan control valve; removing....564
Fan control valve; seal replacing....565
Fan control valve; installing....567
Fan pump; removing....568
Fan pump; installing....570
Fan pump flow; checking....572
29 - MISCELLANEOUS....574
Exhaust Gas Recirculation (EGR); description....575
Exhaust gas recirculation (EGR); component location....580
EGR system; tightening torques....582
EGR reed valve; replacing....584
EGR cooler; replacing....587
EGR valve; replacing....597
EGR actuator; replacing....599
EGR venturi tube; replacing....603
EGR system function; checking....607
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....610
30 - GENERAL....611
Electrical system; description....620
Electronic control system; description....621
Communication with data buses....623
Software....625
Software versions and ECUs_part number; general....626
Software versions and ECUs_part number; checking....628
System voltage....631
Data links; fault tracing with Oscilloscope....632
Preheating of inlet air_12-06....642
Preheating of inlet air....644
Reduced computer communication....646
Hydraulic Oil Level....647
Description of table for software functions....648
Engine oil pressure....649
Engine Oil Level....650
Fuel Level....652
INFO Water in fuel....653
Engine air filter restriction....654
Temperature induction air....655
Charge-air temperature....656
Charge-air pressure....657
Engine coolant level....658
Engine coolant temperature....659
Cooling fan adjustment....660
Reversible cooling fan....662
Increased fan speed for AC....665
Accelerator Pedal....666
Accelerator setting....667
Engine Protection....669
Interruption in computer communication....672
Temperature; ambient air....673
Back-up alarm....674
Transmission oil pressure....675
Transmission oil temperature....677
Transmission oil filter bypass indicator....678
Inching....679
Shifting out of Neutral....680
Shifting and memory gears....681
Inching pedal and memory gears....683
Manual mode....685
Automatic mode....686
Travel mode....687
Engine Over-speed Protection....688
Directional gear shifting....689
Gearshifting solenoids....690
Transmission Stall Protection....694
Inching pedal....695
Power mode....696
VHP....698
Differential lock....700
Service brake differential pressure....702
Parking brake....703
Secondary steering....705
Hydraulic Unload....707
Hydraulic oil temperature....708
Hydraulic oil filter bypass indicator....709
VCADS Pro; Description....710
VCADS Pro; Simulator mode....712
VCADS Pro; 17012-3 - Error Codes....713
VCADS Pro; 17030-3 - Parameter; programming....716
VCADS Pro; 17034-3 - Vehicle information; test....718
VCADS Pro; 17055-3 - Central systems updating; replace control unit....719
VCADS Pro; 17056-3 - Central systems updating; change software....721
VCADS Pro; 17095-3 Handle component....723
VCADS Pro; 21006-3 - Cylinder compression; test....725
VCADS Pro; 23017-3 - Feed pressure; inspection....726
VCADS Pro; 23712-3 - Injectors shut off; manual....727
27102-3 - Accelerator pedal; test....728
VCADS Pro; 28407-3 - Sensor values; monitoring....729
VCADS Pro; 38335-3 - Displayed machine hours; correction....730
VCADS Pro; 39796-3 - MID 142 Control unit; reset....731
VCADS Pro; 41381-3 - Inching pedal; test....732
VCADS Pro; 46813-3 - Differential lock system; check....733
VCADS Pro; 55102-3 - Parking brake system test....734
VCADS Pro service Tool....735
General fault diagnosis information....739
Troubleshooting strategy....740
Collection of basic data....742
SAE error codes; translation to error messages; general....744
Conditions when checking....747
Lead and connector checks....749
Troubleshooting tools....753
Special tools for troubleshooting....754
VCADS Pro service tool ....755
CU2501; description and measuring....759
CU2503; description and measuring....761
DI3801; description and measuring....763
DI5201; description and measuring....764
DI5202; description and measuring....765
DI6401; description and measuring....766
FX1006; description and measuring....767
