Volvo G780B Motor Graders Repair Service Manual11 PDF

0 - Foreword 2
0 - GENERAL 3
1 - STANDARD PARTS; SERVICE 52
2 - ENGINE WITH MOUNTING AND EQUIPMENT 114
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS 251
4 - POWER TRANSMISSION 515
5 - BRAKE 675
6 - STEERING 784
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK
UNIT 914
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE 947
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING
EQUIPMENT; MISCELLANEOUS 988
Service Information
Document Title: Function Group: Information Type: Date:

Service Information 7/9/2020
Profile:
Foreword
WARNING
This warning symbol means risk of fatalities or personal injury if the instructions are not followed.
Read through and follow “Safety and Environment”.

All lifting devices, e.g., straps, slings, ratchet blocks, etc., must meet governing national legislation for lifting devices. Volvo will
not accept any responsibility if lifting devices, tools, or work methods not described in this manual are used.
Volvo works with continuous improvement of the machine's environmental performance.
Perform service work with greatest possible care of the environment.
Operator’s information in Prosis is based on the content of the Operator's manuals. Update cycles for Operator's information in
Prosis and printed Operator's manuals may differ, hence always refer to the printed Operator's manual delivered with the
machine.
We reserve the right to modify specifications and equipment without prior notification.
00 - DESCRIPTION; COMPLETE MACHINE 2
03 - SPECIFICATIONS 9
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION;
OPERATIONG INSTRUCTION 12
07 - STANDARD TIME 42
08 - TOOL 45
09 - MISCELLANEOUS 48
Description 2
Product identification plates 5
Service Information

Description 000 Service Information 9/10/2022
Profile:
G780B Volvo
Description
Showing All Profiles
Valid for serial numbers

Model Production site Serial number start Serial number stop
G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Intended use
The machine is intended to be used under normal conditions for the operations described in the Operator's Manual. If it is used
for other purposes or in potentially dangerous environments, for example, an explosive atmosphere, areas with dust containing
asbestos, etc., special safety regulations must be followed and the machine must be equipped for such use. Contact the
manufacturer or dealer for further information.
Engine
The engine is a four stroke cycle, in line six cylinder, turbocharged diesel with overhead valves and charge air cooler. These
engines are of the low emission type and all models have VHP (Variable Horsepower).
VHP
All Volvo grader models have engines that provide 2 different power levels depending on the gear selected by the operator.
For non-All Wheel Drive equipped graders, forward gears 1, 2, and reverse 1, have reduced power to minimize wheel
slip. In forward gears 3 through 8, and reverse gears 2 through 4, engine power is automatically increased.
For All Wheel Drive equipped models with the All Wheel Drive system turned OFF, the function of the VHP is the same
as above.
For All Wheel Drive equipped models with the All Wheel Drive turned ON, the engine power is increased for all gears.
There is no operator selectable control over the VHP system.
Electrical system
The electrical system is a 24VDC, negative-ground system. Power is supplied by two 12VDC batteries connected in series. Battery
charging is accomplished using a standard 75 amp alternator and an optional 100 amp alternator. Electrical power can be
disconnected using a ground isolation switch.
Clutch
A multiple wet disc clutch is mounted to the engine flywheel and connected to the transmission with a driveshaft. The clutch
must be used when starting to move or when changing direction.
Transmission
The transmission has eight forward and four reverse speeds. It is a fully sequential, direct drive, powershift unit utilizing a
countershaft design.
Final drive/tandems
Final drives are single reduction in models G710B to G746B and double reduction in the G780B. Each has an operator controlled
lock/unlock differential. Rear axles are case hardened, full floating design, supported on double row spherical roller bearings.
Tandem wheels are chain-driven.
Brakes
Hydraulically actuated, oil disc service brakes are located at the four tandem drive wheels. The crossover dual braking circuits
provide even braking on both sides of the grader.
If the engine stalls, or hydraulic boost pressure becomes unavailable, full braking capability is available through a reserve system.
An electric motor supplies the power required to bring the grader to a safe stop.
The parking brake is a spring apply/hydraulic release, disc-type brake. It is driveline-mounted to the transmission output shaft.
An accumulator in the circuit stores system pressure allowing the brakes to remain released in the event of system pressure loss
for about 30 minutes.
Steering
The steering system is a closed-center dynamic signal load sensing system. The hydraulic steering system incorporates two
steering cylinders. The leaning wheel feature and articulated frame can be used to decrease turning radius. There is no manual
steering.
Cab and frame
Either the canopy or fully-enclosed cab are equipped according to the FOPS-ROPS stipulations and provided with heating and
ventilation with air conditioning as an option. All controls and gauges are housed in either the fully adjustable steering pedestal
or the right-hand side console. Ergonomic seating and hydraulic control lever placement ensure operator comfort and efficiency.
The frame articulates 22 degrees right or left and uses anti-drift lock valves to ensure stable operation.
MBCS (Moveable Blade Control System)
Blade mobility permits steep ditch cutting angles and back sloping outside of overall machine width. The circle is held in place by
adjustable clamp plates and guide shoes. Bearing surfaces are DURAMIDE™- faced to maximize service life. Hardened teeth are
cut on the outside of the circle. Oil is directed to the two drive cylinders by a circle timing valve. The cylinders are arranged 90
degrees out of phase to insure consistent power. Moldboard is provided with replaceable cutting edge and end-bits. The
drawbar is a narrow “T” design for optimum visibility to the work area.
Hydraulic system
The closed-center hydraulic system uses a pressure and flow compensated (load-sensing) variable displacement piston pump.
The pump supplies oil to the implements, the steering and the engine cooling fan system.
The cooling fan is driven by a fixed displacement vane-type motor. Fan speed is variable and is determined by various cooling
requirements. The fan operates between predetermined minimum and maximum speeds. The fan remains at its minimum speed
until there is a demand for cooling. Fan speed will automatically increase with the demand for cooling.
Lock valves (counterbalance valves) are incorporated into the blade lift, moldboard tilt, circle shift, wheel lean and articulation
circuits to prevent cylinder drift. The control levers are short throw, feathering type located on an adjustable steering pedestal.
All Wheel Drive - (AWD)
G726B and G746B are All Wheel Drive models. The system operates in gears 1 through 7. It is powered by two electronically
controlled, variable displacement hydraulic pumps in a closed loop system. Each pump supplies one front wheel motor.
Front wheel motors are two-speed, high torque, radial piston, cam lobe type. Each wheel motor has a separate speed sensor.
Equipment and attachments
The circle, drawbar and moldboard equipment is fully maneuverable using hydraulic cylinders. Optional attachments include:
Dozer blade
Rear-mounted ripper-scarifier
Mid-mounted scarifier
Front-mounted scarifier
Windrow eliminator
Push block (counterweight for ripper)
One-way plow
V-plow
Hydraulic snow wing (high and low bench)
A-frame (used with V-plow and One-way plow only)
Service Information

Product identification plates 000 Service Information 9/10/2022
Profile:
G780B Volvo
Product identification plates


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The following illustrations and text show which product plates are installed on the machine. These numbers are recorded at the
factory.
Always quote the motor grader Model Number and the Product Identification Number when ordering spare parts, and in all
telephone inquiries or correspondence.
Figure 1
Product identification plate location
Engine (1)
The engine serial numbers are found on a plate on the left-hand side of the engine on models G710B to G730B. G740B, G746B
and G780B models have the serial number stamped into the right-hand side of the engine block.
Cab (2)
The ROPS and FOPS serial number plates are found inside the cab on the left-hand post behind the operator's seat. The ROPS
plate states the model and serial number, specification, maximum machine mass, and bolt torque. The FOPS plate states the
model, serial number and specification.
Figure 2
ROPS and FOPS plates
Product identification plate (3)
This plate is found on the right-hand side of the frame in front of the cab. It has the Model Number and PIN (Product
Identification Number) stamped on it. The Model Number is broken down as follows: the first digit designates G700 Models; the
next two digits indicate weight and horsepower range.
Figure 3
Product identification plate
The Model Number and PIN must be used in conjunction with the Parts Catalog to order correct replacement parts.
Product identification plate (EU/EEA countries) (4)
In addition to the above information, this plate shows machine weight, engine power, year of manufacture and has a space for
the CE mark. It also is positioned on the right-hand side of the frame in front of the cab.
Figure 4
Product identification plate (EU/EEA)
Product identification plate for TUV (Germany) (5)
This plate is found on the right-hand side of the frame in front of the cab.
Figure 5
Product identification plate TUV
Transmission (6)
The transmission serial number is located on the lower front of the housing.
Figure 6
Transmission plate
Final drive (7)
The final drive serial number is found on the right-hand side on the rear of the final drive on models G710B to G746B. On G780B
models it is found on the top of the center housing.
Figure 7
Final drive plate
Dimensions 2
Service Information

Dimensions 030 Service Information 9/10/2022
Profile:
G780B Volvo
Dimensions

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Dimensions are shown for graders with standard size tires and full cab with ROPS.
Model
Dimension G710B G720B G730B G740B G780B
G726B G746B
A Length 9 093 mm 9 119 mm 9 119 mm 9 271 mm 9 322 mm
(29 ft, 10 in.) (29 ft, 11 in.) (29 ft, 11 in.) (30 ft, 5 in.) (30 ft, 7 in.)
B Width 2 489 mm 2 540 mm 2 540 mm 2 540 mm 2 794 mm
C Height 3 378 mm 3 404 mm 3 404 mm 3 404 mm 3 505 mm
Low profile cab 3 073 mm 3 099 mm 3 099 mm 3 099 mm 3 200 mm
D Wheelbase 6 096 mm 6 096 mm 6 096 mm 6 248 mm 6 248 mm
E Tread width 2 083 mm 2 083 mm 2 083 mm 2 136 mm 2 311 mm
(6 ft, 10 in.) (6 f, 10 in.) (6 ft, 10 in.) (7 ft, 0 in.) (7 ft, 7 in.)
F Bladebase 2 616 mm 2 591 mm 2 591 mm 2 718 mm 2 718 mm
(ISO 7134) (8 ft, 7 in.) (8 ft, 6 in.) (8 ft, 6 in.) (8 ft, 11 in.) (8 ft, 11 in.)
Transporting the machine 2
Storage 7
Grader setup instructions 9
Service Information

Transporting the machine 050 Service Information 9/10/2022
Profile:
G780B Volvo
Transporting the machine


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Use a pressure washer to remove any loose gravel, mud or debris from the grader moldboard, tires or frame.
Install both articulation lock pins before loading the grader onto the trailer bed.
Figure 1
1. Articulation lock pin
Load and unload the grader on a level surface.

Ensure the combined height of the trailer bed and the top of the grader cab is lower than local height restrictions or any
bridges, overpasses or overhead obstructions expected to be encountered during transport. Refer to Dimensions.
Ensure the transporting equipment is adequate to hold the weight and size of the grader.
Place chocks against the truck and trailer wheels.
Use a ramp or loading dock. Ensure the ramp is strong enough and has a low angle of rise to the height of the trailer
bed.
Do not place tie-down cables or chains over or against hydraulic tubes, hoses, cylinders or valves, etc. Attach tie-down
cables or chains securely to front attachment points.
Obey all local laws concerning loading, unloading or transporting the grader. Wide load permits may be required for
graders equipped with tires larger than 14.00.
Keep the trailer bed clean.
The rotating beacon can be lowered for increased clearance. Lift and release the pivot rod handle on the left-hand side
of the bracket. Grasp the handle at the rear of the bracket. Slightly move the bracket upward, and then allow the
bracket to pivot until it reaches the end of its travel limit. Return the pivot rod handle to the locked position.
Figure 2
1. Rotating beacon light

2. Pivot rod handle
3. Lowered position
When loading the grader onto a trailer bed, drive the grader straight and centered with the width of the trailer bed. The
centerline of the grader must be directly over that of the trailer bed or railcar.
Figure 3
Before securing tie-down cables or chains, position the grader on the trailer bed as follows:
1. Place the transmission in neutral and apply the parking brake.

Figure 4
2. Lower the moldboard lengthwise under the grader onto wooden blocks to protect the trailer bed. Do not apply down
pressure. Also, lower any attachments such as a scarifier or ripper.
Figure 5
1. Wooden blocks
3. Place grader in the Service position. Refer to Service positions

4. Install chocks at the front and rear tandem wheels. Wedge and nail the chocks in place.
Figure 6
1. Wheel chocks
5. Relieve residual hydraulic pressure by operating all the control levers.

6. Remove and retain the ignition key. Lock the cab doors.
7. Turn the battery isolation switch off. It is located inside the engine compartment on the left-hand side of the grader.
Figure 7
1. Battery isolation switch
8. Cover the exhaust opening with heavy gauge plastic and secure in place to prevent dust and moisture entering the
engine. Remember to remove the plastic cover before starting the grader.
Figure 8
1. Exhaust opening
Lifting arrangement and tie-down locations
Figure 9
1. 15° maximum lifting angle

2. 10° maximum lifting angle
3. Front and rear tie-down locations (optional or EEC machines)
4. Front and rear lifting points
Service Information

Storage 050 Service Information 9/10/2022
Profile:
G780B Volvo
Storage

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Long-term parking
When a grader is taken out of service for more than 30 days, you must ensure that it is protected from exposure to the elements.
An enclosed structure will protect the grader from rapid temperature changes and decrease the amount of condensation that
forms in fluid reservoirs, e.g., engine oil pan, fuel tank, hydraulic oil tank, etc.
After you have parked the grader and shut down the engine, perform the following steps:
1. Inspect for leaks and other defects. Correct as necessary

2. Thoroughly wash the grader. Be sure to rinse off any caustic residue.
3. Touch up any areas where the paint has worn away.
4. Clean or replace air filter elements.
5. Open the drain valve at the bottom of the fuel tank and drain 1 liter (approx. 1 US quart) of fuel to remove any water
accumulation.
6. Replace engine fuel filters.
7. Add the recommended amount of fuel stabilizer and corrosion inhibitor to the fuel tank.
8. Start and run the engine at 1400 rpm to 1600 rpm with no load for approximately four minutes.
9. Change the engine oil and replace the engine oil filter.
10. Seal the engine exhaust and air intake openings with tape or heavy gauge plastic.
11. If tires are to be left on, raise the grader and place it on blocks to keep the tires off the ground. Deflate and cover the
tires.
12. Turn off the battery isolation switch. Remove batteries and store them in a cool, clean, dry and well-ventilated area
where the temperature is between 0ºC and 21ºC (32ºF and 70ºF). Be sure batteries are fully charged.
13. Remove all objects which do not belong in or on the grader.
14. Place a "Do Not Operate" or similar warning tag on the steering wheel to indicate that the Grader has been taken out of
service and remove the ignition key.
15. Coat all machined and unpainted surfaces (including moldboard) with grease to prevent rust forming.
16. Coat all exposed chrome plated surfaces on hydraulic cylinder piston rods with a thin layer of grease.
17. Grease all door hinges.
18. Latch and lock the cab and compartment doors in the fully closed position and store the keys in a safe place.
Preparing for operation after long-term parking

Perform the following steps before putting the grader back into service:
1. Inspect for leaks and other defects which may have occurred during storage.
2. Thoroughly wash the grader. Remove all grease and coatings installed as Long term parking steps 13 and 14 on the
previous page.
3. Remove the tape or heavy gauge plastic from the engine exhaust and air intake openings.
4. Ensure that all ports, hatches, and openings, including the engine compartment and cooling module areas of the
machine, are free of animal and birds nests or other debris.
5. Lubricate all grease points. Refer to the Operator's Manual.
6. Install fully charged batteries. Turn on the battery isolation switch.
7. Inflate the tires to the correct pressure. Refer to the Operator's Manual. Lower the grader from the storage blocks.
8. Perform all appropriate pre-start checks. Refer to the Operator's Manual.
9. Start and run the engine at 1400 rpm to 1600 rpm with no load for approximately four minutes. If any warning lamps
and the alarm energize or gauges show abnormal readings, shut down the engine. Report the problem and have it
repaired by a qualified service technician.
Service Information

Grader setup instructions 050 Service Information 9/10/2022
Profile:
G780B Volvo
Grader setup instructions


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
General
Volvo motor graders are prepared for export shipment in different configurations. Graders can be shipped as knock-down units
in containers, roll-on/roll-off (RO-RO) machines or complete, drivable graders with a fully assembled cab. RO-RO machines are
also drivable, but the upper part of the cab structure is removed and stowed on the front frame. The doors and upper cab glass
are packaged in a crate attached to the grader front frame.
This section describes the reassembly procedure for a typical grader shipped as a knock-down unit in a standard container.
Optional attachments may accompany the grader in the same container. The reassembly procedure depends on the local
unloading facilities. General shop tools are required.
It may be necessary to drive the machine under it's own power after being unloaded. Before starting and moving the grader,
perform the General walk-around inspection. See below. Refer to the grader Operator's Manual for complete details. The
Operator's Manual is found in the manual box inside the cab behind the seat.
These instructions cover the following machine models, Serial Number 35000 and up:
G710B, G720B, G730B, G740B, G780B, G726B, and G746B.
Knock-down unit – Removal from the container
1. Remove the tarpaulin from the container. Remove the reinforcing rods from the container and swing the mainstay to
one side.
Figure 1
Removing grader from container
WARNING
Only use lifting devices with adequate capacity.
2. Ensure the lifting lug nuts and bolts are tight before lifting the grader. Attach crane hooks to the lifting lugs. Install a
spreader bar between the cables above the rear lifting lugs to prevent damage to the grader. Remove any retaining
wooden blocks and lift the grader out of the container. If there is limited time to use the lifting device, lower the grader
onto the ground. If there is full use of the lifting device, lower the grader just enough to install the rims and tires.
3. Use a safe lifting device to remove the rims and tires from the container. Install the rims and tires onto the front and
rear wheel hubs. Generally, the front tires are mounted with the tread facing the opposite direction of the rear tires. This
promotes self-cleaning of the tire. However, the driving front wheels of an All Wheel Drive grader must have the tire
tread facing the same direction as the rear tire tread.
NOTE!
If an overhead crane or other lifting device is not available to install the wheels, refer to Installing rims and tires without
a crane. See below.
4. Use a tire pressure gauge to check the air pressure in the tires. Adjust the air pressure to 241 kPa (35 psi). Refer to the
Operator's Manual for further information.
5. Lower the grader to the ground. Torque-tighten the rim bolts to 644 – 712 N•m (66 – 73 kgf•m; 475 – 525 lbf•ft) in a
diagonal pattern. Do not torque-tighten the rim bolts in series around the wheel hubs.
6. Sometimes areas of the grader are coated with a surface treatment to protect the machine from corrosion during
transportation.
Figure 2
Removing surface treatment
Remove the protective coating using mineral spirits or degreasing solvents.

Spray on until the surface to be cleaned is completely wetted.
Let stand for 15 minutes.
Wash off with a power washer.
Thoroughly inspect all hydraulic cylinder piston rods and seals for signs of damage or corrosion.
Complete this procedure before operating any of the hydraulic cylinders.
7. Remove the plastic covering from the engine air intake stack and exhaust pipe.
8. Install the air cleaner rain cap or precleaner (optional).
Figure 3
1. Air cleaner rain cap

2. Exhaust stack
On models G710B to G730B, torque-tighten the band clamp to 9,6 – 11 N•m (1 kgf•m; 7 – 8 lbf•ft).
On models G740B to G780B, torque-tighten the bolts to 50 – 70 N•m (5 – 7 kgf•m; 37 – 52 lbf•ft).
9. Install the exhaust stack. Torque-tighten the bolts to 50 – 70 N•m (5 – 7 kgf•m; 37 – 52 lbf•ft).
NOTE!
If it is necessary to move the machine to another location before continuing with the rest of the assembly, perform the General
walk-around inspection. See below.
General walk-around inspection

Figure 4
Perform the following general walk-around inspection.
Look for oil and coolant leaks. Check for tire damage, pinched hoses and loose bolts. Repair as necessary.
Visually check the levels of the engine coolant, engine oil, hydraulic oil and transmission oil as outlined on the following
pages. Replenish fluids as required.
Ensure all tools and other loose objects are removed from the machine. Turn the battery isolation switch to the “I”
position. Ensure the transmission is in NEUTRAL and the parking brake is engaged (control knob pushed in).
Visually check around the machine. Ensure all personnel are clearly away from the area. Signal the intention to start the
engine. Start the engine when it is safe to do so. When it is safe to do so, release the parking brake and move the
grader.
Check the engine oil level
Figure 5
Check the engine oil level with the engine off.

The machine should be parked on level ground to check the engine oil. Check the oil when the engine is cold.
The oil filler cap and dipstick are located on the left-hand side of the engine.
Withdraw the dipstick and check the oil level. The oil level must be between the marks on the dipstick.
Add engine oil as required. Refer toRecommended lubricants for correct oil type.
Check the oil for contaminants or water.

Checking coolant
Figure 6
The expansion tank should be 2/3 full, at the MAX mark when the engine is warm. The control lamp for the coolant level lights
up when the level in the expansion tank is too low. Top up when required. Refer to Coolantfor more information.
The coolant level must never be below the minimum mark.
Transmission oil level
Figure 7
1. Transmission oil level sight glass
Prior to starting the machine, ensure the transmission oil level sight glass is full. (The oil level sight glass is located on the left-
hand side of the transmission case.) The sight glass should be full when the engine is shut down.
Check the transmission oil level at operating temperature with the engine running.
To check the oil:
Park the grader on level ground and place the transmission in NEUTRAL.
Apply the parking brake and lower the moldboard and all attachments to the ground.
With the engine speed at idle, the oil level should be at the middle of the sight glass. Refer toRecommended lubricants
for correct oil type.
Checking the hydraulic oil fluid level
Figure 8
The hydraulic tank oil filler cap and dipstick are located at the rear of the grader on the left-hand side, inside the rear side door.
Clean any dirt from around the filler cap.

Remove the cap from the hydraulic tank and wipe the dipstick clean.
Replace the cap and seat it firmly. Remove it again and check the oil level. The oil level must be at the “FULL” mark on
the dipstick and not more than 1/4 in. (6 mm) down.
Add clean hydraulic oil as necessary through the filler neck. Refer toRecommended lubricants for correct oil type.
Procedures before starting the machine
Before starting the grader, turn the battery isolation switch on.
Start and operate the grader only from the operator's seat.
Adjust the seat and fasten the seat belt. The seat belt must fit snug and low around the hips. The holding strap must be
free of slack.
Check the transmission shift lever to ensure it is in NEUTRAL before starting the engine.
Ensure the parking brake is applied (control knob pushed in).
Sound the horn before starting the engine. Warn all personnel who may be servicing the grader or are in its path prior
to starting. Do not start the engine until all personnel are clearly away from the grader.
Do not operate the engine in an enclosed area without adequate ventilation.
Do not bypass the battery isolation switch. Have the switch repaired if it is not working properly.
Use jumper cables only in the recommended manner. Improper use can result in battery explosion or unexpected
movement of the grader. Refer to Jump-start procedure.
After the engine has started, check all gauges and indicators for proper readings. Shut down the engine immediately if
any improper readings or energized warning lamps are observed. Refer to the Operator's Manual.
Ensure that the lights work properly.
Check that the hydraulic controls function properly.
Check that the parking and service brakes function properly.
Check that the engine hand throttle and accelerator function properly.
Listen for unusual noises.
Look around and behind the grader before moving it.
Check that the left-hand steering and right-hand steering function properly.
Starting the engine
WARNING
Risk of crushing injuries
NOTE!
Keep clear of the articulation joint when the engine is running.
NOTE!
After starting the engine, run it at low idle speed for at least 30 seconds. This is to ensure proper lubrication pressure.
NOTE!
Do not hold the key in the starting (III) position for more than 20 seconds. This could seriously damage the starting system. Wait
2 minutes, then try to start the engine again.
Figure 9
1. Place the hand throttle lever in the low idle position (pulled back towards the operator).
2. Insert the ignition key in the switch and rotate the key clockwise to position “III” (start position).
3. Release the key when engine starts.
NOTE!
If the engine does not start:
4. Wait until the engine has stopped completely.

5. Turn the key back to the “O” position in order to make a new attempt.
Starting a cold engine

Figure 10
A. Control lamp, preheating element

B. Switch, preheating element
Engine preheating should be used when the engine temperature is below 0ºC (32ºF).
NOTICE
Do not use starting aids (ether, etc.). Serious engine damage could result.
1. Turn the ignition key to position “I” (Running position and preheat position).
2. Momentarily depress the Preheat element switch beside the ignition switch on the side console. The preheat now
remains engaged for up to 50 seconds and the control lamp will illuminate.
3. When the control lamp goes out, turn the ignition key clockwise to position “III” (start position). Release the key when
the engine starts. Making a starting attempt during the preheat cycle will cancel the preheat.
NOTE!
The use of an immersion heater to warm the oil in the engine is highly recommended or, if possible, store the grader
inside a heated facility.
4. After starting, the lamp may come on for a short period of time indicating post heat.
NOTE!
If the control lamp stays on after a 50 second period, the preheating element is still connected. Check the function of
the element as there is a risk of overheating.
Hydraulic controls
Figure 11
1. Left-hand blade lift lever

2. Moldboard slide shift lever
3. Circle turn lever
4. Circle shift lever
5. Front wheel lean lever
6. Right-hand blade lift lever
7. Control lever for scarifier, ripper or windrow eliminator
8. Articulation lever
9. Moldboard tilt lever
10. A-frame attachments lever
Installing rims and tires without a crane
Figure 12
Preparing to raise front axle
If a safe lifting device is not available, use this method to install the rims and tires. Before starting this procedure, perform step 6
of Knock - down unit - Removal from the container and all the steps in General walk-around inspection. See above. Also,
refer to Reassembly – Blade lift cylinders. See below.
WARNING
Never work under/on machines without using recommended support equipment.
1. Turn the battery isolation switch to the “I” position. Ensure the transmission is in NEUTRAL and the parking brake is
engaged. Start the engine when it is safe to do so. Operate the blade lift cylinders and raise the moldboard off the
ground.
2. Center the drawbar and tilt the moldboard fully rearward. Rotate the circle until the moldboard is parallel with the front
axle. Place appropriate wooden blocks under the moldboard. Operate the blade lift cylinders and lower the moldboard
onto the wooden blocks.
3. Continue operating the blade lift cylinders and carefully raise the front axle off the ground. Install the rims and tires
onto the front wheel hubs.
Generally, the front tires are mounted with the tread facing the opposite direction of the rear tires. This promotes self-
cleaning of the tire. However, the driving front wheels of an All Wheel Drive grader must have the tire tread facing the
same direction as the rear tire tread.
4. Lower the front end of the grader to the ground. Torque-tighten the rim bolts to 644 – 712 N•m (66 – 73 kgf•m; 475 –
525 lbf•ft) in a diagonal pattern. Do not torque-tighten the rim bolts in series around the wheel hubs.
5. Raise the front axle until the tires are 1,0 m (3 feet) off the ground. To raise the rear left-hand side of the grader,
operate the control lever and retract the right-hand blade lift cylinder piston rod. Now install the rims and tires onto the
left-hand rear wheel hubs.
6. Extend the right-hand blade lift cylinder piston rod to exert weight on the rear left-hand tires. Torque-tighten the rim
bolts to 644 – 712 N•m (66 – 73 kgf•m; 475 – 525 lbf•ft) in a diagonal pattern. Do not torque-tighten the rim bolts in
series around the wheel hubs.
7. Further extend the right-hand blade lift cylinder piston rod to level the rear of the grader frame.
8. To raise the rear right-hand side of the grader, operate the control lever and retract the left-hand blade lift cylinder
piston rod. Now install the rims and tires onto the right-hand rear wheel hubs.
9. Extend the left-hand blade lift cylinder piston rod to exert weight on the rear right-hand tires. Torque-tighten the rim
bolts to 644 – 712 N•m (66 – 73 kgf•m; 475 – 525 lbf•ft) in a diagonal pattern. Do not torque-tighten the rim bolts in
series around the wheel hubs.
10. Use a tire pressure gauge to check the air pressure in the tires. Adjust the air pressure to 241 kPa (35 psi). Refer to the
Operator's Manual for further information.
11. Remove the safety blocks or stands. Lower the front tires to the ground. Shut down the engine and turn the battery
isolation switch to the “O” position.
Reassembly – Cab structure
WARNING
Heavy and awkward lift. Work carefully when the operator's seat is lifted out.
NOTICE
Use a safe lifting device with the proper rated capacity for the job.
1. Attach a safe lifting device to the crate installed on the cab seat deck. This crate contains the seat, cab and tandem
steps, lights and windshield wipers. Remove the crate and place to one side for unpacking.
Figure 13
Attach a safe lifting device to crate
2. Remove and discard the plastic protective covering from the cab posts.
Figure 14
Removing cab plastic protective covering
3. Cut the metal bands securing the crate installed on the upper cab structure. Carefully raise the front of the crate and
install a wooden wedge between the crate and upper cab structure. This allows the attachment of a safe lifting device to
both ends of the crate. Use extreme caution when lifting and handling the crate. It contains the doors, front cab posts,
front and rear windshields, upper cab glass, window rubbers and locking strips, and all hardware.
Figure 15
Removing crate containing doors and cab glass
4. Open the door crate. Remove the front cab posts and install them while the cab upper structure rests on the grader
front frame.
Figure 16
Installing front cab posts
WARNING
The parts are heavy. Take appropriate safety precautions.
NOTICE
5. Attach a safe lifting device to the cab upper structure. Carefully lift the cab upper structure and guide it into place.
Install the bolts loosely until the cab upper structure is seated on the supports. When the cab upper structure is firmly in
place, torque-tighten the rear post locknuts to 678 – 712 N•m (69 – 73 kgf•m; 500 – 525 lbf•ft) and tighten the
remaining cab mounting plate bolts. For split ROPS cabs, install the right-hand and left-hand joiner plates between the
upper and lower side window openings. The joiner plates and hardware are stored in the tool box on the right-hand
tandem case.
Figure 17
Installing cab rear post hardware
6. Remove and retain the self-tapping screws securing all the plastic headliner pieces. Remove the headliner pieces and
place to one side to prevent them from being damaged.
Figure 18
Temporarily removing cab plastic headliner pieces
Reassembly – Electrical, HVAC, seat

Electrical system
Figure 19
Battery isolation switch
NOTE!
Before working on any part of the electrical system, be sure the battery isolation switch is turned off to the “O” position. It is
located in the engine compartment on the left-hand side of the machine.
1. Connect the upper cab and lower cab wiring harnesses inside the right-hand door post at the terminals. Ensure the
connections are tight. Even though grader options may vary, all wires are tagged for identification. The plug ends are
coated with corrosion protective compound that does not have to be removed.
2. Install all cab mounted electrical components, e.g., headlights, horn, wiper motors and defroster fans and connect these
units to the wiring harness.
Figure 20
Connecting upper and lower cab wiring harnesses
3. Install the plastic headliner pieces and secure them with the self-tapping screws originally supplied.
4. Install the remaining electrical components, such as the rear lights, working lights and back-up alarm.
5. Install the front and rear wipers (as equipped) and reconnect the windshield washer hoses.
Figure 21
Installing cab mounted electrical components
Figure 22
HVAC system
Figure 23
Installing HVAC ducting to seat deck
1. Tie wraps
2. Left post duct
3. Right post duct
1. If equipped, install the HVAC hose ducting to the seat deck. Secure the hoses with tie-wraps included in the box. Cut off
the excess ends.
2. Install the left-hand cover moulding and the right-hand louver housing.
Figure 24
1. Left-hand cover moulding

2. Right-hand louver housing
3. Install the optional 24V to 12V equalizer/converter or fire extinguisher on the bracket at the rear left-hand corner of the
cab (as equipped).
Figure 25
1. Installation mounts for optional equalizer/converter or fire extinguisher
Figure 26
– 24V to 12V equalizer/converter wiring diagram
Figure 27
Install the door post covers
1. Right-hand door post

2. Left-hand door post
4. Install the door post covers. Note that some louvers have been removed from the covers for shipping and need to be
reinstalled. All louvers are installed to close in the downward position.
Seat
Figure 28
Installing seat onto seat deck plate
1. Open and unpack the seat crate. Install the cab left-hand step. Install the outside mirror frames, if applicable. Install the
outside mirrors, which are stored in the tool box.
2. Install the seat on the seat deck plate. Ensure that the seat slider latches securely.
3. Install the seat belt anchors. Ensure that the seat belts are not twisted and that the buckle fastens properly.
Reassembly – Window and door installation
1. Install the rubber channel onto and around the front windshield opening. Ensure that the widest groove of the channel
is used for the glass perimeter and the locking strip groove is facing outwards from the cab. When the rubber channel
is installed, allow an overlap of 25 mm (1 in.) and force the overlap into place.
Figure 29
Installing cab front windshield rubber channel
2. Remove the front windshield glass from the door crate. Inspect the glass for damage. Apply a soap solution to the
rubber channel. Carefully lift the glass into place and insert into one corner of the rubber channel. Use an appropriate
installation tool to fully install the glass. Ensure the glass is secure in the rubber channel groove.
Figure 30
Installing cab front windshield glass
3. Use an appropriate tool to install the rubber locking strip into the groove of the rubber channel. To achieve a proper
seal, start the locking strip on the opposite side to the rubber channel joint. Install the locking strip with the wide bead
to the outside.
Figure 31
Using rubber locking strip tool
4. Cut the locking strip 25 mm (1 in.) longer than appears necessary and force the overlap into place. When the glass,
rubber channel and locking strip are completely installed, check that the glass is securely in place.
Figure 32
Installing rubber locking strip
5. Repeat steps 1 through 4 for the rear windshield and upper cab glass.
WARNING
NOTICE
6. Attach a safe lifting device to the cab door. Maneuver the door into position and engage the hinge pins and hinges.
Swing the door back and forth to seat the pins firmly in the hinges. Repeat this procedure for the second door.
7. Check the operation of the door handles. Ensure that the doors open and close properly and remain latched when shut.
Adjust the door striker pins as necessary.
Figure 33
Installing cab door
Reassembly – Blade lift cylinders
1. Ensure that the protective coating has been removed from the blade lift hydraulic cylinder piston rods and ball pin
surfaces. Thoroughly inspect the piston rods and seals for signs of damage or corrosion. Remove the tie wraps securing
the blade lift cylinders in their shipping position.
Figure 34
Aligning ball cap halves
2. Connect the hydraulic hoses at the circle turn cushion valve and blade lift counterbalance or float valve.
3. Attach a safe lifting device to the top of the blade lift cylinder. Pivot the cylinder until the ball cap is at the bottom.
Separate the ball cap halves – this is a matched set. Retain the hardware and shims.
NOTE!
Keep the shim packs in their original positions. Do not mix shims or shim positions.
4. Turn the battery isolation switch to the “I” position. Ensure the transmission is in NEUTRAL and the parking brake is
engaged. Start the engine when it is safe to do so. Operate the blade lift cylinder and extend the piston rod until the
ball cap engages the ball pin on the drawbar.
5. Align the stamped marks and install the ball cap halves. Install the shim packs and retain the ball caps with the bolts
and lock washers. Torque-tighten the bolts to 644 – 712 N•m (66 – 73 kgf•m; 475 – 525 lbf•ft).
6. Repeat steps 3, 4 and 5 for the other blade lift cylinder. Once both blade lift cylinders are installed, carefully remove the
shipping cables securing the circle and drawbar assembly.
Figure 35
Removing circle and drawbar shipping retention cables
Other hydraulic connections

Circle
Figure 36
1. Circle turn counterbalance valve
Reconnect the circle turn hose at the counterbalance valve on the drawbar.
Mid-mount scarifier (if equipped)
1. Connect the scarifier hydraulic hose at the left-hand side of the grader nose.
2. Carefully remove the shipping cables.
Pictorial torque guide

Figure 37
Torque value
Item N•m kgf•m lbf•ft
1 644 – 712 66 – 73 475 – 525 lbf•ft
2 644 – 712 66 – 73 475 – 525 lbf•ft
3 50 – 70 5–7 37 – 52 lbf•ft
4 Band clamp – Models G710B to G730B:
9,6 – 11 N•m 1 7 – 8 lbf•ft
4 Bolts – Models G740B to G780B:
50 – 70 5–7 37 – 52 lbf•ft
5 678 – 712 69 – 73 500 – 525 lbf•ft
6 102 – 136 10 – 14 75 – 100 lbf•ft
Operation numbers for additional work 2
Service Information

Operation numbers for 070 Service Information 9/10/2022
additional work
Profile:
Motor Graders
Operation numbers for additional work


R100E Volvo
These operations can be used to identify work that is not included in the time guide or described in the methods in the Service
Manual. When these operations are used, a description of the work that has been performed must be provided.
Other work related to engine

Op. no. 070-210
This operation can be used when work has been done related to the engine and function group 2 when no applicable method
description was available. When this operation is used, additional information is required:
Description of work that has been done
Other work related to electrical system

Op. no. 070-310
This operation can be used when work has been done related to the electrical system and function group 3 when no applicable
method description was available. When this operation is used, additional information is required:
Other work related to transmission, gearbox, travel motor, swing motor

Op. no. 070-410
This operation can be used when work has been done related to the transmission, gearbox, travel motor or swing motor and
function group 4 when no applicable method description was available. Hhen this operation is used, additional information is
required:
Other work related to drive axle

Op. no. 070-470
This operation can be used when work has been done related to the drive axle and function group 46 when no applicable
Description of required work that have been done
Other work related to brake system

Op. no. 070-510
This operation can be used when work has been done related to the brake system and function group 5 when no applicable
Other work related to steering system

Op. no. 070-610
This operation can be used when work has been done related to the steering system and function group 6 when no applicable
Other work related to frame link, axle suspension

Op. no. 070-710
This operation can be used when work has been done related to the frame link, axle suspension and other parts related to
function group 7 when no applicable method description was available. When this operation is used, additional information is
required:
Other work related to cab, air conditioning

Op. no. 070-810
This operation can be used when work has been done related to the cab, air conditioning and other parts related to function
group 8 when no applicable method description was available. When this operation is used, additional information is required:
Other work related to hydraulic system

Op. no. 070-910
This operation can be used when work has been done related to the hydraulic system and other parts related to function group
9 when no applicable method description was available. When this operation is used, additional information is required:

G700B Special tools 2
Service Information

G700B Special tools 080 Service Information 9/10/2022
Profile:
G780B Volvo
G700B Special tools


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Group code Tool P/N Tool description Tool application Applicable models
421 29858 Depth gauge Transmission bearing spacers All
421 29859 Deep reach socket wrench Transmission clutch pack shaft nuts All
463 18511 Installation drift Final drive, outer bushing into side G780B
housing
463 18512 Installation drift Final drive, inner and outer bushings into G780B
side housing
463 18513 Installation guide Final drive, inner bushing into side G780B
housing
463 33171 Installation drift Final drive, oil seal into flanged sleeve G780B
463 33172 Installation drift Final drive, axle bearing G780B
463 42749 Bearing driver Final drive, bearing onto drive axle G710B to G746B
463 43004 Deep reach socket wrench Final drive, pinion bearing preload G780B
463 45294 Depth setting gauge Final drive, pinion and gear backlash G780B
setting
463 58439 Yoke installation tool Final drive, input yoke G710B to G746B
463 12735263 Chain joiner tool Tandem Chain, assembly puller G780B
463 12734846 Chain Link remover tool Tandem Chain, press fit link removal G780B
463 12734778 Chain Link press tool Tandem Chain, press fit link installation G780B
517 89405 Assembly tool OIl disc brake All
622 18516 Socket wrench Front wheel bearing locknut G710B to G746B
914 56474 Gauge Accumulator charging kits G780B
914 56475 Charging kit Piston-type accumulators G780B
920 89130 Cylinder wrench 3 in., 3 1/2 in., 4 in., 4 1/2 in. diameter All
cylinders
920 89131 Cylinder wrench 5 in. diameter cylinder All
Removing corrosion protective coating 2
Service Information

Removing corrosion 091 Service Information 9/10/2022
protective coating
Profile:
G780B Volvo
Removing corrosion protective coating


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Graders shipped overseas are often subjected to corrosion during shipment. A temporary shipment coating has been used to
protect the grader. The following instructions describe the removal of the corrosion protective coating.
1. Use mineral spirits to remove coating.

