Volvo G960B Motor Grader Workshop Repair Service Manual PDF Download - MVLVCONG960B.zip
Full-service repair documentation, complete with electrical wiring diagrams, for the Volvo G960B Motor Grader — everything needed to service, troubleshoot, fix, and overhaul these machines the way trained technicians do.
This workshop manual from Volvo Construction covers the G960B Motor Grader and contains:
* 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