Volvo G960 Motor Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo G960 Motor, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions G960 Motor 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 G960 Motor Graders Repair Service Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,342 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_{29-58}...39
Transporting the machine_{29-10}...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_{14-22}...62
Recommended lubricants_{13-59}...64
Alternative fuels...66
17 - SERVICE...69
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_{07-38}...89
Engine belt tension; checking_{07-07}...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
19 - GENERAL...162
CE-marking; EMC-directive...163
Safety concerns everybody!...167
Checking function...168
Safety rules when servicing...169
Safety when handling the machine...172
Service position...177
Some simple rules regarding tyre handling...179
Safety when lifting and supporting complete machine...181
Safety when using lifting equipment...184
Safety when handling oil and fuel...185
Safety when working with batteries...186
Starting with booster batteries_37-59...188
Check list after fire or heat exposure...190
Safety when working with air conditioning refrigerant...192
Safety when working on hydraulic systems...195
Environmental handling for the future...197
Waste handling...198
Environmentally safe handling...199
Environmentally hazardous fluids...202
Working in environmentally contaminated areas...203
Health hazards with paint; plastics and rubber...204
Decontamination...207
Fire prevention measures...209
Electric welding...212
Precaution when working on the electrical system...213
2 - ENGINE WITH MOUNTING AND EQUIPMENT...214
20 - GENERAL...215
Engine; description...216
VCADS Pro; MID 128; programming E-ECU ...218
V-ECU; replacing_27-46...219
21 - ENGINE...221
Engine; specifications...222
Engine; volume...223
Engine; removing...224
Engine; installing...232
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope...239
Engine; tighten torques...245
Cylinder head; description...246
Cylinder head gasket; description...248
Valve cover; description and operation...249
Crankcase ventilation; changing...251
D7 cylinder block with crankcase ventilation; description and operation...253
Pistons; description...254
Cylinder liner; description...256
Cylinder liner; checking and measuring wear...258
Valve system specifications...260
Valves; adjusting...261
Valves; description...273
Internal Exhaust Gas Recirculation (IEGR); description...274
Valve cover; fitting new gasket each...279
Engine timing gear; description...281
Camshaft; description...282
Crankshaft; description...283
Connecting rod; description...285
Vibration damper; description...287
Oil sump; description...288
Engine mounting; description...289
Engine mounting rear; changing...291
Engine mount front; replacing...294
22 - LUBRICATING SYSTEM...298
Lubricating system; description...299
Lubrication system D7; specifications...302
Oil pump; description...303
23 - FUEL SYSTEM...305
Fuel system; description...306
Fuel system; tightening torques...308
Fuel feed pump; description...309
Feed pump; replacing...310
Fuel system; bleeding...313
Fuel tank; volume...315
Fuel tank; removing...316
Fuel tank; installing...319
Ventilation filter; replacing...321
Injectors; description...323
Injectors; replacing...326
High pressure fuel pump; checking...329
Fuel control valve (FCV); checking...333
Fuel control valve (FCV); replacing...336
Pressure relief valve (PRV); inspecting...339
Pressure relief valve (PRV); replacing...342
Delivery pipe; replacing one...345
Fuel rail pressure sensor; replacing...347
25 - INLET & EXHAUST SYSTEM...349
Inlet system; description...350
Exhaust system; description...351
Silencer; removing...352
Silencer; installing...358
Turbocharger; description...364
Turbocharger; removing...365
Turbocharger; installing...366
Turbocharger; inspecting...367
Air cleaner; removing...369
Air cleaner; installing...370
Air cleaner; preheater; specifications...372
Intercooler specifications...373
Charge air cooler; replacing...374
26 - COOLING SYSTEM...376
Cooling system D7; specification...377
Cooling system; volume...378
Cooling system; description...379
Cooling system; flushing...381
Radiator; replacing...384
Coolant pump; replacing...386
Fan belt and_or alternator belt; replacing...389
Cooling fan motor; replacing...391
Fan shroud; replacing...395
Maximum fan speed; checking ...398
Low fan speed; checking ...402
Fan control valve; removing ...404
Fan control valve; seal replacing ...405
Fan control valve; installing ...407
Fan pump flow; checking ...408
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...410
30 - GENERAL...411
Electrical system; description...420
Electronic control system; description...421
Communication with data buses_{27-19}...423
Communication with data buses_{26-54}...425
Software...427
Software versions and ECUs_part number; general...428
Software versions and ECUs_part number; checking...430
Software versions and ECUs_part number; list...433
V2006.2.0; change specification...435
V2006.3.0; change specification...436
V2006.4.0; change specification...437
V2006.5.0; change specification...438