2. Spray on the surface to be cleaned until the surface is completely wetted.
3. Let stand for 15 minutes.
4. Wash off with water from a power washer.
16 - LUBRICANT; FUEL; OTHER FLUID 2
17 - SERVICE 13
19 - GENERAL 26
Fuel system 2
Recommended lubricants 3
Grease 5
Coolant 6
Tandem_oil disc brake oils 7
Alternative fuels 9
Service Information

Fuel system 160 Service Information 9/10/2022
Profile:
G780B Volvo
Fuel system

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Fuel Recommendations:
The fuel used must be clean, completely distilled, stable and non-corrosive. Distillation range, cetane level and sulphur content
are most important when selecting fuel for optimum combustion and minimum wear.
Engine working conditions and ambient temperature influence the selection of the fuel with respect to cold handling properties
and cetane levels.
In cold weather conditions, below 32ºF (0ºC), the use of lighter distillate or higher cetane level fuel are recommended. (Final
boiling point max. 660ºF (349ºC) and cetane min 45.)
To avoid excessive deposit formation and to minimize the emissions of sulphur dioxide into the ambient air, the sulphur content
of the fuel should be the lowest available. The diesel fuels recommended for use in Volvo engines should meet ASTM
designation: D 975 No. ID (C-B) or No. 2D (T-T); with a cetane level above 42 and sulphur content not exceeding 0.5 percent by
weight.
Service Information

Recommended lubricants 160 Service Information 9/10/2022
Profile:
G780B Volvo
Recommended lubricants

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Component Oil grade Recommended viscosity at ambient temperatures

(Fluid code) °C -40 -30 -20 -10 0 +10 +20 +30 +40 +50
°F -40 -22 -4 +14 +32 +50 +68 +86 +104 +122
Engine (EO) Engine oil SAE 0W-30
Global DHD-1 plus VDS-2 SAE 10W-30
or ACEA-E5 plus VDS-2
** SAE 15W-40
or API CH-4 plus VDS-2
or VDS-3
Hydraulic system Hydraulic oil[1] (*) ISO HVI 15
(HO) Premium quality HVI (High (*) ** ISO HVI 46
Viscosity Index)
(*) ISO HVI 68
Transmission Premium quality SAE 0W-30
(EO) engine oil[2] ** SAE 10W
API CD/CE
SAE 30
Qualified to Allison
C-3 and TO-2 Specifications
Tandems/ Volvo WB 101
Oil disc brakes For trade names and oil ** Volvo WB 101
requirements, see Tandem/
oil disc brake oils
Master cylinders Petroleum base fluid[3]
– Oil disc brakes ** Shell Aeroshell Fluid 41
and clutch (PBF)
Final drive –Lock/ Hypoid gear oil SAE 75W-90

unlock API GL-5 ** SAE 80W-90
differential (GO)
SAE 85W-140
Volvo WB101
Pump drive Hypoid gear oil SAE 75W-90
gearbox – API GL-5 ** SAE 80W-90
All Wheel Drive
SAE 85W-140
(GO)
Front wheel Multi-purpose grease, ** NLGI EP2 FRONT WHEEL BEARINGS
bearings (MPG) extreme pressure NLGI EP0 or EP1
lithium soap base
All grease fittings ** NLGI EP2
(MPG)
°C -40 -30 -20 -10 0 +10 +20 +30 +40 +50

°F -40 -22 -4 +14 +32 +50 +68 +86 +104 +122
(*) Warm-up required in low temperatures

** Standard factory fill
Fluid codes
MPG – Multi-purpose Grease
PBF – Petroleum Base Fluid
GO – Gear Oil
HO – Hydraulic Oil
EO – Engine Oil
NLGI – National Lubricating Grease Institute
[1]See Cold weather operation in Operator Manual.
[2]See Cold weather operation in Operator Manual.
[3]Incorrect fluid will cause brake failure. Severe personal injury or death could result.
Service Information

Grease 160 Service Information 9/10/2022
Profile:
G780B Volvo
Grease

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Grease with a lithium base together with EP additives and consistency No. NLGI-2 without molybdenum disulphide additive
(MoS2).
Service Information

Coolant 160 Service Information 9/10/2022
Profile:
G780B Volvo
Coolant

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Coolant with anti-freeze and corrosion protection

Anti-freeze
Check the anti-freeze every 250 hours. Use accurate, reliable equipment to measure coolant antifreeze levels.
The engine cooling system is filled at the factory with an antifreeze coolant solution of 60% antifreeze and 40% water. This
ensures protection against freezing down to –52º C (–62º F).
If coolant concentration has been diluted, care must be taken to ensure that the antifreeze concentration is a minimum 40%
which gives protection down to –25º C (–13º F). If there is a risk that the ambient temperature falls below this, ensure that the
concentration is adjusted to provide adequate protection for the anticipated temperature.
Corrosion protection
Anti-freeze contains active anti-corrosion additives in order to protect the engine and radiator. These additives have a limited
durability. Therefore, change the coolant every 2000 hours or once a year.
Coolant with corrosion protection only
If the climate conditions are such that anti-freeze is not necessary, an additive should still be used.
Service Information

Tandem/oil disc brake oils 160 Service Information 9/10/2022
Profile:
G780B Volvo
Tandem/oil disc brake oils


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Oil grade Volvo WB 101

Requirements
Property Unit WB 101 Test method

Density kg/m To be stated ASTM D 1298
Flash point COC ºC min. 180 ASTM D 92
Pour point ºC min. –27 ASTM D 97
Viscosity at 40ºC (104ºF) mm/s (cSt) To be stated ASTM D 445
Viscosity at 100ºC (212ºF) mm/s (cSt) min. 9.0 ASTM D 445
max. 12.5 DIN Draft 51350
Viscosity at 100ºC after shearing 30 cycles mm/s (cSt) min. 8.8 CEC-L-14-A-78
Viscosity at 20ºC (68ºF) mPas max. 3500 ASTM D 2602
Rust protection 24 h No rust ASTM D 665A
API class GL-4 ASTM STP-512A
Additives Lubrizol/Unizol
LZ 9990A
Oronite OLOA
9725XV
Oronite OLOA
9727V
Solid particles code max. 18/13 ISO 4406
Examples of oils which meet the requirements according to the table are on the next page.
Other requirements
The oil should meet the requirements according to the following norms:
FORD– ESN – M2 C134 – D and JD JDQ95
The oil should have properties that counteract oxidation, corrosion and foaming, and be suitable for the stated purpose.
Examples of oils which meet the requirements according to the table on the previous page.
Oil company Trade name

Q8 Q8 T2200
MOBIL MOBILFLUID 424
ESSO TORQUE FLUID 56
SOLENE INDUSTRIAL LUBRICANT SOLENE TRACTELF CH-5
STATOIL TRANSWAY WB
AGROL AGROL HYBRAN
ARAL ARAL FLUID HGS
TEXACO TEXACO TEXTRAN TDH PREMIUM
VALVOLINE VALVOLINE UNITRAC
ELF TRACTELF CH-5
OMV AS OMV AUSTROMATIC IGB
FINA TRANSFLUID JD, 10W-30
AVIA HYDROFLUID JD, 10W-30
CALTEX TEXTRAN TDH PREMIUM
DELTA SPECIAL UTTO 170
TOTAL TRANSMISSION MP
PANOLIN AG PANOLIN HMO 324
PETROBAS LUBRAX UNITRACTOR
The following oils are approved provided the oil contains additive Lubrizol LZ9990A(also appears under the name Unizol).
Oil company Trade name

FUCHS FUCHS RENEGEAR HYDRA MC- ZF 20W/40
CASTROL CASTROL POWERTRANS
SHELL DONAX TD or FT/TD
BP BP TRACTRAN 9
BP HYDRAULIKÖLE TF-JD
ELF ELF TRACTELF BF12
Service Information

Alternative fuels 160 Service Information 9/10/2022
Profile:
Motor Graders
Alternative fuels
This statement is only valid for Volvo branded engines.
Hydro-treated vegetable oil (HVO) and fatty acid methyl ester (FAME) biodiesel are both made from renewable raw materials
such as vegetable oils and animal fats, but they are chemically processed in different ways.
Hydro-treated vegetable oil (HVO)
HVO is created using a chemical process called hydro-treating. Hydro-treating creates an oxygen-free hydrocarbon product that
is very similar to distillate diesel fuel and is well suited for use in diesel engines. HVO fuels complying with the CEN diesel fuel
standard EN 590:2013 or with the European Fuel Quality Directive 98/70/EC are approved for use in all Volvo Construction
Equipment diesel engines with no changes to maintenance intervals. Paraffinic diesel fuels complying with the CEN standard EN
15940 may be used in all machines operating outside the European Union and for EU-certified engines up to the emission level
Stage IV. These fuels may also be used for the EU-certified D11, D13 and D16 engines meeting the emission level Stage V.
Biodiesel
Biodiesel is a product made from renewable resources such as vegetable oils or animal fat. Biodiesel that has been chemically
processed into fatty acid methyl ester (FAME) can be blended with distillate diesel fuel and used in some diesel engines.
Unblended biodiesel is referred to as B100 because it is 100% biodiesel.
Rapeseed methyl ester (RME) is the most common type of FAME used in Europe. Soy methyl ester (SME) and sunflower oil
methyl ester (SOME) are the most common types of FAME used in the US.
Although use of FAME biodiesel is now a legal requirement in some markets, it is not as suitable for use in diesel engines as
conventional diesel fuel or HVO (hydro-treated vegetable oil).
Biodiesel fuel requirements
The FAME biodiesel blends specified in the table below are approved for use if:
The biodiesel is pre-blended by the fuel supplier

The biodiesel used in the blend conforms to EN14214 or ASTM D6751
The distillate fuel used in the blend meets fuel sulphur requirements
The distillate fuel used in the blend conforms to EN590 or ASTM D975
B1-B5 biodiesel blends conform to EN590 or ASTM D975
B6-B7 biodiesel blends conform to EN590 or ASTM D7467
B8-B20 biodiesel blends conform to EN16709(B20) or ASTM D7467
Engine emission designation Engine size Acceptable blend

EU Stage II / US Tier 2 * Below D4 / 4 litres Up to B7
EU Stage IIIA / US Tier 3 *
EU Stage IIIB / US Tier 4 interim
EU Stage IV / US Tier 4 final
EU Stage V
EU Stage II / US Tier 2 * D4–D8 Up to B7
EU Stage IIIB / US Tier 4 interim
EU Stage II / US Tier 2 * D9–D16 Up to B20
US Tier 4 final, special North America arrangement **
EU Stage IIIB / US Tier 4 interim D11–D16 Up to B10
EU Stage IIIB / US Tier 4 interim, equipped with High Sulphur Fuel D4–D16 Up to B20
Conversion Kit (only available in unregulated markets)
EU Stage IV / US Tier 4 final, equipped with High Sulphur Fuel Conversion
Kit (only available in unregulated markets)
EU Stage V D4–D16 Up to B7
* As Tier 2 and Tier 3 emissions regulations ended in 2005 and 2010 respectively, engines produced since then typically meet
Stage II / Stage IIIA regulations, allowing their sale in less regulated markets.
** With additional restrictions and special operating conditions, equipment used in North America may operate on B20 diesel.
NOTE!
Failures directly caused by the use of poor quality biofuel, or any other fuel not conforming to standards, are not factory defects
and the manufacturer’s warranty does not apply.
Maintenance interval requirements

Additional service actions and shorter maintenance intervals are mandatory when using biodiesel blends above B10.
Every 10 hours
Check the engine oil and change if it rises above the maximum fill level
Inspect the fuel system components and replace as necessary
Half of original interval
Change the engine oil and filter

Replace the fuel filter(s)
Every year, regardless of operating hours
Change the engine oil and filter

Clean the fuel tank
Effects of biodiesel on engine oil

Using biodiesel can lead to increased oil dilution. Use engine oil analysis tools frequently to check for fuel dilution and monitor
engine oil condition. Check the engine oil level daily. Always change the engine oil if the oil level rises above the maximum fill
level.
Effects of biodiesel on fuel systems
Biodiesel dissolves and loosens some fuel system deposits. During the initial conversion to biodiesel, loosened deposits will
travel to the fuel filters and require more frequent fuel filter replacements. Start with new fuel filters when using biodiesel for the
first time.
Biodiesel is aggressive to some materials used in fuel system components. Inspect seals, hoses, rubber and plastic components
every 10 hours. Repair or replace any components that are damaged, softened or leaking. Clean biodiesel from painted surfaces
immediately to prevent paint damage.
Biodiesel is more sensitive to bacteria and water contamination than distillate diesel fuel.
Use as much fuel as possible before refilling the fuel tank in order to prevent bacteria growth if a machine is in regular
use, e.g. regularly uses up a tank of fuel within a week. In climates where condensation is a risk, or when the machine is
working for short durations, keep the fuel tank full.
Do not use biodiesel in machines with low utilization or operating time.
Do not store machines for more than 4 weeks without flushing biodiesel out of the fuel system by operating the
machine through at least one full tank of distillate diesel fuel.
Always follow the manufacturer’s storage recommendations and “best-before” dates for each delivery of biodiesel.
Effects of biodiesel on exhaust aftertreatment systems
Biodiesel leaves higher levels of ash in diesel particulate filters and may require more frequent diesel particulate filter (DPF)
regeneration and cleaning. Biodiesel can cause deviations in temperatures and functionality of the DPF burner and may cause
fault codes or errors.
Biodiesel exhaust gas is aggressive to some materials used in selective catalytic reduction systems (SCR) and may require more
frequent cleaning, repairing or replacing of SCR parts.
Effects of biodiesel on cold weather operation
Biodiesel has a high viscosity at temperatures below 0 ˚C (32 ˚F) and may cause problems starting the engine. Use a fuel heater
or park machines in a heated building if possible.
Effects of biodiesel on engine performance
Biodiesel B100 has about 8% lower energy density compared to regular diesel fuel. Blends equal or lower than B20 have a small
impact on engine performance.
Effects of biodiesel on emissions compliance
Engines are certified to comply with U.S. EPA, California and EU emissions standards based upon the use of test fuels with
specifications established by these regulatory agencies. Alternative fuels, including biodiesel, that are not substantially similar to
the required test fuels may adversely affect engine emissions compliance. As a result, Volvo does not warrant that the engine will
conform to applicable Federal or California and EU emissions limits when operated on, or having previously being operated on,
biodiesel or other alternative fuels that are not substantially similar to specified test fuels used for certification, nor if biodiesel /
regular diesel is used in blends that exceed the recommendations.
However, the use of biodiesel up to a maximum of 20% (B20) in and of itself, will not affect the manufacturer's mechanical
warranty as to engine or emissions system, provided the bio fuel used in the blend conforms to the applicable standards and the
additional steps outlined herein are followed.
Arrival Inspection; according to Inspection Programme 2
Delivery Inspection; according to Inspection Programme 3
Maintenance of Stored Machines; according to Inspection Programme 4
Hydraulic oil return filter; replacing 5
Towing 10
Jump-start procedure 13
Service Information

Arrival Inspection, according 171 Service Information 9/10/2022
to Inspection Programme
Profile:
Motor Graders
Arrival Inspection, according to Inspection Programme

Op nbr 171-001
Total procedure time (hr): 0.90
1. This Inspection Programme can be found as a PDF file in the document library in PROSIS.
Service Information

Delivery Inspection, 171 Service Information 9/10/2022
according to Inspection
Programme
Profile:
Motor Graders
Delivery Inspection, according to Inspection Programme

Op nbr 171-002
Service Information

Maintenance of Stored 171 Service Information 9/10/2022
Machines, according to
Inspection Programme
Profile:
Motor Graders
Maintenance of Stored Machines, according to Inspection Programme

Op nbr 171-003
Service Information

Hydraulic oil return filter, 173 Service Information 9/10/2022
replacing
Profile:
G780B Volvo
Hydraulic oil return filter, replacing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 173-649
Standard set of wrenches and sockets sizes 3/8 in. to 1-1/2 in.
Tape measure
Marking device - scriber or fine tip marker
90 degree air drill
Drill bits 1/8 in. (3 mm) and 3/8 in. (10 mm)
Shop towels
Container or drip pan to collect hydraulic oil
The hydraulic oil filters are used for continuous filtration of the hydraulic oil. The main hydraulic system oil filter and hydraulic
system return oil filter elements should be changed every 1000 hours of operation. The main hydraulic filter can be equipped
with an optional bypass indicator sensor. A warning lamp located in the cab on the instrument panel illuminates when the
hydraulic oil should be changed. The oil must be changed when the light illuminates or at the 1000 hour interval; whichever
occurs first. See Operator's Manual.
The hydraulic oil filter is located inside the left-hand engine compartment, next to the radiator shroud. The All Wheel Drive
system filter is a cartridge type element installed inside the filter housing.
The hydraulic return oil filter is located inside the left-hand side of the frame underneath the cab and below the clutch pedal
linkage.
For quick access to the return oil filter element, loosen the top and bottom hexagon screws and washers on one side of the
transmission guard front cover. Remove the top and bottom hexagon screws and washers on the other side of the cover. Use the
hand hole and carefully slide the cover from under the washers of the loosened hexagon screws. After replacing the filter
element, slide the cover under the washers of the loosened hexagon screws. Install and secure all four cover retaining hexagon
screws.
Except for the All Wheel Drive system, the oil filter elements are a spin-on type and can be removed with a filter wrench.
Clean any accumulated dirt from around the filter element and filter head. Make provisions to capture oil that may spill
during filter element removal.
Remove the filter element.
To install a new filter element, first apply a coating of clean hydraulic oil to the gasket. Fill the filter element with fresh
hydraulic system oil.
Install the new element on the filter head and tighten it as far as possible by hand only.
Do not use a filter wrench to tighten the element.
The hydraulic return oil filter is standard equipment on motor graders from serial number 36078 and up. All serial numbers from
35000 - 36077 require a kit part number 12735455 in order to install this return line filter.
Installing the return line filter kit

The purpose of the return line oil filter is to provide additional filtering over and above the continuous filtering provided by the
hydraulic fan circuit. This will also prevent debris introduced into the system during the life of the machine from reaching the
tank and the oil pump inlet circuit. This is accomplished by filtering the oil with a 10-micron filter after it leaves the hydraulic
controls and cylinders before returning to the tank.
The filter element, part number 49076, is also used as the transmission filter element.
If the cleanliness level of the oil in the system (as measured by oil sample analysis) has contamination numbers greater than
18/13, it is strongly recommended that the oil be cleaned. The Volvo approved filter cart should be used to clean the oil at the
time the new return line hydraulic filter is installed. Refer toHydraulic Oil Cleanliness procedures.
Auxiliary hydraulic return line kit installation
Figure 1
Return line filter kit installation diagram
1. Washer
2. Oil filter (50 psi by-pass)
3. Hexagon screw
4. Reducer
5. Connector
6. Hexagon screw
7. Bracket
8. Elbow
9. Lock nut
10. Tee fitting from existing hydraulic assembly
Installation instructions
1. Place the grader in theService positions . Battery isolation switch OFF).
2. Remove the right cab step to provide easier access to the transmission guard below the cab.
3. Remove the front cover for the transmission guard.
NOTE!
The filter kit can be installed with or without lowering the main transmission guard, but there is more room to work if the guard
is lowered. (see step 4).
4. Before removing the front mounting hexagon screws for the transmission guard, place adjustable floor jacks or blocks
under the transmission guard. This is to prevent the transmission guard from dropping when the front mounting
hexagon screws are removed. Remove the two front mounting hexagon screws from the transmission guard and lower
the guard to the ground in a safe manner.
WARNING
5. Locate the return hose line bulkhead welded to the frame under the cab.
6. Mark the location for drilling the 2 holes in the existing bulkhead for attaching the filter bracket. Measurements for
locating the holes are shown on the drawing detail diagram.
Figure 2
Mark the location of holes for mounting bracket
7. Center punch and drill 1/8 inch (3 mm) pilot holes, then drill the pilot holes out to 3/8 inch (10 mm) diameter. Clean the
area after drilling to remove debris. Apply touch up paint to area around newly drilled holes to prevent rust.
8. Disconnect the main hydraulic return line and fittings from both sides of the bulkhead and immediately cap hose ends
and fittings to safeguard against hydraulic system contamination.
9. Disconnect all hose lines to the existing Tee fitting and cap the hose ends. Set the Tee fitting aside, as it will be reused
with the new filter assembly. The inlet and outlet fittings on either side of the bulkhead can be discarded, as new fittings
are supplied with the filter assembly kit.
10. Organize the kit parts near the work area for easier assembly.
11. Remove the packaging and plugs from the filter and filter head assembly.
NOTE!
Moisten the rubber seal on the top of the filter with a light coating of hydraulic oil before threading the filter onto the filter head.
12. Attach the mounting bracket to the top of the filter assembly with the 4 cap screws and washers.
NOTE!
Be sure to attach the mounting bracket so the filter head is mounted in the correct direction of flow as indicated by the
directional arrows on the filter head inlet and outlet ports. Tighten the bolts.
13. Install the new reducer fitting into the inlet port of the filter assembly. Install the new straight connector fitting into the
outlet port of the filter assembly. Tighten both fittings.
NOTE!
Do not attempt to reuse the old inlet and outlet fittings removed from the bulkhead, as they are not the correct size to be used
with the new filter assembly.
14. Lift the filter assembly into position on the backside of the bulkhead and attach the mounting bracket to the bulkhead
with the 2 hexagon screws, washers and lock nuts. Make sure the filter head is level and the filter is vertical before
tightening the hexagon screws and nuts.
15. Remove the hose line cap and attach the rear return hose line to the outlet fitting (5) on the filter head assembly.
Tighten the fittings with a wrench.
16. Install the existing Tee fitting into the reducer fitting in the inlet of the filter head assembly. Hand tighten only.
17. Remove the hose line cap and attach the 2 x 90 degree elbow fittings together on the end of the return hose line from
the valve bank. Do not tighten the fittings so they can swivel freely for assembly to the Tee fitting.
18. Lift the return hose line and turn the 90 degree elbow fittings as required to assemble to the Tee fitting inlet. Hand
tighten only.
19. Reattach the No. 8 hose line to the Tee fitting.
20. If the grader is equipped with the auxiliary manifold option, reconnect the return hose line from the manifold to the Tee
fitting. (This fitting on the Tee will be capped off if the option is not installed).
NOTE!
It may be necessary to cut the plastic hose ties under the cab and re-route the hose line in order to get enough slack to reattach
the hydraulic line from the auxiliary manifold to the Tee fitting.
21. When all hoses have been reconnected, check the hose routing then tighten all hose ends and fittings with the
appropriate size wrenches.
22. If the main transmission guard was lowered before installing the auxiliary filter kit, carefully raise the transmission guard
back into position. Reinstall the mounting hexagon screws and secure the lock nuts.
23. Reinstall the right front cab step before mounting the grader.
24. Refer to the proper Grader setup instructionsafter working on the hydraulic system.
25. Start the grader when it is safe to do so and perform a test of the hydraulic systems for proper function.
26. Check the new kit assembly for leaks then shut down the grader. Tighten fittings, if required.
27. Reinstall the transmission service cover with the 4 hexagon screws and washers.
28. The return line filter should be replaced at service intervals of 1000 hours.
Service Information

Towing 176 Service Information 9/10/2022
Profile:
G780B Volvo
Towing

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
WARNING
The parking brake must be applied and the wheels blocked before making preparations to tow or recover the machine
to prevent it from moving. Great care must be observed when towing to avoid personal or even fatal injury.
WARNING
If the engine cannot be started, the brake and steering functions will be severely limited. In such cases, towing should
only be performed in an emergency situation by experienced and trained personnel and only for the shortest possible
distance (see towing). If possible, transport the machine on a trailer.
General
The operator must be in the operator's seat to control steering and braking when towing the grader.
Do not tow the grader with the engine shut down. Braking and steering capabilities are reduced with the engine shut
down.
To release the parking brake manually, refer to Parking brake, manually releasing.
If the engine runs, ensure the transmission shift lever is in NEUTRAL. Tow the grader with the engine running. On All
Wheel Drive models, make sure the All Wheel Drive system is switched OFF.
Figure 1
Some state and local laws prohibit or limit the use of tow chains on highways. Check state and local regulations.
If the final drive is damaged, do not tow the grader. Do not attempt to start the engine by towing. Damage to the
transmission will result.
Provide adequate shielding for the operator against towline breakage.
Do not tow the grader faster than 8 km/h (5 mph).
Be sure the vehicle which does the towing is at least as heavy as the machine being towed. This will ensure sufficient
engine and braking capabilities to be able to pull and stop both machines on any uphill or downhill slope.
If the towed grader cannot be braked, a tow bar or two towing machines must be used – one in front pulling and one at
the rear to provide braking. Do not tow over long distances.
Ensure the towline or bar is in good condition and is strong enough for the towing situation. Mark the center of the
towline with a flag or brightly colored cloth. Ensure that a `slow moving vehicle sign' is attached to the rear of the
grader.
Ensure the towline angle is less than 20 degrees with respect to the horizontal plane.
Do not allow the towline to contact any components mounted on the grader.
Tow the grader from the hole provided in the noseplate.
Figure 2
Sudden machine movement can cause the towline or tow bar to break. Proceed gradually and smoothly.
Make sure the parking brake is disengaged.
Secure the moldboard and all attachments. Use chains or cables that are in good condition.
Install the articulation lock pins.
Figure 3
1. Lock pin
When turning, keep the towing angle and speed to a minimum.

Turn the hazard lights on while towing.
Figure 4
After towing
The following safety measures should be taken before the towbar, chain or wire rope is disconnected after towing:
Place the machine on level ground.

Apply the parking brake
Block the wheels to prevent the machine from rolling.
Service Information

Jump-start procedure 176 Service Information 9/10/2022
Profile:
G780B Volvo
Jump-start procedure

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
NOTE!
Refer to: Safety when working with batteries and Battery, charging, before starting this procedure.
1. Turn the battery isolation switch off.

2. Connect a jumper cable between the positive terminal on the fully charged booster battery and the positive terminal on
the starter motor of the grader with the dead or low batteries.
3. Connect the other jumper cable from the negative terminal on the booster battery to a frame grounding point on the
machine (a starter mounting bolt or ground strap mounting bolt). Do not connect the booster battery directly to the
discharged battery.
4. Turn on the battery isolation switch.
5. Start the engine of the booster vehicle. Allow the engine to run for a few minutes.
6. Start the engine of the grader from the operator"s seat. Fasten the seat belt. If the engine does not start within 30
seconds, release the ignition key and wait two minutes before trying again. This allows the starter motor to cool. If the
engine does not start on the second or third attempt, stop this procedure. Report the problem and have it repaired by a
qualified service technician.
Do not dismount from the grader with the engine running. Have a qualified service technician disconnect the jumper
cables in the reverse order of connection.
Allow the grader"s engine to run for a few minutes and ensure all controls and instruments are working properly before
driving or operating the grader.
Safety concerns everybody! 2
CE marking and declaration of conformity 3
Environment 5
Safety when handling the machine 7
Service positions 12
Fire prevention measures 17
Health hazards with paint; plastics and rubber 20
Check list after fire or heat exposure 22
Safety when handling tyres 23
Safety when lifting and supporting the machine 24
Safety when handling oil and fuel 25
Safety when working on the electrical system 26
Safety when working with batteries-4746 27
Safety when working with batteries 28
Battery; charging 30
Safety when working with air-conditioning refrigerant 32
Safety when working on hydraulic systems 34
Safety concerns everybody! 35
Electric welding 36
Service Information

Safety concerns everybody! 191 Service Information 9/10/2022
Profile:
G780B Volvo
Safety concerns everybody!


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Always keep the Operator's Manual in the machine for handy reference.
Many hours of skilled and careful design have gone into manufacturing the safest and most efficient motor grader possible. All
of this time and effort could be wasted if an operator or service person does not read and follow safety instructions and
procedures. Unfortunate accidents and personal injury can result from failure to replace guards, climbing on slippery areas
instead of using a ladder, using hoses or other parts instead of hand rails, and failing to use correct tools and procedures.
Properly operated, maintained and serviced machines rarely cause accidents. Human error is the greatest cause. Maintain and
promote safe and efficient machine operation, and always use genuine spare parts designed and intended for each specific
machine.
WARNING
Any person who does not follow the safety instructions and who ignores warnings in this manual must make absolutely
sure that their work method is safe. Otherwise, there is a great risk of serious accidents and injuries, perhaps even
fatalities.
WARNING
WARNING SYMBOL
This symbol will appear at various places in this manual along with a warning statement. It means: "Warning, be alert!
Your safety is involved!"
Become familiar with the capacity and limits of the machine!
Service Information

CE marking and declaration 191 Service Information 9/10/2022
of conformity
Profile:
G780B Volvo
CE marking and declaration of conformity


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
(Applies only to machines marketed within the EU/EEA)

This machine is CE marked, indicating that on delivery it meets applicable “Essential Health and Safety Requirements” listed in
the EU Machinery Safety Directive. If changes are made that affect the safety of the machine, responsibility for these changes
rests with the individual who carried them out.
Volvo Motor Graders Limited issues an EU Declaration of Conformity with the machine as proof that these requirements are met.
This valuable documentation should be kept in a safe place for at least ten years. In the event a machine is sold, the document
should be surrendered to the new owner.
If the machine is used for other purposes, or with attachments other than those described in this manual, safety must be
observed at all times. Any person who carries out such an action assumes responsibility for that action, and in some cases may
require a new CE marking and the issuance of a new EU Declaration of Conformity.
EU EMC directive
In some cases, the electronic equipment installed on the machine may cause interference to other electronic equipment, or may
itself suffer from the effects of external electromagnetic interference; which may constitute safety risks.
The EU EMC directive on “Electromagnetic conformity” provides a general description of the demands that can be made on the
machine from a safety point of view. Where permitted, limits have been determined and assigned according to international
standards.
A machine or device that meets the requirements should be CE marked. Our machines have been tested specifically for
electromagnetic interference. The machine's CE marking and the declaration of conformity both cover the EMC directive.
If other electronic equipment is fitted to the machine, that equipment must be CE marked and tested on the machine with
regards to electromagnetic interference.
Modifications
Modifications of any kind to this product including the fitting of unauthorized attachments, accessories, assemblies or parts
could affect the integrity of the product and/or the ability of the product to perform as designed or intended.
It is policy that no modification of any kind is to be made to this product unless officially approved by Volvo Motor Graders. A
modification includes, but is not restricted to, the use of attachments, accessories, assemblies and parts not approved by Volvo
Motor Graders and/or not installed in a factory approved manner.
Modifications are officially approved if at least one of the following conditions is met:
1. The attachment, accessory, assembly or part is manufactured or distributed by Volvo and installed in a factory approved
manner as described in the publications available from Volvo; or
2. The modification has been approved in writing by the Engineering Department of Volvo Motor Grades.
Volvo Motor Graders disclaims responsibility for any situation that may arise as a result of a non - approved modification. If any
person or organization modifies or contributes in any way to a non - approved modification, the person or organization will be
deemed to have assumed all the risks associated with such a modification, including but not limited to, product failure, product
damage, property damage, loss of production, injury or death.
If any claims result from a non - approved modification, Volvo Motor Graders will protect its interest by taking whatever action is
appropriate.
Volvo Motor Graders warranty shall not apply to any product or part which fails or is damaged by, or whose functioning or
operation is adversely affected by non-approved modification.
Unauthorized modifications of the Roll Over Protective Structure (ROPS)
Never make unauthorized alterations to the ROPS such as lowering the height of the ceiling, drilling or welding to it, to install
fire extinguisher, radio aerial or other brackets or equipment
Such unauthorized modifications will affect the structural limits of the ROPS cab and will void the certification.
The Roll Over Protective Structure (ROPS) has been approved after testing and meets the standard according to ISO 3471 1994
and SAE 1040 APR 88.
Some optional cabs have also been tested and approved according to the FOPS (Falling Object Protective Structure) standard as
defined by ISO 3449 1992, SAE J231 JAN 81, and meet the requirements for “Overhead guards for high-lift rider trucks” ISO 6055
1979 and “Operator seat belt requirements” SAE J386 JUN 93.
All planned alterations must be reviewed in advance by our Engineering Department to determine whether the alteration can be
made within the limits of the certifying tests.
It is important that all persons in your organization, including management, be made fully aware of these rules involving the
ROPS.
If anyone within your organization discovers that a certain machine has been altered in any way that has not been
approved, your organization must inform the customer and the manufacturer in writing about the nature of the
modification, and the specific machine that has been modified.
NOTE!
Modifications to, or removal of sound insulating, damping or absorbing material is not permitted; nor is it permitted to make
openings or holes in the cab or engine compartment. This can raise the sound level in the cab.
Service Information

Environment 191 Service Information 9/10/2022
Profile:
G780B Volvo
Environment

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The global environment is under constant stress from increased industrialization in all parts of the world. Every day, humans,
animals and the natural environment are exposed to great health risk due to exposure to the use and disposal of various
chemicals. There are however, no oils or coolants available which are not harmful to the environment. It is imperative then that
those who handle, service and repair machinery use equipment and methods that will enable them to carry out their work in an
environmentally friendly manner.
Observe the following precautions to avoid environmental contamination:
Reclamation
Wherever possible, submit waste materials to organizations that specialize in recycling or incineration of those
materials.
Batteries and other parts
Components such as batteries, plastic objects and other parts must be discarded in an environmentally correct manner.
Disposal by conventional means can constitute environmental hazard.
Discarded batteries in particular, contain dangerous substances such as lead and acid and they must be handled in a
safe and responsible manner according to local and national regulations.
Oils and other liquids
Oil and fuel that is released or spilled will harm the environment and pose a significant fire risk. Take special care to
avoid spillage when draining oil and fuel.
Waste oil and other liquids should be disposed of by an authorized organization.
Be alert to the presence of leaks. Correct oil and other fluid leakage immediately.
Air conditioning
The refrigerant in the air conditioning system for the cab adds to the greenhouse effect. It should never be intentionally
released into the open air. Special training and certification is required to service air conditioning systems in many
countries and jurisdictions. See Section 8 of this manual for more precautions regarding the air conditioning system.
Working in a contaminated environment
Used cab and engine filters from machines that operate in environments containing asbestos or other dangerous dust must be
placed in a tight-sealing plastic bag. It must then be disposed of in a lawful manner.
Any machine that must operate in a hazardous atmosphere must be specially equipped for that environment before it is
introduced to that hazard. There may also be additional regulations regarding the repair and service of a machine in
such a situation.
Service Information

Safety when handling the 191 Service Information 9/10/2022
machine
Profile:
G780B Volvo
Safety when handling the machine


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Volvo Construction Equipment is only responsible if:
the machine has been used correctly and has been maintained according to instructions in Service Manuals and the
Operator's Manual.
prescribed service and prescribed inspections have been performed at the stipulated points in time.
the lubricant recommendations in the manual have been followed.
no security seals have been broken by unauthorized persons.
all modifications and repairs have been performed as prescribed by Volvo.
only Volvo genuine spare parts/accessories or attachments that meet Volvo's requirements have been used.
WARNING
Machine operators must have sufficient skills and knowledge of the content in the Operator's Manual before operating
the machine.
It is important that the operator reads and follows the instructions in the machine's Operator's Manual.
An untrained operator may cause serious injuries and fatalities.
Never operate a machine for which there is no Operator's Manual available.
Learn to understand the warning plates, symbols and operating instructions for the machine before you start operating.
A few simple safety rules

General
Figure 1
Maintain 3 points of support when entering and leaving machine. Decal is found on both sides of the cab
Repair malfunctions or defects that affect safety as soon as possible.

Always wear a hard hat, safety glasses, work gloves, protective footwear and other protective articles as required.
Avoid standing in front of or behind the machine when the engine is running.
Avoid unnecessary climbing on the machine. Use long handled brushes or ice scrapers to clean the outside of the cab
windows.
Use a ladder for servicing in high places.
Make sure that stepping surfaces, service areas, handles and other surfaces are free of oil, fuel, dirt, ice and snow.
Replace any step components that are missing or damaged. Make sure that all step components are securely fastened
to the machine.
Always face the machine when mounting or dismounting, and use the steps and hand rails. Always use the three point
method: both hands and one foot, or one hand and both feet. Do not jump.
Before operating
Figure 2
This safety sign is located inside the cab on the front of the pedestal
Read the Operator's Manual and the AEM Grader Safety Manual. Follow the pre-start instructions.
Test that the control lamps are working correctly using the instructions in the Operator's Manual.
Perform all safety checks outlined in the Operator's Manual.
WARNING
Never operate the machine if you are tired or under the influence of alcohol, medicine or other drugs.
Before starting the engine indoors, make sure that there is sufficient ventilation capacity to extract the exhaust. Diesel
exhaust is harmful you your health. Operate the engine for only a short period if you suspect that the ventilation may
not be adequate.
Read all plates and instructions that are fastened to the machine and in the Operator's Manual before you operate or
service the machine. These instructions contain important safety, handling and service information about the machine.
Always use the seat belt when you operate the machine.
Always sit in the operator's seat to start the engine.
Never operate a machine that is not fully operational. Always make repairs to safety related systems before the machine
is operated to avoid the potential of an accident.
Do not operate the machine for long periods without ventilation or adequate cab air flow. There is a risk of lack of
oxygen.
Use only the cab steps, handrails and other surfaces that are designed for mounting or dismounting the machine.
Seat belt
Figure 3
This safety sign is located inside the cab on the pedestal
Make sure the belt retractor is in good working order.

Replace a worn or damaged seat belt immediately.
If a machine has been involved in an accident, replace the seat belt if it has been subjected to strain.
Never make any modifications to the seat belt or its mounting.
The seat belt is designed and intended for use by one adult only.
The seat belt should be kept coiled in the retractor when not in use.
If the seat belt must be washed, use a mild soap and water solution, and allow the belt material to air dry before it is
allowed to retract.
When the engine is running
Observe and respond to warning indicators. Red lamps indicate the need for immediate action or attention. See the
machine Operator's Manual for more details.
Apply the parking brake and make sure that all implements and attachments are lowered to the ground before leaving
the cab.
Avoid lubrication or mechanical adjustments with the grader in motion or the engine operating. If the engine must be in
operation to make certain adjustments, place the transmission in NEUTRAL, apply the parking brake, place the grader in a safe
position, lower the moldboard and attachments, securely block the wheels and use extreme caution.
NOTICE
There is a risk of crushing even with the engine off if the machine is equipped with an electric secondary steering pump.
Stay out of the frame articulation area unless the articulation lock is in place.
If the machine is to be operated on a roadway, follow the instructions in the machine Operator's Manual to position the
moldboard and other implements for roading.
Shut down the engine, remove the ignition key and turn the battery isolation switch to the “Off” position if you must
leave the machine unattended.
When there is a risk of overturning

The cab is designed to protect the operator and it meets the requirements, testing and standards for a Roll Over Protective
Structure (ROPS). See also CE marking and declaration of conformity. One condition of this design is that the operator is wearing
a seat belt and remains in the cab in the event of a machine rollover. If the machine should begin to overturn, firmly hold on to
the steering wheel. Do not jump from the cab!
Falling objects
The cab is designed to protect the operator from objects falling onto the cab roof according to the requirements for a FOPS
(Falling Object Protective Structure). See also CE marking and declaration of conformity.
Cab Escape Route
Figure 4
The left-hand door opening is the commonly used entrance.

The right-hand door opening can be used as the EXIT in case of an emergency.
Models equipped with a snow wing are supplied with an emergency hammer located inside the left-hand door post. It
can be used to break the glass in the event of a rollover.
Towing Precautions
When it is necessary to tow the grader, do not exceed 8 km/h (5 mph).
Be sure the towing machine has sufficient braking capacity to stop the towed load.
If the towed grader cannot be braked, a tow bar or two towing machines must be used - one in front pulling and one at the rear
to provide braking. Do not tow over long distances.
Use the tow hitch when using the grader for towing. If a cable or chain is used, keep people away from the towline.
Shielding of the operator(s) against towline breakage must be provided.
Safety rules when servicing
This section provides general safety rules for service and routine maintenance checks. Other rules, information and warnings are
written in the machine Operator's Manual.
CE marking
This machine is CE marked, indicating that on delivery it meets applicable “Essential Health and Safety Requirements” listed in
the EU Machinery Safety Directive. If changes are made that affect the safety of the machine, responsibility for these changes
rests with the individual who carried them out. This means for example that:
When installing a two-way radio, mobile telephone and similar equipment, follow the manufacturer's installation
instructions in order to eliminate interference with the function of the electronic system and components on the
machine. See also CE marking and declaration of conformity.
When retro-fitting equipment in or to the cab, do not drill, weld or cut into the cab structure. This could interfere with
the ability of the cab to protect the operator in the event of a rollover. See also CE marking and declaration of
conformity.
Before you begin any service work on the machine:

Do not attempt to repair or adjust grader unless you are a qualified service technician.
Make sure you have sufficient skills, knowledge and understanding of service procedures, and that you have the correct tools
and equipment required. Repair or replace and damaged tools and equipment.
Failure to follow the instructions or heed the warnings could result in severe personal injury or death. Proper care is your
responsibility. Contact your Dealer or Volvo for replacement parts.
Service Information

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Service positions

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WARNING
If work must be done on the machine before it has cooled down; beware of hot fluids and hot components that can
cause severe burns.
Before performing any service, maintenance or inspection procedure, the grader must be placed in the Service Position.
Figure 1
Service position
1. Park the grader on a level surface.

