Volvo G940 G940B G940C Motor Grader Workshop Repair Service Manual PDF - MVOLCONG940B.zip
Volvo G940, G940B, G940C Motor Graders Repair & Service Manual
The full factory-issued service guide covering Volvo G940, G940B and G940C Motor Graders, packed with every piece of workshop data needed to service, troubleshoot, fix and overhaul these machines to the standard of expert technicians.
Volvo Construction G940, G940B, G940C 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.
PRODUCT DETAILS:
Total Pages: 1,311 pages
File Format: PDF (Windows & Mac & Linux)
Language: English
0 - Foreword......2
0 - GENERAL......3
00 - DESCRIPTION; COMPLETE MACHINE......4
Product identification plates......5
03 - SPECIFICATIONS......7
Conversion tables......8
Coolant, specifications......16
Critical mounting torques......17
Hydraulic connections, tightening torques......20
Tightening torque, specifications_{04-33-13}......25
Tightening torque, specifications_{04-33-29}......28
Tightening torques......31
specifications......40
07 - STANDARD TIME......43
Operation numbers for additional work......44
08 - TOOL......46
Drawings, E-tools......47
1 - STANDARD PARTS, SERVICE......50
16 - LUBRICANT; FUEL; OTHER FLUID......51
Alternative fuels......52
Fuel, lubricant and filling capacities_{04-29-36}......55
Fuel, lubricant and filling capacities_{04-29-51}......56
Recommended lubricants_{04-28-53}......57
Recommended lubricants_{04-29-12}......62
17 - SERVICE......67
Arrival Inspection, according to Inspection Programme......69
Cab prefilter, cleaning......70
Cab prefilter, replacing......73
Coolant freezing point, checking......76
Coolant level, checking......77
Coolant, changing......79
Coolers, cleaning......81
Cooling system integrity, checking......83
Delivery Inspection, according to Inspection Programme......84
Diesel particulate filter, checking and cleaning......85
Engine air cleaner primary filter, cleaning......94
Engine air cleaner primary filter, replacing......97
Engine air cleaner secondary filter, replacing......99
Engine belt condition, checking......101
Engine oil and filter, changing......103
Engine oil level, checking......106
Front wheel bearing, repacking......108
Fuel filter, replacing......111
Fuel tank breather filter, replacing......113
Hydraulic oil level, checking......115
Hydraulic oil return filter, replacing......117
Hydraulic oil tank breather filter, replacing......120
Hydraulic oil, changing......122
Maintenance of Stored Machines, according to Inspection Programme......127
Maintenance service, every 10 hours......128
Maintenance service, every 1000 hours......129
Maintenance service, every 1500 hours......131
Maintenance service, every 2000 hours......132
Maintenance service, every 250 hours......134
Maintenance service, every 4500 hours......135
Maintenance service, every 50 hours......136
Maintenance service, every 500 hours......138
Maintenance service, every 6000 hours......140
Master cylinder oil level, checking......141
Master cylinder oil, changing......143
Rear axle oil level, checking......146
Service brake, testing......148
Spark plugs, replacing......149
Tandem breather, checking......151
Tandem oil level, checking......153
Tandem oil, changing......155
Transmission breather filter, replacing......157
Transmission oil filter, replacing......158
Transmission oil level, checking......160
Transmission oil, changing......162
Valves, adjusting......164
Water separator filter, replacing......168
Water separator, checking......170
Wheel nuts torque, checking......171
19 - GENERAL......172
A few simple safety rules......173
Before operating......177
Before service, read......181
CE-marking, EMC-directive......185
Charging batteries......189
Checklist after a fire or heat exposure......193
Cleanliness......196
Decontamination......200
Electrical system......204
Environment......208
Environmental handling for the future......213
Environmentally hazardous fluids......216
Environmentally safe handling......217
Fire prevention measures......220
General......223
Health hazards with paint, plastics and rubber......228
Safety concerns everybody!......232
Safety rules when servicing......236
Safety when handling oil and fuel......239
Safety when handling the machine......242
Safety when lifting and supporting complete machine......247
Safety when using lifting equipment......250
Safety when working on hydraulic systems......251
Safety when working with air conditioning refrigerant......253
Safety when working with batteries......256
Service position......259
Some simple rules regarding tyre handling......262
Working in environmentally contaminated areas......264
2 - ENGINE WITH MOUNTING AND EQUIPMENT......265
20 - GENERAL......266
Component locations......267
E-ECU MID 128 non-programmed, replacing......269
E-ECU MID 128 pre-programmed, replacing......271
Engine, description......273
VCADS Pro, Operations......277
21 - ENGINE......279
Crankcase ventilation separator, replacing......280
Crankcase ventilation, description......282
Cylinder compression, testing......283
Engine mounts, replacing......286
Engine rotation speed sensor (camshaft), replacing......294
Engine rotation speed sensor (crank shaft), replacing......296
Engine, installing......298
Engine, removing......306
Engine, specifications......317
Engine, tightening torques......318
Flywheel, tightening torques......320
Oil sump, tightening torque......322
Valve system, specification......324
22 - LUBRICATING SYSTEM......325
Lubrication oil pressure, checking with pressure gauge......326
Lubrication system, component locations......328
Lubrication system, description......330
Lubrication system, specifications......334
Lubrication system, tightening torques......336
23 - FUEL SYSTEM......338
Carbon dioxide in fuel system, checking......339
Feed pump pressure, checking......341