FX1007; description and measuring....770
FX1008; description and measuring....773
FX1031; description and measuring....776
HE2501; description and measuring....779
MA2301-MA2306; description and measuring....781
MA2508; description and measuring....783
MA2509; description and measuring....785
MA2510; description and measuring....787
MA2512; description and measuring....789
MA2602; description and measuring....791
MA2603; description and measuring....793
MA4601; description and measuring....795
MA5501; description and measuring....797
MA8501; description and measuring....799
MA8701; description and measuring....800
MA9111; description and measuring....802
MA9201; description and measuring....804
MA9202; description and measuring....806
MA9203; description and measuring....808
MA9204; description and measuring....810
MA9205; description and measuring....812
MA9206; description and measuring....814
MA9207; description and measuring....816
MA9208; description and measuring....818
MA9209; description and measuring....820
MA9210; description and measuring....822
MA9220; description and measuring....824
MA9221; description and measuring....826
MA9222; description and measuring....828
MA9223; description and measuring....830
MA9224; description and measuring....832
MA9225; description and measuring....834
MA9226; description and measuring....836
MA9227; description and measuring....838
MA9228; description and measuring....840
MA9229; description and measuring....842
MA9301; description and measuring....844
MA9302; description and measuring....846
MA9321; description and measuring....848
MA9801; description and measuring....850
MO2502; description and measuring....852
MO2503; description and measuring....854
MO3301; description and measuring....856
MO5201; description and measuring....858
Power supply E-ECU; description and measuring....859
PWM2303; description and measuring....860
PWM2601; description and measuring....862
PWM4205 - PWM4212; description and measuring....864
PWM9101; description and measuring....866
PWM9102; description and measuring....868
PWM9103; description and measuring....870
PWM9104; description and measuring....872
PWM9105; description and measuring....874
PWM9121; description and measuring....876
PWM9122; description and measuring....878
PWM9123; description and measuring....880
PWM9124; description and measuring....882
PWM9125; description and measuring....884
RE2501; description and measuring....886
RE3301; description and measuring....888
RE3302; description and measuring....890
RE3502; description and measuring....892
RE3503; description and measuring....894
RE3505; description and measuring_56-44....896
RE3505; description and measuring....898
RE3501; description and measuring_53-30....900
RE3501; description and measuring....902
RE3506; description and measuring_51-04....904
RE3506; description and measuring....906
RE3507; description and measuring_48-10....908
RE3507; description and measuring....910
RE3510; description and measuring....912
RE3512; description and measuring....914
RE3602; description and measuring....916
RE3701; description and measuring....918
RE3702; description and measuring....920
RE3703; description and measuring....922
RE3705; description and measuring....924
RE4201; description and measuring....926
RE5201; description and measuring....928
RE5501; description and measuring....930
RE5502; description and measuring....932
RE6401; description and measuring....934
RE8501; description and measuring....936
RE8701; description and measuring....938
RE8704; description and measuring....940
RE9101; description and measuring....942
RE9111; description and measuring....944
SAE J1708_1587 Information link; description and measuring....946
SAE J1939_CAN1 Control link; description and measuring....948
SAEJ1939_CAN7 Control link; description and measuring....950
SE2203; description and measuring....952
SE2301; description and measuring....955
SE2302; description and measuring....957
SE2303; description and measuring....962