V2006.6.0; change specification...439
V2006.6.1; change specification...441
V2007.1.0; change specification...442
V2007.2.0; change specification...443
V2007.3.0; change specification...444
V2007.4.0; change specification...445
V2007.5.0; change specification...446
V2007.6.0; change specification...449
V2008.1.0; change specification...450
V2008.1.1; change specification...451
V2008.3.0; change specification...452
System voltage...454
Data links; fault tracing with Oscilloscope...455
Electrical system; specifications...465
Preheating of inlet air...466
Reduced computer communication...468
Hydraulic Oil Level...469
Description of table for software functions...470
Engine oil pressure...471
Engine Oil Level...472
Fuel Level_{13-41}...474
Fuel Level_{13-18}...476
INFO Water in fuel...478
Engine air filter restriction...479
Temperature induction air...480
Charge-air temperature...481
Charge-air pressure...482
Engine coolant level...483
Engine coolant temperature...484
Cooling fan adjustment...486
Reversible cooling fan...489
Increased fan speed for AC...492
Accelerator Pedal_{08-51}...493
Accelerator Pedal_{08-29}...495
Accelerator setting_{07-55}...497
Accelerator setting_{07-32}...499
Engine speed for V-ECU...501
Engine Protection_{06-37}...503
Engine Protection_{06-14}...505
Interruption in computer communication...507
Temperature; ambient air...508
Back-up alarm...509
Transmission oil pressure...510
Transmission oil temperature_{03-50}...512
Transmission oil temperature_{03-28}...514
Transmission oil filter bypass indicator...516
Inching_{02-31}...517
Inching_{02-08}...518
Shifting out of Neutral...519
Shifting and memory gears_{01-11}...520
Shifting and memory gears_{00-49}...522
Inching pedal and memory gears_{00-14}...524
Inching pedal and memory gears_{59-51}...526
Manual mode_{59-17}...528
Manual mode_{58-54}...530
Automatic mode_{58-14}...532
Automatic mode_{57-51}...534
Travel mode_{57-17}...535
Travel mode_{56-55}...537
Engine Over-speed Protection...539
Directional gear shifting...540
Gearshifting solenoids...541
Transmission Stall Protection...545
Inching pedal_{54-49}...546
Inching pedal_{54-26}...548
Power mode...550
VHP...552
Differential lock...554
Service brake differential pressure...556
Parking brake_{52-07}...557
Parking brake_{50-59}...559
Secondary steering...561
Hydraulic Unload...564
Hydraulic oil temperature...566
Hydraulic oil filter bypass indicator...568
VCADS Pro; Description...569
VCADS Pro; Simulator mode...571
VCADS Pro; MID187; programming V-ECU...572
VCADS Pro; MID 142; programming W-ECU...574
VCADS Pro; MID 140; programming I-ECU...576
VCADS Pro; MID 128; programming E-ECU...578
VCADS Pro; 17012-3 - Error Codes...580
VCADS Pro; 17030-3 - Parameter; programming...582
VCADS Pro; 17055-3 - Central systems updating; replace control unit...584
VCADS Pro; 17095-3 Handle component...586
VCADS Pro; 17065-3 - Central systems updating; change software...588
VCADS Pro; 21006-3 - Cylinder compression; test...590
VCADS Pro; 23017-3 - Feed pressure; inspection...591
VCADS Pro; 23712-3 - Injectors shut off; manual...592
27102-3 - Accelerator pedal; test...593
VCADS Pro; 28407-3 - Sensor values; monitoring...594
VCADS Pro; 38335-3 - Displayed machine hours; correction...595
VCADS Pro; 39796-3 - MID 142 Control unit; reset...596
VCADS Pro; 41381-3 - Inching pedal; test...597
Transmission; calibrating...598
VCADS Pro; 46813-3 - Differential lock system; check...600
VCADS Pro; 55102-3 - Parking brake system test...601
General fault diagnosis information...602
Troubleshooting strategy...604
Collection of basic data...606
SAE error codes; translation to error messages; general...608
SAE J1708 (Information bus)...610
SAE J1939_ CAN-bus (control bus)...613
Conditions when checking...616
Lead and connector checks...618
Troubleshooting tools...623
Special tools for troubleshooting...624
MA2603; description and measuring...625
MA9201; description and measuring...627
MA9202; description and measuring...629
MA9203; description and measuring...631
MA9204; description and measuring...633
MA9205; description and measuring...635
MA9206; description and measuring...637
MA9207; description and measuring...639
MA9208; description and measuring...641
MA9209; description and measuring...643
MA9210; description and measuring...645
MA9220; description and measuring...647
MA9221; description and measuring...649
MA9222; description and measuring...651
MA9223; description and measuring...653
MA9224; description and measuring...655
MA9225; description and measuring...657
MA9226; description and measuring...659
MA9227; description and measuring...661
MA9228; description and measuring...663
MA9229; description and measuring...665
MA9301; description and measuring...667
MA9302; description and measuring...669
MA9321; description and measuring...671
MO5201; description and measuring...673
PWM2601; description and measuring...674
PWM9101; description and measuring...676
PWM9102; description and measuring...678
PWM9103; description and measuring...680
PWM9104; description and measuring...682
PWM9105; description and measuring...684
PWM9121; description and measuring...686
PWM9122; description and measuring...688
PWM9123; description and measuring...690
PWM9124; description and measuring...692