2. Place the transmission in NEUTRAL and apply the parking brake. Ensure the parking brake is in good working order.
3. Lower the moldboard and all attachments to the ground. Do not apply down pressure.
4. Shut down the engine.
5. Install both articulation lock pins.
6. Install chocks at the front and rear tandem wheels. Wedge the chocks in place.
7. Fasten a `DO NOT OPERATE' or similar warning tag on the steering wheel.
8. Remove and retain the ignition key.
9. Turn the battery isolation switch to the OFF (O) position.
10. Allow the engine and hydraulic system to cool before working in these areas.
11. Be aware of other service personnel in your work area.
If the service procedure includes welding, disconnect the following items:
1. Negative battery cable.

2. Positive battery cable.
3. Power supply and transmission wiring harnesses at the transmission ECU (electronic control unit).
4. Wiring harnesses at the instrument ECU, engine ECU, and fan ECU.
5. Alternator to battery wiring harness.
6. 5 amp 24V-12V convertor (if installed) wiring harness at the fuse panel.
7. 25 amp 24V-12V convertor (if installed) wiring harness at the battery.
8. Float valve module (if installed) wiring harness at the module.
Connect the arc-welder ground cable as close as possible to the work area. Install the battery box cover. After completing your
welding procedures, connect the above items in the reverse order. Ensure you connect the negative battery cable last.
WARNING
Battery charging generates hydrogen gas, which may be explosive. Short-circuiting, an open flame or a spark near the
battery may cause a powerful explosion.
Make sure ventilation is adequate when charging batteries. Never smoke near batteries.
Refer toFire prevention measures , and Health hazards with paint, plastics and rubber.
If the service procedure includes repair to the hydraulic system, you must perform the following steps.
All of the hydraulic implements except the moldboard slide have a lock valve (counterbalance valve) between the main control
valve and the cylinder.
Moving the main control valve levers will not relieve any pressure that is trapped in the cylinder(s). The only exception is the
moldboard slide, which does not have a lock valve (counterbalance valve) in the circuit.
WARNING
If the pressure is not released before opening the system, oil under high pressure will jet out, resulting in serious
personal injuries.
WARNING
Leaking high-pressure hydraulic hoses may cause severe injuries. Fine jets have high penetrating capacity on bare skin.
Use a steel plate or stiff cardboard to check for leaks. Never use your hands to check for hydraulic leaks.
WARNING
Block the wheels to prevent accidental machine movement.
NOTE!
Make sure all personnel are clear of moldboard, attachments or components controlled by the hydraulic circuits.
Unexpected movement of the component could result in severe personal injury or death.
Be careful to place the machine in a position that does not allow any external load on the cylinder(s) or circuit(s) to be
worked on.
Properly block the machine or implement to prevent movement.
Relieving trapped pressure by loosening a fitting may allow the machine or implement to move unexpectedly.
Carefully loosen the appropriate hydraulic line to allow any trapped oil under pressure to be relieved.
Connect blade lift accumulators (if installed) to their hydraulic circuits by turning the shut-off handles counterclockwise.
Relieve residual hydraulic pressure in moldboard slide circuit by operating the control lever.
Some circuits have electrically activated float valves. To relieve pressure in these circuits, turn on the ignition key
without starting the engine and place the control lever in the float detent position.
General
Any machine that is to be used in a contaminated, polluted or unsanitary environment must be specially equipped to
safely work in that environment. In addition, special operating precautions and regulations will apply to that application.
See also Check list after fire or heat exposure.
If someone is assigned to take over a procedure you have started, make sure to advise this person what work has been
completed and what work remains.
When using a high-pressure washer for cleaning, take care not to remove adhesive decals or anti-slip surfaces.
Know and use the proper protective equipment. Equipment such as hard hats, protective glasses, protective shoes,
gloves, reflector type vests, respirators and ear protection may be required.
Figure 2
Protective equipment
Wear gloves to protect hands when handling cable.
Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal articles. These can get caught in
moving parts. Jewelry may also ground a live circuit when working on the electrical system.
WARNING
NOTE!
Hydraulic or mechanical failure could cause the machine to fall resulting in severe personal injury or death.
Ensure that adequate stands or blocks are used to support the grader when servicing.
Securely block the moldboard or any attachments that may fall before working on them.
When servicing the grader, fasten a `DO NOT OPERATE' or similar warning tag on the steering wheel. Be sure that the
isolation switch is in the OFF (O) position and that you remove and retain the ignition key.
Ensure the work area is clean, organized and safe.
Unless otherwise instructed by a specific service procedure, always shut down the engine when doing any service.
If you are instructed to use procedures that must be performed with the engine running, place the transmission in
NEUTRAL, apply the parking brake, place the grader in a safe position, lower the moldboard and attachments, securely
block the wheels and use extreme caution.
Keep your head, body, limbs, feet and hands away from all moving parts. These include circle and moldboard
assemblies, scarifier, ripper and engine fan belts and fan, shafts, etc.
Take care to avoid moving any levers and controls by accident, and make sure to warn any persons in the immediate
area.
Stop the engine before opening or removing engine covers, radiator covers or other parts in the engine area.
Keep engine covers closed when the engine is running, and take care to make sure that no tools are left in the machine
when service is complete.
Figure 3
Keep engine covers etc. closed when engine is running and when the machine is operating
Before the grader is placed back in service, ensure all doors, panels, inspection covers and the battery box cover are in
place and secure.
After servicing the grader, test it in a safe location.
Stay out of the frame articulation area unless the articulation lock is in place.
WARNING
Risk of crushing injuries
NOTICE
There is a risk of crushing even with the engine off if the machine is equipped with an electric secondary steering pump.
Service Information

Fire prevention measures 191 Service Information 9/10/2022
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Fire prevention measures


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General
There may always be a risk of fire. Learn the correct type of fire extinguisher to use, how to use it, and where it is kept.
A fire extinguisher is available as an option on G700B motor graders.
Any on-board fire extinguisher must be kept fully charged and in good working order at all times.
Any on-board fire fighting equipment should be considered as a complement to the operator's own fire fighting efforts.
It is not a replacement.
Never expose diesel fuel to open flame or smoking materials, especially when refueling or the fuel system is open to the
air.
Never use diesel fuel as a cleaner, use an approved cleaning solvent.
Certain solvents are usually flammable and can cause skin rashes or other conditions. Do not inhale solvent vapors.
Engine starting aids are flammable and should be stored in a cool, well-ventilated location. Never use starting aids
when preheating intake air.
Ensure the grader is properly equipped for grading in dry or forested areas. Equipment such as a spark arrestor may be
required.
At the first sign of a fire, take the following actions if the situation will safely permit:
Drive the machine away from the danger area.

Lower the moldboard and other implements and attachments to the ground.
Shut down the engine with the ignition key switch.
Leave the cab quickly and safely.
Turn the battery isolation switch off.
Begin extinguishing the fire and call for assistance if required.
Never expose diesel fuel to open flame or smoking materials, especially when refueling or the fuel system is open to the
air.
Figure 1
Do not smoke when refueling or expose diesel fuel to open flames
Certain solvents are usually flammable and can cause skin rashes or other conditions. Do not inhale solvent vapors.
Engine starting aids are flammable and should be stored in a cool, well ventilated location. Never use starting aids when
preheating intake air.
Cleanliness
Cleanliness is important to effective machine service. Contamination introduced to machine systems can shorten
component service life and cause the machine to malfunction.
Keep the service area clean. Oil or water on the floor can create a dangerous work environment, increasing the risk of
falls and electrocution. Oily and greasy clothing and shop rags are a fire hazard.
The machine should be inspected daily for the build-up of flammable debris. This will reduce the chance of a fire, and
will make it easier to detect loose or leaking parts.
NOTICE
If a high-pressure washer is used when cleaning, work carefully since damage may be caused to electrical
components and insulation of the electrical cabling even at relatively moderate water pressure and temperature.
Protect electrical cabling in a suitable manner.
Take special care to keep machines clean in applications such as coal mines where the risk of fire is greatest. In such
applications, suitable equipment to reduce the risk of fire should be installed and maintained.
Electrical system
Inspect wiring for chafing, breakage, and any routing condition that could expose wiring to damage. This is especially
important for positive electrical wires that could make contact with the frame (ground). Pay special attention to the
cables between the batteries, from the batteries to the starter, and between the alternator and starter.
When reconnecting wires, it is important to connect, route and secure them so they are protected from damage and
wear. They must not be routed in contact with fuel or oil hoses.
If any auxiliary electrical equipment is installed on the machine, wiring must be fused, connected and routed to avoid
exposure to wear or damage.
Fuel, hydraulic and brake systems
Check to make sure fuel, hydraulic and brake hoses are not worn or damaged, and are routed to avoid chafing.
Welding and grinding work

Move the machine to a clean, safe area before welding, grinding or using an oxy/acetylene torch on it. This type of work
should only be done in a clean area and not in places that contain combustible liquids, such as fuel tanks, hydraulic
pipes or similar.
Work with extra care when welding, grinding or torch cutting near flammable objects.
NOTICE
A fire extinguisher should be easily accessible during all welding work.
Welding on painted surfaces releases dangerous fumes and results in a poor weld joint that can result in failure and
potential accidents. Always remove paint from areas to be welded.
See, Health hazards with paint, plastics and rubber

Service Information

Health hazards with paint, 191 Service Information 9/10/2022
plastics and rubber
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Health hazards with paint, plastics and rubber


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Working on painted surfaces

Welding and gas cutting must not be performed on painted surfaces.
All paint disintegrates when heated, forming many different compounds that may be irritating or constitute a serious health
hazard after long or frequent exposure.
The following safety instructions must be followed:
Before welding or gas cutting, remove paint by sandblasting at least 10 cm (4 in.) around the area. Sandblasting is the
recommended method of paint removal.
If a sandblasting machine is not available, use a chemical paint stripper. Paint stripper is corrosive and toxic. Use a
portable air extractor, an approved respirator, goggles, and gloves.
A high-speed grinding machine also heats the paint and must only be used in conjunction with an air extractor. Also
use approved breathing protection/respirator.
Rubber and plastics
WARNING
When heated, rubber and plastics can give off substances that are hazardous to personal health and the environment.
Do not weld or gas cut near polymer materials (plastics and rubber) unless they are shielded and protected from the
heat.
Never burn polymer materials when discarding them.
Be careful when working on machines that have been on fire or have been exposed to intense heat. See also Check list
after fire or heat exposure.
Always use protective gloves, goggles and an approved respirator.
Fluor rubber
WARNING
When hydrogen fluoride rubber is heated, there is a risk of hydrogen fluoride gas build-up already at approx. 320 °C
(610 °F). When inhaled, the gas is extremely corrosive to respiratory tracts.
Certain seals designed to withstand high operating temperatures (for example, in engines, transmissions, axles, brakes, hydraulic
motors, and pumps) may be made of fluor rubber.
If a machine or a component of a machine has burned or been exposed to intense heat, it should be handled by specially trained
personnel. In handling of machines after a fire, wear protective neoprene rubber gloves, goggles, and approved respirator.
The acid may remain on machine parts for a very long time (several years) after a fire. It cannot be rinsed or washed off the skin,
but causes very severe burns that take a very long time to heal. As a rule, injured tissue must be removed surgically.
NOTE!
There may be a delay of several hours after contact with the acid before any symptoms appear.
Seek medical attention immediately if swelling, redness or burning sensations appear.
WARNING
Burning of painted parts, plastic or rubber parts constitutes a health hazard.
NOTE!
Never burn painted parts or parts made of rubber after they have been discarded. This work must be performed by a
licensed waste management plant.
Decontamination
Decontaminate the area around a part that may be made of fluor rubber by thoroughly washing with liberal quantities of lime
water (a solution or suspension of calcium hydroxide). When work is completed, wash cleaning materials in lime water and
discard.
If a machine has been damaged by fire or been exposed to other intense heat, the safety precautions in the following check list
must be followed under all circumstances. See also Check list after fire or heat exposure
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Check list after fire or heat 191 Service Information 9/10/2022
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Check list after fire or heat exposure


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As a precaution, all o-rings and seals should be handled as if they were made of fluor rubber. See also Health hazards
with paint, plastics and rubber.
WARNING
Avoid splashing when washing a machine damaged by fire. For this reason, never use high-pressure washing
equipment.
Never touch burnt components or parts with your bare hands when there is a risk that you may be exposed to contact
with burnt fluor rubber. See section Health hazards with paint, plastics and rubber.
Wear thick, protective neoprene gloves, goggles, and approved respirator.
First, wash thoroughly with plenty of lime water (a solution or a suspension of calcium hydroxide, i.e. slaked lime).
Seek medical attention if skin contact with burnt fluor rubber is suspected. The affected skin should be treated with
Hydrofluoric Acid Burn Jelly or similar.
Symptoms may not appear until several hours after contact with burnt fluor rubber.
Wash with lime water, then discard protective gloves, rags and other items that may have contacted burnt fluor rubber.
Service Information

Safety when handling tyres 191 Service Information 9/10/2022
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Safety when handling tyres


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WARNING
Tyres installed on a split rim may explode and cause very severe injuries.
Inflating tires
Never stand beside a tire that is inflating. Use a self attaching air chuck with a hose long enough to be out of the
trajectory path of the wheel rim when inflating a tire.
Do not fully inflate spare tires. Use only enough air pressure to keep the rim parts in place.
Always use an inflation cage, safety cables or chains when inflating a tire that is not installed on a machine.
Mounting tires on rims
Never mount a tire on a wheel rim that is not clearly recommended for that tire.
Never use wheel parts of different sizes together, and never use damaged or faulty wheel parts.
Use extreme care if you must use a repaired or reworked wheel rim. Faulty welding, brazing or heating can cause weak
areas that can result in failure of the part.
Remove all rust, dirt and debris from the locking ring groove in the rim before installing the ring.
Repairing tires and rims
Never cut or weld on a rim with a tire installed.

Take care when handling bead breakers and a hydraulic jack. Stay out of the trajectory path of the wheel rim when
removing foreign objects from a tire. If a bead break releases, it can do so with sufficient force to cause severe personal
injury and even death.
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Safety when lifting and 191 Service Information 9/10/2022
supporting the machine
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Safety when lifting and supporting the machine


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NOTE!
The machine must be lowered from the jack to a suitable secure stand before the wheel is removed. Do not use the jack to
support the weight of the machine when removing the wheel.
Use only lifting devices with sufficient capacity to safely support the expected weight you are lifting.
All lifting devices (straps, slings, chains, ratchet blocks, etc.) must comply with applicable regulations and certifications.
We can accept no responsibility for the use of sub-standard equipment and work practices.
If you use a jack, the floor or ground must be even and of sufficient strength to support the expected load.
Prevent the machine from rolling by applying the parking brake and wedge tire blocks in front and behind the tires that
are not to be lifted from the ground.
Place the jack under the axle of the wheel to be removed. Make sure it is positioned correctly and that it will safely
support the expected load.
Take care to safely position the supports under the machine.
Service Information

Safety when handling oil 191 Service Information 9/10/2022
and fuel
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Safety when handling oil and fuel


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Hot oil can cause painful burns. Use caution when changing the engine, transmission or hydraulic oil.
Oils and fuel can irritate and damage the eyes, throat and other sensitive skin. Avoid contact.
Oils and fuel are hazardous to the environment. Take special care not to spill or discharge these fluids. Use approved
containers and methods to handle and dispose machine fluids. Use an authorized disposal and recycling company.
Be aware of the risk of fire.
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electrical system
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Safety when working on the electrical system


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Use only test instruments with light-emitting diode (LED) displays to trace electrical faults. Do not use test equipment
that uses light bulbs. The voltage characteristics of light bulbs can destroy sensitive and expensive electronic
components.
When installing a two-way radio, mobile telephone and similar equipment, follow the manufacturer's installation
instructions in order to eliminate interference with the function of the electronic system and components on the
machine.
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Safety when working with 191 Service Information 9/10/2022
batteries
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Safety when working with batteries

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G780B Volvo
Batteries contain corrosive sulfuric acid that can cause corrosive skin burns and equipment damage. Charging batteries release
explosive hydrogen gas. Extreme care must be taken when working with batteries. Observe the following precautions:
Never smoke near batteries, especially when they are charging.
Figure 1
Do not smoke near batteries
Disconnect the negative (ground) terminal first, to avoid the chance of sparks that can cause a fire. Reconnect the
negative terminal last.
Never tilt a battery. Lift it straight to avoid spilling acid electrolyte.
Never connect a discharged battery in series with a fully charged one. There is a risk of explosion.
Take care to avoid battery terminal contact with metal tools and jewelry. There is a risk of injury and fire.
Always cover the tops of batteries with a rag or other non-conductive material when working near them.
Always reinstall the battery terminal protective covers.
Batteries contain lead and acid electrolyte that are hazardous to the environment. They must be disposed of
appropriately by an authorized disposal and recycling company.
Service Information

batteries
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Safety when working with batteries


G710B Volvo
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G780B Volvo
Batteries contain corrosive sulfuric acid that can cause corrosive skin burns and equipment damage. Charging batteries release
explosive hydrogen gas. Extreme care must be taken when working with batteries. Observe the following precautions:
Never smoke near batteries, especially when they are charging.
Figure 1
Do not smoke near batteries
Disconnect the negative (ground) terminal first, to avoid the chance of sparks that can cause a fire. Reconnect the
negative terminal last.
Never tilt a battery. Lift it straight to avoid spilling acid electrolyte.
Never connect a discharged battery in series with a fully charged one. There is a risk of explosion.
Take care to avoid battery terminal contact with metal tools and jewelry. There is a risk of injury and fire.
Always cover the tops of batteries with a rag or other non-conductive material when working near them.
Always reinstall the battery terminal protective covers.
Batteries contain lead and acid electrolyte that are hazardous to the environment. They must be disposed of
appropriately by an authorized disposal and recycling company.
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Battery, charging 191 Service Information 9/10/2022
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Battery, charging

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Explosion hazard
When batteries are charging, they give off an explosive mixture of hydrogen and oxygen gases. A short circuit, spark, open flame
or cigarette can ignite these gases and cause a powerful explosion. Always turn off the battery charger before disconnecting a
charging clip to prevent sparking. If the battery must be charged in a confined space, it must be well ventilated.
Corrosive sulfuric acid
Battery electrolyte contains corrosive sulfuric acid. In case of contact with the skin, wash immediately with plenty of water. In case
of contact with the eyes or other sensitive part of the body, wash immediately with plenty of water and seek immediate medical
attention.
Starting with booster batteries
When using booster batteries or other power source, make sure to use a 24 volt booster.
Figure 1
Battery charging
WARNING
The batteries could explode due to the current surge if a fully charged battery is connected to a completely discharged
battery. Since the batteries contain sulphuric acid, this could result in personal injuries.
Op nbr 311-004
1. Connect a jumper cable between the positive terminal on the fully charged booster battery and the positive terminal on
the starter motor.
Figure 2
Connecting a booster battery
2. Connect the other jumper cable from the negative terminal on the booster battery to a frame grounding point on the
machine (a starter mounting bolt or ground strap mounting bolt). Do not connect the booster battery directly to the
discharged battery.
3. Start the engine.
WARNING
Do not under any circumstances disconnect the cables to the ordinary batteries on the machine!
4. Disconnect the jumper cable between the frame ground and the negative terminal of the booster battery.
5. Disconnect the jumper cable between the positive terminals.

Service Information

air-conditioning refrigerant
Profile:
G780B Volvo
Safety when working with air-conditioning refrigerant


G710B Volvo
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G726B Volvo
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G780B Volvo
WARNING
R134a is hazardous to personal health
NOTE!
Never expose R134a refrigerant to open flame, welding, or smoking materials. Heated refrigerant vapor creates
poisonous gases that are extremely dangerous to inhale. In heavier concentrations, these gases have an unpleasant
smell. A small amount of these gases can cause severe lung damage, even in concentrations so small they cannot be
detected by smell. Symptoms of inhalation can occur several hours to one day after exposure to the gas.
Air conditioning service should only be performed by a certified technician who is approved to handle refrigerants and
is trained in the correct procedures and equipment.
NOTE!
R134a refrigerant was developed as a less environmentally damaging alternative to the R12 Freon¯ -type used on earlier systems.
While R134a does not harm the earth's ozone layer, it does contribute to the greenhouse effect. Like R12, it must not be
intentionally released into the atmosphere.
WARNING
Equipment intended for use on R12 systems must not be used for R134a systems, except for the vacuum pump.
Refrigerants R12 and R134a must never be mixed as this will cause compressor breakdown.
NOTICE
Refrigerant under pressure. Do not disconnect any hoses or connections on the air conditioning, thereby involuntary
releasing refrigerant.
NOTE!
Always evacuate the system in an approved manner. Do not attempt to recharge a system where leaks are suspected. It is
important to know that R134a refrigerant gas is heavier than air, and it will fall to the floor when it escapes.
WARNING
R134a will easily cause frostbite if it comes into contact with bare skin. Therefore, the following safety instructions must
be followed whenever handling refrigerant.
WARNING
R134a is moderately dangerous to one’s health. When handling refrigerant, wear close-fitting goggles and protective
gloves. In liquid form refrigerant can cause frost-bite and when in the form of a gas at high concentration it has an
anaesthetising effect and at lower concentration it primarily affects the nervous system.
In case of exposure to R134a refrigerant:

If you suspect that refrigerant has escaped, all personnel should move away from the area and seek fresh air. Avoid inhaling
R134a refrigerant.
In case of skin contact with R134a liquid, rinse the frostbitten area immediately with lukewarm water. If the contact area was
extensive, warm clothing should be used along with lukewarm water to reduce frostbite damage to the skin and then seek
medical attention.
In case of eye contact with R134a liquid, rinse the eyes with clean, lukewarm water until the irritation is relieved and then seek
medical attention.
Air conditioning system recharging, general
NOTE!
If a system must be recharged in cold weather, you may use warm water at a temperature of no more than 40ºC (104ºF) to warm
refrigerant cylinders. Never heat refrigerant containers directly. Do not put the charge valve in the warm water. Do not use
refrigerant containers that have been damaged or dented. Never store refrigerant containers in direct sunlight or where
temperatures can exceed 40ºC (104ºF).
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Safety when working on 191 Service Information 9/10/2022
hydraulic systems
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Safety when working on hydraulic systems


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The hydraulic system operates at high oil pressures. The system must be properly maintained to avoid the potential for accidents
and injury. It is important that each person who comes in contact with the machine be alert to any faults.
Follow these basic precautions:
Never adjust a pressure relief valve or other pressure-limiting device to a higher pressure than specified.
Replace any hydraulic hose immediately that shows signs of swelling, wear, leaks or damage before it bursts.
Never discard a hydraulic accumulator without first carefully drilling a 3 mm (1/8 in.) hole in the cylinder to eliminate the
risk of explosion.
Releasing hydraulic pressure

When you shut down the engine, there will still be residual pressure at various point is the hydraulic system. Never disconnect
any hydraulic hose, fitting or component without first relieving residual pressure.
WARNING
personal injuries.
WARNING
Never use your hands to check for oil leaks. Use a piece of cardboard.
Never tighten leaky fittings with the engine running, or before the residual pressure has been released.
Pressure accumulators have a pressurized gas charge as well as residual hydraulic pressure. Use extreme care when
working with accumulators.
Check valves, lock valves and similar hydraulic components are designed to retain pressure or oil flow. See Section 9 for
specific procedures to relieve residual pressure with these components in a hydraulic circuit.
Service Information

Safety concerns everybody! 191 Service Information 9/10/2022
Profile:
G780B Volvo
Safety concerns everybody!


G710B Volvo
G720B Volvo
G726B Volvo
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G740B Volvo
G746B Volvo
G780B Volvo
Always keep the Operator's Manual in the machine for handy reference.
Many hours of skilled and careful design have gone into manufacturing the safest and most efficient motor grader possible. All
of this time and effort could be wasted if an operator or service person does not read and follow safety instructions and
procedures. Unfortunate accidents and personal injury can result from failure to replace guards, climbing on slippery areas
instead of using a ladder, using hoses or other parts instead of hand rails, and failing to use correct tools and procedures.
Properly operated, maintained and serviced machines rarely cause accidents. Human error is the greatest cause. Maintain and
promote safe and efficient machine operation, and always use genuine spare parts designed and intended for each specific
machine.
WARNING
Any person who does not follow the safety instructions and who ignores warnings in this manual must make absolutely
sure that their work method is safe. Otherwise, there is a great risk of serious accidents and injuries, perhaps even
fatalities.
WARNING
WARNING SYMBOL
This symbol will appear at various places in this manual along with a warning statement. It means: "Warning, be alert!
Your safety is involved!"
Become familiar with the capacity and limits of the machine!
Service Information

Electric welding 191 Service Information 9/10/2022
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Electric welding

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WARNING
Follow the safety instructions in the Service Manual when carrying out welding and grinding work on the machine.
Before performing any maintenance procedure on the machine, place the grader in the Service Position. See Service positions.
NOTICE
Before starting any electric welding, disconnect the battery connections. All connections to the control units (ECU)
should be disconnected. Connect the welding unit's ground cable as close as possible to the welding point.
Disconnect the following items as listed below:
1. Negative battery cable.

2. Positive battery cable.
3. Power supply and transmission wiring harnesses at the transmission ECU (electronic control unit).
4. Wiring harnesses at the instrument ECU, engine ECU, and fan ECU.
5. Alternator to battery wiring harness.
6. 5 amp 24V - 12V converter (if installed) wiring harness at the fuse panel.
7. 25 amp 24V - 12V converter (if installed) wiring harness at the battery.
8. Float valve module (if installed) wiring harness at the module.
Install the battery box cover.

After completing your welding procedures, connect the above items in the reverse order. Ensure you connect the negative
battery cable last.
WARNING
If the battery's plus terminal is short-circuited to the minus terminal or to the chassis, there is a risk of explosion or fire.
Therefore, always protect the battery terminals.
NOTICE
Connect the welding unit ground connection as close as possible to the welding point.
NOTICE
During electric welding on the machine or attachments connected to the machine, components such as bearings and
electric units may be damaged if the ground cable is connected incorrectly.
20 - GENERAL 2
21 - ENGINE 6
22 - LUBRICATING SYSTEM 64
23 - FUEL SYSTEM 74
25 - INLET & EXHAUST SYSTEM 111
26 - COOLING SYSTEM 125
27 - ENGINE CONTROL 132
Description; D7D_{42-48} 2
Description; D10B_{42-28} 3
General description 4
Service Information

Description, D7D 200 Service Information 9/10/2022
Profile:
G780B Volvo
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Description, D7D

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The engine is a straight six-cylinder, direct injected diesel with 7.15 litres (436 in³) of cylinder capacity. It has a turbocharger,
charge air cooler, electronically controlled fuel injection, and EMS (Engine Management System).
The valve mechanism receives its movement from the camshaft via valve rods and rocker arms. The injectors are mounted in
copper sleeves that are pressed into the cylinder head and directly surrounded by the coolant. The engine also has an electronic
control unit (E-ECU), located on the left-hand side of the cooling module.
The cylinder numbering system for the model D7D engine is opposite to the standard North American configuration. The
number 1 cylinder is adjacent to the flywheel end of the engine.
Figure 1
Service Information

Description, D10B 200 Service Information 9/10/2022
Profile:
G780B Volvo
Description, D10B

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
The engine is a straight six-cylinder, direct injected diesel with 9.6 litres (585 in) of cylinder capacity. It has a turbocharger, charge
air cooler, electronically controlled fuel injection, and EMS (Engine Management System).
The valve mechanism receives its movement from the camshaft via valve rods and rocker arms. The injectors are mounted in
copper sleeves that are pressed into the cylinder head and directly surrounded by the coolant. The engine also has an electronic
control unit (E-ECU), located on the left-hand side of the engine block.
Service Information

General description 200 Service Information 9/10/2022
Profile:
G780B Volvo
General description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The D7D (7 litre) engine is used in G710B to G730B graders. All engines used in these models will use the same ECU hardware.
Only the engine software will change.
The D10B (10 litre) engine is used in G740B, G746B and G780B graders.
All engines are low-emission, six cylinder, four-stroke, direct-injected, turbocharged diesel engines with intercooler. These
engines all have VHP (Variable Horsepower).
The engine serial numbers for the G710B to G730B models are found on a plate on the left-hand side of the engine.
G740B, G746B and G780B models have the serial number stamped into the right-hand side of the engine block.
The engine is installed in a closed space to reduce the external sound level.
Lubrication is achieved with a force-feed lubrication system where an oil pump supplies lube oil to all lubrication points.
The turbocharger supplies the engine with pressurized fresh air, resulting in a surplus of air. Thus, the injected fuel amount can
be increased, giving more engine power. The turbocharger is lubricated and cooled by the engine lube oil, and is driven by the
engine exhaust.
The charge air cooler is located in the induction system between the turbocharger and the intake manifold. The cooled air
contributes to cleaner exhaust and improved engine power.
Specifications; D7D - weight 2
Specifications; D10B - weight 3
Specifications; D7D - capacities_{39-16} 4
Specifications; D10B - capacities_{38-57} 5
Engine; removing_{38-21} 6
Engine; removing_{37-58} 10
Specifications; D7D - tightening torques_{37-25} 14
Specifications; D10B - tightening torques_{37-07} 15
Cylinder compression; testing 16
Cylinder head - D10B; description_{34-55} 21
Cylinder head - D7D; description_{34-34} 23
Cylinder block - D10B; description 25
Oil trap - D10B; description 26
Cylinder liner; piston; D7D description 27
Cylinder liners; D10B description 30
Cylinder liner; piston; D10B 32
Valves; adjusting_{31-10} 34
Valves; adjusting_{30-48} 37
Valves - D7D; description 39
Valve mechanism - D10B; description 41
Valve mechanism - D10B; specifications 43
Engine timing gear - D10B; description 44
Camshaft - D10B; description 46
Connecting rod; D7D-2701 47
Connecting rod; D7D 49
Crankshaft; D7D 51
Torsional vibration damper; D7D 53
Crankshaft rear oil seal; replacing 55
Crankshaft and vibration damper; D10B 57
Service Information

Specifications, D7D - weight 210 Service Information 9/10/2022
Profile:
G780B Volvo
Specifications, D7D - weight


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Engine - D7D, standard 760 kg (1676 lb)

Service Information

Specifications, D10B - 210 Service Information 9/10/2022
weight
Profile:
G780B Volvo
Specifications, D10B - weight


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Engine - D10B, standard 1360 kg (2998 lb)

Service Information

Specifications, D7D - 210 Service Information 9/10/2022
capacities
Profile:
G780B Volvo
Specifications, D7D - capacities


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Engine - D7D, when changing oil incl. filter 32 L (8.5 US gal)

Service Information

capacities
Profile:
G780B Volvo
Specifications, D10B - capacities


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Engine - D10B, when changing oil incl. filter 39,5 L (10.4 US gal)
Service Information

Engine, removing 210 Service Information 9/10/2022
Profile:
G780B Volvo
Engine, removing

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 210-070
Tools:
9998547 Lifting tool
1. Park the machine in the Service Position. Refer to Service position, see Service positions
2. Turn off the electric power with the battery disconnect switch.
WARNING
Hot oil and hot engine coolant can cause severe burns!
3. Drain engine oil (as required for the service performed). Approximate oil pan capacity: 32 L (8.5 US gal).
Place a container of suitable capacity underneath the engine.

Remove the draining valve cap and connect the drain hose adapter.
Figure 1
1. Drain hose adapter

2. Draining valve cap
4. Drain coolant.
Approximate cooling system capacity is 30L (7.9 US gal).

Connect a drain tube to the coolant drain valve located on the lower radiator hose inside the RH cooling
module access door.
Position a suitable sized container to collect the coolant.
Remove the expansion tank cap and open the valve.
Figure 2
Radiator drain valve
5. Remove the engine doors. (Approximate weight is 33 kg [73 lbs].)
Open the doors and remove the upper hinge pins.

Attach lifting straps to the upper door grab handle and connect to an appropriate size lifting device.
Disconnect door supports in the extended position by inserting a screwdriver into the end clip. This will allow
the support to be pulled off of the ball stud.
NOTICE
Door supports are pressurized in the collapsed position.
The doors must be lowered and lifted straight up to disengage from the hinge brackets.
Figure 3
Door support clip removal
6. Remove the engine hood complete with air cleaner, muffler, and coolant reservoir. (Approximate total weight is 59 kg
[130 lb].)
Disconnect the coolant reservoir to engine supply hose and reservoir to radiator breather line, disconnect at
the radiator.
Disconnect and remove the air intake tube and connector hose to turbocharger.
Cover or tape turbocharger and air cleaner openings.
Disconnect exhaust pipe flange from muffler.
Remove the mounting bolts, connect an appropriate size lift strap between the muffler and air filter
assemblies.
Connect to an appropriate size lift device and remove the assembly.
7. Remove the lower engine compartment panels.
8. Remove the fuel tank assembly. Fuel level in the tank should be less than 25% for safety and handling ease.
Approximate total weight empty is 227 kg (500 lb).
Close the fuel tank shut off valves at the supply and return lines. Cover to prevent contamination.
Disconnect fuel line to primer. Cap or tape-off hose and fittings to prevent contamination.
Remove the battery cover and disconnect the battery cables.
Disconnect wiring to the battery isolation switch.
Remove the engine preheater solenoid bracket and tie back for clearance.
Evacuate/reclaim the air conditioning system refrigerant. Disconnect the hoses to the receiver drier and cap-
off (as required).
Remove the hose bundle support bracket.
Disconnect and cap remote greasing hoses.
Attach an appropriate lifting device using 100 mm (4 inch) lift straps. Ensure the tank is supported from all
sides.
Remove the fuel tank mounting bolts and remove the assembly.
9. Disconnect the transmission driveshaft at the clutch yoke.
10. Disconnect the clutch housing supply and drain hoses and cap-off.
11. Disconnect and cap-off clutch slave cylinder hose.
12. Disconnect the transmission pump hoses and cap-off.

13. Disconnect the engine ECU and the main chassis to engine connector.
14. Disconnect the heater hose supply and return hoses.
15. Disconnect the fuel cooler to supply pump hose and cap-off.
16. Disconnect radiator inlet and outlet hoses at the engine.
17. Disconnect and remove the air charge cooler pipes and cap-off or tape all engine and cooler openings.
18. Remove the radiator air intake deflector plate and floor plate.
19. Disconnect the hydraulic pump drive shaft.
20. Disconnect and remove the alternator.
21. Disconnect the air conditioning compressor wiring at the compressor (as required).
22. Disconnect the engine ground strap.
23. Disconnect the starter wiring at the starter.
24. Connect an appropriate lift device to the engine lift brackets.
Figure 4
25. Remove the engine mounting bolts and remove the engine.
26. Lower the engine to floor level and support at the 4 mount brackets or mount to an appropriate size engine stand. (The
engine oil pan must not be used for support).
Service Information

Engine, removing 210 Service Information 9/10/2022
Profile:
G780B Volvo
Engine, removing

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 210-070
Tools:
9998547 Lifting tool
Torque wrench: 0 – 400 N•m (0 – 40 kgf•m)(0 – 295 lbf•ft)
1. Park the machine in the service position. Refer to Service positions.
WARNING
3. When necessary, drain engine oil. Approximate oil pan capacity: 39.5 L (10.4 US gal).
Place a container of suitable capacity underneath the engine.

Remove the draining valve cap and connect the drain hose adapter.
Figure 1
1. Drain hose adapter

2. Draining valve cap
4. Drain coolant.
Connect a drain tube to the coolant drain valve located on the lower radiator hose inside the RH cooling
module access door. Approximate cooling system capacity: 38 L (10.0 US gal).
Position a suitable sized container to collect the coolant.
Remove the expansion tank cap and open the drain valve.
Figure 2
Radiator drain valve
5. Remove the engine doors. Approximate weight is 33 kg (73 lb).
Attach lifting straps to the upper door grab handle and support.
Remove the upper hinge pins and disconnect both door supports.
NOTICE
Door supports are pressurized in the collapsed position.
Disconnect door supports in the extended position by inserting a screwdriver into the end clip. This will allow
the support to be pulled off of the ball stud.
The doors must be lowered and lifted straight up to disengage from the hinge brackets.
Figure 3
Door support clip removal
6. Remove the engine hood complete with air cleaner, muffler, and coolant reservoir. Approximate total weight 59 kg (130
lb).
Disconnect the coolant reservoir to engine supply hose and reservoir to radiator breather line. Disconnect at
the radiator.
Disconnect and remove the air intake tube and connector hose to turbocharger.
Cover or tape turbocharger and air cleaner openings.
Disconnect exhaust pipe flange from muffler.
7. Remove fuel tank assembly. Fuel level in the tank should be less than 25% for safety and handling ease. Approximate
total weight without fuel 227 kg (500 lb).
Close the fuel tank shut off valves at the supply and return lines. Cover to prevent contamination.
Disconnect fuel line to primer. Cap or tape-off hose and fittings to prevent contamination.
Remove the battery cover and disconnect the battery cables.
Disconnect wiring to the battery isolation switch.
Remove the engine preheater solenoid bracket and tie back for clearance.
Evacuate/reclaim the air conditioning system refrigerant. Disconnect the hoses to the receiver-drier and cap-
off.
Remove the hose bundle support bracket.
Disconnect and cap remote greasing hoses, as required.
Attach an appropriate lifting device with two 100 mm (4 in.) lift straps.
Remove the fuel tank mounting bolts and fuel tank assembly.
8. Disconnect the transmission driveshaft at the clutch yoke.
9. Disconnect the clutch housing supply and drain hoses and cap-off.
10. Disconnect and cap-off clutch slave cylinder hose.
11. Disconnect the transmission pump hoses and cap-off.
12. Disconnect the engine ECU and the main chassis to engine connector.
13. Disconnect the heater hose supply and return hoses.
14. Disconnect the fuel cooler to supply pump hose and cap-off.
15. Disconnect radiator inlet and outlet hoses at the engine.
16. Disconnect and remove the charge air cooler pipes and cap-off or tape all engine and cooler openings.
17. Disconnect and remove the alternator.
18. Disconnect the air conditioning compressor wiring at the compressor.
19. Disconnect the hydraulic pump driveshaft at the engine.
20. Disconnect starter wiring at the starter.
21. Connect 9998547 lift yoke to the engine brackets and an appropriate lift device. Engine weight is 1032 kg (2275 lb).
22. Remove the 4 engine mount bolts and lift the engine from the chassis.
23. Lower the engine to floor level and support at the 4 mount brackets or mount to an appropriate size engine stand. (The
engine oil pan must not be used for support.)
Service Information

Specifications, D7D - 210 Service Information 9/10/2022
tightening torques
Profile:
G780B Volvo
Specifications, D7D - tightening torques


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Engine - D7D N•m kgf•m lbf•ft

Engine - engine mount 664 – 746 68 – 76 490 – 550
Crank adapter pulley 68 – 95 7 – 9,7 50 – 70
Service Information

tightening torques
Profile:
G780B Volvo
Specifications, D10B - tightening torques


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Engine - D10B N•m kgf•m lbf•ft

Engine - engine mount 664 – 746 68 – 76 490 – 550
Service Information

Cylinder compression, 210 Service Information 9/10/2022
testing
Profile:
G780B Volvo
Cylinder compression, testing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 210-002
Tools:
9998532 Extractor
9998009 Adapter
9988539 Pressure gauge
Condition: Valves are correctly adjusted, see Valves, adjusting.

Engine at operating temperature
1. Park the machine in the service position.
2. Clean thoroughly around the injectors, also around the connections for the fuel pressure lines and leak-off fuel lines.
WARNING
The fuel pressure lines are pre-shaped and may not be altered for any reason.
If a pre-shaped fuel line is bent or deformed, there is a great risk that it will rupture.
A damaged fuel pressure line must always be changed!
3. Remove the fuel pressure lines. The pipes are clamped in two groups of three. Do not loosen the clamps.
NOTICE
Fit protective caps on all injectors and on the injection pump's connections.
Figure 1
4. Unplug the connector for sensor SE2308 and remove the bracket.
5. Remove the leak-off fuel line between the injectors.