SE2309; description and measuring....964
SE2507; description and measuring....966
SE2512; description and measuring....968
SE2515; description and measuring....970
SE2516; description and measuring....972
SE2518; description and measuring....974
SE2519; description and measuring....979
SE2520; description and measuring....981
SE2521; description and measuring....983
SE2522; description and measuring....985
SE2523; description and measuring....987
SE2524; description and measuring....989
SE2525; description and measuring....991
SE2526; description and measuring....993
SE2603; description and measuring....995
SE2606; description and measuring....997
SE2701; description and measuring....999
SE2702; description and measuring....1001
SE2703; description and measuring....1003
SE2704; description and measuring....1005
SE3802; description and measuring....1007
SE4101; description and measuring....1009
SE4102; description and measuring....1011
SE4201; description and measuring....1013
SE4202; description and measuring....1015
SE4214; description and measuring....1017
SE4215; description and measuring....1019
SE4216; description and measuring....1021
SE4217; description and measuring....1023
SE4307; description and measuring....1025
SE4308; description and measuring....1027
SE4601; description and measuring....1029
SE5201; description and measuring_{07-48}....1031
SE5201; description and measuring_{06-51}....1033
SE5205; description and measuring....1035
SE5206; description and measuring....1037
SE5215; description and measuring....1039
SE5501; description and measuring....1041
SE6401; description and measuring....1043
SE6402; description and measuring....1045
SE8701; description and measuring....1047
SE9104; description and measuring....1049
SE9105; description and measuring....1051
SE9107; description and measuring....1053
SE9801; description and measuring....1055
SW3301; description and measuring....1056
Multimeter 8889 0074....1058
Adapter cable 981 3194....1059
Test pins 999 0008....1060
Adapter cable 999 0014....1061
Adapter cable 999 0020....1062
Extension cable 999 0062....1063
Adapter cable 999 3893....1064
Template 999 3894....1065
Adapter cable 999 8533....1066
Adapter cable 999 8534....1067
Multi-pin breaker box 999 8699....1068
Template 8889 0019....1069
Harness 8889 0016....1070
Adapter cable 999 0216....1071
Component fault diagnosis; description....1072
Test methods; description....1075
VCADS Pro service tool....1078
31 - BATTERY....1082
Battery storage....1083
Battery description....1084
Battery specification....1085
Battery charging capacity; checking....1086
Battery; charging....1088
Batteries; replacing....1090
Battery box; removing....1092
Battery box; installing....1093
32 - ALTERNATOR; CHARGE REGULATOR....1094
Alternator; specifications....1095
Alternator; description....1096
Alternator connections and expected readings....1097
33 - STARTING SYSTEM....1098
Starting system; general description....1099
Starter motor; tightening torques....1100
Electric air pre-heater; description....1103
Start switch; description....1104
Ignition switch; replacing....1106
35 - LIGHTING....1108
Lighting; specifications....1109
Headlights; adjusting....1110
36 - OTHER ELECTRICAL EQUIPMENT....1112
Direction indicator; turn signal description....1113
Direction indicator switch; replacing....1114
Horn; description....1116
Reverse alarm; replacing....1117
Wiper; specifications....1118
Front upper window wiper; description....1120
Rear window wiper; description....1121
Lower front window wiper; description....1122
Lower window wiper; replacing....1123
Connectors; overview....1125
Connectors; configuration_{21-24}....1139
Connectors; configuration_{20-58}....1142
Connectors; position....1146
Instrument control unit I-ECU; description....1156
Vehicle control unit V-ECU; description....1158
Engine control unit E-ECU; description....1160
I-ECU MID 140 non-programmed; replacing....1162
I-ECU MID 140 pre-programmed; replacing....1164