PWM9125; description and measuring...694
RE6401; description and measuring...696
SE5201; description and measuring...698
SE5205; description and measuring...700
SE5206; description and measuring...702
Multimeter 8889 0074...704
Adapter cable 981 3194...705
Test pins 999 0008...706
Adapter cable 999 0014...707
Adapter cable 999 0020...708
Extension cable 999 0062...710
Adapter cable 999 3893...711
Template 999 3894...712
Adapter cable 999 8533...713
Multi-pin breaker box 999 8699...714
Component fault diagnosis; description...715
Test methods; description...718
SAE error codes MID 128 Engine control unit (E-ECU)...721
SAE error codes MID 187 Vehicle control unit (V-ECU)...723
SAE error codes MID 140 Instrument control unit (I-ECU)...726
MID 128 PID 84 Machine travel speed; error codes...727
MID 128 PID 91 Accelerator pedal position...729
MID 128 PID 108 Barometric pressure...730
MID 128 PID 158 Battery voltage; error codes...731
MID 128 PID 251 Clock...733
MID 128 PID 252 Date...734
MID 128 PPID 55 ECU temperature...735
MID 128 PSID 096 Common rail pressure...736
MID 128 PSID 097 Common rail valve (PRV)...738
MID 128 PPID 435 Engine torque...740
MID 128 SID 39 Engine starter motor relay...741
MID 128 SID 70 Air inlet heater driver #1...743
MID 128 SID 211 5 V feed to engine sensors 2; error codes...745
MID 128 SID 232 5 V supply...747
MID 128 SID 240 Program memory...749
MID 128 SID 253 Data set memory (EEPROM); error codes...750
MID 128 SID 254 Engine control unit; error codes...751
MID 128 PID 175 Engine oil temperature...752
MID 128 PID 100 Engine oil pressure...754
MID 128 PID 98 Engine oil level...757
MID 128 PID 94 Fuel delivery pressure...759
MID 128 PID 97 Water in fuel indicator...762
MID 128 PID 164 Injection control pressure...764
MID 128 PID 172 Air inlet temperature...767
MID 128 PID 107 Air filter pressure drop...769
MID 128 PID 105 Intake manifold temperature...771
MID 128 PID 102 Boost pressure...774
MID 128 PID 111 Coolant level...777
MID 128 PID 110 Engine coolant temperature...779
MID 128 SID 22 Timing sensor; crank...782
MID 128 SID 21 Engine position...784
MID 128 SID 1-6 Injectors...786
MID 128 PPID 19 Internal EGR status...789
MID 128 SID 42 Fuel control unit...791
MID 128 PID 45 Inlet air heater status...794
Transmission diagnosis - Gear shifting solenoids...796
Transmission diagnosis - SE4101_SE4102 Sensor; inching pedal position_{52-07}...798
Transmission diagnosis - SE4101_SE4102 Sensor; inching pedal position_{50-47}...802
Transmission diagnosis - SE4201 Sensor; gearshift selector...806
Transmission diagnosis - SE4202 Sensor; transmission oil temperature_{48-17}...809
Transmission diagnosis - SE4202 Sensor; transmission oil temperature_{47-27}...812
Transmission diagnosis - SE4214 Sensor; transmission oil pressure...815
Transmission diagnosis - SE4215 Sensor; transmission filter restriction...818
Transmission diagnosis - SE4216 Sensor; transmission internal shaft speed_{43-40}...820
Transmission diagnosis - SE4216 Sensor; transmission internal shaft speed_{42-51}...823
Transmission diagnosis - SE4217 Sensor; transmission internal shaft speed_{41-49}...826
Transmission diagnosis - SE4217 Sensor; transmission internal shaft speed_{40-59}...829
Transmission diagnosis - SE4307 Sensor; transmission output shaft speed_{39-54}...832
Transmission diagnosis - SE4307 Sensor; transmission output shaft speed_{39-05}...835
Transmission diagnosis - SE4308 Sensor; transmission output shaft speed_{38-06}...838
Transmission diagnosis - SE4308 Sensor; transmission output shaft speed_{37-17}...841
MID 187 PID 96 Fuel level_{36-06}...844
MID 187 PID 96 Fuel level_{35-24}...847
V-ECU diagnosis - SE2702_SE2704 Sensor; accelerator pedal position_{34-31}...850
V-ECU diagnosis - SE2702_SE2704 Sensor; accelerator pedal position_{33-35}...853
V-ECU diagnosis - SE3802 Sensor; ambient air temperature...856
V-ECU diagnosis - SE4601 Sensor; differential lock pressure...858
V-ECU diagnosis - SE5201 Sensor; brake booster pressure...861
V-ECU diagnosis - SE5215 Sensor; brake pressure differential...863
V-ECU diagnosis - SE5501 Sensor; park brake pressure...865
V-ECU diagnosis - SE6401 Sensor; steering pressure...868
V-ECU diagnosis - SE8701 Sensor; A_C pressure...871
V-ECU diagnosis - SE9104 Sensor; hydraulic oil level...874
V-ECU diagnosis - SE9105 Sensor; hydraulic oil temperature...876
V-ECU diagnosis - SE9107 Sensor; hydraulic filter restriction...879
V-ECU diagnosis - MA2602 Solenoid; Fan control - direction...881
V-ECU diagnosis - MA2603 Solenoid; Fan control - shutoff...883
V-ECU diagnosis - PWM 2601 Solenoid; fan speed control...885
V-ECU diagnosis - MA4601 Solenoid; Differential lock...887
V-ECU diagnosis - MA5501 Solenoid; Park brake...889
V-ECU diagnosis - MA9111 Solenoid; hydraulic unload_{10-40}...891
V-ECU diagnosis - MA9111 Solenoid; hydraulic unload_{09-38}...893
I-ECU diagnosis - SW3301 Ignition switch...895
I-ECU diagnosis - SW3801 switch_keypad...897
Auxiliary hydraulic system...899
V-ECU diagnosis - SE2607 Sensor; cooling fan speed_{03-11}...902
V-ECU diagnosis - SE2607 Sensor; cooling fan speed_{02-26}...905
31 - BATTERY...908
Starting with booster batteries...909
Battery storage...911
Battery; specifications_{59-46}...912
Battery; specifications_{59-23}...913
