Volvo G940 Motor Grader Workshop Repair Service Manual PDF Download - MVOLCONG940.zip

A full service and repair guide, complete with electrical wiring schematics, for the Volvo G940 Motor Grader—packed with everything needed to service, troubleshoot, fix, and overhaul the machine at a professional mechanic's level.

This workshop service and repair manual for Volvo Construction Equipment's G940 Motor Grader covers:

* 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 G940 Motor Graders Repair Service Manual.pdf

PRODUCT DETAILS:

Total Pages: 2,322 pages

File Format: PDF

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_{35-28}...39

Transporting the machine_{35-07}...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_{30-41}...62

Recommended lubricants_{30-23}...64

17 - SERVICE...66

Alternative fuels...68

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_{25-29}...89

Engine belt tension; checking_{25-11}...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

Starting with booster batteries...162

Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump ...164

19 - GENERAL...166

CE-marking; EMC-directive...167

Safety concerns everybody!...171

Checking function...172

Safety rules when servicing...173

Safety when handling the machine...176

Service position...181

Some simple rules regarding tyre handling...183

Safety when lifting and supporting complete machine...185

Safety when using lifting equipment...188

Safety when handling oil and fuel...189

Safety when working with batteries...190

Starting with booster batteries ...192

Check list after fire or heat exposure...194

Safety when working with air conditioning refrigerant...196

Safety when working on hydraulic systems...199

Environmental handling for the future...201

Waste handling...202

Environmentally safe handling...203

Environmentally hazardous fluids...206

Working in environmentally contaminated areas...207

Health hazards with paint; plastics and rubber...208

Decontamination...211

Fire prevention measures...213

Electric welding...216

Precaution when working on the electrical system...217

2 - ENGINE WITH MOUNTING AND EQUIPMENT...218

20 - GENERAL...219

Engine; description...220

VCADS Pro; MID 128; programming E-ECU ...222

V-ECU; replacing ...223

21 - ENGINE...225

Engine; specifications...226

Engine; volume...227

Engine; removing...228

Engine; installing...236

Camshaft and flywheel signals; checking with Tech Tool and oscilloscope...243

Engine; tighten torques...249

Cylinder head; description...250

Cylinder head gasket; description...252

Valve cover; description and operation...253

Crankcase ventilation; changing...255

D7 cylinder block with crankcase ventilation; description and operation...257

Pistons; description...258

Cylinder liner; description...260

Cylinder liner; checking and measuring wear...262

Valve system specifications...264

Valves; adjusting...265

Valves; description...277

Internal Exhaust Gas Recirculation (IEGR); description...278

Valve cover; fitting new gasket each...283

Engine timing gear; description...285

Camshaft; description...286

Crankshaft; description...287

Connecting rod; description...289

Vibration damper; description...291

Oil sump; description...292

Engine mounting; description_47-53...293

Engine mounting; description...295

Engine mounting rear; changing...297

Engine mount front; replacing...300

22 - LUBRICATING SYSTEM...304

Lubricating system; description...305

Lubrication system D7; specifications...308

Oil pump; description...309

23 - FUEL SYSTEM...311

Fuel system; description...312

Fuel system; tightening torques...314

Fuel feed pump; description...315

Feed pump; replacing...316

Fuel system; bleeding...319

Fuel tank; volume...321

Fuel tank; removing...322

Fuel tank; installing...325

Ventilation filter; replacing...327

Injectors; description...329

Injectors; replacing...332

High pressure fuel pump; checking...335

Fuel control valve (FCV); checking...339

Fuel control valve (FCV); replacing...342

Pressure relief valve (PRV); inspecting...345

Pressure relief valve (PRV); replacing...348

Delivery pipe; replacing one...351

Fuel rail pressure sensor; replacing...353

25 - INLET & EXHAUST SYSTEM...355

Inlet system; description...356

Exhaust system; description...357

Silencer; removing...358

