Volvo G740 G740 VHP G740B Motor Grader Workshop Repair Service Manual PDF D7D D10B - MVLVCONG740BOPEK.zip

A full service and repair manual featuring electrical wiring schematics for the Volvo G740, G740 VHP, and G740B Motor Graders, offering the same workshop guidance professionals use to service, troubleshoot, fix, and rebuild these machines.

This Volvo Construction Equipment G740, G740 VHP, and G740B 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.

PRODUCT DETAILS:

Total Pages: 1,263 pages

File Format: PDF (Windows & Mac & Linux)

Language: English

TABLE OF CONTENTS

0 - Foreword................2

0 - GENERAL................3

00 - DESCRIPTION; COMPLETE MACHINE................4

Description................5

Product identification plates................8

03 - SPECIFICATIONS................11

Dimensions................12

05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION................14

Transporting the machine................15

Storage................20

Grader setup instructions................22

07 - STANDARD TIME................44

Operation numbers for additional work................45

08 - TOOL................47

G700B Special tools................48

09 - MISCELLANEOUS................50

Removing corrosion protective coating................51

1 - STANDARD PARTS; SERVICE................52

16 - LUBRICANT; FUEL; OTHER FLUID................53

Fuel system................54

Recommended lubricants................55

Grease................57

Coolant................58

Tandem_oil disc brake oils................59

Alternative fuels................61

17 - SERVICE................64

Maintenance of Stored Machines; according to Inspection Programme................65