NOTE!
If compression check is to be performed on cylinder 6, loosen and fold aside the pipe between the turbocharger and
intercooler.
6. Remove the nuts for the injector yokes and remove the yokes.
Figure 2
7. Remove the rubber seals around the injectors.
8. Remove the injector for cylinder 1 by turning the injector and pulling up at the same time. If needed, use puller
9998532 to remove the injector.
Figure 3
1. Injector
9. Make sure that the copper washer located between the injector and the copper sleeve comes out as well. If not, use a
steel wire hook to get it out.
Figure 4
1. Copper washer
10. Fit the adapter 9998009 and bolt it down with the injector yoke and nut.
Tightening torque: 50 N•m (5 kgf•m)(37 lbf•ft).
NOTE!
Check that the compression gauge's seal ring is intact.
Figure 5
1. 9998009 Adapter
2. 9998539 Compression gauge
11. Connect compression gauge 9988539.
12. Press in the Safety stop. The safety stop is located on the right side of the operator's panel. This is to prevent fuel from
flowing out from the pressure valves on the injection pump when the engine is turned with the starter motor.
Research the proper methods to shut fuel off when checking compression.
13. Check that the gearshift selector is in neutral.
14. Turn over the engine with the starter motor for 5 seconds and read off the value.
15. Remove the checking equipment and refit the injector with new copper washer and rubber seal.
16. Perform compression check on cylinders 2, 3, 4, 5 and 6 in the same way as for cylinder 1.
Normal compression pressure is 3.8 MPa (38 bar)(551 psi) at 180 rpm.
NOTICE
A difference of up to 10% in compression between cylinders is acceptable and does not indicate a need for further
action, i.e. reconditioning of the valves.
17. Fit the yokes and the nuts.

Figure 6
18. Fit the leak-off fuel line, use new copper washers.
NOTE!
If compression check has been performed on cylinder 6, fit the pipe between the turbo and the intercooler.
WARNING
19. Fit the fuel pressure lines. Make sure that the area is clean and that the fuel pressure lines are not bent or altered in any
way. Tighten the pressure line nuts.
Tightening torque: 15 – 25 N•m (1.5 – 2.5 kgf•m)(11 – 18 lbf•ft).
Figure 7
20. Fit the bracket and sensor SE2308.
21. Restore the stop function. Start the engine and check to make sure that there are no leaks.
22. Run the engine with increased engine speed for approx. 5 minutes to remove any remaining air.
Service Information

Cylinder head - D10B, 211 Service Information 9/10/2022
description
Profile:
G780B Volvo
Cylinder head - D10B, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The engine has six cylinder heads, each covering one cylinder. Each cylinder head is bolted down by 4 bolts evenly spaced
around the cylinders. The cylinder head's gasket is made of solid steel sheet metal. A flame edge on the cylinder liner protects
the gasket from the combustion pressure and the combustion temperature.
Figure 1
Service Information

Cylinder head - D7D, 211 Service Information 9/10/2022
description
Profile:
G780B Volvo
Cylinder head - D7D, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The cylinder head of the D7D engine is made of grey cast iron and designed as a block-type head. The combustion air enters
vertically and the exhaust air is discharged laterally. Inlet and outlet are located on one side of the cylinder head.
Figure 1
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Cylinder block - D10B, 212 Service Information 9/10/2022
description
Profile:
G780B Volvo
Cylinder block - D10B, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The cylinder block is cast in one piece and is equipped with wet, replaceable cylinder liners. The tensile stresses caused by the
combustion pressure to the cylinder head bolts are transferred through reinforced sections in the cylinder block walls directly to
the main bearings.
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Oil trap - D10B, description 212 Service Information 9/10/2022
Profile:
G780B Volvo
Oil trap - D10B, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The oil trap removes oil droplets present in the crankcase ventilation's exhaust air. The oil is then directed back to the oil sump.
The cleaned air is directed out into the surrounding air.
Figure 1
Oil trap
1. Crankcase ventilation
2. Ventilation to air
3. Oil to oil sump
Service Information

Cylinder liner; piston, D7D 213 Service Information 9/10/2022
description
Profile:
G780B Volvo
Cylinder liner; piston, D7D description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The D7D engine has a cylinder block made of high-alloy grey cast iron.
Cylinder liner
The wet liners can be replaced. The sealing surfaces of the O-ring seals must be wetted with oil before being inserted.
Figure 1
Pistons
The pistons of the D7D engine are made of a special aluminium alloy. The piston bowl has a small amount of eccentricity to the
piston pin.
The piston must be installed so that the flywheel symbol (1) on the piston top faces the flywheel. The pistons are equipped with
3 piston rings. The 1st ring has a ring carrier (2) of cast iron.
The cross section of the 1st piston ring is asymmetrical. The cross section of the 2nd piston ring is conical (compression ring).
When installing the piston, the TOP mark at the ring gap must point upwards. The 3rd ring is the bevelled-edge oil control ring.
Figure 2
Piston cooling
The piston is cooled by spraying lubrication oil against the inside of the piston top.
The piston cooling nozzles are made of plastic and fitted in the main bearing pedestals.
Figure 3
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Cylinder liners, D10B 213 Service Information 9/10/2022
description
Profile:
G780B Volvo
Cylinder liners, D10B description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The wet, replaceable cylinder liners are designed with a "flame edge" flange that fits into a groove in the cylinder head. This
mechanical joint reduces the stress on the cylinder head gasket.
Figure 1
Cylinder block and liner
1. Cylinder block
2. Cylinder liner
Three rubber O-rings are used for the external sealing of the cylinder liner. Sealing the upper part of the cylinder liner is achieved
partly by the O-ring under the liner flange and partly by the cylinder head gasket pressing down the liner flange against the
bottom of the recess in the cylinder block. The two lower O-rings are installed in grooves machined in the cylinder block. These
O-rings are made of different materials. The upper O-ring is black in color, and the lower O-ring is violet in color.
Service Information

Cylinder liner; piston, D10B 213 Service Information 9/10/2022
Profile:
G780B Volvo
Cylinder liner; piston, D10B


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Cylinder liner
The cylinder liners are centrifugal cast and seal against the block with rubber rings. The upper rubber ring is made of EPDM
rubber and is placed in a recess groove under the liner collar.
The bottom cylinder seal consists of rubber rings mounted in grooves in the block. The upper ring is made of EPDM rubber
(black) and the lower ring is made of fluor rubber (purple).
The seal between the cylinder head and the liner consists of a solid steel gasket and with a flame edge on the liner, and a
corresponding groove in the cylinder block. The sealing surface on the liner against the steel gasket is slightly convex and its
height above the block's surface is 0.15 – 0.20 mm (0.0059 – 0.0078 in.).
Figure 1
Pistons
The pistons are made of aluminium and are cooled with oil through piston cooling nozzles, which are mounted in the cylinder
block. Each piston is equipped with two compression rings and an oil ring. The upper compression ring is of the “Keystone” type
and is located in a cast-embedded piston ring holder made of cast iron.
Service Information

Valves, adjusting 214 Service Information 9/10/2022
Profile:
G780B Volvo
Valves, adjusting

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 214-012
Tools:
9993590 Gear wheel
WARNING
In order to eliminate the risk of engine start when the crankshaft is rotated, the emergency stop should be pressed in,
the ignition key should be turned off and the engine should be cold.
3. Clean around the valve covers, loosen and remove them.

Figure 1
4. Remove the hexagon headed plug (1) from the boss on the top right-hand side of the flywheel housing. Take care not
to damage the gasket (2).
Figure 2
5. Fit the gear 9993590 in the hole (1) in the flywheel housing. Use a standard ratchet handle that can be combined with a
universal joint and extension from a 1/2 in. socket wrench set if needed.
6. Adjust the valve clearance according to the two-position method:

Rotate the crankshaft in the engine's rotational direction (clockwise) until the piston for cylinder 1 is at the upper break-
over point after compression (TDC).
The valves for cylinder 6 should rock (break over) and the flywheel should stand at 0º.
Adjust valves 1, 2, 4, 5, 8, and 9.
Loosen the lock bolt and set the correct measurement with a screwdriver.
Inlet valve clearance should be 0.40 mm (0.016 in.) and exhaust valve clearance should be 0.70 mm (0.028 in.) – cold
engine.
Adjust the valve clearance according to the two-position method.
Figure 3
7. Then rotate the flywheel another full turn in the engine's rotational direction (clockwise) until the piston for cylinder 6 is
at the upper break-over point. The valves for cylinder 1 should rock (break over) and the flywheel should stand at 0º.
– Adjust valves 3, 6, 7, 10, 11, and 12.
NOTICE
Valve adjustment with the engine running is not allowed since the valves may strike the piston, causing severe
damage.
Figure 4
Inlet
Exhaust
8. Secure the lock bolt. Tightening torque: 20 N•m (14.8 lbf•ft).
9. Remove gear 9993590 from the flywheel housing. Install the hexagon headed plug and gasket in the flywheel housing
threaded boss.
10. Refit and tighten down the valve covers. Tightening torque: 24 N•m (2.4 kgf•m) (18 lbf ft).
11. Test-run the engine. Check for leaks.

Service Information

Valves, adjusting 214 Service Information 9/10/2022
Profile:
G780B Volvo
Valves, adjusting

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 214-012
Tools:
9998681 Rotation tool
Feeler Gauges
The valve clearance must be checked and adjusted at 1000 hour intervals. To do this, the engine oil temperature must be
between 20ºC and 80ºC.
Valve clearance:
Inlet: 0.3 +0.1 mm (0.012 +0.004 in.)

Outlet: 0.5 +0.1 mm (0.020 +0.004 in.)
WARNING
In order to eliminate the risk of engine start when the crankshaft is rotated, the emergency stop should be pressed in,
the ignition key should be turned off and the engine should be cold.
1. Remove rocker cover.
2. Turn crankshaft until both valves in cylinder 1 overlap (exhaust valve about to close, inlet valve about to open).
3. Adjust clearance of valves marked in black in figure. Mark respective rocker arm with chalk to show that adjustment has
been done.
Figure 1
4. Turn crankshaft one full revolution (360º). Now adjust clearance of valves marked black in figure.
Figure 2
Service Information

Valves - D7D, description 214 Service Information 9/10/2022
Profile:
G780B Volvo
Valves - D7D, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The D7D engine has one inlet and one exhaust valve per cylinder. In the upper area of the valve guide, O-rings seal the valve
stem to prevent excessive oil consumption and hydrocarbon emission. The valve guides are shrunk in the cylinder head. The
valve seat inserts are made of high-quality steel and are also shrunk in the cylinder head.
The valves are turned by eccentric actuation through the rocker arms. The new compressed cone connection permits easy
turning of the valve despite stress load.
NOTE!
The valve springs of the D7D engine have no special installation direction.
Rocker arm lubrication is integrated in the lubrication oil circuit. The oil is supplied via tappets and push-rods.
Valve seat angle:
Inlet: 30º
Exhaust: 45º
Figure 1
Service Information

Valve mechanism - D10B, 214 Service Information 9/10/2022
description
Profile:
G780B Volvo
Valve mechanism - D10B, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The valve mechanism receives its movement from the camshaft via push rods and rocker arms. The valve stems are equipped
with oil seals. The valves seats are replaceable. The oversize seat has a bigger outside diameter and is used if the cylinder head
requires machining of the valve seat positions.
The valve tappets are made of steel and are carried in bearings in the cylinder block, and their contact surface with the camshaft
is slightly convex. The tappets' movement is transmitted to the valve stems via push rods and rocker arms. The rocker arms have
press-fitted bushings made of bronze.
The rocker arm shaft is made of steel. Each rocker arm shaft is separately lubricated via drilled channels that pass through the
cylinder head and block.
Both the inlet valves and exhaust valves have double springs and hardened, durable caps between the valve stems and rocker
arms.
Figure 1
Service Information

Valve mechanism - D10B, 214 Service Information 9/10/2022
specifications
Profile:
G780B Volvo
Valve mechanism - D10B, specifications


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Valve mechanism
Valve device Top valves
Valve clearance, warm/cold engine
Inlet valves 0.40 mm (0.016 in.)
Exhaust valves 0.70 mm (0.028 in.)
Service Information

Engine timing gear - D10B, 215 Service Information 9/10/2022
description
Profile:
G780B Volvo
Engine timing gear - D10B, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The timing gear mechanism is located under a separate casing at the front end of the engine. It consists of hardened cylindrical
gears with bevelled gear teeth. The injection pump and camshaft are driven from the crankshaft gear via a transfer gear. The oil
pump is driven in the same way.
The timing gears' surfaces are treated with three different surface treatment methods: case hardening, tough-hardening and
nitro-carburization. The gears are matched to each other in a predetermined pattern depending on engine version.
Figure 1
Engine timing gear
A. Transfer gear (2) lubrication

B. Ball bearing for coolant pump's transfer gear (5)
1. Gear, crankshaft
2. Transfer gear, injection pump and driveshaft
3. Gear, injection pump
4. Transfer gear, coolant pump
5. Transfer gear, coolant pump
6. Gear, compressor
7. Gear, camshaft
8. Transfer gear, lube oil pump
9. Gear, lube oil pump
Service Information

Camshaft - D10B, 215 Service Information 9/10/2022
description
Profile:
G780B Volvo
Camshaft - D10B, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Camshaft, description
The camshaft is carried in seven bearing housings that are bolted on the cylinder head. The bearing housings have different
diameters that gradually decrease towards the rear end of the engine.
The axial clearance (run-out) is determined by the camshaft gear, the shoulder on the camshaft's front bearing pin, and the
thrust washer that is bolted on the cylinder block's front face.
Service Information

Connecting rod, D7D 216 Service Information 9/10/2022
Profile:
G780B Volvo
Connecting rod, D7D


G780B Volvo
The forged steel connecting rod is fitted at the big end bearing bore with a balance weight (1) in order to compensate the
manufacturing tolerances with regard to weight and position of the center of gravity.
The number markings (A) on the big end eye and the bearing cap must be on one side and identical.
Locating lugs (2) are provided in the lower and upper bearing shells to prevent the bearing shells from rotating in their seat;
these lugs engage in adequately shaped grooves in the big end eye and big end bearing cap.
The piston must be so installed that the flywheel symbol (B) on the piston top faces the flywheel.
When assembling the connecting rod and piston, the centering pins (3) for locating the connecting rod bearing cap must be
fitted on the upper face of the piston on the side of the flywheel symbol (B).
Figure 1
Service Information

Connecting rod, D7D 216 Service Information 9/10/2022
Profile:
G780B Volvo
Connecting rod, D7D


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The forged steel connecting rod is fitted at the big end bearing bore with a balance weight (1) in order to compensate the
manufacturing tolerances with regard to weight and position of the center of gravity.
The number markings (A) on the big end eye and the bearing cap must be on one side and identical.
Locating lugs (2) are provided in the lower and upper bearing shells to prevent the bearing shells from rotating in their seat;
these lugs engage in adequately shaped grooves in the big end eye and big end bearing cap.
The piston must be so installed that the flywheel symbol (B) on the piston top faces the flywheel.
When assembling the connecting rod and piston, the centering pins (3) for locating the connecting rod bearing cap must be
fitted on the upper face of the piston on the side of the flywheel symbol (B).
Figure 1
Service Information

Crankshaft, D7D 216 Service Information 9/10/2022
Profile:
G780B Volvo
Crankshaft, D7D

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The forged crankshaft of the D7D engine series has integrated balance weights. The drive gear for the timing gears and the
flywheel flange are a shrink fit.
Figure 1
The material microstructure of the fillet radius on the bearing journals is strengthened by rolling. Re-machining of the fillet radii
is therefore not permissible.
Figure 2
In case of repair, there are two 0.25 mm (0.010 in.) undersizes available (diameter) for the crankpins and main bearing journals.
Figure 3
The thrust bearing face can only be re-machined once (oversize: 0.2 –0.4 mm [0.008 – 0.016 in.] each side). Thrust bearing
clearance of the crankshaft in installed condition: 0.1 – 0.28 mm (0.004 – 0.011 in.)
Figure 4
Service Information

Torsional vibration damper, 216 Service Information 9/10/2022
D7D
Profile:
G780B Volvo
Torsional vibration damper, D7D


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The D7D engine has a crankshaft vibration damper as standard equipment.

Figure 1
Service Information

Crankshaft rear oil seal, 216 Service Information 9/10/2022
replacing
Profile:
G780B Volvo
Crankshaft rear oil seal, replacing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 216-018
Tools:
9998672 Installation tool
E14 TORX
E20 TORX
WARNING
Please pay attention to the safety instructions in the Operator's and Service Manuals concerned.
1. Place the grader in the Service Position.
2. Remove the fuel tank and clutch assembly using the instructions listed in the Clutch housing, removing.
NOTE!
Removing the fuel tank with the fuel level at more than 25 percent full is not recommended. Removal of the engine
compartment hood and doors is not required if the hood is properly supported.
3. Remove the flywheel.
4. Support the rear of the engine and remove the rear engine mounts.
5. Remove the starter.
6. Remove the flywheel housing bolts, the housing is retained by four large bolts, TORX E20 socket size, and one small
bolt, TORX E14 socket size.
7. Remove the flywheel housing.
8. Remove the rear crankshaft seal.
NOTICE
Work carefully to avoid scratching the surface.
NOTE!
Use care not to damage the sealing surface on the crankshaft.
9. Use seal driver 9998672 to install the new seal.
10. Install new O-ring seals at the flywheel housing to timing gear chest. Install flywheel housing.
Torque-tighten M12 bolt to 99 N.m (73 lbf.ft).
Torque-tighten M16 bolts to 243 N.m (179 lbf.ft).
11. Install flywheel. Torque-tighten flywheel bolts as follows -

Initial tightening torque value:
Bolts 30 - 45 mm long: 20 to 30 N.m (15 to 22 lbf.ft).
Bolts 50 - 85 mm long: 30 to 40 N.m (22 to 30 lbf.ft).
First tightening angle:

Bolts 30 - 85 mm long: 60 degrees
Second tightening angle:
12. Install starter.

Tighten starter bolts to 70 N.m (52 lbf.ft).
13. Use the instructions listed inClutch housing, removing for the balance of the assembly procedure.
NOTE!
Use thread sealer at the engine mount to flywheel housing bolts.
Service Information

Crankshaft and vibration 216 Service Information 9/10/2022
damper, D10B
Profile:
G780B Volvo
Crankshaft and vibration damper, D10B


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The crankshaft is drop-forged and also has induction hardened bearing surfaces and recess hollows. It is carried in seven main
bearings, where the middle bearing also is the thrust bearing. The thrust bearing consists of thrust washers, placed at the middle
main bearing. The crankshaft is statically and dynamically balanced. At the front end, the crankshaft is provided with a polygon
profile, and the rear end has a flange on which the flywheel is bolted down.
The front crankshaft seal consists of a rubber seal ring and a felt ring. The rear crankshaft seal consists of a rubber seal ring and
an oil deflector ring.
The vibration damper is the hydraulic type. In the damper, an oscillating steel ring can rotate freely and is not mechanically
connected to the damper housing. The space between the steel ring and the housing is filled with high-viscosity silicone oil.
When the crankshaft turns, pulsations (oscillations) are created in the crankshaft due to the piston force impulses. Through the
action of the high-viscosity silicone oil, the pulsating rotation of the crankshaft and the even rotation of the steel ring is
neutralized, and the vibrations (oscillations) are dampened. The crankshaft is sealed against the flywheel housing with a lip (flat)
seal.
The flywheel is bolted to the crankshaft's rear flange with 14 bolts. The flywheel's peripheral surface includes the starter ring gear
as well as a number of machined grooves for the injection system's speed (rpm) sensor.
Figure 1
Crank mechanism and vibration damper
Specifications; D7D 2
Lubrication oil circuit; D7D engine– Models G710B to G730B 3
Lubrication system - D10B; description 6
General; Lubrication oil pump D7D 9
Service Information

Specifications, D7D 220 Service Information 9/10/2022
Profile:
G780B Volvo
Specifications, D7D

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Item Description Remark

7 Oil filter With bypass valve
Bypass valve oil filter Opens at:
2.5 0.5 bar (36 7 psi)
8 Pressure regulating valve Opens at:
4 0.4 bar (58 6 psi)
9 Pressure relief valve Opens at:
10 1 bar (145 14.5 psi)
10 Lubrication oil pump Rotary pump
flow at 2500 rpm = 90 L/min (23.7 gpm)
Service Information

Lubrication oil circuit, D7D 220 Service Information 9/10/2022
engine– Models G710B to
G730B
Profile:
G780B Volvo
Lubrication oil circuit, D7D engine– Models G710B to G730B


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
1. Oil pressure sensor

2. Tappet with pulse lubrication
3. Pushrod, oil supply for rocker arm lubrication
4. Rocker arm
5. Return line to oil sump
6. Spray nozzle for piston cooling
7. Lubrication oil filter with integrated bypass valve
8. Oil pressure relief valve (4 ±0,5 bar; 58 ±7 psi)
9. Safety valve (10 ±1 bar; 145 ±14.5 psi opening pressure)
10. Lubrication pump
Lubrication oil ducts

The D7D engine has force-fed circulation lubrication with a lubrication oil cooler and lubrication oil filter arranged in full flow.
The lubrication oil is supplied by the oil pump through the oil cooler to the oil filter. Both components are mounted to the
lubrication oil cooler housing which is flanged to the cylinder block. Downstream of the filter the oil flows into the main oil
gallery and secondary oil gallery. From here the oil is ducted to the lubricating points.
The main oil gallery supplies:
Crankshaft
Camshaft
Valve tappets
Roller tappets
The secondary oil gallery supplies:
Exhaust turbocharger
Lubrication of the rocker arms is affected via the tappets and pushrods.
Figure 2
1. From oil filter

2. Main oil gallery
3. Oil duct to crankshaft
4. Oil duct to camshaft
5. Secondary oil gallery
6. Pressure regulating valve
7. Duct to pressure relief valve
I Crankshaft bearing
II Cam shaft bearing
Service Information

Lubrication system - D10B, 220 Service Information 9/10/2022
description
Profile:
G780B Volvo
Lubrication system - D10B, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The D10B engine is equipped with a force-feed lubrication system with two full-flow filters, a partial-flow filter, and oil cooler. It
is lubricated by an oil pump driven by the crankshaft via a transfer gear. The bilge pump is the single-pump type. It provides the
lubrication system with oil and transports oil from the rear part of the oil sump to its front part. This is to ensure that the force-
feed pump receives oil when operating on steep uphill grades. The force-feed pump forces the oil via the oil cooler, both full-
flow filters, the engine block channels and pipes to all lubrication points. The oil flow is controlled by four spring-loaded valves.
Function of the valves
1. The reduction valve controls the engine oil pressure and the excess oil is returned to the oil sump.
2. The function of the bypass valve is to lead oil past the oil cooler during the engine's warm-up phase. In this way, the
engine receives lubrication faster during cold-starts, and also results in shorter warm-up time. This valve is thermostat-
controlled and senses the oil temperature.
3. The overflow valve for the full-flow filters opens if the filters become clogged in order to ensure lubrication of the
engine.
4. The piston cooling valve is pressure-sensing and opens just above normal idle pressure. The oil is directed into the
longitudinal channel in the block and is sprayed via nozzles, one for each piston, on the inside of the pistons.
Figure 1
1. Reduction valve
2. Bypass valve
3. Overflow valve
4. Piston cooling valve
Lubrication system, principle

The oil pump (5) pumps oil to the full-flow filters (7). On its way to the filter housings, the oil passes through the reduction valve
(1) which controls the engine's oil pressure. Excess oil is returned to the oil sump.
The oil cooler circuit is equipped with a bypass valve (2). This valve opens when the pressure across the oil cooler (6) is too high,
for example, during cold-starts. The oil is directed past the oil cooler and thus reaches the lubrication system faster. If the engine
already is at operating temperature, the bypass valve remains closed, which means that oil is directed through the cooler.
The overflow valve (3) is a safety valve which opens if the fullflow filters become clogged for some reason. When it opens, it
allows unfiltered oil to enter the lubrication system.
The piston cooling valve (4) opens when the oil pressure is just above normal idle pressure, and it allows some of the oil to flow
to the piston cooling channel in the cylinder block.
Six nozzles (8) are connected to the channel, from which oil is sprayed on the underside of the pistons.
From the cylinder block's longitudinal channels (9), drilled channels lead to all engine bearings. The oil is directed to external
components, for example, the turbocharger (10) and the injection pump (11).
Figure 2
Lubrication system, principle
1. Reduction valve
2. Overflow valve for bypassing filters
3. Overflow valve
4. Piston cooling valve
5. Oil pump
6. Oil cooler
7. Full-flow filters
8. Nozzles
9. Cylinder block channels
10. Turbocharger
11. Injection pump
Oil pump and oil cooler

The oil pump is located at the front of the oil sump and is driven by the crankshaft via a transfer gear. It is of the double-pump
type with two pairs of gears. The front part constitutes the force feed pump (main pump) and the rear part constitutes the bilge
pump. The bilge pump transports oil from the rear of the oil sump to the front, where the force-feed pump's suction pipe is
located.
The oil cooler is all-welded and must be changed as a complete unit in case of leakage. The oil transports heat away from the
hottest parts of the engine and evens out temperature differences within the engine during its circulation. In the oil cooler, heat
is removed from the oil using the coolant system.
Service Information

General, Lubrication oil 221 Service Information 9/10/2022
pump D7D
Profile:
G780B Volvo
General, Lubrication oil pump D7D


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The lubrication oil pump is designed as rotary pump and installed in the front cover. The inner rotor (1) is seated on and driven
by the crankshaft (4). Its driver contour has no 120º partition, i.e. the rotor can only be slid onto the crankshaft in a specific
position.
Figure 1
1. Inner rotor
2. Delivery chamber towards cylinder block
3. Suction chamber
4. Crankshaft
Fuel system; description_{20-11} 2
Fuel system; description_{19-51} 3
Fuel system components; D10B 11
Fuel flow; D10B 13
Fuel feed pump - D10B; description 15
Water trap; D10B 17
Injection pump - D10B; specifications 18
Injection pump - D10B; description 19
Fuel shut-off valve; D10B 21
Overflow valve; D10B 23
Injectors - D10B; specification 24
Injectors - D10B; description 25
Injectors; replacing 28
Injection system - D7D; E-ECU overview 34
Service Information

Fuel system, description 230 Service Information 9/10/2022
Profile:
G780B Volvo
Fuel system, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
According to governing legislation, all low emission engines must meet established emission (exhaust) standards. In order to
ensure compliance with all requirements, the engine is carefully specified and set.
Optimal combustion requires that fuel is injected into the combustion chamber under very high pressure, in the correct amount
and at the right time, depending on the engine rpm, load, temperature, etc.
A control unit (E-ECU) receives signals from the throttle pedal and a number of sensors on the engine. The sensors monitor/
sense the factors that affect injection and sends signals to the control unit.
The fuel system for D10B has an electronically controlled injection pump through the use of EMS (Electronic Management
System).
The fuel system also has a built-in diagnostics system, where it is possible to detect and search for malfunctions in the system
with the use of electronics.
The injection pump is bolted to a separate bracket on the engine's left side. It is driven by the engine's timing gear via a
mechanical injection timing adjustment and a short shaft. The injectors' opening pressure is adjusted using washers of varying
thickness that are mounted above the spring. The water trap and the fuel filter are located on the right-hand side of the engine.
Both the water trap and main fuel filter are also equipped with a hand-operated auxiliary pump.
Most of the fuel passes through the overflow valve to the tank's return line. This fuel flow cools the injection pump and ensures a
more constant fuel temperature. Variations in fuel temperature are compensated by the engine's electronics.
Service Information

Fuel system, description 230 Service Information 9/10/2022
Profile:
G780B Volvo
Fuel system, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
All models are equipped with a primary fuel filter/water separator, priming pump, and a secondary fuel filter.
Figure 1
1. Primer pump
2. Filter element
3. Filter bowl
4. Drain valve
5. Drain hose
All models up to G730B with the D7D engine are equipped with a fuel cooler mounted in the cooling module on the left-hand
side of the machine.
The fuel tank is located in an elevated position, directly behind the cab above the frame rails. A contaminate trap with drain
valve, supply port and shut off valve are located on the lower left-hand side. The return port and shut off valve are located on
the lower right-hand side. Fuel level is monitored by an electric float-type sender, mounted in the top of the tank. The tank is
vented through the filler cap.
Figure 2
1. Sediment bowl on fuel tank

2. Fuel shut - off valve
3. Drain valve
Figure 3
D7 fuel flow (early models)
1. Fuel tank outlet in sump

2. Return to tank
3. Fuel/water separator
4. Inlet to fuel pump
5. Fuel cooler
6. Outlet from engine
7. Hand primer
Figure 4
D7 fuel flow (current models)
1. Fuel tank outlet in sump

2. Return to tank
3. Hand primer
4. Fuel/water separator
5. Fuel cooler
6. Outlet from engine
7. Inlet to fuel pump and secondary filter
Figure 5
D7 unit pump and injector
1. Valve section
2. Injector
3. Pump section
Figure 6
D7 unit pump components
1. Spring retainer
2. Armature
3. Solenoid
4. Spacer plate
5. Spring
6. Fuel inlet
7. High pressure fuel line
8. Fuel line nut
9. Inlet filter
10. Spring seat
11. Spool valve
12. Spool stop
13. Cover
14. Cylinder block
15. Fuel return passage
16. Pump body
17. Cam actuated plunger
When the solenoid is de-energized, the unit pump is filled with fuel at supply pump pressure. Excess fuel flows back to tank
through the fuel outlet port and overflow valve. This provides cooling and lubrication of the pump components.
Figure 7
Filling operation
1. Fuel inlet
2. Fuel outlet
Fuel continues to flow through the pump. As the plunger begins to rise, excess fuel is displaced through the outlet port to the
tank.
Figure 8
Metering operation
1. Displaced fuel
When the E-ECU has determined the optimum fuel quantity and start of injection timing, it will energize the solenoid. This action
isolates the high pressure passage from the fuel return port and, as the plunger rises, injection occurs.
Figure 9
Start of injection operation
When the E-ECU has determined when end of injection should occur, it will de-energize the solenoid. This opens the high
pressure fuel passage to the return port, and fuel pressure in the injection line rapidly decreases. This action brings a "clean" end
of injection at the injector nozzle.
Figure 10
End of injection operation
1. Displaced fuel
Service Information

Fuel system components, 230 Service Information 9/10/2022
D10B
Profile:
G780B Volvo
Fuel system components, D10B


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
1. The injector for cylinder 1 is equipped with an inductive needle movement sensor, located in the nozzle holder. It is
magnetized by a current from the control unit and senses when the nozzle's needle opens for injection.
2. The feed pump is of the piston type and is driven by a push rod from the injection pump's camshaft. The drive shaft has
two seals that seal against fuel and oil.
3. The hand pump is mounted directly in the filter housing, which also contains the hand pump's non-return valve. It
closes automatically after use.
4. The overflow valve is located in the return line from the cylinder head, and maintains an even pressure in the fuel space
around the injection pump elements. On the return line, there is also an electro-hydraulic fuel shut-off valve.
5. The injection pump is mounted on a pump shelf on the engine's right side.
Figure 1
Service Information

Fuel flow, D10B 230 Service Information 9/10/2022
Profile:
G780B Volvo
Fuel flow, D10B


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The fuel tank is located in an elevated position, directly behind the cab above the frame rails. A contaminate trap with drain
valve, supply port and shut off valve is located on the lower left-hand side. The return port and shut off valve are located on the
lower right-hand side. Fuel level is monitored by an electric float-type sender, mounted in the top of the tank. The tank is vented
through the filler cap. All models are equipped with a primary fuel filter/water separator, priming pump and a secondary fuel
filter.
Fuel flows from the fuel tank outlet to the primer pump, primary fuel filter/water separator, and ECU cooler. Then, the fuel flows
on through the electro-hydraulic fuel shut-off valve to the feed pump's suction side. From the feed pump, fuel is pumped
through the main fuel filters to the injection pump's feed side via the fuel shut-off valve.
The injection pump then forces the fuel through the pressure lines to the injectors, which under high pressure, finely disperse the
fuel in the engine's combustion chambers. Leak-off fuel from the injectors is returned to tank on the lower right-hand side
through the leak-off fuel line. The leak-off fuel line from the injectors is connected to the fuel shut-off valve via the suction line
connection.
The engine electronics also compensate for varying fuel temperatures.
Figure 1
Fuel flow 24 V voltage
Figure 2
Fuel flow 0 V voltage
Service Information

Fuel feed pump - D10B, 233 Service Information 9/10/2022
description
Profile:
G780B Volvo
Fuel feed pump - D10B, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
In order for the injection pump to function, it must be supplied with fuel at a certain pressure. This function is handled by the
piston-type feed pump.
The feed pump is located on the injection pump and is driven by the injection pump's camshaft. The feed pressure is determined
by the fuel system's overflow valve.
The pump shaft's cam displaces the feed pump's piston via the push rod. Then, a determined amount of fuel is transferred from
the suction strainer via the non-return valve to its pressure side, at the same time as the piston spring is tensioned. The pump
camshaft turns and the piston spring presses back the pump piston, and the fuel is pumped out through the non-return valve
and further via the fuel filter into the injection pump.
Hand pump
The hand pump is located on the feed pump and is used to pump fuel to the filter and injection pump when the engine is not
running. It is also used to pump up fuel when bleeding air from the system.
Figure 1
Hand pump and main fuel filter
1. Air bleeder nipple

2. Drain nipple
3. Hand pump
NOTE!
The hand pump must not be used when the engine is running.
Fuel filter
There is a large fuel filter in the system on the rear right-hand side of the engine. The filter cartridge consists of a folded filter
made of special paper with very good filtration capacity. On the fuel filter, there is a drain nipple and an air bleeder nipple.
Service Information

Water trap, D10B 233 Service Information 9/10/2022
Profile:
G780B Volvo
Water trap, D10B


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The function of the water trap is to separate the water in the fuel and to collect it at the bottom of the filter. The diesel fuel
enters via the hand pump, then flows through the middle of the water trap where a filter lets the water through. The fuel then
flows out through another filter on the way to the engine's main fuel filter. The water trap should be inspected every 50 hours to
check if there is a need to drain. When changing the filter in the water trap, the container should be filled with diesel fuel to
facilitate starting up the system again.
Figure 1
Water trap, cutaway view
Service Information

Injection pump - D10B, 236 Service Information 9/10/2022
specifications
Profile:
G780B Volvo
Injection pump - D10B, specifications


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Injection pump
Type In-line pump
Designation PE6H110320RS32
Pump setting Marking 5ºBTDC
Service Information

Injection pump - D10B, 236 Service Information 9/10/2022
description
Profile:
G780B Volvo
Injection pump - D10B, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The injection pump is located on a shelf on the engine's right side and is driven via a pump coupling from the engine's timing
gear mechanism. Injection volume and injection timing are electronically controlled by the engine's control unit (E-ECU).
Lubrication is achieved through a connection to the engine's lubrication system. The lube oil line is located externally and the
return oil is returned to the oil sump via an external oil pipe.
Figure 1
Injection pump RP43
The injection pump is a straight mechanical slide pump with electronic control. There are two electromagnets (solenoids) in the
governor. One works horizontally and controls the fuel volume via the push rod in a traditional manner. The other electromagnet
(solenoid) for adjusting injection timing works vertically and turns the setting shaft via a link system. Each pump element has a
slide that can be moved vertically by the setting shaft. With the use of the adjustable slide on the pump piston, start of fuel feed
for respective injector can be changed in relation to the pump camshaft's position. Early injection takes place with the slide in the
lowest position. Subsequently, later injection takes place when the slide is moved up.
On the regulator housing, there is a sensor that receives signals from the gear that is mounted on the pump camshaft. The gear
has a total of 7 teeth, one for each cylinder plus an extra tooth for cylinder 1. The main function of the sensor is to identify this
cylinder when the engine has started, but it is also used as an extra speed (rpm) sensor.
Basic adjustment of the engine's injection pump is performed in a traditional manner (see service manual “D10B”). The exact
adjustment is performed by the engine's control system when the engine is started.
The length and timing of the current impulse determines the injection volume and injection timing, respectively.
Figure 2
Injection pump, cutaway view
1. Electromagnet (solenoid)
2. Control rod
3. Electromagnet (solenoid)
4. Setting shaft
5. Pump element
6. Slide
7. Sensor
8. Gear
Service Information

Fuel shut-off valve, D10B 236 Service Information 9/10/2022
Profile:
G780B Volvo
Fuel shut-off valve, D10B


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
There is an electro-hydraulic fuel-shut off valve on the injection pump's suction side. At a voltage of 24 V (1), the valve is open
for normal function. Without voltage (2), the fuel's flow direction is reversed and the fuel is drained to tank. Thus, suction is
generated in the pump's fuel chamber and the engine stops within two seconds. Due to the short stop time, this valve is used as
an emergency stop valve.
Figure 1
Fuel shut-off valve
NOTE!
When bleeding the system, the valve must be supplied with voltage (ignition key in position ON).
Figure 2
1. Fuel flow at 24 V voltage

2. Fuel flow without voltage
Service Information

Overflow valve, D10B 236 Service Information 9/10/2022
Profile:
G780B Volvo
Overflow valve, D10B


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The overflow valve controls the feed pressure in the fuel system and is located on the fuel shut-off valve. Opening pressure is
approx. 3.5 bar (50.8 psi). It ensures continuous bleeding of air from the fuel system.
Figure 1
Overflow valve
Service Information

Injectors - D10B, 237 Service Information 9/10/2022
specification
Profile:
G780B Volvo
Injectors - D10B, specification


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Type Multi-hole nozzle

Opening pressure 25 MPa (250 bar)(3626 psi)
Setting pressure with new spring 26 MPa (260 bar)(3771 psi)
Hole diameter (nozzles) 6 X 0.236 mm (0.009 in.)
Marking (nozzles) 571
Service Information

Injectors - D10B, description 237 Service Information 9/10/2022
Profile:
G780B Volvo
Injectors - D10B, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The injectors finely disperse the fuel jets in the combustion chamber so that a mixture of air and fuel is obtained to ensure
ignition and combustion.
Figure 1
1. Nozzle holders
2. Nozzles
3. Injector needle
4. Spring
5. Adjusting washers
6. Thrust pin
7. Guide pins
8. Guide
9. Guide pins
10. Injector sleeve
11. Union screw
12. Seals
Each injector consists mainly of a nozzle holder (1) and a nozzle (2). The fuel is forced in through an opening from the injection
pump. When the fuel pressure has increased to the set value (opening pressure), the injector needle (3) is lifted against the thrust
spring (4) and finely dispersed fuel is injected into the engine through precisely calibrated holes in the nozzle.
A small portion of the fuel flows along the injector needle up through the thrust spring and out to an opening which is
connected to the leak-off fuel line. The function of the leak-off fuel is to lubricate and cool the injector.
The setting of the thrust spring determines the injector's opening pressure. Spring tension is adjusted with adjusting washers (5).
To avoid unnecessary replacement and adjusting of injectors, they should not be checked until there are clear indications that
their function is abnormal, which is shown by, for example:
significant increase in exhaust smoke

engine start is difficult
rough running
fuel consumption too high
poor performance
The injector for cylinder 1 is equipped with an inductive needle movement sensor, located in the nozzle holder. It is magnetized
by a current from the control unit and senses when the nozzle's needle lifts and opens for injection.
Service Information

Injectors, replacing 237 Service Information 9/10/2022
Profile:
G780B Volvo
Injectors, replacing

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 237-002
Tools:
9998532 Extractor
9812546 End brush
Drill (10 mm, 3/8 in.)
Torque wrench
NOTICE
Maintain greatest possible cleanliness when working on the fuel system.
2. Clean the area around the injectors, pressure (delivery) lines and the top part of the injection pump.
Removing
3. Remove the fuel pressure lines. The pipes are clamped in two groups of three. Do not loosen the clamps. The pressure
lines are pre-shaped and must not be altered in any way under any circumstances.
Fit protective caps on all injectors and on the injection pump's connections.
Figure 1
4. Unplug the connector for sensor SE2308 and remove the bracket.
5. Loosen and fold aside the pipe between the turbocharger and intercooler.
NOTICE
Always cover open air connections with a plastic bag and rubber bands. Gravel, dust and other particles in these
connections may result in engine failure!
WARNING
Figure 2
6. Remove the leak-off fuel line from between the injectors. Plug the connections.
7. Remove the nuts for the injector yokes and remove the yokes.
Figure 3
8. Remove the rubber seals around the injectors.
9. Twist the injectors and pull them up at the same time. If needed, use puller 9998532.
Figure 4
1. 9998532 Puller
10. Make sure that the copper washer located between the injector and the copper sleeve comes out as well. If not, use a
steel wire hook to get it out.
Figure 5
1. Copper washer
11. Clean the surface on the copper sleeves facing the injectors. Use the cleaning brush 9812546. The brush comes with a
mounting sleeve.
Before the brush is inserted into the copper sleeve, press down the sleeve over the brush to keep the parts together.
Figure 6
Cleaning brush 9812546
12. Fit the mounting sleeve over the copper sleeve.

