Volvo G990 Motor Grader Workshop Repair Service Manual PDF Download with Wiring Diagrams - MVLVCONG990.zip

A full repair and service manual, complete with Electrical Wiring Diagrams, for the Volvo G990 Motor Graders — packed with everything a shop needs to service, troubleshoot, fix, and rebuild these machines just like factory-trained technicians.

The Volvo G990 workshop service & 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 G990 Motor Graders Repair Service Manual.pdf

PRODUCT DETAILS:

Total Pages: 2,201 pages

File Format: PDF (Windows & Mac & Linux)

Language: English

TABLE OF CONTENTS

0 - Foreword...2

0 - GENERAL...3

00 - DESCRIPTION; COMPLETE MACHINE...4

Description; complete machine...5

Product identification plates...8

03 - SPECIFICATIONS...10

Volvo standard tightening torques...11

Critical mounting torques...19

Conversion tables...22

Machine dimensions...30

05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION...32

Transporting the machine_{018-52}...33

Transporting the machine_{018-38}...35

Removing and assembly of machine from shipping container...37

07 - STANDARD TIME...48

Operation numbers for additional work...49

08 - TOOL...51

Drawings; E-tools...52

1 - STANDARD PARTS; SERVICE...55

16 - LUBRICANT; FUEL; OTHER FLUID...56

Recommended lubricants_{14-25}...57

Recommended lubricants_{14-12}...59

Alternative fuels...61

17 - SERVICE...72

Start of VCADS Pro computer and reading machine data...74

Arrival Inspection; according to Inspection Programme...75

Delivery Inspection; according to Inspection Programme...76

Maintenance of Stored Machines; according to Inspection Programme...77

Maintenance service; every 10 hours...78

Maintenance service; every 50 hours...80

Maintenance service; every 250 hours...82

Maintenance service; every 500 hours...84

Maintenance service; every 1000 hours...86

Maintenance service; every 1500 hours...88

Maintenance service; every 2000 hours...90

Engine belt tension; checking...92

Engine oil level; checking...93

Engine oil and filter; changing...95

Water separator; checking...99

Fuel filter; replacing...101

Fuel tank breather filter; replacing...104

Engine air cleaner primary filter; replacing...106

Oil-bath air cleaner reservoir oil; checking...109

Coolant level; checking...111

Coolant; changing...113

Coolers; cleaning...116

Battery; checking...120

Transmission oil level; checking...122

Transmission oil; changing...124

Transmission breather filter; replacing...127

Rear axle oil level; checking...128

Tandem oil level; checking...130

Tandem oil; changing...132

Service brake; testing...134

Master cylinder oil level; checking...136

Master cylinder oil; changing...138

Parking brake function; checking...141

Front wheel bearing; repacking...142

Tyre wear and air pressure; checking...144

Wheel nuts torque; checking...146

Cab prefilter; cleaning...147

Cab main filter; cleaning...150

Hydraulic oil level; checking...153

Hydraulic oil; changing...155

Hydraulic oil return filter; replacing...160

Hydraulic oil tank breather filter; replacing...162

Starting with booster batteries ...164

Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump...166

19 - GENERAL...168

Service position...169

Safety concerns everybody!...171

CE-marking; EMC-directive...172

Safety when handling the machine...175

Safety rules when servicing...180

Checking function...183

Fire prevention measures...184

Check list after fire or heat exposure...187

Some simple rules regarding tyre handling...189

Precaution when working on the electrical system...191

Safety when handling oil and fuel...192

Safety when using lifting equipment...193

Safety when lifting and supporting complete machine...194

Safety when working on hydraulic systems...197

Safety when working with air conditioning refrigerant...199

Starting with booster batteries...201

Safety when working with batteries...203

Environmental handling for the future...205

Environmentally safe handling...206

Environmentally hazardous fluids...209

Health hazards with paint; plastics and rubber...210

Working in environmentally contaminated areas...213

Decontamination...214

Waste handling...216

Electric welding...218

2 - ENGINE WITH MOUNTING AND EQUIPMENT...219

20 - GENERAL...220

VCADS Pro; MID 128; programming E-ECU...221

V-ECU; replacing...222

Engine D9B; description and operation...224

21 - ENGINE...226

Engine; specifications...228

Engine; volume...229

Engine; removing...230

Engine; installing...239

Camshaft and flywheel signals; checking with Tech Tool and oscilloscope...244

Engine; tightening torques_{42-44}...250

Engine; tightening torques_{42-31}...251

Cylinder head; description and operation...252

Cylinder head gasket; description...253

Cylinder head guides...255

Valve cover; description and operation...257

Cylinder block; description...258

Crankcase ventilation; changing...263

Pistons; description...265

Cylinder liner; description...267

Valve system specifications...269

Valve mechanism; description...271

Valves; adjusting...273

Double rocker arm; description...280

Engine timing gear; description...284

Camshaft; description...286

Crankshaft and vibration damper; description D9...287

Crankshaft front oil seal; replacing...289

Crankshaft rear oil seal; replacing...293

Connecting rod; description...295

Oil sump; description D9_00-23...297

Oil sump; description D9...299

Engine mounting; description...301

