Volvo G976 Motor Grader Service Repair Manual Instant Download

1
Service Information
Document Title Engine D9B, description and operation Function Group 200 Information Type Service Information Date 2014/12/22
Profile GRD, G976 GB Profile GRD, G976 GB Profile GRD, G976 GB Profile GRD, G976 GB
Engine D9B, description and operation D9B - tier
3 compliant The D9B engine configuration consists
of a four stroke, straight six cylinder,
turbocharged, direct injected diesel engine with
charge air cooling and wet, replaceable cylinder
liners. The engine has an overhead camshaft and
unit injectors, which are centered above the
pistons and controlled by the camshaft and a
control unit (E-ECU). The D9 uses V-ACT (Volvo
Advanced Combustion Technology). The V-ACT D9B
engine features a flexible high pressure fuel
injection with dual solenoid injectors and
optimized air handling with a fixed geometry
turbocharger. Electronically controlled IEGR
(Internal Exhaust Gas Recirculation) reduces NOx
formation and lowers emissions without the need
for exhaust after treatment. Volvo's latest
engine management system, EMS2 is used to control
all engine electronic functions. The cylinders
are numbered consecutively beginning at the
pulley end. Engine rotational direction is
counterclockwise as seen from the flywheel end.
Figure 1 D9B
2
Service Information
Document Title VCADS Pro, MID 128, programming E-ECU Function Group 200 Information Type Service Information Date 2014/12/22
Profile GRD, G976 GB Profile GRD, G976 GB Profile GRD, G976 GB Profile GRD, G976 GB

• VCADS Pro, MID 128, programming E-ECU
• Op nbr 200-009
• MID 128, E-ECU for D9
• ? Turn on battery disconnect switch.
• Start up the computer.
• Connect VCADS Pro computer to the data link port
  in the machine.
• Create a new job card.
• Perform the operations no 28423-2 MID 128 ECU,
  programming.
• Save performed work.
• Shut down the computer and disconnect the adapter
  cable from data link port.
• Turn off battery disconnect switch.

3
Service Information
Document Title Engine, removing Function Group 210 Information Type Service Information Date 2014/12/22
Profile GRD, G976 GB Profile GRD, G976 GB Profile GRD, G976 GB Profile GRD, G976 GB
Engine, removing Op nbr 210-070 9998547 Lifting
tool Lifting strap 2m, qty. 2 Puller Engine,
removal - D9 models G970, G976 and G990 1. Place
the machine in the 191 Service position.
WARNING

• Do not disconnect or loosen connections for the
  air conditioning unit (AC). Risk of gas leakage.
• Remove the hydraulic oil tank covers and engine
  side doors. Refer to 821 Engine hood, removing.
• Remove the engine lower side panel on both sides
  of the machine. On the right side of the machine,
  drain the washer bottle. Tag and disconnect the
  hoses. Remove the washer bottle with the lower
  side panel.

Figure 1 Washer bottle and lower side panel
WARNING
Open the expansion tank cap slowly and carefully.
The cooling system operates at high pressure and
hot coolant may rush out and cause severe
burns. 4. Remove the expansion tank pressure
cap. Add a 3/8" nipple to the draining
valve. NOTE! Be sure that the valve does not turn.
NOTICE
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5
Always handle oils and other environmentally
hazardous fluids in an environmentally safe
manner. 5. Connect a drain hose to the
nipple. Drain the engine coolant into a
suitable container. 260 Cooling system, volume
(Models G930 - G940).
Refer to
Figure 2 Draining the engine coolant
WARNING
Hot oil and hot engine coolant can cause severe
burns! 6. Drain the engine oil. Refer to 210
Engine D7, volume.
WARNING
Only use lifting devices with adequate
capacity. 7. Attach a safe lifting device to the
engine hood assembly. Refer to 821 Engine hood,
removing. NOTE! Be sure to seal all charge air
tubes as soon as they are removed from the
machine.
6

• Figure 3
• Left side of engine
• Wiring harness
• Air intake tube
• Air temperature restriction indicator
• Bolt
• Exhaust pipe
• Charge air tube
• Turbocharger
• Left side
• ? Disconnect the air intake tube at the
  turbocharger
• Disconnect the wiring harness from the engine
  hood assembly.
• Disconnect the exhaust pipe at the turbocharger
• Disconnect the air temperature restriction
  indicator
• Disconnect the coolant lines from the expansion
  tank.
• Remove the bolts attaching the engine hood
  to the engine support frame legs. Refer to
  821 Engine hood, removing.

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NOTE! Be sure to seal all charge air tubes as
soon as they are removed from the machine.