Figure 7
Mounting sleeve over copper sleeve
1. Mounting sleeve
2. Copper sleeve
13. Press the brush down into the copper sleeve. Fit a drill on the brush handle and clean the copper sleeve.
Figure 8
Drill on brush handle
14. After cleaning, use compressed air to remove any debris.
15. Fit the new injectors with new copper washers.
16. Fit new rubber seals around the injectors.
17. Fit the yokes and the nuts.

18. Fit the leak-off fuel line, use new copper washers.
19. Fit the pipe between the turbocharger and the intercooler.
WARNING
20. Fit the bracket and sensor SE2308.
21. Fit the fuel pressure lines. Maintain greatest possible cleanliness and make sure that the lines are not re-shaped in any
way. Tighten the pipe nuts.
Tightening torque: 15 – 25 N•m (1.5 – 2.5 kgf•m)(1 – 2 lbf•ft).
22. Start the engine and check that there are no leaks.
Service Information

Injection system - D7D, E- 238 Service Information 9/10/2022
ECU overview
Profile:
G780B Volvo
Injection system - D7D, E-ECU overview


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Sensors are essential for the engine control system. They collect operational parameters and parameters for the surroundings so
that the engine can function in the correct manner. These parameters are converted into electrical signals which are sent to the
E-ECU. The processor in the ECU compares incoming data and sends signals to the injection pumps for regulation of fuel
quantity and injection timing.
EMS (Engine Management System)
This system is divided into two elements:
1. Injection pumps with high pressure tube injectors

2. Electronic system with sensors, switches, and wiring harnesses
The Unit Pump System controls diesel injection and allows optimal control of injection quantity and injection timing for each
cylinder.
Figure 1
1. Engine speed (cam)

2. Coolant temperature
3. Boost pressure
4. Boost temperature
5. Fuel temperature
6. Oil pressure
7. Engine speed (crank)
8. E-ECU
Figure 2
1. Engine speed (crank)

2. Engine speed (cam)
3. Low idle switch
4. Boost pressure
5. Boost temperature
6. Coolant temperature
7. Fuel temperature
8. Oil pressure
9. Terminal 15
10. Accelerator pedal
11. Solenoid valve power stages
12. Other power stages
13. Interfaces
14. Solenoid valve
15. Cold start power stage
16. Reserve
17. Diagnostic request
Unit pump function

The solenoid valve closes the bypass in the plunger space, as a result the injection pressure increases. Injection starts when the
nozzle opening pressure is exceeded. When the injection process is to be terminated, the solenoid valve opens the bypass; the
system pressure drops and spring force closes the nozzle needle.
Figure 3
1. Solenoid valve
The solenoid valve is activated by the E-ECU according to the operating parameters. The system is in a position to make available
comprehensive emergency (limp-home) functions in case sensors have failed. This allows reliable and safe termination of the
driving or working operation.
Exhaust system - D7D engine 2
Exhaust system - D10B engine 4
General 6
Air cleaner 8
Preheating coil; D10B 10
Intercooler D10B; specifications 12
Intercooler; D10B 13
Service Information

Exhaust system - D7D 252 Service Information 9/10/2022
engine
Profile:
G780B Volvo
Exhaust system - D7D engine


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The muffler is located inside the engine compartment, above the engine. An outer shield and insulation barrier provide noise
and heat control. Exhaust outlet is routed into a large stack which is open to the engine compartment at the bottom and the
outside at the top. Exhaust air flow produces a venturi effect in the stack that draws hot engine air from the compartment along
with exhaust. Exhaust aspirators are included on all mufflers.
Figure 1
1. Ejector pipe
2. Bolt
3. Washer
4. Exhaust pipe
5. Gasket
6. Muffler
7. Bolt
8. Washer
9. Gasket
10. Exhaust pipe
11. Washer
12. Nut
Service Information

Exhaust system - D10B 252 Service Information 9/10/2022
engine
Profile:
G780B Volvo
Exhaust system - D10B engine


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The muffler is located inside the engine compartment, above the engine. An outer shield and insulation barrier provide noise
and heat control. Exhaust outlet is routed into a large stack which is open to the engine compartment at the bottom and the
outside at the top. Exhaust air flow produces a venturi effect in the stack that draws hot engine air from the compartment along
with exhaust. Exhaust aspirators are included on all mufflers.
Figure 1
1. Ejector pipe
2. Bolt
3. Washer
4. Exhaust pipe
5. Bolt
6. Washer
7. Gasket
8. Muffler
9. Gasket
10. Exhaust pipe
11. Washer
12. Bolt
13. Clamp
14. Exhaust pipe
15. Clamp
Service Information

General 255 Service Information 9/10/2022
Profile:
G780B Volvo
General

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The turbocharger is driven by the exhausts that pass the turbine housing on the way out to the exhaust system.
Figure 1
A. Supply of lubricating oil

B. Exhaust gases from engine into turbocharger
C. Exhaust gases from turbocharger
D. Inlet air via air cleaner
E. Air to inlet manifold
The exhaust flow turns the turbine in the turbine housing. On the same shaft as the turbine, there is a compressor rotor. The
compressor rotor is located in a housing that is connected between the air cleaner and the engine induction manifold.
When the compressor rotor turns, air is drawn (sucked) from the air cleaner. The air is compressed and pressed into the engine
cylinders, after having been cooled down during passage through the intercooler.
Lubrication is obtained with pressure directly from the partial flow filter (fine filter).
Turbochargers may or may not be equipped with a wastegate. A wastegate is a valve used to regulate how much exhaust gas
flows through the turbocharger and how much is bypassed. As the intake manifold pressure increases, the valve gradually opens
to allow exhaust gas to bypass the turbine; thus leveling off its speed.
Service Information

Air cleaner 256 Service Information 9/10/2022
Profile:
G780B Volvo
Air cleaner

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The air filter assembly is mounted horizontally in the engine compartment above the engine. Service access is from the left-hand
side of the grader.
Figure 1
1. Air cleaner
2. Hose, exhaust aspirator
The filter design provides two stage cleaning with a tangential inlet for integral precleaning ahead of the primary filter.
A safety filter protects the engine during filter changes.
All models are equipped with an exhaust ejector connected to the filter end cap and a rain cap on the air inlet pipe.
The control lamp in the center display panel will illuminate when the vacuum inside the air cleaner reaches 50 ±5 millibar (20 ±2
in.) water.
Figure 2
Service Information

Preheating coil, D10B 256 Service Information 9/10/2022
Profile:
G780B Volvo
Preheating coil, D10B


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
There is an electric preheating coil on the induction side of the intake manifold. The preheating coil is engaged when the ignition
key is turned to the “I” position, the preheating button is depressed, and the engine temperature is below 20ºC (68ºF).
Preheating and post-start heating times are controlled by the engine control system. The advantage is easier starting as well as
less white smoke in the exhausts.
Figure 1
Preheating coil HE2501
The indicator light on the instrument panel is lit when the preheating coil is engaged, but also has the function of warning when
there is a malfunction of the coil.
The function of the preheating coil is to warm the air in the induction manifold when the engine is started. The warm air
facilitates starting at low temperatures and reduces smoke during cold starts.
The following conditions must be fulfilled for the preheating coil to be engaged:
ignition key in “I” position

engine turned off
preheat switch activated
engine temperature is below 20ºC (68ºF)
The connection period of the preheating coil is completely dependent on the coolant temperature and is controlled by the
engine's control unit (E-ECU). When the engine is started, preheating is deactivated automatically.
The preheating coil can be engaged again for post-start heating when the engine is running. The engine control unit (E-ECU)
controls the time for post-start heating, which in turn is dependent on the engine temperature.
Service Information

Intercooler D10B, 258 Service Information 9/10/2022
specifications
Profile:
G780B Volvo
Intercooler D10B, specifications


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Charge air cooler (intercooler)

Type Air/air maximum 50ºC (122ºF)
Correct value (command variable) at outside temperature above 50ºC (122ºF)
25ºC (77ºF)
Correct value (command variable) at outside temperature below Outside temperature + maximum 25ºC (77ºF)
25ºC (77ºF)
Service Information

Intercooler, D10B 258 Service Information 9/10/2022
Profile:
G780B Volvo
Intercooler, D10B

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The function of the intercooler is to lower the temperature of the air before it is pressed into the engine's cylinders.
Turbocharging the engine (the turbocharger presses air into the cylinders) increases the air temperature. When the air is cooled
after the turbo, the air volume decreases and more air (oxygen) can be pressed into the cylinders. This cooling is called charge-
air cooling (intercooling) and makes it possible to inject more fuel into the cylinders, which results in a significant power increase.
The intercooler lowers the air temperature by approx. 100ºC (212ºF) and this increases engine power by approx. 10%. The engine
torque is also increased and fuel consumption is reduced.
A turbocharged diesel engine with charge-air cooling (intercooling) has the highest efficiency of all combustion engines.
A contaminate drain is located at the left rear corner of the charge air cooler.
Figure 1
Charge air cooler, right hand side
1. Intake air from air cleaner

2. Turbocharger
3. Intake manifold
4. Charge air cooler
Figure 2
Charge air cooler, left hand side
1. Contaminate drain
Cooling system - D7D engine; description 2
Cooling system - D10B engine; description 5
Service Information

Cooling system - D7D 260 Service Information 9/10/2022
engine, description
Profile:
G780B Volvo
Cooling system - D7D engine, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The engine cooling system is designed to meet the engine's cooling needs and warm the interior of the cab. Engine cooling
relies on two separate systems.
The first system cycles coolant from the engine block through a water/air radiator. (Refer to D7D engine coolant cycle diagram).
A belt driven coolant pump on the rear of the engine pumps the coolant through the engine block. The warm coolant flows to
the radiator where it is cooled and returned to the engine block. An expansion tank is located above the engine to allow for
changes in volume as the coolant fluid is heated and cooled under normal operation of the engine.
Figure 1
Cooling module, rear of grader
1. Cooling fan
2. Fan motor
3. Engine radiator
The second system consists of a hydraulically driven cooling fan that controls air flow through the cooling module. The cooling
module fan speed is relative to coolant temperature, charge air temperature, and hydraulic oil temperature. The cooling fan is
hydraulically driven at variable speeds. Oil flow and pressure are supplied from the main hydraulic circuit. Coolant temperature,
charge air temperature and hydraulic oil temperature send information to the fan electronic control unit (F-ECU). The F-ECU
sends a signal to the fan control valve. The system with the highest cooling demand will determine fan speed. Fan speed is
relatively proportional to temperature. When one of these systems reaches a specified temperature, the fan will start to increase
in speed. The fan will continue to increase in speed if temperature continues to increase.
The F-ECU is a stand-alone system that is not connected to the engine or instrument electronic control units.
Figure 2
D7D engine coolant cycle
1. Expansion tank
2. Overflow line
3. Overflow line to engine
4. Circuit fill line
5. Radiator overflow line
6. Return line to radiator
7. Radiator
8. Return line from radiator
9. Thermostat
10. Coolant pump
11. Expansion tank restrictors
Service Information

Cooling system - D10B 260 Service Information 9/10/2022
engine, description
Profile:
G780B Volvo
Cooling system - D10B engine, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The engine cooling system is designed to meet the engine's cooling needs and warm the interior of the cab. Engine cooling
relies on two separate systems.
The first system cycles coolant from the engine block through a filter and water/air radiator. (Refer to D10B engine coolant cycle
diagram).
A gear driven coolant pump on the lower right side pumps the coolant through the engine block. A bypass filter is located on
the left side. The coolant returns to the radiator where it is cooled and returned to the engine block. An expansion tank is
located above the engine to allow for changes in volume as the coolant fluid is heated and cooled under normal operation of
the engine.
Figure 1
Cooling module, rear of grader
1. Cooling fan
2. Fan motor
3. Engine radiator
The second system consists of a hydraulically driven cooling fan that controls air flow through the cooling module. The cooling
module fan speed is relative to coolant temperature, charge air temperature, and hydraulic oil temperature. The cooling fan is
hydraulically driven at variable speeds. Oil flow and pressure are supplied from the main hydraulic circuit. Coolant temperature,
charge air temperature and hydraulic oil temperature send information to the fan ECU (F-ECU). The F-ECU sends a signal to the
fan control valve. The system with the highest cooling demand will determine fan speed. Fan speed is relatively proportional to
temperature. When one of these systems reaches a specified temperature, the fan will start to increase in speed. The fan will
continue to increase in speed if temperature continues to increase.
The F-ECU is a stand-alone system that is not connected to the engine or instrument electronic control units.
Figure 2
D10B engine coolant cycle
1. Radiator
2. Radiator overflow line
3. Expansion tank
4. Overflow line
5. Overflow line to engine
6. Circuit fill line
7. Coolant filter, left side
8. Return line from radiator
9. Coolant pump
10. Expansion tank restrictors
Accelerator_decelerator pedal 2
Hand Throttle 4
VHP (Variable Horsepower) 6
Service Information

Accelerator/decelerator 271 Service Information 9/10/2022
pedal
Profile:
G780B Volvo
Accelerator/decelerator pedal

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Accelerator/decelerator pedal is used in grader operation to speed up or slow the engine speed. It is operated as follows:
Figure 1
Accelerator/decelerator pedal
1. Pedal toe
2. Pedal heel
1. Depress the pedal toe to increase rpm.

2. Release the pedal to decrease engine rpm.
3. Use the pedal to override the hand throttle setting.
4. Depress the pedal heel to decrease engine rpm when the hand throttle is set.
5. When the foot is removed from the pedal, the engine speed will return to the preset hand throttle position. Refer to
Hand Throttle.
NOTE!
If the engine is started with the hand throttle above low idle position, the accelerator will not function. Move the hand throttle
lever to low idle position to obtain accelerator response.
Service Information

Hand Throttle 272 Service Information 9/10/2022
Profile:
G780B Volvo
Hand Throttle

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The hand throttle provides a fixed engine speed control during grading.
Figure 1
1. Hand throttle
2. Slide mechanism
3. Cable
4. Floor plate
5. Accelerator/decelerator pedal
6. Cab floor
The hand throttle is self-locking in any position. Moving the throttle handle releases the locking mechanism and allows free
movement of the lever. When starting the engine, the hand throttle lever must be in the low idle position (pulled back towards
the operator) to achieve accelerator function.
Service Information

VHP (Variable Horsepower) 278 Service Information 9/10/2022
Profile:
G780B Volvo
VHP (Variable Horsepower)


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
All Volvo grader models have engines that provide 2 different power levels depending on the gear selected by the operator.
For non-All Wheel Drive equipped graders, forward gears 1, 2, and reverse 1, have reduced power to minimize wheel
slip. In forward gears 3 through 8, and reverse gears 2 through 4, engine power is automatically increased.
For All Wheel Drive equipped models with the All Wheel Drive system turned OFF, the function of the VHP is the same
as above.
For All Wheel Drive equipped models with the All Wheel Drive turned ON, the engine power is increased for all gears.
There is no operator selectable control over the VHP system.
30 - GENERAL 2
31 - BATTERY 18
32 - ALTERNATOR; CHARGE REGULATOR 24
33 - STARTING SYSTEM 28
35 - LIGHTING 33
36 - OTHER ELECTRICAL EQUIPMENT 39
37 - CABLE; FUSE; RELAY 47
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM 246
Description 2
Operation 4
General 5
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
All Volvo G700B graders are equipped with a 24VDC, negative ground electrical system. The electrical system includes electrical
and electromechanical devices such as batteries, solenoid valves, switches, sensors, fuses and relays. The I-ECU (Instrument
Electronic Control Unit) and E-ECU (Engine Electronic Control Unit) communicate with each other via a data bus system. The I-
ECU receives inputs from the T-ECU (Transmission Electronic Control Unit) for VHP signal, parking brake, and neutral status. In
AWD (All Wheel Drive) machines, an AWD-ECU replaces the T-ECU and sends the same inputs to the I-ECU.
A 25 amp converter/equalizer is available to supply 12 VDC power for accessory items such as a 2-way radio, cigar lighter and
other options.
Figure 1
Battery isolation switch
Electric power is disconnected using an isolation switch located inside the engine compartment. The isolation switch disconnects
the ground circuit between the grader frame and the batteries. It is located on the left-hand side of the grader inside the engine
compartment.
The Volvo 8400 transmission operates using a series of solenoids. The T-ECU controls and energizes the correct solenoid for the
gear selected.
Other electronic control devices include the blade and front float systems, signal light switch, and the optional AWD control
system for those models equipped with it.
Because of the wide use of electronic components on Volvo graders, extra care must be taken when troubleshooting the
electrical system to prevent stray voltage spikes. Welding on the machine can also produce stray voltage spikes that will damage
components. Follow the complete Service Position instructions in the Safety section of this manual.
Service Information

Operation 300 Service Information 9/10/2022
Profile:
G780B Volvo
Operation

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
When the isolation switch is open and the key switch is in the “ON” position, power is supplied to the fuse panel through a 200
amp accessory solenoid for distribution throughout the electrical circuits.
Once the isolation switch is closed, power is still available to certain safety circuits regardless of the position of the key switch.
The optional supplemental steering, starter circuit and the standard emergency braking system become live without the key
switch being energized. Refer to the Battery isolation switch in the Operator's Manual.
Service Information

Profile:
G780B Volvo
General

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Engine oil pressure

This function monitors the engine oil pressure and warns the operator if the pressure is too low or if there is a system
malfunction.
Input Signals Conditions for output Output

Engine oil pressure sensor Low engine oil pressure Warning limit for – Indicator light
low oil pressure for all models: < 50 kPa – Red central warning
(7.3 psi) at 550 rpm < 100 kPa (14.5 psi) – Buzzer
at 1000 rpm < 150 kPa (21.8 psi) at 1500 ........ WARNING.....
rpm Low
Engine
Oil Pressure
Monitoring sensor System malfunction, signal beyond limits – Amber central warning
........ ERROR.....
Monitoring
Engine Oil Pressure
Refer to electrical schematics 4 and 5, E-ECU.

Conditions for error detection:
If the sensor voltage detected by the E-ECU falls outside the 0.5V to 4.5V range.
Possible cause:
Sensor not connected (open circuit)

Contact resistance in the circuit
Signal line open circuit, short circuit to ground or short circuit to higher voltage
Feed line (5V) open or short circuit to ground
Ground cable open circuit
Defective sensor
Engine coolant level

This function monitors the level of the coolant in the expansion tank and warns the operator if the level is too low.
Input Signals Conditions for out functions Out functions

Engine coolant level SE2602 Low coolant level – Red central warning
– Buzzer
........ WARNING.....
Low
Engine
Coolant level
Monitoring sensor System malfunction ........ ERROR.....
Monitoring
Coolant level

Other possible causes for warning:
Defective sensor
Ground cable short circuit to voltage
Signal line short circuit to ground
Engine coolant temperature

This function monitors the engine coolant temperature and informs the operator if the temperature is too high or if there is a
system malfunction.

Engine coolant temperature sensor High coolant temperature for all models: – Temperature gauge advances the pointer
>103ºC (217ºF) 14º as soon as the alarm signal is received.
– Amber central warning
– Buzzer
........ WARNING.....
High
Engine Coolant
Temperature
........ WARNING.....
Impending
Engine Shutdown
........ ERROR.......
Monitoring
Engine Coolant
Temperature

If the ECU detects a short circuit (resistance of 0 ohms) or an abnormally high resistance of: > 6 kohms for G710B to
G730B models, 4.4 kohms for G740B to G780B models.
Possible causes:

Signal line short circuit to higher voltage
Ground cable short circuit to voltage or open circuit
Defective sensor
Charge air temperature

This function monitors the temperature of the air at the intake manifold of the engine and informs the operator of a system
malfunction.

Engine charge air temperature High charge air temperature – Amber central warning
sensor ........ INFO.......
High
Temperature
Charge Air
........ ERROR.......
Monitoring
Charge Air Temperature
XXXX YYY
XXXX = PPID, PID, or SID
YYY = Numeric value 1 – 999

Detected if the voltage detected by the E-ECU falls outside the 0.5V to 4.5V range.
Possible causes:

Feed line (5V) open or short circuit to ground
Defective sensor
Transmission oil pressure

This function monitors the charge pressure in the transmission and informs the operator when the pressure is too low while the
engine is on. It also identifies system malfunctions when the engine is off.

– Transmission oil pressure SE4202 – Low transmission oil pressure: – Red central warning
– Engine ON <1172 kPa (11.7 bar)(170 psig) falling – Red indicator lamp
– Buzzer
........ WARNING.......
Low
Transmission
Oil Pressure
Monitoring SE4202 System malfunction, incorrect signal – Amber central warning
........ ERROR.......
Monitoring
Transmission
Oil Pressure
Refer to electrical schematic 19, Sensors.

If the ECU detects a high signal indicating normal operating pressure when the engine is off.
Possible causes:
Signal line short circuit to voltage

Defective sensor
Transmission oil filter (optional)

This function monitors the pressure differential at the transmission filter and notifies the operator when the filter should be
changed or when there is a system malfunction.
The transmission oil filter must be changed to avoid the bypass valve opening. Bypassing the filter would cause unfiltered oil to
be circulated in the system.
There are two settings for the filter:
1. Warning pressure signal (e.g. 276 kPa; 2,8 bar; 40 psid).

2. Actual bypass open (e.g. 344 kPa; 3,4 bar; 50 psid).

Transmission filter bypass SE4201 – Pressure differential: >344.8 kPa (3.4 – Amber central warning
bar)(50 psi) – Amber indicator lamp
........ INFO.......
Clogged
Transmission
Oil Filter
Monitoring SE4201 System malfunction, wrong sensor state – Amber central warning
when engine is off. ........ ERROR.......
Monitoring
Transmission
Oil Filter
Refer to electrical schematic 19, Sensors.

ECU detects a low signal from the sensor when the engine is off (error text is displayed)
Possible causes:
Open circuit, defective sensor or signal line short to ground

Signal line short circuit to voltage or defective sensor
Secondary steering
This function monitors the pressure in the steering hydraulic circuit and notifies the operator when the steering pressure is low.
In addition the operator is notified if there is a malfunction in the monitoring system. This function is only available with the
supplemental steering option.

– Secondary steering pressure – Low steering system hydraulic pressure: – Flashing red central warning
switch SE6401 closed at zero pressure; open at normal – Red steering indicator lamp
– Engine status – on/off pressure. Switch opens at 344 34.5 kPa – Buzzer
– Engine run status – has engine (3.44 0.35 bar)(50 5 psi) – Amber secondary steering indicator lamp
been started – Engine is on ........ WARNING.......
– Engine has been started Low
– Stalled engine, loss of hydraulic Steering System
pressure Pressure
Monitoring SE6401 System malfunction – Amber central warning
........ ERROR.......
Monitoring
Steering
Oil Pressure
Refer to electrical schematic 21, Secondary steering.

The I-ECU receives a low signal (open switch) when the engine is on and the hydraulic pressure is normal.
Possible causes:
Defective switch
Open circuit in wiring, signal line short to ground
NOTE!
A defective switch or a signal line short to voltage could also cause a warning display when the hydraulic pressure is at normal
conditions.
Hydraulic oil filter (optional)

This function monitors the pressure differential at the hydraulic filter and notifies the operator when the filter should be changed
or when there is a system malfunction.
The hydraulic oil filter must be changed to avoid opening the bypass valve. Bypassing the filter will cause the circulation of
unfiltered oil through the system.
There are two settings for the filter:
1. Warning pressure signal (e.g. 276 kPa; 2,8 bar; 40 psid).

2. Actual bypass open (e.g. 344 kPa; 3,4 bar; 50 psid).

– Hydraulic filter bypass switch – Pressure differential >344 kPa (3.44 – Amber central warning
SE9103, SE4407 (AWD) bar)(50 psi) – Amber indicator lamp
........ INFO.......
Clogged
Hydraulic
Oil Filter
Monitoring SE9103, SE4407 (AWD) System malfunction, wrong sensor state – Amber central warning
when engine is off ........ ERROR.......
Monitoring
Hydraulic
Oil Filter
Refer to electrical schematics 17, AWD transmission controller; and 19, Sensors.
ECU detects a low signal from the sensor when the engine is off (Error text is displayed).
Possible causes:

Signal line short circuit to voltage or defective sensor
Hydraulic temperature
This function monitors the hydraulic oil temperature and notifies the operator if the temperature is too high or if there is a
system malfunction.

– Hydraulic oil temperature SE9102, – High hydraulic oil temperature: – Red central warning
SE4410 (AWD) normally closed, opens at 85ºC (185ºF) – High hydraulic temperature indicator
indicator lamp
– Buzzer
........ WARNING.......
High
Hydraulic
Oil Temperature
Refer to electrical schematics 17, AWD transmission controller; and 19, Sensors.
Possible causes for an incorrect warning:
Open circuit, signal line short circuit to ground

Defective sensor
Service brake system

This function monitors the service brake system circuits. A flow switch is incorporated into the system to inform the operator
when the brakes are applied and there is no hydraulic fluid flow. Sensors monitor the pressure differential between the two
service brake circuits.

– Brake no flow SE5201 – No brake flow: NC, open with flow – Red central warning
– Brake delta pressure SE5202 – Circuit pressure differential: NO with no – Red service brake warning lamp
– Engine run status pressure differential – Buzzer
– Engine is running or has run ........ WARNING.......
Service
Brake
System
Refer to electrical schematic 20, Brake circuit/lights.

Possible causes for an incorrect warning:
Either sensor signal lines short circuit to voltage

Either sensor defective
Voltage monitoring
This function monitors the voltage level at the power supply of the I-ECU. The operator is notified when the voltage level is too
low or too high.

– 10 amp power feed from main – Ignition on – Amber central warning
relay – High voltage >31 volts ........ INFO.......
High
Voltage
– 10 amp power feed from main – Ignition on – Amber central warning
relay – Low voltage <21 volts ........ INFO.......
Low
Voltage
Engine intake air filter restriction monitoring

This function monitors the pressure differential at the intake air filter and notifies the operator if the air filter is blocked. The
operator is also notified when the system malfunctions.

– Air filter restriction SE2601 – Pressure differential: NC, opens at 5 kPa – Intake restriction warning indicator lamp
(50 mbar)(0.73 psi) – Amber central warning
– 330 ohms - closed
– 2200 ohms - open
– Monitoring SE2601 – System malfunction – Amber central warning
........ ERROR.......
E ECU
XXXX YYY
Refer to electrical schematic 4 or 5, E-ECU.

E-ECU receives a low signal at it's terminal indicating an open switch
Possible causes:

Defective switch
Ambient air temperature

This function monitors the temperature at the air intake filter and notifies the operator if the temperature goes outside the
normal range or when the system malfunctions.

– Monitoring SE2501 – Temperature out of range: – Display "---" in place of temperature
>60ºC (140ºF)
<– 40ºC (–40ºF)
– Monitoring SE2501 System malfunction – Amber central warning
– Display "Er" in place of temperature
........ ERROR.......
E ECU
XXXX YYY
Refer to electrical schematic 4 or 5, E-ECU.

E-ECU receives a low signal (0V) or a high signal (24V) indicating an open switch
Possible causes:
Open circuit, signal line short circuit to ground

Short circuit, signal line short circuit to ground
Defective sensor
Fuel level monitoring

This function monitors the fuel level in the fuel tank and informs the operator when the fuel level is low. The operator is also
notified when a system malfunction occurs.

– Fuel level SE2302 – Low fuel: <17% of full tank – Fuel gauge pointer at 13ºor less
– Resistance > 370 ohms – Low fuel lamp beside gauge is illuminated
– Monitoring SE2302 – System malfunction, sensor resistance – Amber central warning
out of range ........ ERROR.......
Monitoring
Fuel Level
Refer to electrical schematic 7, Throttle position/fuel sensor.

I-ECU receives a low signal due to a sensor resistance of 370 ohms or more
Possible causes:
Open circuit, signal line short circuit to ground or broken wire

Defective sensor
Parking brake system

This function notifies the operator when the parking brake is applied.

– Parking brake SW5201 – Parking brake engaged: closed switch – Red park brake indicator lamp
– Gear selection SW4201 – Transmission in neutral: signal from pin
D is 0 volts
– Parking brake SW5201 – Parking brake engaged: closed switch – Red park brake indicator lamp
– Gear selection SW4201 – Transmission in gear: signal from D is – Red central warning
24 V – Buzzer
........ WARNING.......
Applied
Parking Brake
Refer to electrical schematics 20, Brake circuit/lights; and 16, Transmission ECU.
Possible causes for incorrect warning:
Shifter signal line short circuit to voltage

Parking brake signal line short circuit to voltage
Defective Sensors
Differential lock monitoring

This function monitors the state of the differential and notifies the operator when the differential is in the locked state.

– Differential lock SE4601 – Differential in lock position: switch – Amber differential lock indicator light
closed
Refer to electrical schematic 15, Rotating beacons/MBCS/differential lock.

Signal line short circuit to voltage

Defective sensor
Communication monitoring
This function monitors the communication between the I-ECU and E-ECU and notifies the operator when one of the data buses
is interrupted. The operator is also informed when both of the buses have failed.

– High-speed bus – Interrupted signal lines on either of the – Red central warning
– Low-speed bus buses ........ ATTENTION!.......
Reduced
Computer Function
– High-speed bus – Interrupted signal lines on both buses – Red central warning
– Low-speed bus – Buzzer
........ STOP!.......
Computer Failure
STOP VEHICLE
Refer to electrical schematic 29, Communication E-ECU/I-ECU.


Signal lines short circuit to voltage
Break in signal lines
Engine speed
This function monitors the engine speed sensors and notifies the operator when there is a malfunction in the system.

– Engine crankshaft speed sensor – Either of the speed sensor signals – Amber central warning
– Engine cam shaft speed sensor absent or interrupted ........ ERROR.......
– Engine injection pump speed E ECU
sensor XXXX YYY

Possible causes for warning display:
Signal lines short circuit to ground

Signal lines short circuit to voltage
Break in signal lines
Accelerator pedal
This function monitors the accelerator pedal operation and informs the operator when there is a system malfunction.

– Accelerator (APS signal) – APS signal out of range – Amber central warning
– Idle Validation Signal (IVS) SE2701 – IVS not active ........ ERROR.......
Accelerator Pedal
Refer to electrical schematic 7, E-ECU.
Detected if the voltage monitored by the I-ECU is outside the 0.5V to 4.5V range for the APS signal.
Detected if the voltage monitored by the I-ECU is greater than 2.75V for the APS signal and the IVS signal is low (0
volts).
Possible cause:

Sensor supply voltage (5V) open or short circuit to ground
24V feed line open or short circuit to ground
Defective sensor
Preheat control
This function monitors the status of switching relay and heater coil and informs the operator if there is a system malfunction.

– Preheat sense signal – System malfunction – Amber central warning
........ ERROR.......
Preheat System

Detected if the signal monitored by the E-ECU is low
Possible cause:
Open circuit in the switching relay circuit

Open circuit in the heater coil circuit
Hydraulic oil level

This function monitors the oil level in the hydraulic tank and notifies the operator when the level is too low.

Hydraulic oil level SE9101 / SE4409 – Low oil level: Open switch – Red oil level warning indicator lamp
(AWD) – Red central warning
– Buzzer
........ WARNING.......
Low
Hydraulic
Oil Level
Refer to electrical schematics 17, AWD ECU; and 19, Sensors.

Possible causes for incorrect warning display:

Open circuit, broken wire
Defective switch
Speedometer
This function is available with the optional speedometer. It monitors the ground speed of the grader and notifies the operator
when there is a system malfunction.

Speed sensor SE3801 – Speed sensor output out of range – Display "Er" instead of speed
Refer to electrical schematics 16 T-ECU, and 17 AWD-ECU.

The I-ECU detects an open circuit (0 volts)
Possible cause:
Signal short circuit to ground

Signal short circuit to voltage
Disconnected wire
Defective sensor
Engine ECU monitoring

The objective of this function is to inform the operator that the engine ECU has detected a warning code.

PPID, PID, and SID codes listed – Error code received by I-ECU – Red or amber central warning according to
below from engine ECU – In case of several errors, highest status status error.
error has priority ........ ERROR.......
E ECU
XXXX YYY
Error reference table

ER Code Component/function G710B to G730B G740B to G780B
PID 102 Charge air pressure X X
PID 108 Atmospheric pressure X X
PID 158 Battery voltage X X
PID 172 Air temperature inlet X X
PID 174 Fuel temperature X X
SID 1 – 6 Injection cylinders X
SID 17 Fuel shut-off X
SID 20 Actuator injection angle (timing) X
SID 21 Revolutions – camshaft X
SID 21 Cylinder 1 - needle movement sensor X
SID 22 Revolutions – flywheel X X
SID 64 rpm sensor – in-line pump X
SID 230 Idle switch X X
SID 232 5 V supply X X
SID 240 Program memory X X
NOTE!
In the case where a serious malfunction has occurred, the operator is informed to turn the engine off immediately.

SID 23, 24, 240, 253, or 254 – Error code received by I-ECU – Red central warning
– Buzzer
........ STOP!.......
Turn Engine Off
XXXX YYY
Inputs:
SID 24 = Rack position sensor

SID 23 = Rack actuator
SID 240 = Program memory
SID 253 = Calibration memory
SID 254 = Controller number 1
Description- 2
Specifications- 3
Non-maintenance batteries; testing 4
Explosion hazard 5
Battery box 6
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Power is supplied by a series connection of two 12VDC BCI 31 (Battery Council International Group Number) batteries, creating a
total system voltage of 24VDC. The two batteries are housed in a battery box mounted on top of the left-hand tandem of the
grader.
Service Information

Specifications 310 Service Information 9/10/2022
Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Electrical system
System voltage 24 VDC
Battery
Quantity 2[1]
Ground connection Negative
Cold cranking amps 660 (G710B to G730B)
950 (G726B, G740B, G746B, G780B)
1300 (G710B - G780B - optional)
Battery disconnect switch Connected to negative ground
(chassis connection)
[1]Maintenance free
Service Information

Non-maintenance batteries, 310 Service Information 9/10/2022
testing
Profile:
G780B Volvo
Non-maintenance batteries, testing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Volvo motor graders use 2 non-maintenance type batteries to supply power to the electrical system. Non-maintenance type
batteries do not need to be checked and tested as often as serviceable batteries. The Volvo batteries do include removable caps
to allow the electrolyte level and specific gravity to be checked. The level should be 10 mm (3/8 in.) above the cell plates. A
specific gravity reading below 1.230 indicates a discharged battery.
If the life or the condition of the battery is questionable, a load test can be performed to determine if the battery should be
replaced. Use a load tester that draws one half of the rated current output of the battery under cranking load conditions (330
amps for G710B to G730B, 475 amps for G740B to G780B). The test should be performed for a minimum of 15 seconds. A
reading of less than 9.5 volts for a 12 V battery (while under load) means that the battery should be replaced. After the 15
seconds, a voltage reading should again be taken. This bounce-back voltage should be between 9.5V and 12.45V. A reading
outside this range means the battery should be replaced.
Service Information

Explosion hazard 311 Service Information 9/10/2022
Profile:
G780B Volvo
Explosion hazard

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
When a battery is being charged, a potentially explosive mixture of oxygen and hydrogen gas is formed. A short circuit, open
flame or spark near the battery can cause a powerful explosion. Always turn off the main power to the battery charger before
disconnecting the charging clamps. Ventilate the area well, especially if the battery is being charged in a confined space.
Service Information

Battery box 313 Service Information 9/10/2022
Profile:
G780B Volvo
Battery box

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The battery box that houses the two batteries is located on top of the left-hand tandem. It is 11 gauge thick sheet metal and is
approximately 280 X 203 X 864 mm (11 X 8 X 34 in.) in size. It has a hinged enclosure on the top for easy access to the batteries.
Voltage regulator 2
Specifications 3
Alternator; description 4
Service Information

Voltage regulator 320 Service Information 9/10/2022
Profile:
G780B Volvo
Voltage regulator

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Both the standard alternator and the optional alternator contain a heavy-duty integral charging system with built-in diode
rectifier and voltage regulator. Both alternators include a solid-state integrated circuit, good flat temperature compensation, low
parasitic draw, increased RFI suppression, low turn-on speed and load dump protection. The voltage regulator limits the
maximum voltage that the alternator produces at the output terminal because of its ability to control the magnetic field present
in the stationary field. The rectifying diodes allow the current to satisfy the electrical loads of the system.
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Alternator with regulator

Type Alternating current
Output 75 A - 2100 W (S/N 35000 - 36363)
100 A - 2800 W
Voltage at + 20ºC (68ºF) 27.5 V
Current, maximum 75 and 100 A
Alternator with regulator

Type Alternating current
Output 80 A - 2240 W (S/N 36364 -)
100 A - 2800 W
Voltage at + 25° C (82.4° F) 28.3 V
Current, maximum 80 and 100 A
Service Information

Alternator, description 321 Service Information 9/10/2022
Profile:
G780B Volvo
Alternator, description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
G710B to G780B models are equipped with a 24V, 75 amp alternator, from S/N 35000 - 36363. At S/N 36364 and up, all G710B
to G780B models come equipped with 24V, 80 amp alternators. G710B to G780B models can also be equipped with an optional
24V, 100 amp alternator. The alternator is included in the system to charge the battery and produce system voltage when the
engine is running.
Specifications 2
Starting system; general description 3
Neutral start relay 4
Electric air - preheater 5
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Starter motor – G710B to G730B

Output 5.4 kW
Starter motor – G740B to G780B

Output 8.0 kW
Service Information

Starting system, general 330 Service Information 9/10/2022
description
Profile:
G780B Volvo
Starting system, general description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The function of the starting system is to initiate engine cranking by using a starter motor located at the base of the engine. This
system also includes an electric air pre-heater and a neutral start system. The neutral start system will only allow the grader to be
started when the transmission is in neutral. This system will also actuate an audible alarm and warning light if the transmission is
in forward or reverse gear when the parking brake is applied.
The 42 MT starter is a heavy duty starter that offers overcrank protection for use in adverse starting conditions such as cold
weather, low battery capacity, high starting circuit resistance, or operator misuse. The existence of a positive-engagement shift
mechanism assures pinion-to-ring gear engagement prior to cranking. This helps in the reduction of milled ring gears and
pinions. The solenoid is enclosed in a one-piece case with an O-ring seal to help prevent water entry. Special alloys are used in
the solenoid contact disk and the four 1-piece brushes to extend service life.
Service Information

Neutral start relay 330 Service Information 9/10/2022
Profile:
G780B Volvo
Neutral start relay


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
A neutral start relay is incorporated into the system to help prevent accidents and damage to the machine. A signal must be
received from the transmission indicating it is in neutral otherwise this relay will not allow the engine to start.
Service Information

Electric air - preheater 330 Service Information 9/10/2022
Profile:
G780B Volvo
Electric air - preheater


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The function of the electric air pre-heater is to warm up the inlet air during cold conditions both before and after cranking of
engine at start-up. The pre-heat will be temporarily turned off while the engine is cranking to avoid excessive battery current
draw. This service gives better starting from an environmental standpoint and ensures start-up at very low temperatures.
The operator initiates the pre-heat function using the switch found on the right-hand console. When the pre-heat switch is
engaged, the I-ECU will send a signal to the engine's E-ECU which, in turn, will energize the pre-heat element that will be used to
heat the air. When the ignition switch is turned to crank the engine, the E-ECU will turn off the element until post-heating is
required. The E-ECU will keep the post-heat active for a length of time that is dependent on the engine's coolant temperature.
The indicator lamp on the instrument panel inside the cab is directly wired to the pre-heat element and will turn on whenever
the element is active.
General 2
Lighting; front 3
Lighting; rear 4
Lighting; interior 5
Lighting; side 6
Service Information