Battery charging capacity; checking...914
Battery; charging...916
Batteries; replacing...918
Battery box; removing...920
Battery box; installing...922
32 - ALTERNATOR; CHARGE REGULATOR...924
Alternator; specifications_{55-44}...925
Alternator; specifications_{55-23}...926
Alternator; tightening torques...927
Alternator; description...928
Alternator; removing...929
Alternator; installing...932
33 - STARTING SYSTEM...933
Starter motor D7; specifications...934
Starting system; general description...935
Starter motor; removing...936
Starter motor; installing...937
Cold-start device; specifications...938
Electric air pre-heater; description...939
Start switch; description_49-18...940
Start switch; description...942
Starter switch (engine start switch); replacing...944
35 - LIGHTING...947
Lighting; specifications...948
Headlights; adjusting...949
36 - OTHER ELECTRICAL EQUIPMENT...951
Direction indicator; turn signal description...952
Direction indicator switch; replacing...953
Horn; description...954
Reverse alarm; replacing...955
Wiper; specifications...956
Front upper window wiper; description...958
Rear window wiper; description...959
Lower front window wiper; description...960
Lower window wiper; replacing...961
Windscreen wiper rear; replacing motor...963
Windscreen wiper front motor; replacing...965
Windscreen wiper; replacing pivot linkage...967
Windscreen wiper; install and adjust...969
Connectors; overview...971
Connectors; configuration_{36-12}...979
Connectors; configuration_{35-47}...981
Connectors; position...984
Instrument control unit I-ECU; description...994
Vehicle control unit V-ECU; description...996
Engine control unit E-ECU; description...998
I-ECU; replacing...1000
V-ECU; replacing...1001
37 - CABLE; FUSE; RELAY...1003
Electrical symbols and designations...1007
Explanation of wiring diagrams...1011
Additional component list...1014
Component list; motors...1016
Component list; PWM valves...1018
Component list; sensors...1021
Component list 1 alternator; batteries; capacitors; electronic units...1030
Component list 2 diodes...1031
Component list 3 fuses_{24-18}...1032
Component list 3 fuses_{23-53}...1036
Component list 4 heating coils; instruments; service connections...1040
Component list 5 lights...1041
Component list 6 control-; warning lights...1044
Component list 7 solenoid valves...1046
Component list 9 relays_{21-31}...1048
Component list 9 relays_{21-06}...1052
Component list 9 relays_{20-41}...1056
Component list 11 sensors...1060
Component list 12 switches...1063
Wiring diagram 1_{19-00}...1066
Wiring diagram 1 – Main diagram_Positive feeds_Chassis connections_{18-35}...1068
Wiring diagram 2_{17-46}...1070
Wiring diagram 2 Feeds V-ECU; I-ECU_{17-21}...1072
Wiring diagram 2 Feeds V-ECU; I-ECU_{16-55}...1074
Wiring diagram 3_{16-18}...1076
Wiring diagram 3_{15-53}...1078
Wiring diagram 3_{15-28}...1080
Wiring diagram 4_{14-50}...1082
Wiring diagram 4 – D7 Engine ECU_{14-25}...1084
Wiring diagram 5...1086
Wiring diagram 6_{13-17}...1088
Wiring diagram 6_{12-52}...1090
Wiring diagram 7_{12-15}...1091
Wiring diagram 7_{11-50}...1093
Wiring diagram 8_{11-13}...1095
Wiring diagram 8_{10-47}...1097
Wiring diagram 8_{10-22}...1099
Wiring diagram 9_{09-45}...1101
Wiring diagram 9_{09-20}...1103
Wiring diagram 10_{08-43}...1105
Wiring diagram 10_{08-17}...1107
Wiring diagram 11_{07-40}...1109
Wiring diagram 11 – Work lights_{07-15}...1111
Wiring diagram 12_{06-32}...1113
Wiring diagram 12_{06-07}...1115
Wiring diagram 13_{05-30}...1117
Wiring diagram 13_{05-05}...1119
Wiring diagram 14_{04-28}...1121
Wiring diagram 14_{04-03}...1123
Wiring diagram 15_{03-20}...1125
Wiring diagram 15_{02-56}...1127
Wiring diagram 16_{02-19}...1129
Wiring diagram 16_{01-53}...1131
Wiring diagram 17_{01-16}...1133
Wiring diagram 17_{00-51}...1135
Wiring diagram 18_{00-02}...1137
Wiring diagram 18_{59-37}...1139
Wiring diagram 19_{59-01}...1141
Wiring diagram 19_{58-36}...1143
Wiring diagram 20...1145
Wiring diagram 21_{57-28}...1147
Wiring diagram 21_{57-03}...1149
Wiring diagram 21_{56-39}...1151
Wiring diagram 22_{56-01}...1153
Wiring diagram 22_{55-36}...1156
Wiring diagram 22_{55-11}...1158
Wiring diagram 23_{54-33}...1160
Wiring diagram 23_{54-08}...1162
Wiring diagram 24_{53-31}...1164
Wiring diagram 24_{53-06}...1166
Wiring diagram 25_{52-29}...1168
Wiring diagram 25_{52-04}...1170
Wiring diagram 25_{51-39}...1172
Wiring diagram 26_{51-02}...1174
Wiring diagram 26_{50-37}...1176
Wiring diagram 26_{50-11}...1178
Wiring diagram 27_{49-34}...1180
Wiring diagram 27_{49-09}...1182
Wiring diagram 28_{48-26}...1184
Wiring diagram 28_{48-01}...1186
Wiring diagram 28_{47-35}...1188
Wiring diagram 28_{47-10}...1190
Wiring diagram 29_{46-28}...1192
Wiring diagram 29_{46-03}...1194
Wiring diagram 29_{45-38}...1196
Wiring diagram 29_{45-12}...1198
Wiring diagram 30_{44-35}...1200
Wiring diagram 30_{44-10}...1202
Wiring diagram 30_{43-45}...1204
Wiring diagram 31_{42-56}...1206
Wiring diagram 31_{42-31}...1208
Wiring diagram 31_{42-06}...1210
Wiring diagram 32_{41-28}...1212
Wiring diagram 32_{41-04}...1214
Wiring diagram 33...1216
Wiring diagram 34...1218
Wiring diagram 35...1221
Wiring diagram 36...1224
Wiring diagram 37...1226
Wiring diagram 38...1229