Engine mounting rear; replacing...303

Engine mount front; replacing...307

Engine; tightening torques_{44-39}...311

Engine; tightening torques_{44-26}...312

Engine; tightening torques_{44-01}...313

Engine; tightening torques_{43-48}...314

22 - LUBRICATING SYSTEM...315

Lubricating system; description...316

Lubrication system D9; specifications...318

Piston cooling system; description...319

Oil pump; description...321

Oil cooler; description...323

23 - FUEL SYSTEM...325

Fuel system; description...326

Fuel feed pump; specifications...329

Fuel head D9B; description...330

Fuel tank; volume...333

Fuel tank; removing...334

Fuel tank; installing...337

Ventilation filter; replacing...339

Unit injector; Delphi; description...341

25 - INLET & EXHAUST SYSTEM...343

Inlet system; description...344

Exhaust system; description...345

Silencer; removing...346

Silencer; installing...349

Turbocharger; removing...351

Turbocharger; installing...352

Air cleaner; removing...354

Air cleaner; installing...355

Air cleaner; preheater; specifications...357

Intercooler specifications...358

Charge air cooler; replacing...359

26 - COOLING SYSTEM...361

Cooling system D9; specification...362

Cooling system; volume...363

Cooling system; description D9...364

Cooling system; flushing...366

Radiator; replacing...369

Radiator hose upper; replacing...371

Radiator hoses lower; replacing...372

Expansion tank; replacing...373

Coolant pump; replacing...375

Coolant pump belt; replacing...379

Thermostat; description...381

Thermostat; replacing...383

Cooling fan motor; replacing...386

Fan shroud; replacing...390

Maximum fan speed; checking...393

Low fan speed; checking...397

Fan control valve; removing...399

Fan control valve; seal replacing...400

Fan control valve; installing...402

Fan pump flow; checking...403

3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...405

30 - GENERAL...406

Electrical system; description...415

Electronic control system; description...416

Communication with data buses_{012-25}...418

Communication with data buses_{012-11}...420

Software...422

Software versions and ECUs_part number; general...423

Software versions and ECUs_part number; checking...425

Software versions and ECUs_part number; list...428

V2006.2.0; change specification...430

V2006.3.0; change specification...431

V2006.4.0; change specification...432

V2006.5.0; change specification_09-34...433

V2006.5.0; change specification...434

V2006.6.0; change specification...435

V2006.6.1; change specification...437

V2007.1.0; change specification...438

V2007.2.0; change specification...439

V2007.3.0; change specification...440

V2007.4.0; change specification...441

V2007.5.0; change specification...442

V2008.1.0; change specification...445

V2008.1.1; change specification...446

V2008.3.0; change specification...447

System voltage...449

Data links; fault tracing with Oscilloscope...450

Electrical system; specifications...460

Preheating of inlet air...461

Reduced computer communication...463

Hydraulic Oil Level...464

Description of table for software functions...465

Engine oil pressure...466

Engine Oil Level...467

Engine crankcase pressure...469

Fuel Level_{003-02}...470

Fuel Level_{002-49}...472

INFO Water in fuel...474

Engine air filter restriction...475

Temperature induction air...476

Charge-air temperature...477

Charge-air pressure...478

Engine coolant level...479

Engine coolant temperature...480

Cooling fan adjustment...482

Reversible cooling fan...485

Increased fan speed for AC...488

Accelerator Pedal_{059-51}...489

Accelerator Pedal_{059-38}...491

Accelerator setting_{059-15}...493

Accelerator setting_{059-01}...495

Engine speed for V-ECU...497

Engine Protection...499

Interruption in computer communication...501

Temperature; ambient air...502

Back-up alarm...503

Transmission oil pressure...504

Transmission oil temperature_{056-54}...506

Transmission oil temperature_{056-40}...508

Transmission oil filter bypass indicator...510

Inching_{055-58}...511

Inching_{055-44}...512

Shifting out of Neutral...513

Shifting and memory gears_{055-06}...514

Shifting and memory gears_{054-53}...516

Inching pedal and memory gears_{054-30}...518

Inching pedal and memory gears_{054-16}...520

Manual mode_{053-54}...522

Manual mode_{053-40}...523

Automatic mode_{053-17}...525

Automatic mode_{053-04}...527

Travel mode_{052-41}...528

Travel mode_{052-28}...530

Engine Over-speed Protection...531

Directional gear shifting...532

Gearshifting solenoids...533

Transmission Stall Protection...537

Inching pedal_{051-04}...538

Inching pedal_{050-50}...540

Power mode...542

VHP...544

Differential lock...546

Service brake differential pressure...548

Parking brake_{049-26}...549

Parking brake_{049-12}...551

Parking brake_{048-59}...553

Parking brake...555

Secondary steering...557

Hydraulic Unload...560

Hydraulic oil temperature...561

Hydraulic oil filter bypass indicator...562

VCADS Pro; Description...563

VCADS Pro; Simulator mode...565

VCADS Pro; MID187; programming V-ECU_46-47...566

VCADS Pro; MID187; programming V-ECU...568

VCADS Pro; MID 142; programming W-ECU_46-12...570

VCADS Pro; MID 142; programming W-ECU...572

VCADS Pro; MID 140; programming I-ECU_45-36...574

VCADS Pro; MID 140; programming I-ECU...576

VCADS Pro; MID 128; programming E-ECU_45-01...578

VCADS Pro; MID 128; programming E-ECU...580

VCADS Pro; 17012-3 - Error Codes...582