• Figure 4
• Right side of engine
• Wiring harness
• Bolt
• Right rear engine support leg
• Adapter - preheater to charge air cooler
• Right side
• ? Disconnect the wiring harness from the engine
  hood assembly.
• Remove the bolts retaining the engine hood
  assembly to the engine support frame legs
• Disconnect the wiring harness from the rear
  engine support frame leg.
• Remove the right rear engine support frame leg
• Remove the right rear motor mount to frame bolts
• Disconnect the alternator wiring harnesses
• Disconnect the wiring harnesses at the air
  conditioner, if equipped with air conditioning
• Remove the adapter connecting the preheater to
  the charge air cooler
• Relieve the tension from the accessory drive
  belt. Remove the belt from the alternator and air
  conditioning

8

• compressor
• Remove the mounting bolts from the air
  conditioning compressor to the mounting bracket
• NOTE!
• Pay attention to hose routing, particularly in
  the right rear corner of the machine. It will be
  helpful in the 210 Engine, installing procedure.
• NOTE!
• Do not discharge the air conditioning compressor.
  Set the air conditioning compressor to the side
  without opening the system.
• Remove the alternator
• NOTE!
• Use a suitable container to collect any fuel that
  may leak out.
• NOTE!
• Clearly identify all hoses and connections prior
  to disconnecting them.
• Disconnect the fuel lines at the fuel cooler ECU,
  pump outlet connection, the secondary filter
  return line connection and the wiring harness at
  the filter head. Cut all cable ties

Figure 5 Fuel line connections

1. Remove the left rear engine support leg mounting
   bolts. Disconnect the wiring harness clamps from
   the leg. Cut all cable ties. Remove the leg form
   the machine.
2. Disconnect the wiring harness to the starter. Cut
   all cable ties.
3. Remove the mounting bolts securing the charge air
   tube to the engine. Remove the clamps on both
   ends of the

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charge air tube. Remove the charge air tube. 13.
Loosen the clamps and disconnect the two heater
coolant hoses. Disconnect the upper and lower
radiator hoses.
WARNING

• Only use lifting devices with adequate capacity.
• Use an appropriate lifting strap and attach it to
  the rear cooling module. Before removing the
  mounting bolts, take up the slack in the lifting
  strap, in order to support the cooling module.
  Weight 363 kg (800 lbs)
• Remove the four mounting bolts from the cooling
  module. Cut the plastic ties that hold the
  hydraulic hoses in place in order to gain enough
  slack to lift the cooling module.
• Carefully raise the cooling module and move it to
  the rear of the machine enough to give clearance
  between the engine and the cooling module. Rest
  the cooling module securely on the fuel tank.
• NOTE!
• Pay attention when lowering the cooling module on
  top of the fuel tank. Avoid pinching the hoses to
  the fuel sender and the hydraulic hoses to the
  coolers.
• NOTE!
• It may be necessary to remove the fuel cap or
  place blocking under the back of the cooling
  module in order to prevent resting the cooling
  module on the fuel fill spout.
• Remove the engine clutch drain.

Figure 6 1. Engine clutch drain 18. Install
devices to support the pump drive prior to engine
removal. Mount the support devices using the
flange bolt on both sides of the pump drive.
10

• Figure 7
• Support device
• Wooden block
• NOTE!
• It is not necessary to remove the upper
  driveshaft or the protective cover.
• 19. Place wooden blocking under the upper
  driveshaft to prevent it from falling.

WARNING

• Only use lifting devices with adequate capacity.
• Attach a safe lifting device to the engine. Use
  toll number 9998547.Engine weight 1089 kg (2400
  lbs)
• Remove the bolts from under the rear engine mount.

• Figure 8
• Rear engine mount bolts from underneath the
  machine
• Remove the bolts at the left rear engine support
  cross member bracket. Allow the support bracket
  to roll out of the way once the weight is taken
  off of it.
• Remove the bolts retaining the pump drive to the
  engine. Be sure to remove the top bolt last.

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24. Remove the front engine mount bolts.

• Figure 9
• Front engine mount bolt
• Carefully, remove the engine from the machine and
  set it in an engine stand.
• Transfer all necessary parts from the engine to
  the replacement engine.

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Service Information
Document Title Engine, installing Function Group 210 Information Type Service Information Date 2014/12/22
Profile GRD, G976 GB Profile GRD, G976 GB Profile GRD, G976 GB Profile GRD, G976 GB
Engine, installing D9 - models G970, G976 and
G990 Op nbr 210-072 9998547 Lifting
tool Lifting strap 2m, qty. 2 1. Install a new
O-ring between the pump drive and the flywheel
housing. Ensure that the O-ring is lubricated.
WARNING

• Only use lifting devices with adequate capacity.
• Using a safe lifting device, carefully place the
  engine into position. Weight 1089 kg (2400 lbs).
• Reinstall the front engine mount bolts and the
  rear engine mount cross member bolts to help in
  alignment purposes. Do not tighten the bolts at
  this point.
• Reinstall the bolts that retain the pump drive to
  the engine. Torque to specification, where
  possible.
• Reinstall the bolts on both sides of the rear
  engine mount cross member. Torque to
  specification.