Positive feed...1231
Battery disconnect switch ...1232
Battery main switch; checking...1234
Battery disconnect switch...1236
Grounding points; frame connections...1238
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...1240
Revolution sensor (hydraulic cooling fan); replacing...1241
Transmission; revolution sensor; replacing...1242
Transmission sensor and connection; checking...1245
Fuel level sender; replacing...1247
39 - MISCELLANEOUS...1249
CareTrack system; description...1250
CareTrack W-ECU; description...1251
Radio; removing...1253
Radio; installing...1254
Speaker; replacing...1255
Antenna; replacing...1256
Voltage converter; replacing...1258
4 - POWER TRANSMISSION...1259
41 - CLUTCH; TORQUE CONVERTER...1260
Inching pedal; function check...1261
Inching pedal; replacing...1262
42 - TRANSMISSION; HYDRAULIC CONTROL...1264
Transmission; component locations_{25-56}...1265
Transmission; component locations_{25-31}...1268
Transmission; specifications_{24-54}...1270
Transmission; specifications_{24-32}...1271
Hydraulic transmission; volume...1272
Transmission; tightening torques...1273
Type HTE840 transmission; description and operation...1274
Type HTE1160 transmission; description and operation...1276
Transmission; changing oil and filter...1278
Transmission control HTE840_HTE1160; description and operation...1281
Transmission hydraulic system; description and operation...1284
Transmission circuit hydraulic schematic...1285
Transmission; component locations...1287
Transmission oil pressure; checking...1291
Transmission; removing...1294
Transmission; installing...1299
Transmission pump; removing...1301
Transmission pump; installing...1305
Transmission temperature sensor; replacing...1307
Transmission pressure sensor; replacing...1309
Transmission solenoid; replacing...1311
Transmission oil filter restriction sensor; replacing...1313
Gear selector; replacing...1314
Transmission mounting; description and operation...1316
Rubber cushion; changing...1317
44 - HYDROSTATIC DRIVE...1319
Charge pump; replacing...1320
Pump drive; tighten torques...1323
Pump drive; description and operation...1324
Pump drive; removing...1331
Pump Drive; reconditioning...1334
Spring coupling; changing...1347
Pump drive; installing...1349
Control neutral adjustment for EDC controls...1351
Filter description...1353
45 - PROPELLER SHAFT...1354
Driveshaft - upper; description and operation...1355
Driveshaft - lower and midship; description and operation...1357
Drive shaft; removing_07-04...1359
Drive shaft; installing_06-35...1361
Drive shaft; removing...1362
Drive shaft; installing...1364
Drive shaft; repair...1365
Universal joint; replacing...1368
46 - FRONT AXLE; REAR AXLE...1371
Axle; tightening torques...1372
Front axle; specification...1374
Tandem assembly...1375
Tandems; volume...1377
Tandem inspection...1378
Tandem drive chain; installing ...1380
Tandem drive chain; removing...1382
Tandem drive chain; installing...1385
Tandem drive sprocket; removing...1387
Tandem drive sprocket; installing...1389
Final drive axle (APR70 and APR90); description and operation...1391
Final drive; specifications (Models G930 - G960)...1392
Final drive; volume (Models G930 - G960)...1393
Final drive; tighten torques...1394
Final drive axle seal; removing...1395
Final drive axle seal; installing...1397
Four point bearing; replacing...1399
Tandem; removing...1403
Tandem; installing...1407
Axle; removing...1410
Axle; installing...1412
Differential lock and control; description and operation...1414
Sensor unit (differential lock); replacing...1416
49 - MISCELLANEOUS...1419
Transmission oil cooler; description and operation...1420
Hydraulic oil cooler; removing ...1422
Hydraulic oil cooler; installing ...1424
5 - BRAKE...1425
50 - GENERAL...1426
Brake system; overview...1427
51 - WHEEL BRAKE...1430
Service brakes; specifications...1431
Service brakes; tightening torques...1432
Service brakes function; checking...1433
Wheel brake; description...1434
Brake circuit hydraulic schematic...1438
Service brakes warning system; checking...1440
Oil disc brake assembly; removing...1442
Oil disc brakes; disassembling...1445
Oil Disc Brake - Cleaning and Inspection...1451
Brake housing; pre-assembling...1453
Tandem axle oil seal installation...1455
Tandem axle seal; installing...1458
Oil disc brakes ; assembling...1465
Oil Disc Brakes - Bench Adjustment...1469
Oil disc brake; installing...1471
52 - HYDRAULIC BRAKE SYSTEM...1474
Hydraulic brake system; specifications...1475
Hydraulic brake system; tightening torques...1476
Brake system; specifications...1477
Brake system hydraulic function; checking...1478
Brake master cylinder and power booster; description...1481
Brake circuit; operation...1491
Brake pedal switch; replacing...1493
Brake system; bleeding...1495
Hydraulic brake system; description...1497
Brake pedal stop; adjusting...1501
Brake master cylinder and power booster; removing...1504
Power booster; disassembling...1506
Power booster; assembling...1508
Master cylinder oil; changing...1510
Brake master cylinder; disassembling...1513
Brake master cylinder; assembling...1517
Brake master cylinder; installing...1520
Adjustment checks...1522
Foot brake valve; removing...1524
Foot brake valve; installing...1529
Brake pedal angle; adjusting...1533