Fuel control valve (FCV), replacing......343
Fuel pump, replacing......348
Fuel system, bleeding......352
Fuel system, component location......354
Fuel system, description......356
Fuel system, specifications......363
Fuel system, tightening torques......364
Fuel tank, installing......371
Fuel tank, removing......373
High pressure fuel pump, replacing......376
Injectors, replacing......379
Pressure relief valve (PRV), replacing......386
25 - INLET & EXHAUST SYSTEM......389
ACM (Aftertreatment control module) non-programmed, replacing......391
ACM (Aftertreatment control module) pre-programmed, replacing......394
Air cleaner, installing......397
Air cleaner, removing......399
Air pump safety valve, replacing......401
Air pump, replacing......404
Burner function, checking......407
Burner, replacing......413
Charge air cooler, inspecting......419
Charge air cooler, installing......421
Charge air cooler, removing......423
DOC (Diesel oxidation catalyst), replacing......425
DPF (Diesel particulate filter), checking and cleaning......435
Exhaust Aftertreatment System, component location......444
Exhaust Aftertreatment System, description......446
Exhaust aftertreatment system T-junction, replacing......457
Exhaust aftertreatment system, specifications......459
Exhaust aftertreatment system, tightening torques......461
Exhaust pipe flexible tube, replacing......463
Fuel metering unit A, replacing......466
Fuel metering unit B, replacing......473
Glow plug control unit, replacing......479
Glow plug, replacing......485
Inlet and exhaust system, component location......487
Inlet and exhaust system, description......489
Inlet and exhaust system, tightening torques......495
NOx sensor, replacing......496
Regeneration process, description......502
Spark plug cable, replacing......505
Spark plug control unit, replacing......508
Spark plug, inspecting......510
Spark plug, replacing......512
Throttle, replacing......514
Turbocharger, description......516
Turbocharger, replacing......518
Turbocharger, tightening torques......522
Wastegate, checking......524
26 - COOLING SYSTEM......526
Coolant pump, replacing......527
Cooling fan motor, replacing......531
Cooling fan rpm, specifications......534
Cooling system pressure, checking......535
Cooling system, component location......537
Cooling system, description......538
Expansion tank, replacing......540
Fan control valve, installing......542
Fan control valve, removing......543
Fan control valve, seal replacing......544
Fan pump flow, Checking......546
Fan pump, Installing......548
Fan pump, Removing......550
Fan shroud, replacing......552
Low fan speed, checking-[4321]......555
Low fan speed, checking......556
Maximum fan speed, checking-[4417]......558
Maximum fan speed, checking......561
Radiator, replacing......563
Thermostat, specifications......567
29 - MISCELLANEOUS......569
EGR actuator, replacing......570
EGR cooler, replacing......574
EGR reed valve, replacing......584
EGR system function, checking......587
EGR system, tightening torques......591
EGR valve, replacing......593
EGR venturi tube, replacing......595
Exhaust Gas Recirculation (EGR), description......599
Exhaust gas recirculation (EGR), component location......604
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS......606
30 - GENERAL......607
1587 Information link, description and measuring......616
27102-3 - Accelerator pedal, test......618
Accelerator Pedal......619
Accelerator setting......620
Adapter cable 981 3194......622
Adapter cable 999 0014......623
Adapter cable 999 0020......624
Adapter cable 999 0216......625
Adapter cable 999 3893......626
Adapter cable 999 8533......627
Adapter cable 999 8534......628
Automatic mode......629
Back-up alarm......630
CAN1 Control link, description and measuring......631
CAN7 Control link, description and measuring......633
CU2501, description and measuring......635
CU2503, description and measuring......637
Charge-air pressure......639
Charge-air temperature......640
Collection of basic data......641
Communication with data buses......643
Component fault diagnosis, description......645
Conditions when checking......648
Cooling fan adjustment......650
DI3801, description and measuring......652
DI5201, description and measuring......653
DI5202, description and measuring......654
DI6401, description and measuring......655
Data links, fault tracing with Oscilloscope......656
Description of table for software functions......666
Differential lock......667
Directional gear shifting......669
Electrical system, description......670
Electronic control system, description......671
Engine Oil Level......673
Engine Over-speed Protection......675
Engine Protection......676
Engine air filter restriction......679
Engine coolant level......680
Engine coolant temperature......681
Engine oil pressure......682
Extension cable 999 0062......683
FX1006, description and measuring......684
FX1007, description and measuring......687
FX1008, description and measuring......690
FX1031, description and measuring......693
Fuel Level......696
Gearshifting solenoids......697
General fault diagnosis information......701
HE2501, description and measuring......702
Harness 8889 0016......704
Hydraulic Oil Level......705
Hydraulic Unload......706
Hydraulic oil filter bypass indicator......707
Hydraulic oil temperature......708
INFO Water in fuel......709
Inching pedal and memory gears......710
Inching pedal......712
Inching......713
Increased fan speed for AC......714
Interruption in computer communication......715
Lead and connector checks......716
MA2301-MA2306, description and measuring......720
MA2508, description and measuring......722
MA2509, description and measuring......724
MA2510, description and measuring......726
MA2512, description and measuring......728
MA2602, description and measuring......730
MA2603, description and measuring......732