Profile:
G780B Volvo
General

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The lighting system on all grader models operates on the 24VDC system. The grader's electrical wiring harnesses supply the
power for the lights. Lights can be located in the front rear and both sides of the grader. They can also be found as interior lights
in the cab and in the engine compartment. Working lights can also be found on grader attachments.
Service Information

Lighting, front 350 Service Information 9/10/2022
Profile:
G780B Volvo
Lighting, front

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
There are various types of lighting options that are available at the front section of the grader. The front of the cab contains the
standard headlights near the left-hand and right-hand corners of the upper cab above the windshield. Between the headlights is
an indicator light bar with three covered bulbs with amber lenses.
For European versions, there are no lights situated on the cab. Instead, the headlights are fastened to arms located at the front
of the frame. The headlights are positioned above and to either side of the frame at the front.
Service Information

Lighting, rear 350 Service Information 9/10/2022
Profile:
G780B Volvo
Lighting, rear

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Lighting behind the cab is located directly on the back of the cab across the top of the rear window. Light assemblies are also
located at the very back end of the grader, mounted at both sides of the radiator enclosure. These are the tail lights, stop lights
and back-up lights.
For the European version machines, the same light assemblies are mounted on the end of arms attached to the radiator
enclosure. They are located farther out from the side and lower than the standard location. Red indicator lights are located in the
middle, top of the cab similarly to the indicator lights at the front.
Service Information

Lighting, interior 350 Service Information 9/10/2022
Profile:
G780B Volvo
Lighting, interior

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Inside the cab there is one dome light located on the ceiling. The dome light switch is located on the right-hand doorpost.
Lights are also incorporated into the switches on the pedestal and the right-hand console. These lights will illuminate when the
switches are activated with the accessory power on or the machine is running.
Service Information

Lighting, side 350 Service Information 9/10/2022
Profile:
G780B Volvo
Lighting, side

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Lighting on the sides of the grader is only available as an option. Floodlights can be mounted at 2 positions on either side of the
cab just above the cab doors.
Description 2
Direction indicator; turn signal 3
External warning system 4
Ignition switch 5
Automatic control_blocking function 7
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The electrical system also consists of various electrical switches that are used throughout the grader. The grader is equipped with
directional indicators and an outside warning system that is controlled by the operator. The electrical system also powers the
windshield wipers operated by electric motors. Standard wipers are located at the upper front windshield. Optional wipers can
be located at the lower front windows as well as the rear windows.
The instrument panel potentiometer is located in the cab, to the right of the driver on the side console. It controls the level of
brightness for the instrument panel and switches.
The accelerator pedal potentiometer relays information to the I-ECU. Accelerator position is sent via the data bus to the E-ECU.
Using the position of the accelerator pedal, it then controls the fuel flow to the injectors.
Every machine is equipped with ECU's that monitor sensor activities and inputs from relays and switches. The E-ECU is located on
the left-hand side of the engine compartment. It is mounted on the frame for models G710B to G730B and mounted on the
engine for G740B to G780B models. The E-ECU contains software for controlling engine functions. Information is received by the
E-ECU via a data bus. The E-ECU will also send information to the I-ECU via the data bus. The I-ECU is located in the cab, next to
the pedestal. It contains software that is mainly used for presentation of operator information. The two ECU's send and receive
information with one another, resulting in proper machine operation and display of operator information.
A T-ECU is found in the right-hand console of every machine. This ECU contains software for operation of the grader's
transmission. The The I-ECU receives inputs from the T-ECU (Transmission ECU) for VHP signal, parking brake, and neutral status.
The T-ECU receives information from switches and the gear selector and sends information to the independent transmission
display and transmission solenoids. The T-ECU also runs a self-diagnostic program to detect electrical failures in the transmission
system. Should a failure occur, the pedestal transmission display immediately alerts the operator of the error. In AWD models,
the T-ECU is replaced by an AWD-ECU. It is located in the same position and monitors the same functions plus information from
the additional AWD components.
The blade float system is controlled electrically by a module located in the pedestal. The module receives information from
detent switches located at the main control valve. With the float valves power switch turned on, operating the blade lift levers
(located at both sides of the pedestal) activates the detent switches. When the levers are pushed forward to the fourth detent
position, the module will send a signal to the float valve solenoids located at the blade lift cylinders. The same system can be
used for optional attachments such as a front dozer blade.
An additional control module is used to regulate the speed of the radiator fan. This module receives information from sensors
that monitor the charge air temperature, the engine coolant temperature, and the hydraulic oil temperature. If a sensor indicates
that an area is out of the operating range, it's electrical signal will notify the control module and the fan will then be activated.
Service Information

Direction indicator; turn 360 Service Information 9/10/2022
signal
Profile:
G780B Volvo
Direction indicator; turn signal


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The operator activates the directional indicator/turn signal from inside the cab. The signal lights can be located at the front of
the machine and at the rear. At the front, they are found in the housing for the cab headlights. At the rear, they are found in the
housing for the brake lights and tail lights.
European model machines have their turn signal indicators in the headlight housing at the front of the machine. The rear turning
signals are mounted on the end of arms attached to the radiator enclosure instead of the standard rear location.
Service Information

External warning system 360 Service Information 9/10/2022
Profile:
G780B Volvo
External warning system


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The outside warning system consists of a horn, a rotating beacon, a back-up siren, and a back-up light. The rotating beacon is
available as an option in amber or blue. There are 3 areas where beacons can be placed on top of the cab. European cabs require
a beacon on the right front corner and on the rear left corner of the cab roof. An option for one or two beacons is available. The
beacon action is available as rotating beacons or strobe/flasher beacons.
Service Information

Ignition switch 360 Service Information 9/10/2022
Profile:
G780B Volvo
Ignition switch

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
The ignition switch has four positions.
O Turned off
R Radio position
I Running position and preheating
II (not used)
III Starting position
O (OFF position)
In the “O” position, the engine stops immediately and the electrical system is turned off.
R (Radio position)
When the ignition key is in the “R” position:
Current is supplied to some electrical equipment

The engine is off in this position
I (Running position and preheat position)

In the “I” position:
The electrical system is turned on

Engine preheating can be engaged
The engines runs in this position
III (Start position)

The starter will be engaged with the ignition key in the “III” position.
Service Information

Automatic control/blocking 360 Service Information 9/10/2022
function
Profile:
G780B Volvo
Automatic control/blocking function


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
E-ECU (Engine Electronic Control Unit)

This control unit is the central part of the injection system. It is located on the left side of the engine on the G740B to G780B
models with the D10 engine and on the left-hand side of the frame on the G710B to G730B models with the D7 engine. The E-
ECU is installed with rubber vibration isolators.
The control unit receives continuous information from the throttle pedal and a number of sensors on the engine, and calculates
the fuel volume as well as the timing of the fuel injection into the cylinders. The control signals for the unit injectors are sent via
cabling to the unit injectors' fuel valves.
Since the control unit senses the engine speed through the flywheel sensor, as well as changes of engine speed during a
revolution, the control unit ensures that each unit injector receives exactly the right amount of fuel.
The control unit stores information if a malfunction should occur, or if something in the system is abnormal. Intermittent
malfunctions are also stored in the control unit and can be traced at a later time.
I-ECU (Instrument Electronic Control Unit)
The I-ECU does a similar job as the E-ECU. The I-ECU controls many functions throughout the grader. It is constantly
communicating with the E-ECU through two different types of bus systems. A high-speed bus referred to as the SAE J1939/
CAN-bus communication, and a low speed bus known as the SAE J1708 communication. The high-speed bus is known as the
control bus, which operates at 256kbits/s which is a pre-requisite for the control of the system to function and quickly adjust to
varying operating conditions. The J1708 bus operates at 9.6 kbit/s, which is significantly slower than the high-speed bus. The
low-speed bus is mainly used for information and diagnostic signals.
The I-ECU, which is housed in the instrument panel, receives signals from sensors throughout the machine and will display the
received information using indicator lights, an information display and other needle indicators that are built into the instrument
panel. For every input into the I-ECU, the information will be carried to the E-ECU on the bus. The software for the E-ECU
determines what information will be read and what information will be ignored. The same situation exists with information sent
to the I-ECU through the bus system. The I-ECU can also relay signals from inputs and transport them to initiate an action
through hard wiring.
T-ECU (Transmission Electronic Control Unit) and shifter assembly
The T-ECU is a sealed, non-serviceable solid state component. It contains a 9-position joystick that relocates a magnet on a
replaceable printed circuit board. The circuit board will transmit signals to the T-ECU for forward, reverse, upshift or downshift.
The T-ECU will send 24 volts to the appropriate coils on the transmission for the gear ratio required. Only 2 or 3 of the 6 coils will
be activated for any particular gear. The ECU also controls VHP (Variable Horsepower), and the backup alarm. The VHP signal is
the only connection that integrates the T-ECU with the E-ECU. The transmission shifter assembly operates a relay that controls
the neutral start safety function and the parking brake warning light and buzzer through the T-ECU.
The T-ECU detects electrical failures in the transmission system. Should a failure occur, the error code is immediately shown in
the pedestal display to alert the operator.
AWD-ECU (All Wheel Drive Electronic Control Unit)
The AWD-ECU replaces the T-ECU in All Wheel Drive graders. The AWD electrical system centers around a microprocessor based
control unit with fast processing speed and high resolution. It receives inputs from the system and provides outputs to control
the displacement of the drive pumps and motors. It will also alert the operator of any conditions that exist which are outside of
normal operating parameters.
When the AWD switch is turned on, the AWD-ECU energizes the freewheeling solenoid to shift the freewheeling valves. Once the
transmission controller has been placed in gear and the clutch and brake pedals released, the AWD-ECU energizes the
appropriate bypass valve and solenoids (forward or reverse) and sets the EDC (Electric Displacement Control) current to a
nominal value to suit the appropriate direction and speed selected. It then samples the front wheel speed and compares it to
transmission output speed (rear wheel speed). It then sets the EDC currents to match wheel speed, based on the setting of the
AWD Aggression selection dial. At setting number 1, the pumps will be displacing enough fluid to simply have the front wheels
follow the rear. At setting 16, the front wheels are attempting to overdrive the rear wheels.
During Creep Mode, the transmission remains in neutral and only the front wheels drive. Once the transmission controller has
been placed “in gear”, the ECU samples the engine speed input and then sets the electric displacement currents based on engine
speed and direction.
Electrical symbols and designations 4
Description 6
Cable; Battery isolation switch 7
Electrical component list 8
Wiring diagram 1 – Main diagram_Positive feeds_Chassis connections_{47
-29} 15
Wiring diagram 1 – Main diagram_Positive feeds_Chassis connections_{47
-08} 18
Wiring diagram 2 – Positive feed_Chassis connection I-ECU_E-ECU_{46-
38} 21
Wiring diagram 2 – Positive feed_Chassis connection I-ECU_E-ECU_{46-
17} 23
Wiring diagram 3 – Engine_{45-45} 25
Wiring diagram 3 – Engine_{45-24} 28
Wiring diagram 4 – D7 Engine ECU_{44-53} 31
Wiring diagram 6 – D7; D10 Engine ECU_{42-57} 42
Wiring diagram 6 – D7; D10 Engine ECU_{42-37} 45
Wiring diagram 7 – Accelerator pedal_Fuel level_{42-02} 47
Wiring diagram 7 – Accelerator pedal_Fuel level_{41-41} 50
Wiring diagram 8 – Fan ECU_{41-10} 53
Wiring diagram 8 – Fan ECU_{40-46} 56
Wiring diagram 9 – Headlights_Turn signals_Horn_{40-09} 59
Wiring diagram 9 – Headlights_Turn signals_Horn_{39-45} 63
Wiring diagram 10 – EEC Headlights and flashers_{39-15} 66
Wiring diagram 10 – EEC Headlights and flashers_{38-53} 69
Wiring diagram 11 – Work lights_{38-22} 72
Wiring diagram 11 – Work lights_{38-02} 75
Wiring diagram 12 – EEC Worklights_{37-31} 78
Wiring diagram 12 – EEC Worklights_{37-10} 81
Wiring diagram 13 – Windshield wiper systems_{36-40} 84
Wiring diagram 13 – Windshield wiper systems_{36-19} 87
Wiring diagram 14 – 25 amp_60 amp converter_equalizer_{35-49} 91
Wiring diagram 14 – Rotating beacons_ Differential lock_MBCS_Articulatio-
n sensor_{35-28} 94
Wiring diagram 15 – Transmission ECU_{34-52} 97
Wiring diagram 15 – Rotating beacons_differential lock_MBCS_{34-31} 100
Wiring diagram 16 – AWD ECU_{34-01} 103
Wiring diagram 16 – Transmission ECU_{33-40} 106
Wiring diagram 18 – Sensors_{31-50} 123
Wiring diagram 19 – Sensors_{31-20} 126
Wiring diagram 19 – Brake circuit; lights_{30-59} 129
Wiring diagram 20 – Brake circuit; lights_{30-28} 132
Wiring diagram 20 – Secondary steering_{30-07} 135
Wiring diagram 21 – Climate control unit_{29-28} 138
Wiring diagram 21 – Secondary steering_{28-51} 142
Wiring diagram 22 – Front and rear defroster fans_{28-19} 145
Wiring diagram 22 – Climate control unit_{27-59} 148
Wiring diagram 23 – Front defroster fans_{27-27} 152
Wiring diagram 23 – Radio_Heated mirrors_{27-06} 155
Wiring diagram 24 – Blade float module_{26-35} 157
Wiring diagram 24 – Radio_Dome light_Heated mirrors_{26-14} 160
Wiring diagram 25 – Front float module_{25-44} 163
Wiring diagram 25 – Blade float module_{25-23} 166
Wiring diagram 26 – Tire pump_{24-53} 169
Wiring diagram 26 – Front float module_{24-31} 171
Wiring diagram 27 – Rear float module_{24-00} 174
Wiring diagram 27 – Communication; E-ECU_I-ECU_{23-40} 176
Wiring diagram 28 – Tire pump_Power outlet_{23-09} 179
Wiring diagram 28 – Keyboard_{22-48} 182
Wiring diagram 29 – Communication; E-ECU_I-ECU 184
Wiring diagram 30 – Keyboard 187
Electrical distribution box fuses; relays 189
Data link port 191
Ground stud - locations 192
Service Information

Electrical symbols and 370 Service Information 9/10/2022
designations
Profile:
G780B Volvo
Electrical symbols and designations


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Designation Symbol Explanation

ALT Alternator with charging regulator
BA Battery
DI Diode
E-ECU Engine control unit
FC Fuse
FH
FU
I-ECU Instrument control unit
LA Lamp, steady light

Lamp, flashing
LC LED, steady lamp
MA Solenoid valve or PWM valve for control of oil
MO Electric motor
Starter motor
R Resistor
Rheostat
RE Relay
No operating current on 86–85 contact position 30–87A
Operating current on 86–85 contact position 30–87
SE Frequency sensor, e.g. transmission speed (analog)
Level sensor (digital)

Temperature sensor (digital)
Temperature sensor (analog)
Pressure sensor (digital)

Pressure sensor (analog)
Mechanical monitor (digital)

SW Single pole switch with manual On/Off, e.g. engagement of
air conditioning unit
Backup alarm/horn
V-ECU Vehicle control unit
T-ECU Transmission control unit
Ground connection
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Electric power is transmitted using many sizes of cables ranging from 1 gauge at the battery and starter to 22 gauge throughout
most of the grader. Wire harnesses are factory installed and include circuits for optional components that can be added. All the
cables in the wiring harnesses are color-coded and numbered according to the circuit they belong to.
Electric power is disconnected using an isolation switch located inside the engine compartment on the left-hand side of the
grader. The isolation switch disconnects the ground circuit between the grader frame and the batteries.
The electrical distribution box is located in the right-hand console and it contains the fuses and relays that are included in the
electrical circuits.
Service Information

Cable; Battery isolation 370 Service Information 9/10/2022
switch
Profile:
G780B Volvo
Cable; Battery isolation switch


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The series-connected batteries are connected to the starter from the positive terminal of one of the batteries. The connection is
made by a large diameter, 1 gauge cable. The negative terminal of the other battery is connected to one terminal on the
isolation switch. The other terminal of the switch is connected to ground. Every one of these connections is made by similar 1
gauge cable.
When the isolation switch is on and the key switch is in the “ON” position, power is supplied to the fuse panel through an 200
amp accessory solenoid for distribution throughout the electrical circuits.
Once the isolation switch is closed, power is still available to certain safety circuits regardless of the disposition of the key switch.
The optional supplemental steering and the standard emergency braking system become live without the key switch being
energized.
Service Information

Electrical component list 370 Service Information 9/10/2022
Profile:
G780B Volvo
Electrical component list


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Harness plugs
Plug number Description Location

P1 I-ECU Front harness
Pl1 Front bulkhead Console harness
Pl1 Front bulkhead Front harness
Pl2 Rear bulkhead Console harness
Pl2 Rear bulkhead Rear harness
Pl3 Transmission controller Console harness
Pl5 Service tool Console harness
Pl6 Upper cab wipers Console harness
Pl6 Upper cab wipers Upper cab
Pl7 Upper cab fans Console harness
Pl7 Upper cab fans Upper cab
Pl8 Upper cab Console harness
Pl8 Upper cab Upper cab
Pl9 Engine connector Front harness
Pl9 Engine connector Rear harness
Pl10 Rear connector Front harness
Pl10 Rear connector Rear harness
Pl11 Engine communication Front harness
Pl11 Engine communication Rear harness
Pl12 Blade floats
Pl12 Blade floats
Pl13 EEC headlights
Pl13 EEC headlights
Pl14 AWD logging
Pl14 AWD logging
Pl16 Transmission display
Pl17 Blade float module
Pl17 Blade float module
Pl18 Front float module
Pl18 Front float module
Pl19 Lower wipers
Pl19 Lower wipers
Pl20 MBCS
Pl20 MBCS
Pl21 Transmission
Pl21 Transmission
Pl22 Articulation sender
Pl22 Articulation sender
Pl23 Front float
Pl23 Front float
Pl24 AWD module
Pl25 AWD controller
Pl26 AWD – EDC controller
Pl27 716 jumper
Pl27 716 jumper
Pl28 AWD sensor bulkhead
Pl28 AWD sensor bulkhead
Pl29 AWD datalink bulkhead
Pl29 AWD datalink bulkhead
Pl30 Rear lights
Pl30 Rear lights
Pl31 Tail lights
Pl31 Tail lights
Pl32
Switches
Switch number Description Location Schematic No.[1]

SW3301 Starter Console switch plate 1, 3, 21
SW3701 Battery disconnect Engine compartment RH 1
SW2101 Pre-heat Console switch plate 3
SW2601 70% fan speed jumper 8
SW3501 Dome light Left door post 24
SW3502 Headlights/parking lights Console switch plate 9, 10
SW3503 Extra headlights Console switch plate 9,1 0
Sw3504 Moldboard floodlights Console switch plate 11, 12
SW3505 Rear floodlights Console switch plate 11, 12
SW3506 Side wing floodlights Console switch plate 11, 12
SW3601 Turn signal/horn/high-low beam Pedestal 9
SW3602 Hazard Pedestal switch plate 9
SW3603 Amber rotating beacon Console switch plate 15
SW3604 Blue rotating beacon Console switch plate 15
SW3605 Front wiper/washer Console switch plate 13
SW3606 Rear wiper/washer Console switch plate 13
SW3608 Parking lights dimmer Console 9
SW3607 Lower front wiper/washer Console switch plate 13
SW4201 Transmission gear shifter Console 16
SW4401 AWD On/Off Left door post 18
SW4402 Creep mode On/Off Lower door post 18
SW4403 AWD aggression Lower door post 18
SW4601 Differential lock Pedestal switch plate 15
SW5201 Electrical brake Under cab 20
SW5501 Parking brake Pedestal 3, 21
SW6401 Secondary steering test Pedestal switch plate 21
SW8701 Heater fan speed Console upper switch plate 22
Sw8702 Heater temperature control Console upper switch plate 22
SW8703 Air conditioner On/Off Console upper switch plate 22
SW8801 Keypad Pedestal switch plate 30
SW8802 Front RH defrost fans Console upper switch plate 23
SW8803 Front LH defrost fans Console upper switch plate 23
SW8901 Heated mirrors Console upper switch plate 24
SW9101 Blade/front float enable Pedestal 25, 26
SW9102 Right hand detent float Manifold 25
SW9103 Left hand detent float Manifold 25
SW9104 Front detent float Manifold 26
SW9105 Rear-1 float Lower door post 27
SW9106 Rear-2 float Lower door post 27
SW9107 Rear float enable Lower door post 27
SW9801 MBCS lock cylinder Pedestal switch plate 15
SW9901 Tire pump Tire pump remote box 28
Sensors
Sensor number Description Location Schematic No.[2]
SE2202 Engine oil temperature Engine 5

SE2203 Engine oil pressure Engine 4, 5
SE2301 Fuel pressure Engine 5
SE2302 Fuel level sender Fuel tank 7
SE2306 Fuel temperature Engine 4, 5
SE2308 Needle movement sensor (injector timing) Engine 5
SE2501 Induction air temperature Air intake 4, 5
SE2502 Air filter restriction Air intake 4, 5
SE2507 Charge air temperature Engine 4, 5
SE2508 Charge air pressure Engine 4, 5
SE2603 Engine coolant level Expansion tank 4, 5
SE2604 Fan control charge air temp. RH charge air tube 8
SE2605 Fan control - hydraulic oil temperature Front lower hydraulic tank 8
SE2606 Coolant temperature Engine 4, 5
SE2607 Fan control water coolant temperature Upper engine coolant pipe 8
SE2701 Engine speed Engine 4, 5
SE2702 Accelerator pedal Below cab floor - pedal 7
SE2703 Camshaft frequency Engine 4, 5
SE3801 Transmission speed sensor Park brake disc 7
SE3803 Ambient sensor Air intake tube
SE4201 Transmission filter bypass Filter housing 19
SE4202 Transmission oil pressure Transmission 19
SE4401 AWD RH speed Sensor RH Wheel motor 17
SE4402 AWD LH speed Sensor LH Wheel motor 17
SE4403 AWD rear speed Sensor Park brake disc 18
SE4404 AWD clutch pressure Clutch master cylinder 18
SE4405 AWD hydraulic brake pressure Brake master cylinder 18
SE4406 AWD hydraulic brake pressure Brake master cylinder 18
SE4407 Hydraulic filter bypass Filter housing 17, 19
/SE9103
SE4408 AWD charge pressure Hydraulic filter 18
SE4409 Hydraulic oil level Hydraulic tank 17, 19
/SE9101
SE4410 Hydraulic oil temperature Hydraulic tank 17, 19
/SE9102
SE4601 Differential lock cylinder ball switch Final drive housing 19
SE5201 Brake no flow Brake power booster 20
SE5202 Brake delta pressure Brake master cylinder 20
SE5501 Park brake hydraulic pressure Park brake caliper 16
SE6401 Steering hydraulic pressure Secondary steering box 21
SE8701 Air conditioning temperature Air conditioning box evaporator 22
SE8702 Air conditioning pressure Air conditioning receiver/dryer 22
SE9801 MBCS lock cylinder ball switch Lock pin 19
Relays
Relay number Description Location Schematic No.[3]

RE2101 Pre-heat Engine compartment 3
RE3001 Accessories Console side wall 1
RE3301 Start Console side wall 3
RE3302 Ignition latch Console convenience center 21
RE3501 Cab headlight Console convenience center 9, 10
RE3502 Front headlight Console convenience center 9, 10
RE3503 Signal flasher Console convenience center 9
RE3504 EEC work light Console side wall 12
RE3601 Backup Console convenience center 16
RE3602 I-ECU Console convenience center 2
RE3603 Electronics Console convenience center 1
RE3604 Lower wipers Cab center - front behind pedestal 13
RE3901 24V –12V Equalizer Console side wall 14
RE3902 Radio Console convenience center 1
RE3903 24V - 12V 60 amp-1 equalizer Cab 14
RE3904 24V - 12V 60 amp-2 equalizer Cab 14
RE4201 Neutral start Console convenience center 3
RE5201 Brake motor Console side wall 20
RE5202 Brake no-flow Console convenience center 20
RE6401 Secondary steering Console convenience center 21
Lamps
Lamp number Description Location Schematic No.[4]

LA3501 Interior light Cab interior
LA3502 RH cab headlight Front upper cab 9
LA3503 LH cab headlight Front upper cab 9
LA3504 RH front headlight Grader nose 10
LA3505 LH front headlight Grader nose 10
LA3506 Front clearance lights Front upper cab
LA3507 Rear clearance lights Rear upper cab
LA3508 RH extra headlight Grader nose 9, 10
LA3509 LH extra headlight Grader nose 9, 10
LA3510 Work light - moldboard right Front box frame 11, 12
LA3511 Work light - moldboard left Front box frame 11, 12
LA3512 Work light - cab rear right Rear upper cab 11, 12
LA3513 Work light - cab rear left Rear upper cab 11, 12
LA3514 Work light - side front Side upper cab 11, 12
LA3515 Work light - side rear Side upper cab 11, 12
LA3601 EEC right direction indicator Drawbar 10
LA3602 EEC left direction indicator Drawbar 10
LA3603 Rotating flasher amber Upper cab 15
LA3604 Strobe flasher amber Upper cab 15
LA3605 Rotating flasher blue Upper cab 15
LA3606 Strobe flasher blue Upper cab 15
LA3607 Light pod rear right Radiator casing 20
LA3608 Light pod rear left Radiator casing 20
LA3609 Light license plate Rear frame 20
LA9101 Light float enable Pedestal 25, 26
LA9102 Light float enable Right door post 27
Solenoids
Solenoid number Description Solenoid location Schematic No.[5]

MA2301 Injector - Cam 1 Engine harness 6
MA2307 5
MA2601 Fan control solenoid Fan control valve 8
MA4201 Transmission solenoid A Transmission 16
MA4202 Transmission solenoid B Transmission 16
MA4203 Transmission solenoid D Transmission 16
MA4204 Transmission solenoid H Transmission 16
MA4205 Transmission solenoid L Transmission 16
MA4206 Transmission solenoid R Transmission 16
MA4401 AWD - DCV1 two-speed valve Frame nose 18
MA4402 AWD - DCV2 freewheeling valve Right front rear frame 18
MA4403 AWD - DCV3 LH forward bypass Frame nose 18
MA4404 AWD - DCV4 LH reverse bypass Frame nose 18
MA4405 AWD - DCV5 RH forward bypass Frame nose 18
MA4406 AWD - DCV6 RH reverse bypass Frame nose 18
MA4407 AWD - EDC (RH) Drive pump RH Drive pump 17
MA4408 AWD - EDC (LH) Drive pump LH Drive pump 17
MA4601 Hydraulic differential valve Rear harness 15
MA5501 Park brake solenoid Park brake valve 16
MA8701 Air conditioning clutch Air conditioning compressor 22
MA8702 Climate unit motorized valve Air conditioning box heater hose 22
MA9101 Hydraulic RH blade float – top RH Blade lift cylinder 25
MA9102 Hydraulic RH blade float – bottom RH Blade lift cylinder 25
MA9103 Hydraulic LH blade float – top LH Blade lift cylinder 25
MA9104 Hydraulic LH blade float – bottom LH Blade lift cylinder 25
MA9105 Hydraulic front float – top Frame nose 26
MA9106 Hydraulic front float – bottom Frame nose 26
MA9107 Hydraulic rear-1 float – top Rear attachment 27
MA9108 Hydraulic rear-1 float – bottom Rear attachment 27
MA9109 Hydraulic rear-2 float – top Rear attachment 27
MA9110 Hydraulic rear-3 float – bottom Rear attachment 27
MA9801 Hydraulic MBCS valve MBCS 15
Motors
Motor number Description Location Schematic No.[6]

MO3301 Engine starter motor Engine 1,3
MO3601 Front wiper motor Upper cab - front 13
MO3602 Rear wiper motor Upper cab - rear 13
MO3603 Lower front left wiper motor Lower front left - cab 13
MO3604 Lower front right wiper motor Lower front right - cab 13
MO3605 Front washer motor Washer reservoir 13
MO3606 Rear washer motor Washer reservoir 13
MO3607 Lower front washer pump Washer reservoir 13
MO5201 Brake master cylinder and power Right rear - below cab 20
booster assembly
MO6401 Secondary steering motor Secondary steering box 21
MO8701 Climate unit condenser fans Rear cooling module 22
MO8702 Climate unit blower motors Climate control box 22
MO8801 Left hand defrost fan Upper cab 23
MO8802 Right hand defrost fan Upper cab 23
MO9901 Tire pump motor RH side - tandem 28
Components
Component number Description Location Schematic No.[7]

AL3201 Alternator Engine 1
BA3301 12 volt battery Battery box 1
BA3302 12 volt battery Battery box 1
HE2101 Preheat element Engine 3
HE8901 RH heated mirror Upper cab 24
HE8902 LH heated mirror Upper cab 24
PO3901 12 volt power outlet RH Door post 14
PO9901 24 volt power outlet Console box - front 28
RA3901 Radio Upper cab 24
SA2701 I-ECU buzzer Pedestal 7
SA3601 Horn Upper cab 9
SA4201 Backup buzzer Rear fan door 16
SA4401 AWD buzzer AWD console 17
SO3901 25 amp converter Cab 14
SO3902 40/60/80 amp converter Cab 14
SO3903 Radio converter Upper cab 24
[1]See Electrical schematics, Wiring diagram 1
[5]See Electrical schematics, starting at Wiring diagram 1

Service Information

Wiring diagram 1 – Main 370 Service Information 9/10/2022
diagram/Positive feeds/
Chassis connections
Profile:
G780B Volvo
Wiring diagram 1 – Main diagram/Positive feeds/Chassis connections


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
No. Part Description Std./ Specification Location

designation Opt.
1 BA3301 Battery Std. 12 VDC BCI 131 Battery box
3 SW3701 Isolation switch Std. Double pole, double Front left-hand side of engine
throw compartment
4 MO3301 Starter motor Std. Output: Front of engine, right-hand side
G710B to G730B – 5.4 kW
G740B to G780B – 8.0 kW
5 AL3201 Alternator Std. 75 A standard G710B to G730B – Rear of engine
100 A optional compartment, right-hand side
Voltage out = 27.5V G740B to G780B – Rear of engine
Coil resistance 6.9 – 8.1 compartment, left-hand side
ohms
6 FU5 Fuse Std. 7.5 A Fuse panel, convenience center
7 SW3301 Ignition switch Std. 5 pole, single throw Side console switch plate
8 RE3603 Electronics relay Std. Double pole, single throw Side console, convenience center
9 RE3001 Accessory relay Std. Double pole, single throw Console sidewall
10 FU1 I-ECU fuse Std. 10 A Fuse panel, convenience center
11 FU2 Preheat fuse Std. 5A Fuse panel, convenience center
12 FU3 Gear shifter fuse Std. 3A Fuse panel, convenience center
13 FU18 Sensor feed fuse Std. 5A Fuse panel, convenience center
Figure 1

Figure 2
Service Information

Wiring diagram 1 – Main 370 Service Information 9/10/2022
diagram/Positive feeds/
Chassis connections
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
No. Part Description Std./Opt. Specification Location

designation
3 SW3701 Isolation switch Std. Double pole, double throw Front left-hand side of engine
compartment
G710B to G730B – 5.4 kW
G740B to G780B – 8.0 kW
5 AL3201 Alternator Std. 75 A standard - S/N 35000 - G710B to G730B – Rear of engine
36363 compartment, right-hand side
80 A standard - S/N 36364 G740B to G780B – Rear of engine
and up compartment, left-hand side
100 A optional
Voltage out = 27.5V
Coil resistance 6.9 – 8.1
ohms
6 FU5 Fuse Std. 7.5 A Fuse panel, convenience center
7 SW3301 Ignition switch Std. 5 pole, single throw Side console switch plate
8 RE3603 Electronics relay Std. Double pole, single throw Side console, convenience center
9 RE3001 Accessory relay Std. Double pole, single throw Console sidewall
12 FU3 Gear shifter fuse Std. 3A Fuse panel, convenience center
14 RE3902 Radio relay Opt. Double pole, single throw Side console, convenience center
Figure 1
Circuit No. Color Description

1 Red Battery output
1B Red Cab feed
12B White 12V equalizer output
12T Purple Equalizer relay feed
15EA Red/white Electronics relay output
25 Brown/blue AWD RPM signal
74 Red Accessory relay output
24V Red (CH) Feed from fuse 18
Red/light green (FH)
Brown/dark blue (RH)
BS Red/white Battery sense input
CHG Green 12V battery charge
DR Red/blue Electronics relay control
P14 Red Radio relay output
P119 Brown/white (FH) Alternator charge indicator
Orange (FH)
RA Orange Radio relay control
GND Black ground/earth
FH = Front harness
RH = Rear harness
Wiring diagram 1 - Main diagram/Positive feeds/Chassis connections
Figure 2
S/N 35061 and up, including 35050 and 35051

Service Information

Wiring diagram 2 – Positive 370 Service Information 9/10/2022
feed/Chassis connection I-
ECU/E-ECU
Profile:
G780B Volvo
Wiring diagram 2 – Positive feed/Chassis connection I-ECU/E-ECU


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
2 FU7 I-ECU switched Std. 10 A Fuse panel, convenience center
fuse
3 FU8 E-ECU switched Std. 20 A Fuse panel, convenience center
fuse
4 RE3602 I-ECU relay Std. Single pole, double throw Convenience center
Figure 1
Figure 2
Service Information

Wiring diagram 2 – Positive 370 Service Information 9/10/2022
feed/Chassis connection I-
ECU/E-ECU
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation
2 FU7 I-ECU switched fuse Std. 10 A Fuse panel, convenience center
3 FU8 E-ECU switched fuse Std. 20 A Fuse panel, convenience center
4 RE3602 I-ECU relay Std. Single pole, double throw Convenience center
Figure 1
1B Red Cab feed
CC Red/black E-ECU power feed
CO White E-ECU ground/earth
DF Red/black E-ECU power feed
DG White E-ECU ground/earth
DH Red/black E-ECU power feed
DJ White Ground/earth
EGN Red (FH) I-ECU ground/earth
Black (RH)
EM9 Red/white (CH) E-ECU power feed
White (RH)
P11 Red Fuse 7 and 8 feed
Brown/yellow (CH)
P114 Yellow/red (FH) I-ECU power feed
Orange/black (CH)
P130 Green/orange (FH) I-ECU power feed
Red/brown (CH)
P321 Black (FH) I-ECU relay ground control
GND Black Ground/earth
CH = console harness
FH = front harness
RH = rear harness
Wiring diagram 2 - Positive feed/Chassis connection I-ECU/E-ECU
Figure 2

Service Information

Wiring diagram 3 – Engine 370 Service Information 9/10/2022
Profile:
G780B Volvo
Wiring diagram 3 – Engine


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation
1 SW3301 Starter/ignition Std. 5 pole, single throw Console switch plate
switch
2 SW5501 Parking brake switch Std. Double pole, double throw Pedestal
NO
3 SW4201 Transmission gear Std. 1. Triple pole, single throw Side console
shifter switch 2. Double pole, single throw
Momentary, normally
neutral (off)
4 RE3301 Start relay Std. Single pole, single throw Console side wall
5 RE4201 Neutral start relay Std. Single pole, single throw Console convenience center
G710B to G730B – 5.4 kW
G740B to G780B – 8.0 kW
8 SW2101 Pre-heat switch Std. Single pole, single throw Side console switch plate
NO, momentary
9 FH2 Preheat control lamp Std. 125 A In line engine harness
fuse
10 FH1 Preheat main power Std. 5A Under fuel tank, right-hand side
fuse
11 RE2101 Preheat relay Std. Double pole, single throw Engine compartment under fuel tank,
right-hand side
12 HE2101 Preheat element Std. _ amps In engine intake manifold
Figure 1

1B Red Cab feed
3 Pink Start solenoid feed
121 Pink Neutral start relay control
169 Red/orange Starter motor control circuit
169A Light blue/white Starter motor control circuit
170 Red Starter motor control circuit
1B Red Cab feed
19 Red/black Preheat element feed
31A Purple/grey (CH,RH) Switch lighting
Purple/white (FH, AWD CH)
CH Light blue/red Preheat relay activation
CK Red I-ECU preheat indicator
DQ Light green/white I-ECU preheat indicator
DR Light green/white E-ECU preheat indicator
DW Black Preheat relay feed
EM6 Red/white (CH) Preheat relay feed
Purple (RH)
P104 Brown (FH) I-ECU preheat indicator
Light blue/red (RH)
P218 Brown/grey (CH) Preheat I-ECU switch input
Red (FH)
Wiring diagram 3 - Engine

Figure 2

Service Information

Wiring diagram 3 – Engine 370 Service Information 9/10/2022
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 SW3301 Starter/ignition Std. 5 pole, single throw Console switch plate
switch
2 SW5501 Parking brake Std. Double pole, double Pedestal
switch throw
NO
3 SW4201 Transmission gear Std. 1. Triple pole, single throw Side console
shifter switch 2. Double pole, single
throw
Momentary, normally
neutral (off)
4 RE3301 Start relay Std. Single pole, single throw Console side wall
5 RE4201 Neutral start relay Std. Single pole, single throw Console convenience center
G710B to G730B – 5.4 kW
G740B to G780B – 8.0 kW
8 SW2101 Pre-heat switch Std. Single pole, single throw Side console switch plate
NO, momentary
9 FH2 Preheat control Std. 125 A In line engine harness
lamp fuse
10 FH1 Preheat main Std. 5A Under fuel tank, right-hand side
power fuse
11 RE2101 Preheat relay Std. Double pole, single throw Engine compartment under fuel
tank, right-hand side
Figure 1

Figure 2
Service Information

Wiring diagram 4 – D7 370 Service Information 9/10/2022
Engine ECU
Profile:
G780B Volvo
Wiring diagram 4 – D7 Engine ECU


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Service Information

Engine ECU
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation
1 SE2603 Engine coolant level Std. R = (open) level normal Coolant expansion tank
R = (closed) level low
2 SE2502 Air filter restriction Std. R = 330 ohms (not clogged) Air cleaner outlet tube
R = 2.2k ohms (clogged)
3 SE2501 Induction air Std. R = 16.3 k ohms (0° - 32°F) Air cleaner outlet tube
temperature R = 6.2 k ohms (20°C - 68°F)
4 SE2703 Camshaft frequency Std. R = 1.2 k ohms Engine left side (above flywheel
housing)
5 SE2701 Engine speed Std. R = 0.9 k ohms Behind engine crankshaft vibration
damper
6 SE2507 Charge air Std. R = 5.5 k ohms (0°C - 32° F) Engine inlet manifold (by preheat
temperature sensor R = 2.4 k ohms (20°C - 68° F) housing)
7 SE2306 Fuel temperature Std. R = 0.76 - 12.1 k ohms Injector fuel tube (between 5 and 6
depending on temperature injector)
8 SE2606 Coolant temperature Std. R = 0.76 - 12.1 k ohms Engine head (above flywheel)
depending on temperature
9 SE2203 Engine oil pressure Std. V = 0.5V(engine OFF) Engine left side (at engine oil cooler)
V = 4.5V (fuel pressure) 10
bar/145 psi
10 SE2508 Charge air pressure Std. V = 1.1V (engine OFF) at 0 Engine inlet manfold (above flywheel)
meters sea level)
NOTE!
D7 charge air temperature sensor SE2507 and charge air pressure sensor SE2508 were combined into one sensor at G710B S/N
36743, G720B S/N 36681, G726B S/N 36820 and G730B S/N 36829

AD Brown Charge air pressure signal
AG Light green Charge air temperature (+)
AJ Yellow/white Coolant temperature (+)
AL Light green Fuel temperature (+)
AM Brown/white Sensor - ground/earth
AP Light blue/black Crankshaft speed (-)
AR Light green/white Engine oil pressure and charge air
pressure (+)
AT Light blue/red Crankshaft speed (+)
AV Light green Engine oil pressure signal
CA Yellow Camshaft speed (+)
CB Brown/white Camshaft speed (-)
CD Light blue/black Coolant level sensor - ground/earth
CE Light blue/black Coolant level sensor (+)
CR Purple/white Ambient air temperature sensor -
ground/earth
CV Grey/white Air filter restriction sensor - ground/earth
CW Grey/white Air filter restriction sensor signal
CY Light blue/yellow Ambient air temperature sensor (+)
CZ Grey/white Sensor - ground/earth
FA Light green/white Charge air pressure sensor (+)
FB Light green/white Engine oil pressure (+)
FC Brown/white Camshaft sensor shield
FD Brown/white Charge air sensor - ground/earth
FE Brown/white Coolant temperature sensor - ground/
earth
FF Brown/white Charge air temperature sensor - ground/
earth
FG Brown/white Crankshaft speed sensor shield
FH Brown/white Fuel temperature sensor - ground/earth
FJ Brown/white Engine oil pressure sensor - ground/
earth
Wiring diagram 4 - D7 Engine ECU