Delivery Inspection; according to Inspection Programme................66

Arrival Inspection; according to Inspection Programme................67

Hydraulic oil return filter; replacing................68

Towing................73

Jump-start procedure................76

19 - GENERAL................77

Safety concerns everybody................78

CE marking and declaration of conformity................79

Environment................81

Safety when handling the machine................83

Service positions................88

Fire prevention measures................93

Health hazards with paint; plastics and rubber................96

Check list after fire or heat exposure................98

Safety when handling tyres................99

Safety when lifting and supporting the machine................100

Safety when handling oil and fuel................101

Safety when working on the electrical system................102

Safety when working with batteries................103

Battery; charging................105

Safety when working with air-conditioning refrigerant................107

Safety when working on hydraulic systems................109

Safety concerns everybody!................110

Electric welding................111

2 - ENGINE WITH MOUNTING AND EQUIPMENT................113

20 - GENERAL................114

Description; D7D_{01-06-37}................115

Description; D10B_{01-06-13}................116

General description ................117

21 - ENGINE................118

Specifications; D7D - general_{01-04-17}................120

Specifications; D10B - general_{01-03-56}................121

Specifications; D7D - weight................122

Specifications; D10B - weight................123

Specifications; D7D - capacities_{01-02-41}................124

Specifications; D10B - capacities_{01-02-19}................125

Engine; removing_{01-01-46}................126

Engine; removing_{01-01-19}................130

Specifications; D7D - tightening torques_{01-00-41}................134

Specifications; D10B - tightening torques_{01-00-19}................135

Cylinder compression; testing................136

Cylinder head - D10B; description_{12-58-54}................141

Cylinder head - D7D; description_{12-58-28}................143

Cylinder block - D10B; description................145

Oil trap - D10B; description................146

Cylinder liner; piston; D7D description................147

Cylinder liners; D10B description................150

Cylinder liner; piston; D10B................152

Valves; adjusting_{12-52-27}................154

Valves; adjusting_{12-51-59}................157

Valves - D7D; description................159

Valve mechanism - D10B; description................161

Valve mechanism - D10B; specifications................163

Engine timing gear - D10B; description................164

Camshaft - D10B; description................166

Connecting rod; D7D................167

Crankshaft; D7D................169

Torsional vibration damper; D7D................171

Crankshaft rear oil seal; replacing................173

Crankshaft and vibration damper; D10B................175

General; Lubrication oil pump D7D................177

22 - LUBRICATING SYSTEM................179

Specifications; D7D................180

Lubrication oil circuit; D7D engine– Models G710B to G730B................181

Lubrication system - D10B; description................184

23 - FUEL SYSTEM................187

Fuel system; description_{12-41-39}................188

Fuel system; description_{12-41-17}................189

Fuel system components; D10B................197

Fuel flow; D10B................199

Fuel feed pump - D10B; description................201

Water trap; D10B................203

Injection pump - D10B; specifications................204

Injection pump - D10B; description................205

Fuel shut-off valve; D10B................207

Overflow valve; D10B................209

Injectors - D10B; specification................210

Injectors - D10B; description................211

Injectors; replacing................214

Injection system - D7D; E-ECU overview................220

25 - INLET & EXHAUST SYSTEM................224

Exhaust system - D7D engine................225

Exhaust system - D10B engine................227

General ................229

Air cleaner................231

Preheating coil; D10B................233

Intercooler D10B; specifications................235

Intercooler; D10B................236

26 - COOLING SYSTEM................238

Cooling system - D7D engine; description................239

Cooling system - D10B engine; description................242

27 - ENGINE CONTROL................245

Accelerator_decelerator pedal................246

Hand Throttle................248

VHP (Variable Horsepower)................250

3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS................251

30 - GENERAL................252

Description ................253

Operation................255

General ................256

31 - BATTERY................268

Description ................269

Specifications ................270

Non-maintenance batteries; testing................271

Explosion hazard................272

Battery box................273

32 - ALTERNATOR; CHARGE REGULATOR................274

Voltage regulator................275

Specifications ................276

Alternator; description................277

33 - STARTING SYSTEM................278

Specifications-................279

Starting system; general description................280

Neutral start relay................281

Electric air - preheater................282

35 - LIGHTING................283

General ................284

Lighting; front................285

Lighting; rear................286

Lighting; interior................287

Lighting; side................288

36 - OTHER ELECTRICAL EQUIPMENT................289

Description ................290

Direction indicator; turn signal................291

External warning system................292

Ignition switch................293

Automatic control_blocking function................295

37 - CABLE; FUSE; RELAY................297

Electrical symbols and designations................300

Description ................302

Cable; Battery isolation switch................303

Electrical component list................304

Wiring diagram 1 – Main diagram_Positive feeds_Chassis connections_{11-56-27}................311

Wiring diagram 1 – Main diagram_Positive feeds_Chassis connections_{11-56-03}................314

Wiring diagram 2 – Positive feed_Chassis connection I-ECU_E-ECU_{11-55-26}................317

Wiring diagram 2 – Positive feed_Chassis connection I-ECU_E-ECU_{11-55-02}................319

Wiring diagram 3 – Engine_{11-54-25}................321

Wiring diagram 3 – Engine_{11-54-00}................324

Wiring diagram 4 – D7 Engine ECU_{11-53-12}................327

Wiring diagram 4 – D7 Engine ECU_{11-52-49}................329

Wiring diagram 5 – D10 Engine ECU_{11-52-12}................332

Wiring diagram 5 – D10 Engine ECU_{11-51-48}................336

Wiring diagram 6 – D7; D10 Engine ECU_{11-51-12}................338

Wiring diagram 6 – D7; D10 Engine ECU_{11-50-47}................341

Wiring diagram 7 – Accelerator pedal_Fuel level_{11-50-12}................343

Wiring diagram 7 – Accelerator pedal_Fuel level_{11-49-47}................346

Wiring diagram 8 – Fan ECU_{11-49-11}................349

Wiring diagram 8 – Fan ECU_{11-48-43}................352

Wiring diagram 9 – Headlights_Turn signals_Horn_{11-48-05}................355

Wiring diagram 9 – Headlights_Turn signals_Horn_{11-47-40}................359

Wiring diagram 10 – EEC Headlights and flashers_{11-47-03}................362

Wiring diagram 10 – EEC Headlights and flashers_{11-46-38}................365

Wiring diagram 11 – Work lights_{11-46-02}................368

Wiring diagram 11 – Work lights_{11-45-38}................371

Wiring diagram 12 – EEC Worklights_{11-45-02}................374

Wiring diagram 12 – EEC Worklights_{11-44-37}................377

Wiring diagram 13 – Windshield wiper systems_{11-44-01}................380

Wiring diagram 13 – Windshield wiper systems_{11-43-36}................383

Wiring diagram 14 – 25 amp_60 amp converter_equalizer_{11-43-00}................387

Wiring diagram 14 – Rotating beacons_ Differential lock_MBCS_Articulation sensor_{11-42-35}................390

Wiring diagram 15 – Transmission ECU_{11-41-53}................393

Wiring diagram 15 – Rotating beacons_differential lock_MBCS_{11-41-29}................396