V-ECU MID 187 pre-programmed; replacing....1166
V-ECU MID 187 non-programmed; replacing....1168
37 - CABLE; FUSE; RELAY....1170
Electrical symbols and designations....1174
Explanation of wiring diagrams....1178
Component list; Diodes....1182
Component list; fuses....1183
Component list; instruments....1186
Component list; lamps....1188
Component list; lights....1190
Component list; Miscellaneous....1193
Component list; PWM valves....1196
Component list; relays....1200
Component list; resistors....1202
Component list; sensors....1203
Component list; Solenoid valves....1206
Component list; Sounders....1209
Component list; Switches....1210
Wiring diagram 1_{52-53}....1213
Wiring diagram 1_{52-27}....1215
Wiring diagram 2_{51-49}....1217
Wiring diagram 2_{51-24}....1219
Wiring diagram 3_{50-42}....1221
Wiring diagram 3_{50-16}....1223
Wiring diagram 4_{49-39}....1225
Wiring diagram 4_{49-13}....1227
Wiring diagram 5_{48-36}....1229
Wiring diagram 5_{48-11}....1231
Wiring diagram 6_{47-22}....1233
Wiring diagram 6_{46-56}....1235
Wiring diagram 7_{46-20}....1237
Wiring diagram 7_{45-54}....1239
Wiring diagram 8_{45-18}....1241
Wiring diagram 8_{44-53}....1243
Wiring diagram 9_{44-10}....1245
Wiring diagram 9_{43-45}....1247
Wiring diagram 10_{43-07}....1249
Wiring diagram 10_{42-42}....1251
Wiring diagram 11_{42-05}....1253
Wiring diagram 11_{41-40}....1255
Wiring diagram 12_{41-02}....1257
Wiring diagram 12_{40-37}....1259
Wiring diagram 13_{40-00}....1261
Wiring diagram 13_{39-34}....1263
Wiring diagram 14_{38-58}....1265
Wiring diagram 14_{38-33}....1267
Wiring diagram 15_{37-56}....1269
Wiring diagram 15_{37-30}....1271
Wiring diagram 16_{36-53}....1273
Wiring diagram 16_{36-28}....1275
Wiring diagram 17_{35-51}....1277
Wiring diagram 17_{35-26}....1279
Wiring diagram 18_{34-48}....1281
Wiring diagram 18_{34-23}....1283
Wiring diagram 19_{33-47}....1285
Wiring diagram 19_{33-21}....1287
Wiring diagram 20_{32-32}....1289
Wiring diagram 20_{32-07}....1291
Wiring diagram 21_{31-30}....1293
Wiring diagram 21_{31-05}....1295
Wiring diagram 22_{30-28}....1297
Wiring diagram 22_{30-03}....1299
Wiring diagram 23_{29-20}....1301
Wiring diagram 23_{28-55}....1303
Wiring diagram 24_{28-17}....1305
Wiring diagram 24_{27-53}....1307
Wiring diagram 25_{27-16}....1309
Wiring diagram 25_{26-51}....1311
Wiring diagram 26_{26-13}....1313
Wiring diagram 26_{25-49}....1315
Wiring diagram 27_{25-11}....1317
Wiring diagram 27_{24-46}....1319
Wiring diagram 28_{24-09}....1321
Wiring diagram 28_{23-44}....1323
Wiring diagram 29_{23-01}....1325
Wiring diagram 29_{22-36}....1327
Wiring diagram 30_{21-59}....1329
Wiring diagram 30_{21-34}....1331
Wiring diagram 31_{20-51}....1333
Wiring diagram 31_{20-26}....1335
Wiring diagram 32_{19-49}....1337
Wiring diagram 32_{19-24}....1340
Wiring diagram 33_{18-47}....1342
Wiring diagram 33_{18-22}....1344
Wiring diagram 34_{17-39}....1346
Wiring diagram 34_{17-14}....1348
Wiring diagram 35_{16-37}....1351
Wiring diagram 35_{16-12}....1353
Wiring diagram 36_{15-36}....1356
Wiring diagram 36_{15-11}....1358
Wiring diagram 37_{14-22}....1360
Wiring diagram 37_{13-57}....1362
Wiring diagram 38....1365
Battery disconnect switch....1367
Battery main switch; checking....1368
Grounding points; frame connections....1370
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....1372
Revolution sensor (hydraulic cooling fan); replacing....1373
Transmission; revolution sensor; replacing....1374
Fuel level sender; replacing....1377
39 - MISCELLANEOUS....1379
CareTrack system; description....1380
CareTrack W-ECU; description....1381
Radio; removing....1383
Radio; installing....1384
4 - POWER TRANSMISSION....1385
41 - CLUTCH; TORQUE CONVERTER....1386
Inching pedal; replacing....1387
42 - TRANSMISSION; HYDRAULIC CONTROL....1389
Transmission; specifications_{04-21}....1390
Transmission; specifications_{03-59}....1391
Hydraulic transmission; volume....1392
Transmission; tightening torques....1393
Type HTE840 transmission; description and operation....1394