Figure 1

Service Information

Engine ECU
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

description Opt.
1 SE2603 Engine coolant Std. R = (open) normal level Coolant expansion tank
level R = (closed) low level
2 SE2502 Air filter restriction Std. R = 330 ohms (not Air cleaner outlet tube
(combined clogged)
with SE2501) R = 2.2 k ohms (clogged)
3 SE2501 Induction air Std. R = 16.3 k ohms (0°C - 32° Air cleaner outlet tube
(combined temperature F)
with SE2502) R = 6.2 k ohms (20°C - 68°
F)
4 MA2307 Fuel shutdown Std. R = 40 ohms Injection pump
solenoid
5 SE2308 Needle movement Std. R = 65 - 165 ohms Injector 1
sensor (number 1
injector only)
6 SE2703 Camshaft Std. R = 775 - 945 ohms Injection pump
frequency sensor
7 SE2701 Engine speed Std. R = 775 - 945 ohms Flywheel housing (upper side)
sensor
8 SE2202 Engine oil Std. R = 100 ohms (100°C - Engine left side
(combined temperature 212° F
with SE2203) R = 1.9 k ohms (20°C - 68°
F)
9 SE2507 Charge air Std. R = 16.2 k ohms (0°C - 32° Engine left side (center of air
(combined temperature F) intake housing)
with SE2508) R = 6.2 k ohms (20° - 68°
F)
10 SE2306 Fuel temperature Std. R = 100 ohms (100°C - Injection pump
(combined 212°F
with SE2301) R = 1.9k ohms (20°C - 68°
F)
11 SE2606 Coolant Std. R = 1.9 k ohms (20°C - 68° Engine left side (in thermostat and
temperature F) water pump housing)
R = 160 ohms (85°C - 185°
F)
12 SE2203 Engine oil pressure Std. V = 0.5V (engine OFF) Engine left side
(combined V = 4.5V (oil pressure) 7
with SE2202) bar/101.5 psi
13 SE2508 Charge air pressure Std. V = 1.1V (engine OFF) at 0 Engine left side (center of air
(combined meters sea level intake housing)
with SE2507) V = 4.5V (charge air
pressure) 4 bar/ 58 psi
14 SE2301 Fuel pressure Std. V = 0.5V (engine OFF) Injection pump
(combined V = 4.5V (fuel pressure) 7
with SE2306) bar/101.5 psi

AD Green Charge air pressure signal
AE Brown/white Charge air sensor (-)
AF Green/white Fuel pressure sensor (+)
AG Blue/white Charge air temperature sensor (+)
AH Brown/white Engine coolant temperature sensor (-)
AJ Yellow/white Engine coolant temperature sensor (+)
AL Green Fuel temperature sensor (+)
AM Brown/white Sensor (-)
AN Brown/white Fuel pressure sensor signal
AO Brown/white Oil sensor (-)
AP Blue/black Engine speed sensor (-)
AR Green/white Sensor (+)
AS Green/white Oil pressure sensor (+)
AT Blue/red Engine speed sensor (+)
AU Green Oil temperature sensor (+)
AV Brown Oil pressure sensor signal
AX Green/black Injector 1 needle movement sensor (+)
AY Green/red Injector 1 needle movement sensor (-)
AZ Brown/white Fuel sensor (-)
CA Yellow Engine camshaft speed sensor (+)
CB Brown/white Engine camshaft speed sensor (-)
CD Blue/black Coolant level sensor (-)
CE Blue/black Coolant level sensor (+)
CR Purple/white Ambient air temperature sensor (-)
CV Green/white Air filter restriction sensor (-)
CW Green/white Air filter restriction sensor (+)
CY Blue/yellow Ambient air temperature sensor (+)
CZ Green/white Sensor (-)
DF Shut down solenoid (+)
DL Shut down solenoid (+)
Wiring diagram 5 - D10 Engine ECU
Figure 1
Service Information

Engine ECU
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Service Information

Wiring diagram 6 – D7, D10 370 Service Information 9/10/2022
Engine ECU
Profile:
G780B Volvo
Wiring diagram 6 – D7, D10 Engine ECU


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation
1 MA2304 Injector cam 4 Std. Engine harness Engine
7 Std.
8 Std.
9 Std.
10 Std.
11 Std.
12 Std.
Figure 1

BA White Unit injector 1, 2, 3 (+)
BC White Unit injector 1 (+)
BD White Unit injector 2 (+)
BE White Unit injector 3 (+)
BF White Unit injector 4, 5, 6 (+)
BH White Unit injector 4 (+)
BJ White Unit injector 5 (+)
BK White Unit injector 6 (+)
BL White Unit injector cyl. 1 (-)
BM White Unit injector cyl. 2 (-)
BN White Unit injector cyl. 3 (-)
BO White Unit injector cyl. 4 (-)
BP White Unit injector cyl. 5 (-)
BR White Unit injector cyl. 6 (-)
AA Yellow/white Rack position sensor
AB Yellow/green Rack position sensor
AK Orange Timing sleeve (-)
DM Yellow/red Rack drive PWM (+)
DP Green/brown Rack drive PWM (-)
DS Blue/red Rack position sensor
DT Yellow/black Timing sleeve (+)
Wiring diagram 6 - D7, D10 Engine ECU

Figure 2

Service Information

Wiring diagram 6 – D7, D10 370 Service Information 9/10/2022
Engine ECU
Profile:
G780B Volvo
Wiring diagram 6 – D7, D10 Engine ECU


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Service Information

Wiring diagram 7 – 370 Service Information 9/10/2022
Accelerator pedal/Fuel level
Profile:
G780B Volvo
Wiring diagram 7 – Accelerator pedal/Fuel level


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
No. Part designation Description Std./Opt. Specification Location

1 SE2702 Accelerator pedal Std. Sensor resistance: Fuse panel,
sensor 2.5 ± 10% kohms convenience center
Vref = 5 ±0.05 VDC
Output voltage:
0% rotation – 13%
±2% of Vref
100% rotation –
77% ±2% of Vref
IVS signal = 24V =
Idle signal active at
P2.13 of I-ECU
2 SA2701 Buzzer Std. Pedestal
3 SE2302 Fuel level sensor Std. Resistance to Top of fuel tank
ground (no load)
Empty: 240 - 260
ohms
Full: 27.5 - 39.5
ohms
4 I-ECU Instrument Std. Instrument display
electronic control panel
unit
5 R2301 Resistor Std. 100 ohms Harness, top of
tank
6 SE3801 Speed sensor Opt. Transmission
output
Figure 1

119 Red/white Transmission display (+)
31A Purple/grey (CH, RH) Switch lighting

Purple/white (FH, AWD CH)
P119 Brown/white (FH) Alternator charge indicator
Orange (RF)
P126 Black/pink (FH) Speedometer signal
Orange/black (RF)
P210 Pink/orange Display lighting
P213 Orange/blue Idle position input
P303 White/red Accelerator pedal sensor - ground/earth
P309 Yellow/red Accelerator pedal sensor signal
P310 White Accelerator pedal sensor (+)
P314 Red (FH) Fuel level sensor (+)
Yellow/red (RH)
P315 Dark green Speedometer sensor and idle position
sensor feed
P316 Light blue Buzzer feed
Ground Black Ground/earth
FH = front harness
RH = rear harness
AWD CH = AWD console harness
Wiring diagram 7 - Accelerator pedal/Fuel level
Figure 2

Service Information

Accelerator pedal/Fuel level
Profile:
G780B Volvo
Wiring diagram 7 – Accelerator pedal/Fuel level


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
SE2701 Accelerator Std. Sensor resistance: 2.5 10% kohms Fuse panel, convenience
pedal sensor Vref = 5 0.05 VDC center
Output voltage:
0% rotation – 13% 2% of Vref
100% rotation – 77% 2% of Vref
IVS signal = 24V = Idle signal
active at P2.13 of I-ECU
SA4401 Buzzer Std. Pedestal
SE2301 Fuel level sensor Std. Resistance to ground (no load) Top of fuel tank
Empty: 240 – 260 ohms
Full: 27.5 – 39.5 ohms
I-ECU Instrument Std. Instrument display panel
electronic
control unit
Figure 1
Wiring diagram 7 – Accelerator pedal, fuel level

Figure 2
Service Information

Wiring diagram 8 – Fan ECU 370 Service Information 9/10/2022
Profile:
G780B Volvo
Wiring diagram 8 – Fan ECU


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation
1 FU15 Turn signal/Horn Std. 10 A Fuse panel, convenience center
2 SE2604 Charge air Std. Operating temperature range: 50 – Charge air cooler outlet
temperature fan 125ºC (122 – 257ºF)
control sensor Resistance: 811 to 77 ohms
3 SE2607 Water coolant Std. Temperature Resistance Intake to radiator
temperature fan 25ºC (77ºF) – 2252 ohms 5%
control sensor 50ºC (122ºF) – 811 ohms 5%
80ºC (176ºF) – 283 ohms 5%
100ºC (212ºF) – 153 ohms 5%
125ºC (257ºF) – 77 ohms 5%
4 SE2605 Hydraulic oil Std. Temperature Resistance Hydraulic tank, lower front,
temperature fan 25ºC (77ºF) – 2252 ohms 5% left-hand side
80ºC (176ºF) – 283 ohms 5%
100ºC (212ºF) – 153 ohms 5%
125ºC (257ºF) – 77 ohms 5%
5 MA2601 Fan control valve Std. Minimum current = 0.15 A at 500 rpm Below frame in front of
solenoid Maximum current = 0.85 A at hydraulic tank, right-hand side
1750 rpm
6 Fan ECU Fan electronic Std. Below radiator enclosure, left-
control unit hand side in front of fan
7 SW2601 Fan test Std. Connector that comes apart Left side, rear of engine
compartment
Figure 1

81A Light green/red Feed from fuse 17
J102 Red Fan ECU power feed
J103 Orange/red Fan control solenoid (+)
J104 Yellow Fan control solenoid (-)
J105 Light green Fan test switch (-)
J106 Light blue Fan test switch (+)
J109 White/black Charge air temperature sensor (+)
J110 Black/red Charge air temperature sensor (-)
J111 Yellow/black Water coolant temperature sensor (+)
J112 Green/red Water coolant temperature sensor (-)
J113 Red/black Hydraulic oil temperature sensor (+)
J114 Red/light green Hydraulic oil temperature sensor (-)
Ground Black Fan ECU - ground/earth
Wiring diagram 8 - Fan ECU

Figure 2

Service Information

Wiring diagram 8 – Fan ECU 370 Service Information 9/10/2022
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU15 Turn signal/Horn Std. 10 A Fuse panel, convenience
center
2 SE2604 Charge air Std. Operating temperature range: 50º– Charge air cooler outlet
temperature fan 125ºC (122 – 257ºF)
control sensor Resistance: 811 to 77 ohms
3 SE2603 Water coolant Std. Temperature Resistance Intake to radiator
temperature fan 25ºC (77ºF) – 2252 ohms 5%
80ºC (176ºF) – 283 ohms 5%
100ºC (212ºF) – 153 ohms 5%
125ºC (257ºF) – 77 ohms 5%
4 SE2605 Hydraulic oil Std. Temperature Resistance Hydraulic tank, lower front,
temperature fan 25ºC (77ºF) – 2252 ohms 5% left-hand side
80ºC (176ºF) – 283 ohms 5%
100ºC (212ºF) – 153 ohms 5%
125ºC (257ºF) – 77 ohms 5%
5 MA2601 Fan control valve Std. Minimum current = 0.15 A at Below frame in front of
solenoid 500 rpm hydraulic tank, right-hand
Maximum current = 0.85 A at side
1750 rpm
6 Fan ECU Fan electronic Std. Below radiator enclosure,
control unit left-hand side in front of fan
Figure 1

Figure 2
Service Information

Headlights/Turn signals/
Horn
Profile:
G780B Volvo
Wiring diagram 9 – Headlights/Turn signals/Horn


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

1 FU15 Turn signal/horn Std. 7.5 A Fuse panel,
fuse convenience center
2 FU16 Flasher signal fuse Std. 7.5 A Fuse panel,
convenience center
3 FU13 Headlights fuse Std. 15 A Fuse panel,
convenience center
4 FU14 Extra headlights Opt. 15 A Fuse panel,
5 RE3503 Signal flasher relay Std. Convenience center
6 SW3502 Headlights and EEC Std. Single pole, double Side console switch
parking lights throw 3 position plate
switch, double LED
7 SW3503 Extra headlights Opt. Single pole, single Side console switch
switch throw NO plate
8 SW3601 Turn signal/high- Std. 3 function switch Pedestal
low beam/horn - NO, push button
switch (in)
NO, push forward
- double pole,
single throw,
normally neutral
9 SW3602 Hazard light switch Std. Single pole, single Pedestal switch
throw, NO, double plate
LED
10 RE3501 Headlight relay Std. Double pole, single Convenience center
throw
11 FU12 Cab headlights Std. 15 A Convenience center
12 RE3502 EEC and extra front Opt. Double pole, single Convenience center
headlights relay throw
13 SA3601 Horn Opt. 24 V (450 Hz) Front upper cab
14 LA3502 Headlight, front Std. H4 - 24 V x 70 W Front upper cab
right
15 LA3503 Headlight, front left Std. H4 - 24 V x 70 W Front upper cab
16 LA3509 Extra headlight, Opt. H4 - 24 V x 70 W Grader nose
front left
17 LA3508 Extra headlight, Opt. H4 - 24 V x 70 W Grader nose
front switch
18 SW3602 Hazard switch Std. Double pole, single Pedestal switch
throw plate
Figure 1

5 Yellow Park light fuse - 15, 16 feed
11 Light blue/red (CH) (FH) (UCH) Left turn signal bulb feed
Yellow/dark blue (RH) (TH)
12 Dark blue/white (CH) (FH) Right turn signal bulb feed
Dark green (RH) (TH) Dark blue (UCH)
15 Light green Cab headlights high beam
16 Yellow (UCH) Cab headlights low beam
Tan (CH)
43 Light green/red (FH) Front headlights low beam
Dark green/red (AHH)
44 Light green (CH) Front headlights high beam
Tan/red (FH) (AHH)
46 Light blue/white Cab headlight relay control
74 Red Power feed from accessory relay
91 Red/white Turn signal flasher output
1B Red Cab feed
2A Black/yellow Horn feed
31A Purple/grey (CH) (RH) Switch lighting
Purple/white (FH) (AWD CH) (AWD FH)
46A Light blue/white Extra headlight relay feed
5L Yellow/dark green Left taillight bulb feed
5R Yellow/red Right taillight bulb feed
61A Light green/black (CH) High beam relay control
Orange/light green (FH)
76A Orange/black Cab headlight switch feed
77B Black/pink Front headlight switch feed
91A Red/white Feed from fuse 16
91L Red/white Left side hazard switch output
91R Red/white Right side hazard switch output
P116 Purple Turn signal indicator input
P117 Brown/purple (CH) High beam indicator input
Purple/orange (FH)
P3 Red Fuse 12 feed
P4 Red Fuse 13 feed
FH = front harness
RH = rear harness
AWD FH = AWD front harness
AHH = auxiliary headlight harness
UCH = upper cab harness
TH = taillight harness

designation
12 RE3502 EEC and extra front Opt. Double pole, single throw Convenience center
headlights relay
13 SA3601 Horn Opt. Front upper cab
14 LA3502 Headlight, front right Std. Front upper cab
15 LA3503 Headlight, front left Std. Front upper cab
16 LA3509 Extra headlight, front Opt. Grader nose
left
17 LA3508 Extra headlight, front Opt. Grader nose
right
18 SW3602 Hazard switch Std. Pedetsal switch plate
Figure 2
Wiring diagram 9 - Headlights/Turn signals/Horn
Figure 3

Service Information

Headlights/Turn signals/
Horn
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU15 Turn signal/horn Std. 7.5 A Fuse panel, convenience center
fuse
2 FU16 Flasher signal fuse Std. 7.5 A Fuse panel, convenience center
3 FU13 Headlights fuse Std. 15 A Fuse panel, convenience center
4 FU14 Extra headlights Opt. 15 A Fuse panel, convenience center
fuse
5 RE3503 Signal flasher relay Std. Convenience center
6 SW3502 Headlights and EEC Std. Single pole, double throw Side console switch plate
parking lights 3 position switch,
double LED
7 SW3503 Extra headlights Opt. Single pole, single throw Side console switch plate
switch NO
8 SW3601 Turn signal/high- Std. 3 function switch Pedestal
low beam/horn – NO, push button (in)
switch – NO, push forward
– double pole, single
throw, normally neutral
9 SW3602 Hazard light switch Std. Single pole, single throw, Pedestal switch plate
NO, double LED
10 RE3501 Headlight relay Std. Double pole, single throw Convenience center
Figure 1

description Opt.
11 RE3502 EEC and extra front Opt. Double pole, single throw Convenience center
headlights relay
12 SA3601 Horn Opt. Front upper cab
13 LA3502 Headlight, front Std. Front upper cab
right
14 LA3503 Headlight, front left Std. Front upper cab
15 LA3509 Extra headlight, Opt. Grader nose
front left
16 LA3508 Extra headlight, Opt. Grader nose
front right
Figure 2

Figure 3
Service Information

Wiring diagram 10 – EEC 370 Service Information 9/10/2022
Headlights and flashers
Profile:
G780B Volvo
Wiring diagram 10 – EEC Headlights and flashers


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

1 FU13 Extra headlights Opt. 15 A Fuse panel,
2 FU12 Headlights fuse Std. 15 A Fuse panel,
convenience center
3 SW3502 Headlights and EEC Opt. Single pole, double Side console switch
parking lights throw, 3 position, plate
switch double LED, NO
4 SW3503 Extra headlights Opt. Single pole, single Side console switch
switch throw double LED plate
(NO)
5 RE3502 EEC and extra front Opt. Double pole, single Side console
headlights relay throw convenience center
6 RE3501 Headlight relay Opt. Double pole, single Side console
throw convenience center
7 LA3504 EEC headlight, front Opt. 24 V - 70W Grader nose
right
8 LA3505 EEC headlight, front Opt. 24 V - 70W Grader nose
left
9 LA3508 RH Extra headlight Opt. 24 V - 70W Front upper cab
10 LA3509 LH Extra headlight Opt. 24 V - 70W Front upper cab
11 LA3601 EEC right-hand Opt. 24 V - 70W Drawbar
directional
indicator
12 LA3602 EEC left-hand Opt. 24 V - 70W Drawbar
directional
indicator
Figure 1

5 Yellow Park light fuse 15, 16 feed
11 Light blue/red (CH) (FH) (UCH) (EEC HH) Left turn signal bulb feed
Yellow/dark blue (RH) (EEC TH)
12 Dark blue/white (CH) (FH) Right turn signal bulb feed
Dark green (RH) (EEC TH)
Dark blue (UCH) (EEC HH)
15 Light green Extra headlights high beam
16 Tan (CH) Extra headlights low beam
Yellow (UCH)
43 Tan (CH) EEC headlights low beam
Light green/red (FH)
Dark green/red (EEC HH)
44 Light green (CH) EEC headlights high beam
Tan/red (FH) (EEC HH)
46 Light blue/white Extra headlight relay feed
46A Light blue/white EEC headlight relay feed
61A Light green/black (CH) High beam relay control
Orange/light green (FH)
76A Orange/black Extra headlight switch feed
77B Black/pink EEC headlight switch feed
P3 Red Fuse 12 feed
P4 Red Fuse 13 feed
FH = front harness
RH = rear harness
EEC HH = EEC headlight harness
EEC TH = EEC tail light harness
Wiring diagram 10 - EEC Headlights and flashers
Figure 2

Service Information

Headlights and flashers
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU14 Extra headlights Opt. 15 A Fuse panel, convenience center
fuse
2 FU13 Headlights fuse Std. 15 A Fuse panel, convenience center
3 SW3502 Headlights and EEC Opt. Single pole, double throw, Side console switch plate
parking lights 3 position, double LED,
switch NO
4 SW3503 Extra headlights Opt. Single pole, single throw Side console switch plate
switch double LED (NO)
5 RE3502 EEC and extra front Opt. Double pole, single throw Side console convenience center
headlights relay
6 RE3501 Headlight relay Opt. Double pole, single throw Side console convenience center
7 LA3504 EEC headlight, Opt. Grader nose
front right
8 LA3505 EEC headlight, Opt. Grader nose
front left
9 LA3502 Headlight, front Opt. Front upper cab
right
10 LA3503 Headlight, front left Opt. Front upper cab
11 LA3601 EEC right-hand Opt. Drawbar
directional
indicator
12 LA3602 EEC left-hand Opt. Drawbar
directional
indicator
Figure 1

Figure 2
Service Information

Wiring diagram 11 – Work 370 Service Information 9/10/2022
lights
Profile:
G780B Volvo
Wiring diagram 11 – Work lights


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU24 Rear work lights Opt. 7.5 A Fuse panel, convenience center
fuse
2 FU25 Moldboard work Opt. 15 A Fuse panel, convenience center
lights fuse
3 SW3505 Rear floodlights Opt. Single pole, single throw Console switch panel
switch Double LED
4 SW3504 Moldboard work Opt. Single pole, single throw Console switch panel
lights switch Double LED
5 SW3506 Side wing work Opt. Single pole, single throw Console switch panel
6 LA3512 Work light, cab Opt. H3 24V/70W bulb Rear upper cab
right rear
7 LA3513 Work light, cab left Opt. H3 24V/70W bulb Rear upper cab
rear
8 LA3510 Work light, Opt. H3 24V/70W bulb Front box frame
moldboard right
moldboard left
10 LA3514 Work light, side Opt. H3 24V/70W bulb Side upper cab
front
rear
Figure 1

8 Grey Moldboard worklight feed
32 Brown Side worklight feed
36 Tan/black Rear worklight feed
31A Purple/grey (CH RH) Switch lighting
Purple/white (FH) (AWD CH)
77A Pink/white Worklight switch feed from fuse 25
80A Red/black Rear worklight switch feed from fuse 24
RH = rear harness
FH = front harness
Wiring diagram 11 - Work lights
Figure 2

Service Information

Wiring diagram 11 – Work 370 Service Information 9/10/2022
lights
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

description Opt.
1 FU24 Rear work lights Opt. 7.5 A Fuse panel, convenience center
fuse
lights fuse
3 SW3505 Rear floodlights Opt. Single pole, single throw Console switch panel
switch Double LED
4 SW3504 Moldboard work Opt. Single pole, single throw Console switch panel
5 SW3506 Side wing work Opt. Single pole, single throw Console switch panel
6 LA3512 Work light, cab Opt. H3 24V/70W bulb Rear upper cab
right rear
7 LA3513 Work light, cab left Opt. H3 24V/70W bulb Rear upper cab
rear
moldboard right
moldboard left
front
11 LA3515 Work light, side Opt. Side upper cab
rear
Figure 1

Figure 2
Service Information

Worklights
Profile:
G780B Volvo
Wiring diagram 12 – EEC Worklights


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
lights fuse
2 RE3504 EEC Work light Opt. Double pole, single throw Console side wall
relay
3 SW3504 Moldboard Opt. Single pole, single throw, Side console switch plate
floodlights switch double LED
4 SW3506 Side wing flood Opt. Single pole, single throw, Side console switch plate
lights switch double LED
5 LA3510 Work light, Opt. H3 24V/70 W bulb Front box frame
moldboard right
moldboard left
7 LA3514 Work light, side Opt. H3 24V/70 W bulb Side of upper cab
front
rear
9 FU24
10 LA3513
11 LA3512
Figure 1

Figure 2
Service Information

Worklights
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
lights fuse
2 RE3504 EEC Work light Opt. Double pole, single throw Console side wall
relay
3 SW3504 Moldboard Opt. Single pole, single throw, Side console switch plate
floodlights switch double LED
4 SW3506 Side wing flood Opt. Single pole, single throw, Side console switch plate
lights switch double LED
moldboard right
moldboard left
front
rear
9 FU24 Rear work lights Opt. 7.5 A Rear upper cab
10 LA3513 Work lights, cab Opt. H3 24V/70W bulb Upper cab
rear
11 LA3512 Work lights, cab Opt. H3 24V/70W bulb Upper cab
rear
Figure 1

8 Grey Moldboard worklight feed
32 Brown Side worklight feed
36 Tan/black Rear worklight feed
Purple/white (FH AWD CH)
77A Pink/white Worklight switch feed from fuse 25
80A Red/black Rear worklight switch feed from fuse 24
5L Yellow/dark green Left side taillight feed
P10 Red Work light relay feed
RH = rear harness
FH = front harness
Wiring diagram 12 - EEC Worklights
Figure 2

Service Information

Windshield wiper systems
Profile:
G780B Volvo
Wiring diagram 13 – Windshield wiper systems


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU21 Front wiper fuse 5A Fuse panel, convenience center
2 FU22 Rear wiper fuse 5A Fuse panel, convenience center
3 RE3604 Lower wiper relay 8 pole, quad throw
4 SW3605 Front wiper/washer Push button washer Side console switch panel
switch – 2 pole, single throw
– 3 position wiper
5 SW3606 Rear wiper/washer Push button washer Side console switch panel
6 SW3607 Lower front wiper/ Push button washer Side console switch panel
washer switch – 2 pole, single throw
7 MO3601 Front wiper motor 24 V, 93º wipe angle At wiper
8 MO3602 Rear wiper motor 24 V, 93º wipe angle At wiper
9 MO3603 Lower left wiper Fixed: 24 VDC At wiper
motor 1 speed - 60 rpm, no, load
10 MO3604 Lower right wiper Fixed: 24 VDC At wiper
11 MO3605 Front washer motor At washer reservoir, left-hand side
below fuel tank
12 MO3606 Rear washer motor At washer reservoir, left-hand side
below fuel tank
13 MO3607 Lower front washer At washer reservoir, left-hand side
motor below fuel tank
Figure 1

Figure 2
Service Information

Windshield wiper systems
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU21 Front wiper fuse Std. 5A Fuse panel, convenience center
2 FU22 Rear wiper fuse Opt. 5A Fuse panel, convenience center
3 FU23 Lower wiper fuse Opt. 7.5 A Fuse panel, convenience center
4 RE3604 Lower wiper relay Opt. 8 pole, quad throw
5 SW3605 Front wiper/washer Std. Push button washer Side console switch panel
6 SW3606 Rear wiper/washer Opt. Push button washer Side console switch panel
7 SW3607 Lower front wiper/ Opt. Push button washer Side console switch panel
washer switch – 2 pole, single throw
8 MO3601 Front wiper motor Std. 24 V, 93º wipe angle At wiper
9 MO3602 Rear wiper motor Opt. 24 V, 93º wipe angle At wiper
10 MO3603 Lower left wiper Opt. Fixed: 24 VDC At wiper
11 MO3604 Lower right wiper Opt. Fixed: 24 VDC At wiper
12 MO3605 Front washer motor Std. 24 VDC At washer reservoir, left-hand side
below fuel tank
13 MO3606 Rear washer motor Opt. 24 VDC At washer reservoir, left-hand side
below fuel tank
14 MO3607 Lower front washer Opt. 24 VDC At washer reservoir, left-hand side
motor below fuel tank
Figure 1

40 Light blue Front wiper high speed feed
41 Dark blue/tan Front wiper low speed feed
42 White/dark blue Front wiper park feed
70F Orange/light green Front washer motor feed
75A Red/yellow Front wiper switch feed
P2 Red Fuse 21 and 22 feed
66 Light blue/black Rear wiper high speed feed
67 White/black Rear wiper low speed feed
68 White/pink Rear wiper park feed
70R Grey/red (CH) Rear washer motor feed
White/light green (RH)
75B Red/light green Rear wiper switch feed
176 Tan/dark blue (CH) (WH) Lower wiper motor park feed
Dark blue/yellow (FH)
70L White/dark green (CH) Lower washer motor feed
Grey/red (RH)
176A Red Lower wiper motor switch feed
176B White Lower RH wiper motor feed
176C Tan/light green (CH) (WH) Lower LH wiper motor feed
Brown/white (FH)
176 Tan/dark blue (CH) Lower wiper motor park feed
Dark blue/yellow
176A Red Lower wiper motor switch feed
180 Orange Lower RH wiper motor feed
181 Black/white Lower RH wiper ground
182 Orange Lower LH wiper motor feed
183 Black/white Lower LH wiper motor ground
70L White/dark green (CH) Lower washer motor feed
Grey/red (RH)
RH = rear harness
FH = front harness
WH = wiper harness
Wiring diagram 13 - Windshield wiper systems
Figure 2
Service Information

Wiring diagram 14 – 25 370 Service Information 9/10/2022
amp/60 amp converter/
equalizer
Profile:
G780B Volvo
Wiring diagram 14 – 25 amp/60 amp converter/equalizer


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 RE3901 Relay – 24 - 12V Std. Single pole, double throw Console side wall
equalizer
2 RE3903 Relay – 24 - 12V Std. Single pole, double throw
equalizer
3 FU30 12 volt power Std. 15 amp Convenience center
outlet fuse
4 RE3904 Relay – 24 - 12V Std. Single pole, double throw
equalizer
5 SO3902 40/60/80 A Std. 40/60/80 amp Cab rear - lower left
converter
6 SO3901 25 A converter Std. 25 amp Cab floor - behind operator's seat
7 PO3901 12 V power outlet, Std. Right door post
1 cigar lighter
Figure 1

7 White 24V feed
9 Red 12V balancer
27 Red Fuse 30 feed
28 Grey Power outlet feed
318 Red/white 24V feed
CHG Dark green 12V battery charge
27 Red Fuse 30 feed
28 Grey Power outlet feed
12B White 12V battery charge
12E Green 12V balancer
12T Purple Relay control
12V Red 12V fuse feed
1B Red Cab feed
PS Yellow 24V feed
SG1 Black/white Relay ground
SG2 Black/white Relay ground
Wiring diagram 14 - 25 amp/60 amp converter/equalizer

Figure 2

Service Information

Rotating beacons/
Differential lock/MBCS/
Articulation sensor
Profile:
G780B Volvo
Wiring diagram 14 – Rotating beacons/ Differential lock/MBCS/

Articulation sensor

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU27 MBCS/Rotating Std. 7.5 A Fuse panel, convenience center
beacon fuse
2 FU17 Floats/differential Std. 7.5 A Fuse panel, convenience center
lock fuse
3 SW3603 Amber rotating Opt. Single pole, single throw Console switch panel
beacon switch NO, double LED
4 SW3604 Blue rotating Opt. Single pole, single throw Console switch panel
5 SW9801 MBCS lock cylinder Opt. Single pole, single throw Console switch panel
NO
6 SW4601 Differential lock Std. Single pole, single throw Pedestal switch plate
switch NO, double LED
7 LA3603 Amber beacon Opt. Current draw: 1.8 amps at Mounting on top of cab
25.6 VDC
50W halogen bulb
100 flashes/min.
8 LA3604 Blue beacon Opt. Current: 1.8 amps at Mounting on top of cab
25.6 VDC
50W halogen bulb
100 flashes/min.
9 MA9801 Hydraulic MBCS Std. 39.9 10% ohms at 20ºC At valve, left-hand side front frame
valve solenoid (68ºF) in front of the cab.
10 MA4601 Differential lock Std 39.9 10% ohms at 20ºC At valve, rear frame left-hand side
valve solenoid (68ºF) by articulation joint.
11 SE3802 Articulation sensor Std. 10 4 ohms to 18 +4, -3 Front of the left-hand side
ohms articulation hinge
Figure 1
Wiring diagram 14 – Rotating beacons/Differential lock/MBCS/Articulation sensor

Figure 2
Service Information

Transmission ECU
Profile:
G780B Volvo
Wiring diagram 15 – Transmission ECU


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU3 Gear shifter fuse Std. 3A Fuse panel,
convenience center
2 FU4 Transmission ECU Std. 10 A Fuse panel,
3 FU26 Backup lights fuse Std. 5A Fuse panel,
convenience center
4 SW4201 Transmission gear Std. Forward/Neutral/Reverse: Side console
shifter 3 pole, single throw
Shift up/down:
Momentary double pole, single throw,
center position off
5 RE3601 Backup relay Std. Double pole, single throw At parking brake
valve, bottom right-
hand side of cab
6 SE5501 Parking brake Std. NC, opens at 344 34.5 kPa (3.4 0.3 bar) At transmission
hydraulic pressure (50 5 psi) on rising collector caps
sensor
7 MA4201 Transmission Std. Resistance: 28.8 ohms 10% At transmission
solenoid A at 20ºC (68ºF) collector caps
solenoid B at 20ºC (68ºF) collector caps
solenoid D at 20ºC (68ºF) collector caps
solenoid H at 20ºC (68ºF) collector caps
Figure 1

description Opt.
solenoid L at 20ºC (68ºF) collector caps
solenoid R at 20ºC (68ºF) collector caps
13 MA5501 Parking brake Std. 39.9 ohms 10% at 20ºC (68ºF) At valve at back of
solenoid transmission
14 SA3601 Backup alarm Std. 24 volt signal to operate Rear of grader inside
fan enclosure
Figure 2
Figure 3
Service Information

Rotating beacons/
differential lock/MBCS
Profile:
G780B Volvo
Wiring diagram 15 – Rotating beacons/differential lock/MBCS


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU27 MBCS/Rotating Std. 7.5 A Fuse panel, convenience center
beacon fuse
2 SW3603 Amber rotating Opt. Single pole, single throw Console switch panel
3 SW3604 Blue rotating Opt. Single pole, single throw Console switch panel
4 SW9801 MBCS lock cylinder Opt. Single pole, single throw Console switch panel
NO
5 SW4601 Differential lock Std. Single pole, single throw Pedestal switch plate
switch NO, double LED
6 LA3603 Strobe flasher Opt. Current draw: 1.8 amps at Mounting on top of cab
LA3604 Rotating flasher 25.6 VDC
– Amber 50W halogen bulb
100 flashes/min.
7 LA3605 Strobe flasher Opt. Current: 1.8 amps at Mounting on top of cab
LA3606 Rotating flasher 25.6 VDC
– Blue 50W halogen bulb
100 flashes/min.
8 MA9801 Hydraulic MBCS Std. 39.9 ±10% ohms at 20ºC At valve, left-hand side front frame
valve solenoid (68ºF) in front of the cab.
9 MA4601 Differential lock Std 39.9 ±10% ohms at 20ºC At valve, rear frame left-hand side
valve solenoid (68ºF) by articulation joint.
Figure 1

111 Brown MBCS switch feed to solenoid
151 Grey (FH) Differential lock switch feed to solenoid
Yellow/black (UCH)
Purple/white (FH AWD CH)
362A Purple Warning light feed
362B White (CH) Warning light feed
Yellow/black (UCH)
79A Dark green/white Switch feed from fuse 27
P13 Red Fuse 27 feed
FH = front harness
RH = rear harness
Wiring diagram 15 - Rotating beacons/differential lock/MBCS
Figure 2

Service Information

Wiring diagram 16 – AWD 370 Service Information 9/10/2022
ECU
Profile:
G780B Volvo
Wiring diagram 16 – AWD ECU


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU18 Sensor feed fuse Std. 5A Fuse panel,
convenience center
2 FU29 AWD fuse Opt. 15 A Fuse panel,
convenience center
3 MA4407 AWD - EDC (RH) Opt. Output: 14 3 to 85 10 mA At drive pumps
drive pump Coil resistance:
solenoid Forward – 20 ohms at 24ºC (75.2ºF)
Reverse – 16 ohms at 24ºC (75.2ºF)
4 MA4408 AWD -EDC (LH) Opt. Output: 14 3 to 85 10 mA At drive pumps
5 SA4401 AWD buzzer Opt. Operating correct: 2 – 18 mA Right-hand side
Operating voltage: 5 – 30V doorpost, behind
2 beeps/sec at 2900 Hz AWD console
6 SE4401 AWD right-hand Opt. 3 wire NPN proximity switch, 92 At front RH wheel
speed sensor pulses/rev
Sensing distance: 0.8 mm (0.031 in.)
7 SE4402 AWD left-hand Opt. 3 wire NPN proximity switch, 92 At front LH wheel
8 SE4407 AWD filter bypass Opt. Configuration: NC, switch will open Left-hand side, rear
sensor when filter is bypassing. engine compartment
Setting: 345 kPa (3.45 bar)(50 psi)
9 SE4409 Hydraulic oil level Opt. Configuration: NO, open when the oil Front middle of
sensor level falls below the level of the switch hydraulic tank
10 SE4410 Hydraulic oil Opt. Configuration: NC, open at 85 3ºC (185 Lower front left-hand
temperature sensor 6ºF) side of hydraulic tank
Figure 1

Figure 2
Service Information

Transmission ECU
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU3 Gear shifter fuse Std. 3A Fuse panel,
convenience center
2 FU4 Transmission ECU Std. 10 A Fuse panel,
3 FU26 Backup lights fuse Std. 5A Fuse panel,
convenience center
4 SW4201 Transmission gear Std. Forward/Neutral/Reverse: Side console
shifter 3 pole, single throw
Shift up/down:
Momentary double pole, single throw,
center position off
5 RE3601 Backup relay Std. Double pole, single throw Fuse panel,
convenience center
6 SE5501 Parking brake Std. NC, SW closes at 6894.8 kPa ± 51.7 kPa Park brake caliper
hydraulic pressure (69.0 bar ± 0.52 bar) (1000 psi ± 7.5
sensor psi) falling
7 MA4201 Transmission Std. Resistance: 28.8 ohms ±10% At transmission
solenoid A at 20ºC (68ºF) collector caps
solenoid B at 20ºC (68ºF) collector caps
solenoid D at 20ºC (68ºF) collector caps
solenoid H at 20ºC (68ºF) collector caps
Figure 1

designation Opt.
solenoid L at 20ºC (68ºF) collector caps
solenoid R at 20ºC (68ºF) collector caps
13 MA5501 Parking brake Std. 39.9 ohms ±10% at 20ºC (68ºF) At valve at back of
solenoid transmission
14 SA4201 Backup alarm Std. 24 volt signal to operate Rear of grader inside
fan enclosure
Figure 2
Circuit Color Description
35 Light green/black (CH RH) Backup alarm and reverse lights feed
Yellow/dark blue (TH)
112 Tan Shifter forward signal
113 Purple Shifter downshift signal
114 Light blue/yellow Shifter out of neutral signal
115 Light blue/dark green Shifter upshift signal
116 White/yellow Shifter reverse signal
117 Grey Transmission display - clock
118 Light blue Transmission display - data
119 Red/white Transmission display feed
121 Pink Neutral start relay activation
122 Purple/white T-ECU feed
123 Red/blue Shifter feed
125 White Shift solenoid A feed
126 Dark blue (CH FH) Shift solenoid B feed
Light blue (Trans H)
127 Yellow Shift solenoid D feed
128 Light green (CH) (Trans H) Shift solenoid R feed
Dark green (FH)
129 Brown Shift solenoid L feed
130 Orange Shift solenoid H feed
510 Brown/black Park brake solenoid feed
511 Tan Park brake sensor signal
15EA Red/white Fuse 3 feed from electronics relay
Red (CH)
24V Red/light green (FH) Sensor feed from fuse 18
35T Light green/black Backup relay control
81B Yellow/black Backup relay feed
DGR Black Transmission display ground
P109 Black/white (CH) VHP signal
Purple (FH)
P5 Red Fuse 4 feed
P7 Red Fuse 26 feed
SGR Black Shifter ground
FH = front harness
RH = rear harness
TH = taillight harness
Trans H = transmission harness
Wiring diagram 16 - Transmission ECU
Figure 3