Figure 1 Rear engine mount cross member bolts 6.
Reinstall the two rear engine mount bolts. Torque
to specification.
13
Figure 2 Rear engine mount bolts shown from
underneath machine 7. Tighten and torque the
front engine mount bolts to specification.

• Figure 3
• Front engine mount bolt
• Remove the lifting devices. Remove the block
  positioned under the driveshaft.
• Reinstall the clutch drain using a new O-ring.

Figure 4 1. Engine clutch drain
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WARNING

• Only use lifting devices with adequate capacity.
• Using a safe lifting device, move the cooling
  module back into position. It may be necessary to
  use an alignment tool to aid in positioning the
  cooling module. Weight 363 kg (800 lbs)
• Reinstall the bolts that mount the cooling module
  to the machine frame. Remove the lifting device
  from the cooling module.
• NOTE!
• Reinstall the fuel cap, if it was removed.
• Reconnect and clamp the two coolant heater hoses.
  Reconnect and clamp the upper and lower hoses to
  the radiator. Reconnect the cylinder head vent
  hose. Use cable ties to secure the hoses.
• Reinstall the charge air tube from the
  turbocharger to the charge air cooler.
• Reconnect the wiring harnesses to the starter.
  Use cable ties to secure the wiring harnesses.
• Reinstall the post into the mounting bracket.
  Reinstall the left rear support post mounting
  bolts. Do not tighten the bolts at this point.
  Reconnect the wiring harness clamps to the post.
• NOTE!
• Replace all sealing washers at the fuel line
  connections.
• Reconnect the fuel lines at the fuel ECU cooler,
  the pump outlet connection and the secondary
  filter return line connection. Reconnect the
  wiring harness to the filter head. Use cable ties
  to secure the fuel line connections.

Figure 5 Fuel line connections NOTE!
15

• To prevent damage, remove the oil filler cap.
  Cover the oil filler tube to prevent
  contamination.
• Reinstall the air conditioning compressor.
  Replace the oil filler cap.
• Reinstall the alternator. Use cable ties to
  secure the wiring harnesses.
• Reinstall the accessory drive belt on the
  alternator and air conditioning compressor.
• Reinstall the charge air cooler adapter. Torque
  to specification.
• Reconnect the engine wiring harnesses to the
  right side of the engine. Use cable ties to
  secure the wiring harnesses.
• Reinstall the right rear engine support frame
  leg. Install the mounting bolts. Do not tighten
  the bolts at this point.
• 16 kg (35 lbs)

WARNING

• Only use lifting devices with adequate capacity.
• Using a safe lifting device, reinstall the
  engine hood assembly.Weight 136 kg (300
  lbs) Refer to 821 Engine hood, installing.
  Reinstall the engine hood doors and hydraulic
  tank covers.
• Torque tighten the bolts on both rear engine
  mount brackets.
• Reinstall the engine lower side panels on both
  sides of the machine. On the right side,
  reconnect the washer bottle. Use cable ties to
  secure the hoses.
• Fill the engine oil. Refer to 210 Engine D7,
  volume. Install a new engine oil filter. Be sure
  to pour fresh oil into the new filter for
  lubrication.
• Fill the engine coolant. Refer to 260 Cooling
  system, volume (Models G930 - G940).
• Start and warm the engine. Check for any leaks.
• Place the machine back in service.

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Service Information
Document Title Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope Function Group 210 Information Type Service Information Date 2014/12/22
Profile GRD, G976 GB Profile GRD, G976 GB Profile GRD, G976 GB Profile GRD, G976 GB
Camshaft and flywheel oscilloscope Op nbr 210-090
signals, checking with VCADS Pro and
9990014 Break out harness 9990062 Cable 88890040
Oscilloscope VCADS Pro VCADS Pro Service Tool
88890180 Interface 1. Connect 88890040
Oscilloscope to the VCADS Pro computer and
perform 28420-3, Flywheel and camshaft signals,
test. NOTE! Instructions for how to connect the
equipment are described in the VCADS Pro
operation. NOTE! To be able to start the
oscilloscope operation when USB-interface is
default in VCADS Pro, then 88890180 Interface
must be connected to the computer. However, in
this case the interface does not have to be
connected to the machine.
For computers with only one USB-port, the
interface configuration must be changed to
9998555. However, in this cases the interface
does not have to be connected to the machine.
Detailed user support is available under the menu
Help in the software. NOTE! The function Save
overwrites the original file. Therefore, choose
Save as... to save the read-off.
18
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friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
oklibonline.com