Silencer; installing...364

Turbocharger; description...370

Turbocharger; removing...371

Turbocharger; installing...372

Turbocharger; inspecting...373

Air cleaner; removing...375

Air cleaner; installing...376

Air cleaner; preheater; specifications...378

Intercooler specifications...379

Charge air cooler; replacing...380

26 - COOLING SYSTEM...382

Cooling system D7; specification...383

Cooling system; volume...384

Cooling system; description...385

Cooling system; flushing...387

Radiator; replacing...390

Coolant pump; replacing...392

Fan belt and_or alternator belt; replacing...395

Cooling fan motor; replacing...397

Fan shroud; replacing...401

Maximum fan speed; checking ...404

Low fan speed; checking ...407

Fan control valve; removing ...409

Fan control valve; seal replacing ...410

Fan control valve; installing ...412

Fan pump flow; checking ...413

3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...415

30 - GENERAL...416

Electrical system; description...425

Electronic control system; description...426

Communication with data buses_{57-14}...428

Communication with data buses_{56-47}...430

Software...432

Software versions and ECUs_part number; general...433

Software versions and ECUs_part number; checking...435

Software versions and ECUs_part number; list...438

V2006.2.0; change specification...441

V2006.3.0; change specification...442

V2006.4.0; change specification...443

V2006.5.0; change specification...444

V2006.6.0; change specification...445

V2006.6.1; change specification...447

V2007.1.0; change specification...448

V2007.2.0; change specification...449

V2007.3.0; change specification...450

V2007.4.0; change specification...451

V2007.5.0; change specification...452

V2007.6.0; change specification...455

V2008.1.0; change specification...456

V2008.1.1; change specification...457

V2008.3.0; change specification...458

System voltage...460

Data links; fault tracing with Oscilloscope...461

Electrical system; specifications...471

Preheating of inlet air...472

Reduced computer communication...474

Hydraulic Oil Level...475

Description of table for software functions...476

Engine oil pressure...477

Engine Oil Level...478

Fuel Level_{38-40}...480

Fuel Level_{38-21}...482

INFO Water in fuel...484

Engine air filter restriction...485

Temperature induction air...486

Charge-air temperature...487

Charge-air pressure...488

Engine coolant level...489

Engine coolant temperature...490

Cooling fan adjustment...492

Reversible cooling fan...495

Increased fan speed for AC...498

Accelerator Pedal_{34-23}...499

Accelerator Pedal_{34-03}...501

Accelerator setting_{33-25}...503

Accelerator setting_{33-05}...505

Engine speed for V-ECU...507

Engine Protection_{32-03}...509

Engine Protection_{31-43}...511

Interruption in computer communication...513

Temperature; ambient air...514

Back-up alarm...515

Transmission oil pressure...516

Transmission oil temperature_{09-05}...518

Transmission oil temperature_{08-46}...520

Transmission oil filter bypass indicator...522

Inching_{07-58}...523

Inching_{07-39}...524

Shifting out of Neutral...525

Shifting and memory gears_{06-51}...526

Shifting and memory gears_{06-32}...528

Inching pedal and memory gears_{05-54}...530

Inching pedal and memory gears_{05-34}...532

Manual mode_{05-05}...534

Manual mode_{04-46}...536

Automatic mode_{04-17}...538

Automatic mode_{03-58}...540

Travel mode_{03-29}...541

Travel mode_{03-10}...543

Engine Over-speed Protection...545

Directional gear shifting...546

Gearshifting solenoids...547

Transmission Stall Protection...551

Inching pedal_{01-25}...552

Inching pedal_{01-06}...554

Power mode...556

VHP...558

Differential lock...560

Service brake differential pressure...562

Parking brake_{59-17}...563

Parking brake_{58-57}...565

Parking brake_{58-38}...567

Parking brake_{58-18}...569

Secondary steering...571

Hydraulic Unload...574

Hydraulic oil temperature...576

Hydraulic oil filter bypass indicator...578

VCADS Pro; Description...579

VCADS Pro; Simulator mode...581

VCADS Pro; MID187; programming V-ECU_55-49...582

VCADS Pro; MID187; programming V-ECU...584

VCADS Pro; MID 142; programming W-ECU_55-08...586

VCADS Pro; MID 142; programming W-ECU...588

VCADS Pro; MID 140; programming I-ECU_54-26...590

VCADS Pro; MID 140; programming I-ECU...592