Wiring diagram 16 – AWD ECU_{11-40-53}................399

Wiring diagram 16 – Transmission ECU_{11-40-28}................402

Wiring diagram 17 – AWD ECU_{11-39-52}................406

Wiring diagram 17 – AWD ECU_{11-39-27}................410

Wiring diagram 18 – AWD ECU_{11-38-39}................414

Wiring diagram 18 – Sensors_{11-38-15}................419

Wiring diagram 19 – Sensors_{11-37-39}................422

Wiring diagram 19 – Brake circuit; lights_{11-37-15}................425

Wiring diagram 20 – Brake circuit; lights_{11-36-38}................428

Wiring diagram 20 – Secondary steering_{11-36-13}................431

Wiring diagram 21 – Climate control unit_{11-35-38}................434

Wiring diagram 21 – Secondary steering_{11-35-13}................438

Wiring diagram 22 – Front and rear defroster fans_{11-34-36}................441

Wiring diagram 22 – Climate control unit_{11-34-12}................444

Wiring diagram 23 – Front defroster fans_{11-33-36}................448

Wiring diagram 23 – Radio_Heated mirrors_{11-33-11}................451

Wiring diagram 24 – Blade float module_{11-32-35}................453

Wiring diagram 24 – Radio_Dome light_Heated mirrors_{11-32-10}................456

Wiring diagram 25 – Front float module_{11-31-34}................459

Wiring diagram 25 – Blade float module_{11-31-10}................462

Wiring diagram 26 – Tire pump_{11-30-34}................465

Wiring diagram 26 – Front float module_{11-30-10}................467

Wiring diagram 27 – Rear float module_{11-29-34}................470

Wiring diagram 27 – Communication; E-ECU_I-ECU_{11-29-10}................472

Wiring diagram 28 – Tire pump_Power outlet_{11-28-34}................475

Wiring diagram 28 – Keyboard_{11-28-09}................478

Wiring diagram 29 – Communication; E-ECU_I-ECU................480

Wiring diagram 30 – Keyboard................483

Electrical distribution box fuses; relays................485

Data link port................487

Ground stud - locations................488

38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM................496

Description ................497

Diagnostic software................513

Description of tests................514

4 - POWER TRANSMISSION................515

41 - CLUTCH; TORQUE CONVERTER................516

Specifications; engine clutch................517

Description and operation; engine clutch................519

Clutch housing; removing................523

Clutch assembly; removing................526

Clutch assembly; installing................528

Clutch housing; installing................530

Bearing support housing; installing................532

Clutch Slave Cylinder and Pedal Free Play; adjusting ................534

Clutch Slave Cylinder and Pedal Free Play; adjusting................537

Specifications; clutch master cylinder and booster circuit................539

Description; clutch master cylinder and booster................540

42 - TRANSMISSION; HYDRAULIC CONTROL................544

Specifications ................545

Description; 8400 transmission................547

Transmission components................550

Transmission ECU and shifter assembly................552

Transmission oil circuit and operation................555

Transmission hydraulic circuit and operation................560

Transmission troubleshooting................562

Error codes................566

Hydraulic system troubleshooting................569

Transmission; removing................575

Transmission; installing................579

44 - HYDROSTATIC DRIVE................583

Specifications; All Weel Drive system................584

Description; AWD system................585

AWD electrical system................594

AWD hydraulic system................602

All Wheel Drive Operational Checks................611

AWD test procedure and test port locations................613

AWD error codes and troubleshooting................618

All Wheel Drive Pump and Motor Priming Procedure................632

46 - FRONT AXLE; REAR AXLE................635

Specifications; SR final drive................636

Description; SR final drives................637

Operation; SR final drive................638

Lock_unlock function ................640

Final drive assembly; removing ................641

Tandem; removing ................643

Final drive assembly; installing ................644

Specifications; G780B - DR final drive................646

Description; G780B - DR final drive................647

Operation; G780B DR final drive................648

Lock_unlock function................650

Lubrication circuit................651

Final drive assembly; removing................652

Final drive assembly; installing................657

Specifications; tandems................662

Tandem assembly................663

Tandem; removing................665

Differential Lock; G710B - G746B................671

Differential Lock; G780B................673

5 - BRAKE................675

50 - GENERAL................676

Overview................677

51 - WHEEL BRAKE................681

Electrical schematic - Image................682

Brake circuit hydraulic schematic - Image................684

General ................685