Foot brake valve; description...1535
Brake accumulator; specifications...1538
Accumulator (removed) charging pressure; checking...1539
Accumulator; removing...1541
Accumulator; installing...1545
Brake accumulator; description...1548
55 - PARKING BRAKE...1550
Parking brake assembly; installing...1551
Parking brake; description and operation...1554
Parking brake function; checking...1555
Parking brake hydraulic schematic...1556
Parking brake; manually releasing...1559
Parking brake assembly; removing...1562
Parking brake; installing...1565
6 - STEERING...1567
60 - GENERAL...1568
Steering system; specifications...1569
Steering system; description...1570
Steering system function; checking...1571
62 - STEERING AXLE...1572
Steering axle; description and operation...1573
Steering axle; components...1575
Wheel hub; removing...1579
Wheel hub; installing...1580
Front wheel bearing; repacking...1581
Front axle wheel bearing preload; checking and adjusting...1583
Front axle frame; removing...1585
Front axle frame; installing...1587
Drag link; removing...1589
Drag link; installing...1590
Front axle; overhaul...1592
Tie bar; removing...1601
Tie bar; installing...1603
Knuckle; removing...1604
Knuckle; installing...1609
Toe - in; adjustment...1611
64 - STEERING...1613
Steering wheel; tightening torques...1615
Steering wheel; description...1616
Steering column; disassembling...1619
Steering column; assembling...1621
Control lever; adjusting...1623
Pedestal gas shock; replacing...1625
Steering control unit; removing...1627
Steering control unit; installing...1630
Steering cylinders; specification (G930 - G976)...1632
Steering cylinders; specification...1633
Steering cylinders; tightening torques...1634
Steering hydraulic cylinders; description...1635
Steering hydraulic circuit; specifications...1637
Steering hydraulic circuit; description...1638
Steering hydraulic schematics...1639
Steering system working pressure; checking and adjusting...1643
Shock valve; testing...1644
Main implement and steering hydraulic pump; description and operation ...1646
Pressure and flow compensator; description ...1648
Electric unload of main implement and steering pump ...1649
Steering and implement pump controller; removing ...1651
Steering control unit; description and operation...1653
Secondary steering pump; specifications...1657
Secondary steering; description and general information...1658
Secondary steering function; checking...1660
Secondary steering relief valve; adjusting...1661
Secondary steering circuit hydraulic diagram...1664
Secondary steering motor; specifications...1666
Secondary steering hydraulic schematic; relief valve opened...1667
Secondary steering hydraulic schematic; relief valve closed...1670
Wheel lean system; description and operation...1673
Wheel lean hydraulic schematic...1676
Wheel lean cylinders; specification...1679
Wheel lean cylinders; tightening torques...1680
Wheel lean hydraulic cylinder; description...1681
Wheel lean cylinder; removing...1683
Wheel lean cylinder; installing...1684
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...1685
71 - FRAME...1686
Frame; tightening torque...1687
Frame; description...1688
Transmission guard; removing...1690
Transmission guard; installing...1692
Neck and nose cover; removing...1694
Neck and nose cover; installing...1695
74 - FRAME LINK...1696
Frame joint; separating machine...1697
Frame joint; assembly of separated machine...1702
Articulation hydraulics; description...1704
Frame link_articulation; specifications...1706
Articulation cylinders; specifications (Models G930 - G960)...1707
Articulation cylinders; tightening torque (Models G930 - G960)...1708
Articulation cylinder; removing...1709
Articulation cylinder; installing...1712
Articulation hydraulic schematic...1714
Articulation circuit hydraulic diagram...1717
Articulation Indicator - Setup and Adjustment...1719
Articulation indicator cable; removing...1721
Articulation indicator cable; installing...1723
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...1726
Wheels; specifications...1727
Wheels; tightening torques...1728
Wheels; general description...1729
Troubleshooting...1731
Wheel; removing and fitting one...1733
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...1736
80 - GENERAL...1737
Cab description...1738
81 - CAB; NAKED; CANOPY...1740
Cab; specifications...1741
Cab mounts; tightening torques...1742
Cab; removing...1743
Cab; installing...1748
82 - ENGINE HOOD; MUDGUARD; FOOT STEP...1750
Engine hood; removing...1751
Engine hood; installing...1759
Cab ladder; replacing...1764
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING...1766
Reflectors and Decals...1767
Mirrors; tightening torques...1768
Cover; installing...1769
Windows; general...1771
85 - CAB INTERIOR; UPHOLSTERY...1773
Rear headliner; removing...1774
Rear headliner; installing...1775
Front headliner; removing...1776
Front headliner; installing...1777
Floor mats; replacing...1778
Cab interior covers; replacing...1780
Side console covers; replacing...1783
Operator's seat; removing...1786
Operator's seat; installing...1787
Operator seat; tightening torques...1788
87 - AIR CONDITIONING UNIT...1789
Air conditioning; specifications...1790
Air conditioning; tightening torques...1791