Type HTE1160 transmission; description and operation....1396
Transmission control HTE840_HTE1160; description and operation....1398
Transmission hydraulic system; description and operation....1401
Transmission; component locations....1402
Transmission oil pressure; checking....1406
Transmission; removing....1409
Transmission; installing....1414
Transmission pump; removing....1418
Transmission pump; installing....1422
Transmission temperature sensor; replacing....1424
Transmission pressure sensor; replacing....1426
Transmission solenoid; replacing....1429
Transmission oil filter restriction sensor; replacing....1431
Gear selector; replacing....1432
Transmission mounting; description and operation....1434
44 - HYDROSTATIC DRIVE....1435
Charge pump; replacing....1436
Pump drive; tighten torques....1441
Pump drive; description and operation....1442
Pump drive; removing....1449
Pump drive; installing....1451
45 - PROPELLER SHAFT....1453
Driveshaft - upper; description and operation....1454
Driveshaft - lower and midship; description and operation....1456
Drive shaft; removing_49-06....1458
Drive shaft; installing_48-35....1460
Intermediate bearing; replacing....1461
Universal joint; replacing....1467
Drive shaft; removing....1470
Drive shaft; installing....1474
46 - FRONT AXLE; REAR AXLE....1479
Axle; tightening torques....1480
Front axle; specification....1482
Tandem drive chain; removing_{43-00}....1483
Tandem drive chain; removing_{42-35}....1487
Tandem drive chain; installing_{41-47}....1490
Tandem drive chain; installing_{41-22}....1492
Tandem drive sprocket; removing....1494
Tandem drive sprocket; installing....1496
Final drive axle (APR70 and APR90); description and operation....1498
Final drive; specifications....1499
Final drive; volume....1500
Final drive; tightening torques....1501
Four point bearing; replacing....1502
Tandem; removing....1506
Tandem; installing....1510
Axle; removing....1513
Axle; installing....1515
Differential lock and control; description and operation....1517
Sensor unit (differential lock); replacing....1519
49 - MISCELLANEOUS....1521
Transmission oil cooler; description and operation....1522
Transmission oil cooler; removing....1524
Transmission oil cooler; installing....1526
5 - BRAKE....1528
50 - GENERAL....1529
Brake system; overview....1530
51 - WHEEL BRAKE....1533
Service brakes; specifications....1534
Service brakes; tightening torques....1535
Service brakes function; checking....1536
Wheel brake; description....1537
Brake circuit hydraulic schematic....1541
Service brakes warning system; checking....1543
Oil disc brake assembly; removing....1545
Oil disc brakes; disassembling....1548
Oil Disc Brake - Cleaning and Inspection....1554
Brake housing; pre-assembling....1556
Tandem axle oil seal installation....1558
Tandem axle seal; installing....1561
Oil disc brakes ; assembling....1568
Oil Disc Brakes - Bench Adjustment....1572
Oil disc brake; installing....1574
52 - HYDRAULIC BRAKE SYSTEM....1577
Hydraulic brake system; specifications....1578
Hydraulic brake system; tightening torques....1579
Brake system; specifications....1580
Brake system hydraulic function; checking....1581
Brake master cylinder and power booster; description....1584
Brake circuit; operation....1594
Brake pedal switch; replacing....1595
Brake system; bleeding_{26-53}....1597
Brake system; bleeding_{26-29}....1599
Hydraulic brake system; description....1601
Brake pedal stop; adjusting....1605
Brake master cylinder; removing....1608
Power booster; disassembling....1609
Power booster; assembling....1611
Master cylinder oil; changing....1613
Brake master cylinder; disassembling....1616
Brake master cylinder; assembling....1620
Brake master cylinder; installing....1623
Adjustment checks....1625
Foot brake valve; removing....1627
Foot brake valve; installing....1632
Brake pedal angle; adjusting....1636
Foot brake valve; description....1638
Brake accumulator; specifications....1641
