Volvo G960 Motor Grader Workshop Repair Service Manual PDF Electrical Wiring Diagrams - MVLVCONG960.zip

A full-service repair manual, complete with Electrical Wiring Diagrams, covering the Volvo G960 Motor — packed with every technical detail needed to service, troubleshoot, fix, and rebuild it the way professional technicians do.

The Volvo Construction G960 Motor workshop service and repair manual 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 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