Air distribution; specifications...1792
Cooler and Heater assembly; removing...1793
Cooler and Heater assembly; installing...1798
Air distribution; description...1803
Defroster fan; replacing...1805
Fan motor; replacing...1807
Heater core; replacing...1809
Air mix door actuator; replacing...1811
Stepless motor drive; replacing...1813
Heater unit relays; replacing...1815
Heat control valve; replacing...1817
HVAC system...1820
HVAC system components...1822
Air conditioning unit; operation...1825
Air Conditioning System Repairs...1828
Cooling unit; performance test...1830
Cooling unit; leak detection...1832
Troubleshooting; air conditioning unit (AC)...1834
Thermostat; replacing...1837
Evaporator; replacing incl draining and filling...1839
Receiver; replacing incl draining and filling...1842
Condenser; replacing incl draining and filling...1844
HVAC control switch; replacing...1846
88 - INTERIOR EQUIPMENT...1848
Pedestal controls; tilt function...1849
Lap Seat Belts...1852
Seat safety belt; replacing...1853
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...1854
90 - GENERAL...1855
Explanations to hydraulic diagram...1856
Hydraulic components; cleanliness when handling...1861
Hydraulic diagram 1...1862
Hydraulic diagram 2_{51-45}...1866
Hydraulic diagram 2_{51-20}...1868
Main hydraulic schematic - sheet 1...1870
Hydraulic oil cooling system hydraulic schematics...1874
Fan pump hydraulic schematic...1884
Hydraulic circuits; travel_{48-30}...1885
Hydraulic circuits; travel_{48-06}...1887
Scarifier circuit hydraulic schematic...1890
Blade tilt circuit hydraulic schematic...1893
Blade lift system; hydraulic schematics...1896
Blade slide shift circuit hydraulic schematic...1900
Circle turn circuit hydraulic schematic...1903
Circle side shift circuit hydraulic schematic...1906
Hydraulic system; volume...1909
Hydraulic system; description...1910
Oil and filtration...1911
Hydraulic oil; description...1913
Hydraulic oil; storing and handling...1914
Hydraulic components; repairing in workshop...1915
Hydraulic components; storing and transporting...1916
Accumulator; discarding...1917
91 - WORKING HYDRAULIC; SERVO HYDRAULICS...1919
Hydraulic pump; standby pressure; checking and adjusting...1923
Hydraulic couplings; description...1926
Hydraulic couplings; installation instructions...1927
Hydraulic oil tank; changing oil and filter incl.cleaning tank...1929
Hydraulic oil tank - description and operation...1932
Hydraulic oil tank; removing...1935
Hydraulic oil tank; replacing...1941
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump ...1944
Hydraulic oil cooling system...1946
Maximum fan speed; checking_35-19...1952
Maximum fan speed; checking...1955
Low fan speed; checking...1959
Fan motor; specifications...1961
Fan pump specification...1962
Fan pump flow; checking ...1964
Unloading valve; description and operation...1966
Oil cooler line bypass valve (check valve); replacing...1969
Hydraulic return line filter; specification...1971
Return line filter - description and operation...1972
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump...1973
Hydraulic oil cooler; removing...1975
Hydraulic oil cooler; installing...1977
Fan pump flow; checking_{29-42}...1978
Low fan speed; checking_{29-17}...1980
Low fan speed; checking_{28-53}...1982
Fan pump flow; checking...1984
Blade lift system lock pin cylinder solenoid valve; tightening torques...1986
Load sense shuttle valve; description and operation...1987
Load sense shuttle valve; tightening torques...1988
Auxiliary load sense shuttle valve; tightening torques...1989
Auxiliary load sense shuttle valve...1990
Load sense relief valve; specifications...1991
Load sense relief valve; description and operation...1992
Test procedure for external load sense relief valve...1994
Hydraulic cylinder; description...1996
Hydraulic Cylinder Overhaul Procedure...1998
Hydraulic cylinder; disassembling...2000
Hydraulic cylinder; assembling...2006
Special tools...2008
Fan control valve; removing...2009
Fan control valve; seal replacing...2010
Fan control valve; installing...2012
Directional control valve; specifications...2013
Directional control valve - 10 bank; description and operation...2014
Blade lift section assembly - with float; specifications...2016
Blade lift section assembly - without float; specifications...2019
Directional control valve troubleshooting...2021
Directional control valve; removing...2023
Directional control valve; reconditioning...2028
Directional control valve; reconditioning (1 valve section)...2034
Directional control valve; installing...2042
Priority flow valve; specifications...2047
Priority flow valve - description and operation...2049
Priority flow valve; removing...2053
Priority flow valve; disassembling and inspection...2054
Priority flow valve; assembling...2056
Priority flow valve; installing...2058
Main implement and steering hydraulic pump; specifications...2059
Main implement and steering hydraulic pump; description and operation...2061
Pressure and flow compensator; description...2063
Electric unload of main implement and steering pump...2064
Hydraulic pump; standby pressure and working pressure; checking and adjusting...2066
Pump; removing...2070
Pump; installing...2073