Accumulator (removed) charging pressure; checking....1642
Accumulator; removing....1644
Accumulator; installing....1648
Brake accumulator; description....1651
55 - PARKING BRAKE....1653
Parking brake assembly; removing....1654
Parking brake assembly; installing....1657
Parking brake; description and operation....1660
Parking brake function; checking....1661
Parking brake; manually releasing....1662
6 - STEERING....1665
60 - GENERAL....1666
Steering system; specifications....1667
Steering system; description....1668
Steering system function; checking....1669
62 - STEERING AXLE....1670
Steering axle; description and operation....1671
Front wheel bearing preload; adjusting....1673
Front axle frame; removing....1675
Front axle frame; installing....1677
Drag link; removing....1679
Drag link; installing....1680
Tie bar; removing....1681
Tie bar; installing....1683
Toe-in; adjusting....1685
64 - STEERING....1687
Steering wheel; tightening torques....1688
Pedestal gas shock; replacing....1689
Steering column; removing....1691
Steering column; installing....1695
Steering control unit; removing....1698
Steering control unit; installing....1701
Steering cylinders; specifications....1703
Steering cylinders; tightening torques....1704
Steering cylinder; description....1705
Steering hydraulic circuit; specifications....1706
Steering hydraulic circuit; description....1707
Steering hydraulic schematics....1708
Steering system working pressure; checking and adjusting....1712
Main implement and steering hydraulic pump; description and operation....1713
Pressure and flow compensator; description....1715
Electric unload of main implement and steering pump....1716
Steering and implement pump controller; removing....1718
Steering and implement pump controller; installing....1721
Steering control unit; description and operation....1724
Secondary steering pump; specifications....1728
Secondary steering; description and general information....1729
Secondary steering function; checking....1731
Secondary steering relief valve; adjusting....1732
Secondary steering motor; specifications....1735
Wheel lean system; description and operation....1736
Wheel lean cylinders; specification....1738
Wheel lean cylinders; tightening torques....1739
Wheel lean hydraulic cylinder; description....1740
Wheel lean cylinder; removing....1741
Wheel lean cylinder; installing....1742
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....1743
71 - FRAME....1744
Frame; tightening torque....1745
Frame; description....1746
Transmission guard; removing....1748
Transmission guard; installing....1750
Neck and nose cover; removing....1752
Neck and nose cover; installing....1753
74 - FRAME LINK....1754
Frame joint; separating machine....1755
Articulation hydraulics; description....1760
Frame link_articulation; specifications....1762
Articulation cylinders; specifications....1763
Articulation cylinders; tightening torque....1764
Articulation cylinder; removing....1765
Articulation cylinder; installing....1768
Articulation indicator cable; removing....1770
Articulation indicator cable; installing....1774
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....1777
Wheels; specifications....1778
Wheels; tightening torques....1779
Wheels; general description....1780
Wheel; removing and fitting one....1782
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....1785
80 - GENERAL....1786
Cab description....1787
81 - CAB; NAKED; CANOPY....1789
Cab; specifications....1790
Cab mounts; tightening torques....1791
Cab; removing....1792
Cab; installing....1797
82 - ENGINE HOOD; MUDGUARD; FOOT STEP....1802
Engine hood; removing....1803
Engine hood; installing....1810
Cab ladder; replacing....1816
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....1818
Reflectors and Decals....1819
Windows; general....1820
85 - CAB INTERIOR; UPHOLSTERY....1822
Rear headliner; removing....1823
Rear headliner; installing....1824
Front headliner; removing....1825
Front headliner; installing....1826
Cab interior covers; replacing....1827