Steering and implement pump; performance test...2076
Steering and implement pump controller; removing...2078
Steering and implement pump controller; inspection and cleaning...2080
Steering and implement pump controller; installing...2083
Control lever; overhaul and adjustment...2084
Auxiliary hydraulic system control; description_{53-13}...2086
Auxiliary hydraulic system control; description_{52-49}...2090
Joystick control system; description...2094
Joystick control; component locations...2099
Joystick control; wiring diagram 1...2104
Joystick control; wiring diagram 2...2105
Joystick control; wiring diagram 3...2107
Joystick control; wiring diagram 4...2108
Joystick control; wiring diagram 5...2109
Joystick control; wiring diagram 6...2110
Joystick control; wiring diagram 7...2111
Left side controller; replacing...2112
Joystick control; replacing...2115
Display unit; replacing...2118
Rear option controller; replacing...2120
Directional control valve solenoid; replacing...2122
Counter balance steering valve; replacing...2125
Power supply unit; replacing...2127
Relay; replacing...2130
Steering valve solenoid; replacing...2132
Articulation sensor; replacing...2135
Articulation sensor; calibrating...2138
J-ECU controller; replacing...2147
Rear auxiliary valve solenoid; replacing...2149
Steering pressure sensor; replacing...2152
92 - MECHANICAL EQUIPMENT_ATTACHMENT...2154
Push block; specifications...2155
Push block; description and operation...2156
Dozer blade; description...2158
Specifications - utility dozer blade...2160
Front mount scarifier; description and operation...2161
Specifications - front mounted scarifier...2163
Scarifier cylinder; specifications...2165
Scarifier cylinder; tightening torque...2166
Ripper; description and operation...2167
Specifications - ripper...2169
Ripper cylinders; specifications...2170
Ripper cylinders; tightening torque...2171
Support arch; removing...2172
Support arch; installing...2174
Ripper; removing...2176
Ripper; installing...2178
Parallel lift assembly; description and operation...2181
Parallel lift cylinder; specifications...2184
Parallel lift cylinder; tightening torque...2185
98 - FUNCTION FOR ROAD CONSTRUCTION...2186
Mouldboard cutting edge; replacing...2189
Blade lift system lock pin cylinder solenoid valve; specifications...2192
Mouldboard upper slide wear plate; replacing...2193
Mouldboard lower slide tube bearing; replacing...2195
Blade lift; description and operation...2197
Blade lift cylinders; specifications (Models G930 - G960)...2199
Blade lift cylinders; tightening torques...2200
Blade lift circuit hydraulic diagram...2201
Blade lift cylinder; removing...2203
Blade lift cylinder; installing...2205
Blade lift stirrup; removing...2207
Blade lift stirrup bearing; replacing...2209
Blade lift stirrup; installing...2211
Accumulator; specification...2213
Accumulator; description...2214
Accumulators; preventive maintenance...2216
Accumulator precharge pressure; checking...2217
Accumulator -Charging...2220
Accumulator precharge adjustment chart...2222
Accumulator; replacing...2223
Blade slide cylinders; specifications (Models G930 - G960)...2229
Blade slide cylinders; tightening torque (Models G930 - G990)...2230
Blade slide cylinder; replacing...2231
Hydraulic swivel joint; removing...2233
Hydraulic swivel joint; disassembling...2237
Hydraulic swivel joint; assembling...2241
Hydraulic swivel joint; installing...2248
Circle turn cylinders; specifications (Models G930 - G976)...2252
Circle turn cylinders; tightening torque...2253
Circle Turn Valve Overhaul Procedure...2254
Circle turn circuit hydraulic diagram...2255
Circle turn valve; removing...2257
Circle turn valve; disassembling...2259
Circle turn valve; assembling...2263
Circle turn valve; installing...2266
Circle Timing...2268
Circle crank arm; removing...2271
Circle crank arm; installing...2274
Circle; checking...2277
Circle side shift cylinders; specifications (Models G930 - G960)...2282
Circle side shift cylinders; tightening torque (Models G930 - G990)...2283
Circle side shift circuit hydraulic diagram_{12-51}...2284
Circle side shift circuit hydraulic diagram_{12-29}...2286
Circle and drawbar; specifications...2288
Circle and drawbar; tighten torques...2289
Circle and drawbar; description and operation...2290
Circle and drawbar; overview...2293
Circle operation...2294
Circle and drawbar troubleshooting guide...2297
G930 to G976 circle and drawbar...2299
Circle and drawbar; removing and disassembling...2300
Circle and drawbar; assembling and installing...2303
Mouldboard; shimming...2308
Circle turn mechanism; disassembling...2310
Circle turn mechanism; assembling...2312
Drawbar ball stud; disassembling...2315
Drawbar ball stud; assembling...2318
Drawbar Ball Stud – Adjusting...2322
Circle Setup and Timing...2326
Power tilt cylinders; specifications (Models G940 - G976)...2330
Power tilt cylinders; tightening torque (Models G940 - G990)...2331
Blade lift system; tighten torques...2332
Blade lift system; description...2333
Blade lift arm; removing...2336
Blade lift arm; installing...2338
Blade lift system lock cylinder; removing...2339
Blade lift system lock cylinder; disassembling...2341
Blade lift cylinder lock cylinder seal; replacing...2342
Volvo G960 Motor Repair Service Manual