Side console covers; replacing....1830
Operator's seat; removing....1833
Operator's seat; installing....1834
Operator seat; tightening torques....1835
87 - AIR CONDITIONING UNIT....1836
Air conditioning; specifications....1837
Air conditioning; tightening torques....1838
Air distribution; specifications....1839
Cooler and Heater assembly; removing....1840
Cooler and Heater assembly; installing....1845
Air distribution; description....1850
Defroster fan; replacing....1852
Fan motor; replacing....1854
Heater core; replacing....1856
Air mix door actuator; replacing....1858
Stepless motor drive; replacing....1860
Heater unit relays; replacing....1862
Heat control valve; replacing....1864
HVAC system....1866
HVAC system components....1868
Air conditioning unit; operation....1871
Troubleshooting; air conditioning unit (AC)....1874
Thermostat; replacing....1876
Evaporator; replacing incl draining and filling....1878
Receiver; replacing incl draining and filling....1881
HVAC control switch; replacing....1883
88 - INTERIOR EQUIPMENT....1884
Pedestal controls; tilt function....1885
Lap Seat Belts....1887
Seat safety belt; replacing....1888
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....1889
90 - GENERAL....1890
Hydraulic diagram 1 - Image....1891
Hydraulic diagram 2 - Image....1893
Hydraulic oil cooling system hydraulic schematics - Image....1896
Joystick control; hydraulic diagram1 - Image....1902
Hydraulic diagram 1_{31-52}....1903
Hydraulic diagram 1_{31-27}....1907
Hydraulic diagram 2_{30-51}....1911
Hydraulic diagram 2_{30-26}....1913
Hydraulic diagram 2_{30-02}....1915
Hydraulic oil cooling system hydraulic schematics....1917
Joystick control; hydraulic diagram1....1927
Hydraulic system; description....1931
Oil and filtration....1932
Hydraulic oil; description....1934
Hydraulic oil; storing and handling....1935
Hydraulic components; storing and transporting....1936
Accumulator; discarding....1937
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....1939
Hydraulic return line filter; specification....1942
Hydraulic couplings; description....1943
Hydraulic oil tank; cleaning....1944
Hydraulic oil tank - description and operation....1947
Hydraulic oil tank; removing....1950
Hydraulic oil tank; installing....1956
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump....1961
Hydraulic oil cooling system....1963
Fan motor; specifications....1969
Fan pump specification....1970
Fan pump flow; checking....1972
Unloading valve; description and operation....1974
Return line filter - description and operation....1977
Hydraulic oil cooler; removing....1978
Hydraulic oil cooler; installing....1981
Blade lift system lock pin cylinder solenoid valve; tightening torques_18-06....1983
Blade lift system lock pin cylinder solenoid valve; tightening torques....1984
Load sense shuttle valve; description and operation....1985
Load sense shuttle valve; tightening torques....1986
Auxiliary load sense shuttle valve; tightening torques....1987
Auxiliary load sense shuttle valve....1988
Load sense relief valve; specifications....1989
Load sense relief valve; description and operation....1990
Hydraulic cylinder; description....1992
Directional control valve - 10 bank; description and operation....1993
Blade lift section assembly - with float; specifications....1995
Blade lift section assembly - without float; specifications....1997
Directional control valve; removing....1999
Directional control valve; installing....2004
Priority flow valve; specifications....2008
Priority flow valve - description and operation....2010
Priority flow valve; removing....2014
Priority flow valve; disassembling and inspection....2016
Priority flow valve; installing....2018
Accumulator precharge pressure; checking ....2020
Hydraulic swivel joint; removing....2022
Hydraulic swivel joint; installing....2026
Circle turn valve; tightening torques....2030
Circle turn valve; removing....2031
Circle turn valve; installing....2034
Main implement and steering hydraulic pump; specifications....2036
Main implement and steering hydraulic pump; description and operation....2038
Pressure and flow compensator; description....2040
Electric unload of main implement and steering pump....2041
Fan pump; removing....2043
Fan pump; installing....2045
Steering and implement pump; removing....2047
Steering and implement pump; installing....2050
Control lever; adjusting....2053
Control levers; replacing....2055
Auxiliary hydraulic system control; description....2057
Joystick control system; description....2060
Joystick control; component locations....2065
Joystick control; wiring diagram 1....2070
Joystick control; wiring diagram 2....2071
Joystick control; wiring diagram 3....2073
Joystick control; wiring diagram 4....2074
Joystick control; wiring diagram 5....2075
Joystick control; wiring diagram 6....2076
Joystick control; wiring diagram 7....2077
Left side controller; replacing....2078
Joystick control; replacing....2081
Display unit; replacing....2084
Rear option controller; replacing....2086
Directional control valve solenoid; replacing....2088
Counter balance steering valve; replacing....2091
Power supply unit; replacing....2093
Relay; replacing....2096
Steering valve solenoid; replacing....2098
Articulation sensor; replacing....2101
Articulation sensor; calibrating....2104
J-ECU controller; replacing....2113
Rear auxiliary valve solenoid; replacing....2115
Steering pressure sensor; replacing....2118
92 - MECHANICAL EQUIPMENT_ATTACHMENT....2120
Push block; specifications....2121
Utility dozer blade; specifications....2122
Front mounted scarifier; specifications....2123
Scarifier cylinder; specifications....2124
Scarifier cylinder; tightening torque....2125
Ripper; specifications....2126
Ripper cylinders; specifications....2127
Ripper cylinders; tightening torque....2128
Support arch; removing....2129
Support arch; installing....2131
Parallel lift cylinder; specifications....2133
Parallel lift cylinder; tightening torque....2134
98 - FUNCTION FOR ROAD CONSTRUCTION....2135
Circle Setup and Timing....2137
Circle operation....2141
Mouldboard lower slide tube bearing; replacing....2144
Mouldboard upper slide wear plate; replacing....2147
Mouldboard cutting edge; replacing....2150
Blade lift system; description....2152
Blade lift; description and operation....2155
Blade lift cylinders; specifications....2157
Blade lift cylinders; tightening torques....2158
Blade lift cylinder; removing....2159
Blade lift cylinder; installing....2162
Blade lift stirrup; removing....2165
Blade lift stirrup; installing....2167
Blade slide cylinders; specifications....2169
Blade slide cylinders; tightening torques....2170
Blade slide cylinder; replacing....2171
Circle side shift cylinders; specifications....2175
Circle crank arm; removing....2176
Circle crank arm; installing....2179
Circle and drawbar; overview....2182
Circle and drawbar; description and operation....2183
Circle and drawbar; specifications....2186
Circle and drawbar; tightening torques....2187
Circle and drawbar; removing....2188
Circle and drawbar; installing....2192
Mouldboard; shimming....2197
Circle turn cylinders; specifications....2199
Circle turn cylinders; tightening torques....2200
Circle side shift cylinders; tightening torques....2201
Blade lift arm; removing....2202
Blade lift arm; installing....2204
Blade lift system lock pin cylinder solenoid valve; specifications....2205
Blade lift system; tighten torques....2206
Blade lift system lock cylinder; removing....2207
Blade lift system lock cylinder; installing....2209
Power tilt cylinders; specifications (Models G940B - G960B)....2210
Power tilt cylinders; tightening torques (Models G940B - G960B)....2211
Accumulator; description....2212
Accumulator; specifications....2214
Accumulator precharge adjustment chart....2215
Accumulator; replacing....2216
Accumulator -Charging....2222
Accumulator precharge pressure; checking....2224
Circle; checking....2227
Volvo G960B Motor Graders Repair Service Manual