Service Information

ECU
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

description Opt.
convenience center
2 SW4401 AWD on/off switch Opt. NO, single throw, single pole Upper door post
Switched with LED
3 SW4402 Creep mode on/off Opt. NO, single pole, single throw, Upper door post
switch momentary switch with LED
4 SW4403 AWD aggression Opt. 16 bit binary output switch Upper door post
switch
5 SE4403 AWD rear speed Opt. Output: 3V peak to peak At parking brake disc,
sensor Gap: 0.002 0.00008 mm (0.050 0.002 rear of transmission
in.)
Plug 1: 750 – 1100 ohms
Plug 2: 1100 – 1500 ohms
6 SE4404 AWD clutch Opt. NC, opens when brake is applied At brake booster
pressure sensor Setting: 1034 kPa 52 kPa
(10.3 0.5 bar)(150 7.5 psig)
7 SE4405 AWD hydraulic Opt. NC, opens when brake is applied At brake booster
brake pressure Setting: 1034 kPa 52 kPa
sensor (10.3 0.5 bar)(150 7.5 psig)
8 SE4406 AWD hydraulic Opt. NC, opens when brake is applied At brake booster
brake pressure Setting: 1034 kPa 52 kPa
sensor (10.3 0.5 bar)(150 7.5 psig) falling
9 SE4408 AWD charge Opt. NO, closed when pressure is within Left-hand rear engine
pressure sensor acceptable limits compartment at filter
Setting: 1724 52 kPa bracket
(17.2 0.5 bar)(250 7.5 psig) falling
10 MA4401 AWD DCV1 Opt. 39.9 ohms 10% at 20ºC (68ºF) At valve
2 speed valve
solenoid
Figure 1

designation Opt.
11 MA4402 AWD DCV2 Free Opt. 39.9 ohms 10% at 20ºC (68ºF) At valve
wheeling valve
solenoid
12 MA4403 AWD DCV3, left- Opt. 28.8 ohms 10% at 20ºC (68ºF) At valve
hand forward
bypass solenoid
13 MA4404 AWD DCV4, left- Opt. 28.8 ohms 10% at 20ºC (68ºF) At valve
hand reverse
bypass solenoid
14 MA4405 AWD DCV5 right- Opt. 28.8 ohms 10% at 20ºC (68ºF) At valve
hand forward
bypass solenoid
15 MA4406 AWD DCV6 right- Opt. 28.8 ohms 10% at 20ºC (68ºF) At valve
hand reverse
bypass solenoid
16 AWD ECU AWD ECU Opt. Convenience center
17 SE3801 Transmission speed Opt. Output saturation voltage: 700 mV At parking brake disc,
sensor max. rear of transmission
Output current: 25 mA max.
Figure 2

Figure 3
Service Information

ECU
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU18 Sensor feed fuse Std. 5A Fuse panel,
convenience center
convenience center
3 MA4407 AWD - EDC (RH) Opt. Output: 14 ±3 to 85 ±10 mA At drive pumps
4 MA4408 AWD -EDC (LH) Opt. Output: 14 ±3 to 85 ±10 mA At drive pumps
5 SA4401 AWD buzzer Opt. Operating correct: 2 – 18 mA Right-hand side
Operating voltage: 5 – 30V doorpost, behind
2 beeps/sec at 2900 Hz AWD console
6 SE4401 AWD right-hand Opt. 3 wire NPN proximity switch, 92 At front RH wheel
7 SE4402 AWD left-hand Opt. 3 wire NPN proximity switch, 92 At front LH wheel
8 SE4407 AWD filter bypass Opt. Configuration: NC, switch will open Left-hand side, rear
sensor when filter is bypassing. engine compartment
Setting: 345 kPa (3.45 bar)(50 psi)
9 SE4409 Hydraulic oil level Opt. Configuration: NO, open when the oil Front middle of
sensor level falls below the level of the switch hydraulic tank
10 SE4410 Hydraulic oil Opt. Configuration: NC, open at 85 ±3ºC Lower front left-hand
temperature sensor (185 6ºF) side of hydraulic tank
Figure 1

25 Brown/light blue (FH) Engine RPM signal to AWD T-ECU
255 Brown/white AWD hydraulic oil filter bypass signal
256 Brown/black High hydraulic oil temperature signal
257 Brown/orange Low hydraulic oil level
262 Dark blue (AWD CH) Engine RPM signal to AWD T-ECU
Brown/blue (AWD FH)
264 Light green (AWD CH) RH front speed sensor signal
Red (AWD FH)
265 Light green LH front speed sensor signal
266 Yellow (AWD CH) AWD - EDC RH forward motor (-)
Yellow/black (AWD RH)
267 Light green (AWD CH) AWD - EDC RH forward motor (+)
Dark green/white (AWD RH)
268 Light green (AWD CH) AWD - EDC RH reverse motor (+)
White/light green (AWD RH)
269 Yellow (AWD CH) AWD - EDC RH reverse motor (-)
White/light blue (AWD RH)
270 Yellow (AWD CH) AWD - EDC LH forward motor (-)
Grey/white (AWD RH)
271 Light green (AWD CH) AWD - EDC LH forward motor (+)
Dark blue/white (AWD RH)
272 Light green AWD - EDC LH reverse motor (+)
273 Yellow AWD - EDC LH reverse motor (-)
275 Red AWD T-ECU power feed
285 Red/white (AWD CH) AWD front speed sensors power feed
White (AWD FH)
292 Red AWD buzzer feed
24V Red (CH AWD RH) Sensor feed from fuse 18
Red/purple (RH Trans H)
P108 Black/grey I-ECU hydraulic oil level signal
P111 Tan/dark blue I-ECU hydraulic filter bypass signal
P204 Light blue (FH) I-ECU hydraulic oil temperature signal
Brown/purple (RH)
FH = front harness
RH = rear harness
AWD RH = AWD rear harness
Wiring diagram 17 - AWD ECU
Figure 2

Service Information

ECU
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
convenience center
2 SW4401 AWD on/off switch Opt. NO, single throw, single pole Upper door post
Switched with LED
3 SW4402 Creep mode on/off Opt. NO, single pole, single throw, Upper door post
switch momentary switch with LED
4 SW4403 AWD aggression Opt. 16 bit binary output switch Upper door post
switch
5 SE4403 AWD rear speed Opt. Output: 3V peak to peak At parking brake disc,
sensor Gap: 0.002 ±0.00008 mm (0.050 ±0.002 rear of transmission
in.)
Plug 1: 750 – 1100 ohms
Plug 2: 1100 – 1500 ohms
6 SE4404 AWD clutch Opt. NC, opens when clutch is applied At clutch master
pressure sensor Setting: 1034 kPa ±52 kPa cylinder
(10.3 ±0.5 bar)(150 ±7.5 psig)
7 SE4405 AWD hydraulic Opt. NC, opens when brake is applied At brake master
brake pressure Setting: 1034 kPa ±52 kPa cylinder
sensor (10.3 ±0.5 bar)(150 ±7.5 psig)
8 SE4406 AWD hydraulic Opt. NC, opens when brake is applied At brake master
brake pressure Setting: 1034 kPa ±52 kPa cylinder
sensor (10.3 ±0.5 bar)(150 ±7.5 psig) falling
9 SE4408 AWD charge Opt. NO, closed when pressure is within Left-hand rear engine
pressure sensor acceptable limits compartment at filter
Setting: 1724 ±52 kPa bracket
(17.2 ±0.5 bar)(250 ±7.5 psig) falling
10 MA4401 AWD DCV1 Opt. 39.9 ohms ±10% at 20ºC (68ºF) At valve
2 speed valve
solenoid
Figure 1

designation Opt.
11 MA4402 AWD DCV2 Free Opt. 39.9 ohms ±10% at 20ºC (68ºF) At valve
wheeling valve
solenoid
12 MA4403 AWD DCV3, left- Opt. 28.8 ohms ±10% at 20ºC (68ºF) At valve
hand forward
bypass solenoid
13 MA4404 AWD DCV4, left- Opt. 28.8 ohms ±10% at 20ºC (68ºF) At valve
hand reverse
bypass solenoid
14 MA4405 AWD DCV5 right- Opt. 28.8 ohms ±10% at 20ºC (68ºF) At valve
hand forward
bypass solenoid
15 MA4406 AWD DCV6 right- Opt. 28.8 ohms ±10% at 20ºC (68ºF) At valve
hand reverse
bypass solenoid
16 AWD ECU AWD ECU Opt. Convenience center
Figure 2

250 Dark blue/brown AWD - DCV1 motor displacement
solenoid feed
251 Dark blue/yellow AWD - DCV3 LH forward bypass solenoid
feed
252 Dark blue/purple AWD DCV4 LH reverse bypass solenoid
feed
253 Dark blue/light green (AWD CH) AWD DCV5 RH forward bypass solenoid
Light blue/dark green (AWD FH) feed
254 Dark blue/red (AWD CH) AWD - DCV6 RH reverse bypass solenoid
Light blue/red (AWD FH) feed
258 Dark blue/black (AWD CH) AWD - DCV2 freewheeling solenoid feed
Light blue/black (AWD FH)
259 Grey/yellow AWD - clutch sensor signal
260 Grey/brown AWD brake sensor signal
261 Grey/purple AWD brake sensor signal
263 Brown/light green AWD charge pressure sensor signal
274 Light green (AWD CH) AWD transmission speed sensor signal
Dark blue (AWD RH)
276 Red/yellow (AWD CH) (AWD RH) AWD switch and sensor feed
Red/light green (AWD FH)
279 Grey/brown AWD creep mode indicator
280 Grey/yellow AWD oil temperature indicator
281 Grey/red AWD charge pressure indicator
282 Grey/light green AWD hydraulic oil filter indicator
283 Grey/white AWD hydraulic oil level indicator
284 Grey/orange AWD (ON) indicator
286 Purple/brown AWD aggression switch 1
287 Purple/light green AWD aggression switch 2
288 Purple/light blue AWD aggression switch 3
289 Purple/red AWD aggression switch 4
290 Orange AWD ON/OFF switch signal
291 Grey AWD creep mode signal
P123 Purple/red (FH) AWD ON/OFF logging
Orange (AWD CH) (AWD FH)
P124 Orange (FH) Creep mode logging
Grey (AWD CH) (AWD FH)
P219 Dark green/orange (FH) AWD aggression switch 1 logging
Purple/brown (AWD CH) (AWD FH)
P220 Red/white (FH) AWD aggression switch 2 logging
Purple/light green (AWD CH) (AWD FH)
P221 Light green/orange (FH) AWD aggression switch 3 logging
Purple/light blue (AWD CH) (AWD FH)
P222 Light blue/red (FH) AWD aggression switch 4 logging
Purple/red (AWD CH) (AWD FH)
RH = rear harness
AWD RH = AWD rear harness
Figure 3

Service Information

Wiring diagram 18 – Sensors 370 Service Information 9/10/2022
Profile:
G780B Volvo
Wiring diagram 18 – Sensors


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
2 SE4201 Transmission filter Opt. NC, switch will open when Front, right-hand side of
bypass sensor filter is bypassing at transmission
345 kPa (3.45 bar)(50 psi)
3 SE4202 Transmission oil Std. NC, Setting: Front, left-hand side of
pressure sensor Close at 1172 kPa transmission
(11.7 bar)(170 psi)
Open at 1379 kPa
(13.7 bar)(200 psi)
4 SE9103 Hydraulic filter Opt. Configuration: NC, switch Engine compartment, rear left-
bypass sensor will open when filter is hand side
bypassing.
Setting: 345 kPa (3.45 bar)
(50 psi)
5 SE9101 Hydraulic oil level Std. Configuration: NO, open Hydraulic tank, front middle
sensor when oil level falls below
the level of the switch
6 SE9102 Hydraulic oil Std. Configuration: NC, open at Lower front of hydraulic tank, left-
temperature sensor 85 3ºC (185 6ºF) hand side
7 I-ECU Instrument ECU Std. Instrument display panel
8 SE4601 Differential lock Std. Rear harness
cylinder ball switch
9 SE9801 MBCS lock cylinder Std. MBCS harness
ball switch
Figure 1

Figure 2
Service Information

Wiring diagram 19 – Sensors 370 Service Information 9/10/2022
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
2 SE4201 Transmission filter Opt. NC, switch will open when Front, right-hand side of
bypass sensor Std. on filter is bypassing at transmission
AWD 345 kPa (3.45 bar)(50 psi)
3 SE4202 Transmission oil Std. NC, Setting: Front, left-hand side of
pressure sensor Close at 1172 kPa transmission
(11.7 bar)(170 psi)
Open at 1379 kPa
(13.7 bar)(200 psi)
4 SE9103 Hydraulic filter Opt. Configuration: NC, switch Engine compartment, rear left-
bypass sensor Std. on will open when filter is hand side
AWD bypassing.
Setting: 345 kPa (3.45 bar)
(50 psi)
5 SE9101 Hydraulic oil level Opt. Configuration: NO, open Hydraulic tank, front middle
sensor Std. on when oil level falls below
AWD the level of the switch
6 SE9102 Hydraulic oil Opt. Configuration: NC, open at Lower front of hydraulic tank, left-
temperature sensor Std. on 85 3ºC (185 6ºF) hand side
AWD
8 SE4601 Differential lock Std. Rear harness
cylinder ball switch
9 SE9801 MBCS lock cylinder Std. NC setting open at 34.5 MBCS harness
ball switch kpa ± 13.8 kpa (0.34 bar ±
0.14 bar) (5 psi ± 2 psi)
Figure 1

15EA Red/white Fuse 18 feed from electronics relay
24V Red (CH) Sensor feed from fuse 18
P102 Pink/white Transmission filter bypass indicator
Purple/orange (trans H) signal
P108 Black/grey Hydraulic oil level indicator signal
P111 Tan/dark blue Hydraulic filter bypass signal
P122 Purple/light blue MBCS indicator signal
P204 Light blue (FH) Hydraulic oil temperature signal
Brown/purple (RH)
P206 Brown Low transmission pressure signal
Purple/yellow (trans H)
P216 Red/light blue (FH) Differential lock indicator signal
Light green/dark blue
FH = front harness
RH = rear harness
Wiring diagram 19 - Sensors
Figure 2

Service Information

Wiring diagram 19 – Brake 370 Service Information 9/10/2022
circuit, lights
Profile:
G780B Volvo
Wiring diagram 19 – Brake circuit, lights


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU6 Brake fuse Std. 5A Fuse panel, convenience center
2 RE5201 Brake motor relay Std. One pole, single throw Console side wall
NC
3 RE5202 Brake No Flow Std. One pole, single throw Convenience center
relay NC
4 SE5201 Brake No Flow Std. NC with no flow Under cab, right-hand side, rear
sensor corner
5 SE5202 Brake delta Std. NO, closed with a pressure Under cab, right-hand side, rear
pressure sensor difference between the corner
dual brake circuits
6 MO5201 Brake master Std. 2 leads: Under cab, right-hand side, rear
cylinder/booster 1. 24V corner
motor 2. Ground
7 SW5201 Electrical brake Std. NC, closed when brake is Under cab at brake pedal
switch engaged.
8 LA3607 Light pod, rear Std. Backup light bulb – 21W Rear of grader
right-hand side Tail light bulb – 5W
Reflector light bulb – 5W
Brake light bulb – 21W
Signal light bulb – 21W
9 LA3608 Light pod, rear left- Std. Backup light bulb – 21W Rear of grader
hand side Tail light bulb – 5W
Figure 1

Figure 2
Service Information

Wiring diagram 20 – Brake 370 Service Information 9/10/2022
circuit, lights
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
NC
3 RE5202 Brake No Flow Std. One pole, single throw Convenience center
relay NC
sensor corner
5 SE5202 Brake delta Std. NO, closed with a pressure Under cab, right-hand side, rear
pressure sensor difference between the corner
dual brake circuits
motor 2. Ground
7 SW5201 Electrical brake Std. NC, closed when brake is Under cab at brake pedal
switch engaged.
8 LA3607 Light pod, rear Std. Backup light bulb – 21W Rear of grader
right-hand side Tail light bulb – 5W
10 LA3609 License plate light Rear frame
Figure 1

6 Purple/black (CH) Brake light feed
Brown/red (FH) (RH)
Brown (TH)
11 Light blue/red (CH) (FH) (UCH) Left turn signal bulb feed
Yellow/dark blue (RH) (TH)
30 Orange Dome light switch feed
35 Light green/black (CH) (RH) Reverse lights feed
Yellow/dark blue(TH)
155 Orange/brown Brake motor feed
156 Orange/white (CH) Brake motor relay activation
Orange (FH)
158 Orange/dark green Brake motor relay feed
167 Grey/yellow Feed from ignition switch
1B Red Cab feed
6A Purple/black Brake switch feed from fuse 6
P103 Black/orange (CH) Low brake pressure signal
Orange/yellow (FH)
P207 Tan Low brake pressure signal
FH = front harness
RH = rear harness
TH = tail light harness
Wiring diagram 20 - Brake circuit, lights
Figure 2

Service Information

Secondary steering
Profile:
G780B Volvo
Wiring diagram 20 – Secondary steering


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU28 Secondary steering Opt. 3A Fuse panel, convenience center
fuse
2 MO6401 Secondary steering Opt. 2 leads: Secondary steering box, right-
motor 1. 24V hand side, rear engine
2. Ground compartment
3 RE3302 Ignition latch relay Std. Double pole, single throw Convenience center
4 RE6401 Secondary steering Opt. Double pole, single throw Convenience center
relay
5 RE6402 Secondary steering Opt. Double pole, single throw Secondary steering box, right-
power relay hand side, rear engine
compartment
6 SE6401 Steering hydraulic Opt. NC opens at 344 ±34 kPa Secondary steering box, right-
pressure sensor (3.5 ±0.34 bar)(50 ±5 psi) hand side, rear engine
compartment
7 SW3301 Ignition switch Std. 5 pole, single throw Console switch panel
switch throw; NO
9 SW6401 Secondary steering Opt. Single pole, single throw Pedestal switch plate
test switch momentary; NO with LED
Figure 1

Figure 2
Service Information

Wiring diagram 21 – Climate 370 Service Information 9/10/2022
control unit
Profile:
G780B Volvo
Wiring diagram 21 – Climate control unit


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU10 Condenser fan fuse Opt. 20 A Fuse panel, convenience center
2 FU11 Heater fuse Opt. 25 A Fuse panel, convenience center
3 FU12 Air conditioner fuse Opt. 25 A Fuse panel, convenience center
4 MA8701 Compressor Opt. Single plate dry clutch Right-hand side, rear of engine
solenoid 24 VDC, 3.75 A max. compartment at compressor
CW/CCW
5 MA8702 Climate unit valve Opt. Motor: 12V nominal, 0.5 amps Climate control box unit
assembly (maximum) underneath operator seat
Pinout: 7 - ground
8 - Input
10 - Ignition
5, 6, 9 not used
6 MO8701 Condenser fan Opt. Current = 17 A at 27V At condenser, rear of grader
Capacity: 30,000 Btu/h at
38ºC (100ºF) air temperature.
Ball bearings and long life
brushes
7 RE8701 Condenser relay Opt. Single pole, single throw
8 RE8702 Climate control Opt. Single pole, single throw Inside climate control box,
unit high speed fan underneath operator seat
relay
9 SW8701 Heater fan speed Opt. 4 position, 3 pole Side console switch plate
switch single throw, NO (off)
10 SW8702 Heater Opt. Potentiometer Side console switch plate
temperature 10 kohms
control
Figure 1
Wiring diagram 21 – Climate control system

designation Opt.
11 SW8703 AC on/off switch Opt. Single pole, single throw, Side console switch plate
double LED
12 SE8701 AC temperature Opt. Cold cut out: –3.3ºC (26º F) Inside climate control box unit
sensor Cold cut in: 1.1ºC (34ºF)
13 SE8702 AC pressure sensor Opt. Limiting high pressure: Front left-hand side of engine
2648 kPa (26.5 bar)(384 psig) compartment at receiver/dryer
Limiting low pressure: filter
193 kPa (1.9 bar)(28 psig)
14 MO8702 Climate control box Opt. 2, 3-speed recirculation fan Inside climate control box unit
motors – 24 V, 9 A
1 pressurizer fan motor –
24 V, 5 A
Figure 2

Figure 3
Service Information

Secondary steering
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU28 Secondary steering Opt. 3A Fuse panel, convenience center
fuse
2 MO6401 Secondary steering Opt. 2 leads: Secondary steering box, right-
motor 1. 24 V hand side, rear engine
2. Ground compartment
3 RE3302 Ignition latch relay Std. Double pole, single throw Convenience center
4 RE6401 Secondary steering Opt. Double pole, single throw Convenience center
relay
5 RE6402 Secondary steering Opt. Double pole, single throw Secondary steering box, right-
power relay hand side, rear engine
compartment
6 SE6401 Steering hydraulic Opt. NC opens at 344 ±34 kPa Secondary steering box, right-
pressure sensor (3.5 ±0.34 bar)(50 ±5 psi) hand side, rear engine
compartment
7 SW3301 Ignition switch Std. 5 pole, single throw Console switch panel
switch throw; NO
9 SW6401 Secondary steering Opt. Single pole, single throw Pedestal switch plate
test switch momentary; NO with LED
Figure 1

1B Red Cab feed
167 Grey/yellow Feed from ignition switch
169 Red/orange Ignition switch start feed
172 Brown Secondary steering sensor feed
174 Red Secondary steering motor relay feed
175 Red Secondary steering motor feed
508 Black/grey Park brake switch feed
509 Black/white Park brake switch signal
167B Grey/white (CH) Secondary steering relay activation
Grey/black (FH)
169A Light blue/white Start circuit activation
169B Light blue/white Ignition latch relay activation
172A Brown Secondary steering relay feed from fuse
28
DR Red/dark blue Ignition switch feed to latch relay
White (FH)
P118 Purple (RH) Secondary steering (ON) indicator
Red/yellow (SSH)
Light green (FH)
P205 Dark blue/orange (RH) Primary steering pressure indicator signal
Yellow/purple (SSH)
FH = front harness
RH = rear harness
SSH = secondary steering harness
Wiring diagram 21 - Secondary steering
Figure 2

Service Information

Wiring diagram 22 – Front 370 Service Information 9/10/2022
and rear defroster fans
Profile:
G780B Volvo
Wiring diagram 22 – Front and rear defroster fans


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU19 Defrost fan fuse 7.5 A Fuse panel, convenience center
2 SW8802 Front defrost fans Double pole, double Side console, upper switch plate
switch throw
3 position, double LED
3 SW8803 Rear defrost fans Double pole, double Side console, upper switch plate
switch throw
4 MO8801 Front defrost fan High speed: 27 VDC, 2.0 A; At front defrost fan
motor 190 cfm at 4200 rpm
Low speed: 27 VDC 1.1 A;
137 cfm at 2950 rpm
5 MO8802 Rear defrost fan High speed: 27 VDC, 2.0 A; At front defrost fan
motor 190 cfm at 4200 rpm
137 cfm at 2950 rpm
Figure 1
Wiring diagram 22 – Front and rear defroster fans

Figure 2
Service Information

Wiring diagram 22 – Climate 370 Service Information 9/10/2022
control unit
Profile:
G780B Volvo
Wiring diagram 22 – Climate control unit


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU10 Condenser fan fuse Opt. 20 A Fuse panel, convenience center
2 FU11 Heater fuse Opt. 25 A Fuse panel, convenience center
3 MA8701 Compressor Opt. Single plate dry clutch Right-hand side, rear of engine
solenoid 24 VDC, 3.75 A max. compartment at compressor
CW/CCW
4 MA8702 Climate unit valve Opt. Motor: 12V nominal, 0.5 amps Climate control box unit
Pinout: 7 - ground
8 - Input
10 - Ignition
5, 6, 9 not used
5 MO8701 Condenser fan Opt. Current = 17 A at 27V At condenser, rear of grader
Capacity: 30,000 Btu/h at
38 ºC (100ºF) air temperature.
Ball bearings and long life
brushes
6 RE8701 Condenser relay Opt. Single pole, single throw Console right side
7 SW8701 Heater fan speed Opt. Potentiometer Side console switch plate
switch
8 SW8702 Heater Opt. Potentiometer Side console switch plate
temperature 10 kohms
control
Figure 1

designation Opt.
11 SW8703 AC on/off switch Opt. Single pole, single throw, Side console switch plate
double LED
12 SE8701 AC temperature Opt. Cold cut out: –3.3ºC (26º F) Inside climate control box unit
13 SE8702 AC pressure sensor Opt. Limiting high pressure: Front left-hand side of engine
2648 kPa (26.5 bar)(384 psig) compartment at receiver/dryer
Limiting low pressure: filter
193 kPa (1.9 bar)(28 psig)
14 MO8702 Climate control box Opt. 2, 3-speed recirculation fan Inside climate control box unit
1 pressurizer fan motor –
24 V, 5 A
Figure 2
870 Orange HVAC switch and box feed
871 Red AC condenser relay feed
872 Dark blue/white AC switch feed
873 White/brown AC switch output
874 Light blue Temperature control (+)
875 White Temperature control signal
876 Black Temperature control (-)
877 White/yellow Fan speed control (+)
878 White/dark green Fan speed control signal
879 White/purple Fan speed control (-)
880 White/black Pressurizer fan relay feed
871A Red AC condenser fan relay feed
AC White/red AC pressure sensor feed
AC1 Light green AC compressor clutch feed
P1 Red Fuse 11 feed
Wiring diagram 22 - Climate control system

Figure 3

Service Information

defroster fans
Profile:
G780B Volvo
Wiring diagram 23 – Front defroster fans


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU23 Defrost fan fuse 7.5 A Fuse panel, convenience center
2 SW8802 Right-hand defrost Double pole, double Side console, upper switch plate
fan switch throw
3 SW8803 Left-hand defrost Double pole, double Side console, upper switch plate
fan switch throw
4 MO8801 Left-hand front High speed: 27 VDC, 2.0 A; At front defrost fan
defrost fan motor 190 cfm at 4200 rpm
137 cfm at 2950 rpm
5 MO8802 Right-hand front High speed: 27 VDC, 2.0 A; At front defrost fan
defrost fan motor 190 cfm at 4200 rpm
137 cfm at 2950 rpm
Figure 1

37L Orange/white RH defroster fan low speed feed
37H Orange/white RH defroster fan high speed feed
38H Yellow/red LH defroster fan high speed feed
38L Yellow/red LH defroster fan low speed feed
78A Dark blue/white Defroster fan switch feed
FH = front harness
RH = rear harness
Wiring diagram 23 – Front defroster fans
Figure 2
Service Information

Wiring diagram 23 – Radio/ 370 Service Information 9/10/2022
Heated mirrors
Profile:
G780B Volvo
Wiring diagram 23 – Radio/Heated mirrors


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU9 Radio/heated Opt. 10 A Fuse panel, convenience center
mirror fuse
2 SW8901 Heated mirrors Opt. Single throw Console, upper switch plate
switch Single pole
Double LED
3 SW3501 Dome light fuse Std. Single throw Lower doorpost
Single pole
Double LED
4 HE8901 Heated mirror Opt. Outside cab doors
6 24V/12V 24V/12V convertor Opt. 5A Behind radio installation
Convertor
7 Backup Opt. Regulator powered by 2, Behind radio installation
Module 9V batteries
8 LA3501 Interior light Std. 24V bulb Cab interior roof
9 RADIO Radio Opt. – 3 leads Upper left cab
– 12V switched
– 12V constant ground
Figure 1
Wiring diagram 23 - Front defroster fans
Figure 2

Service Information

Wiring diagram 24 – Blade 370 Service Information 9/10/2022
float module
Profile:
G780B Volvo
Wiring diagram 24 – Blade float module


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU17 Floats/Differential Std. 7.5 A Fuse panel, convenience center
lock fuse
2 SW9102 Right-hand detent Opt. Single pole, single throw, At main directional control valve
float switch detent style, NO
3 SW9103 Left-hand detent Opt. Single pole, single throw, At main directional control valve
4 SW9101 Float enable switch Opt. Double pole, double Pedestal
throw
Momentary, normally
neutral (off)
5 LA9101 Float enable switch Opt. 2 separate filaments Pedestal
Max resistance: 10
milliohms
6 MA9101 Right-hand blade Opt. 28.8 ohms 10% At right-hand blade lift cylinder
float solenoid (up) at 20ºC (68ºF) counterbalance valve
7 MA9102 Right-hand blade Opt. 28.8 ohms 10% At right-hand blade lift cylinder
float solenoid at 20ºC (68ºF) counterbalance valve
(down)
8 MA9103 Left-hand blade Opt. 28.8 ohms 10% At left-hand blade lift cylinder
9 MA9104 Left-hand blade Opt. 28.8 ohms 10% At left-hand blade lift cylinder
(down)
10 Float module Float module Opt. Pedestal
Figure 1

Figure 2
Service Information

Wiring diagram 24 – Radio/ 370 Service Information 9/10/2022
Dome light/Heated mirrors
Profile:
G780B Volvo
Wiring diagram 24 – Radio/Dome light/Heated mirrors


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU9 Radio/heated Opt. 10 A Fuse panel, convenience center
mirror fuse
2 SW8901 Heated mirrors Opt. Single throw Console, upper switch plate
switch Single pole
Double LED
3 SW3501 Dome light fuse Std. Single throw Lower doorpost
Single pole
Double LED
6 SO3903 24V/12V convertor Opt. 5A Behind radio installation
7 Backup Opt. Regulator powered by 2, Behind radio installation
Module 9V batteries
8 LA3501 Interior light Std. 24V bulb Cab interior roof
9 RA3901 Radio Opt. – 3 leads Upper left cab
– 12V switched
– 12V constant ground
10 LA3506 Front clearance Opt. 24 V bulb Front upper cab
lights
11 LA3507 Rear clearance Opt. 24 V bulb Rear upper cab
lights
Figure 1

30 Orange Dome light feed
90 Orange/black 24V/12V converter feed
30A Orange Dome light bulb feed
5L Yellow/green LH taillight feed
5R Yellow/red RH taillight feed
90A Black Heated mirror switch feed
841 White (CH) Heated mirror feed
Yellow (UCH)
IGN/12V Orange/white 12V converter output
MEM Yellow 12V converter output
P14 Red Fuse 9 feed
Ground Black Ground
NOTE!
Radio portion of the wiring diagram applies to S/N 35521 and up.
Wiring diagram 24 - Radio/Dome light/Heated mirrors

Figure 2

Service Information

float module
Profile:
G780B Volvo
Wiring diagram 25 – Front float module


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU17 Floats/Differential Std. 7.5 A Fuse panel, convenience center
lock fuse
2 SW9104 Front float detent Opt. Single pole, single throw, At main directional control valve
switch detent style, NO
throw
Momentary, normally
neutral (off)
4 LA9101 Float enable light Opt. 2 separate filaments Pedestal
Maximum resistance: 10
milliohms
5 MA9105 Front float solenoid Opt. 28.8 ohms 10% At front counterbalance valve,
(up) at 20ºC (68ºF) nose of grader
6 MA9106 Front float solenoid Opt. 28.8 ohms 10% At front counterbalance valve,
(down) at 20ºC (68ºF) nose of grader
Figure 1

Figure 2
Service Information

Wiring diagram 25 – Blade 370 Service Information 9/10/2022
float module
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU17 Floats/Differential Std. 15 A Fuse panel, convenience center
lock fuse
2 SW9102 Right-hand detent Opt. Single pole, single throw, At main directional control valve
3 SW9103 Left-hand detent Opt. Single pole, single throw, At main directional control valve
throw
Momentary, normally
neutral (off)
5 LA9101 Float enable switch Opt. 2 separate filaments Pedestal
Max resistance: 10
milliohms
6 MA9101 Right-hand blade Opt. 28.8 ohms ±10% At right-hand blade lift cylinder
7 MA9102 Right-hand blade Opt. 28.8 ohms ±10% At right-hand blade lift cylinder
(down)
8 MA9103 Left-hand blade Opt. 28.8 ohms ±10% At left-hand blade lift cylinder
9 MA9104 Left-hand blade Opt. 28.8 ohms ±10% At left-hand blade lift cylinder
(down)
Figure 1

72 Grey/orange RH blade float solenoid feed
73 Grey/light blue LH blade float solenoid feed
72A Grey/white RH blade float switch output
73A Grey/white LH blade float switch output
81A Light green/red Float feed
82B Grey/red Blade float enable switch output
83B Grey/orange Blade float indicator output
Wiring diagram 25 - Blade float module

Figure 2

Service Information

Wiring diagram 26 – Tire 370 Service Information 9/10/2022
pump
Profile:
G780B Volvo
Wiring diagram 26 – Tire pump


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU20 Tire pump/remote Opt. 15 A Fuse panel, convenience
receptacle fuse center
2 SW9901 Tire pump switch Opt. Single pole, single throw Side console switch plate
NO, double LED
3 RE9901 Tire pump relay Opt. Double pole, single throw Console side wall
4 MO9901 Tire pump motor Opt. 2 lines: Front upper engine
1. 24V enclosure, next to expansion
2. Ground tank
Figure 1
Wiring diagram 26 – Tire pump
Figure 2
Service Information

float module
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU17 Floats/Differential Std. 15 A Fuse panel, convenience center
lock fuse
2 SW9104 Front float detent Opt. Single pole, single throw, At main directional control valve
switch detent style, NO
throw
Momentary, normally
neutral (OFF)
4 LA9101 Float enable light Opt. 2 separate filaments Pedestal
Maximum resistance: 10
milliohms
5 MA9105 Front float solenoid Opt. 28.8 ohms ±10% At front counterbalance valve,
(up) at 20ºC (68ºF) nose of grader
6 MA9106 Front float solenoid Opt. 28.8 ohms ±10% At front counterbalance valve,
(down) at 20ºC (68ºF) nose of grader
Figure 1

53 Grey/orange Front float solenoid feed
53A Grey/orange Front float switch output
82F Grey/brown Front float enable switch output
83F Grey/yellow Front float indicator feed
Wiring diagram 26 - Front float module

Figure 2

Service Information

Wiring diagram 27 – Rear 370 Service Information 9/10/2022
float module
Profile:
G780B Volvo
Wiring diagram 27 – Rear float module


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU17 Float module fuse Opt. 15 A Fuse panel - convenience center
2 SW9105 Rear 1 float switch Opt. Single pole, single throw Lower door post
3 SW9106 Rear 2 float switch Opt. Single pole, single throw Lower door post
4 SW9107 Rear float enable Opt. Single pole, double throw Lower door post
switch
5 LA9102 Float enable lamp Opt. 24 V bulb Right side door post
6 MA9107 Hydraulic rear float Opt. 28.8 ohms ± 10% at 20° C Rear attachment
1 solenoid – top (68° F)
1 solenoid – (68° F)
bottom
2 solenoid – top (68° F)
2 solenoid – (68° F)
bottom
10 Float module Float module Opt. Right side console

84 Yellow/pink Rear float solenoid 1 feed
85 Yellow/purple Rear float solenoid 2 feed
82R Yellow/light green Rear float enable switch output
83R Yellow/red Rear float indicator feed
84A Yellow/dark blue Rear float switch 1 output
85A Yellow/orange Rear float switch 2 output
Wiring diagram 27 - Rear float module
Figure 1

Service Information

Communication, E-ECU/I-
ECU
Profile:
G780B Volvo
Wiring diagram 27 – Communication, E-ECU/I-ECU


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU1 I-ECU Fuse Std. 10 A Fuse panel, convenience center
2 E-ECU Engine ECU Std. G710B to G730B – Engine
compartment, right-hand side on
frame
G740B to G780B – Right hand side
of engine
4 Service tool Convenience center
Figure 1

Figure 2
Service Information

Wiring diagram 28 – Tire 370 Service Information 9/10/2022
pump/Power outlet
Profile:
G780B Volvo
Wiring diagram 28 – Tire pump/Power outlet


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU20 Tire pump/remote Opt. 15 A Fuse panel, convenience
receptacle fuse center
2 SW9901 Tire pump switch Opt. Single pole, single throw Side console switch plate
NO, double LED
3 RE9901 Tire pump relay Opt. Double pole, single throw Console side wall
4 MO9901 Tire pump motor Opt. 2 lines: Front upper engine
1. 24V enclosure, next to expansion
2. Ground tank
5 PO9901 24 V power outlet Opt. 24 V Front console (lower)
Figure 1

206 Red Power outlet feed
31A Purple/grey Switch lighting
TP1 Red Tire pump feed
TP2 Red/yellow Tire pump relay feed
TP3 Red/white Tire pump relay feed
74A Red Feed from fuse 5
169 Red/orange Starter motor control circuit
900 White Hydraulic unload solenoid (+)
901 White/black Hydraulic unload solenoid (-)
Wiring diagram 28 - Tire pump/Power outlet

Figure 2

Service Information

Keyboard
Profile:
G780B Volvo
Wiring diagram 28 – Keyboard


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 SW8801 Keypad Std. Pedestal switch plate
2 I-ECU Instrument ECU Std. Instrument panel display
Figure 1

Figure 2
Service Information

Communication, E-ECU/I-
ECU
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 FU1 I-ECU Fuse Std. 10 A Fuse panel, convenience center
2 E-ECU Engine ECU Std. G710B to G730B – Engine
compartment, right-hand side on
frame
G740B to G780B – Right hand side
of engine
4 Service tool Convenience center
Figure 1

DB Yellow J1939 communication
DC Light green J1939 communication
DD Grey J1708 communication
DE Orange J1708 communication
DZ Yellow/black EOL enable (flash memory)
EOL Dark green/yellow (RH) EOL enable
Light green/yellow (CH)
JMP Red/white Service tool jumper
P101 Yellow (FH) J1939 communication
Red (RH)
P107 Black/purple (CH) J1587 communication
Dark green (FH)
Yellow (RH)
P114 Brown/yellow (CH) Fuse 1 feed
Yellow/red (FH)
P115 Dark blue (FH) J1939 communication
Orange (RH)
P121 Red/brown (CH) J1587 communication
Orange (FH)
Light blue (RH)
P201 Black/brown (CH) Service tool - connection
White/black (FH)
P211 Tan (CH) Service tool - down arrow
White (FH)
P212 Brown/red (CH) Service tool - right arrow
Pink (FH)
P318 Brown/grey (CH) Service tool - data
Red/dark green (FH)
P319 Brown/white (CH) Service tool - clock
Dark green/light blue (FH)
FH = front harness
RH = rear harness
Wiring diagram 29 - Communication, E-ECU/I-ECU
Figure 2

Service Information

Keyboard
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation Opt.
1 SW8801 Keypad Std. – Pedestal switch plate
2 I-ECU Instrument ECU Std. – Instrument panel display
Figure 1
Wiring diagram 30 - Keyboard

Figure 2

Service Information

Electrical distribution box: 379 Service Information 9/10/2022
fuses, relays
Profile:
G780B Volvo
Electrical distribution box: fuses, relays


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
1. Instrument ECU – 10 A fuse
2. Engine preheat – 5 A fuse
3. Transmission shifter – 3 A fuse
4. Transmission ECU – 10 A fuse
5. Ignition switch – 7.5 A fuse
6. Brakes – 5 A fuse
7. Instrument ECU, switched – 10 A fuse
8. Engine ECU, switched – 20 A fuse
9. Radio/heated mirrors – 10 A fuse
10. Climate control condenser fans – 20 A fuse
11. Heater – 25 A fuse
12. Cab headlights – 15 A fuse
13. Front headlights – 15 A fuse
14. Right-hand park lights – 5 A fuse
15. Left-hand park lights – 5 A fuse
16. Horn/flasher – 7.5 A fuse
17. Floats/differential lock – 15 A
18. Sensor feed – 5 A fuse
19. Spare
20. Tire pump/remote receptacle – 15 A fuse
21. Front wipers – 5 A fuse
22. Rear/lower wipers – 10 A fuse
23. Right and left-hand defroster fans – 7.5 A fuse
24. Rear worklights – 7.5 A fuse
25. Wing/moldboard lights – 15 A fuse
26. Backup lights – 5 A fuse
27. MBCS/beacon – 7.5 A fuse
28. Secondary steering – 3 A fuse
29. All Wheel Drive - 15 A fuse
30. Cigar lighter and 12 V supply - 15 A fuse
31. Electronics relay
32. Neutral start relay
33. Back-up/Alarm lights relay
34. Headlights relay
35. Secondary steering relay
36. EEC and extra headlights relay
37. Directional indicator flasher module
38. Brake no-flow relay
39. Instrument ECU relay
40. Ignition latch relay
41. Radio relay
A. AM/FM radio/heated mirrors

B. Climate control condenser fans
C. Spare
D. Tire pump/remote receptacle
E. All Wheel Drive
F. 12 Volt feed
Service Information

Data link port 379 Service Information 9/10/2022
Profile:
G780B Volvo
Data link port


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
The machine data link port is located in the right-hand side console. This link enables a technician to gain access to the grader's
electronics in order to program them or retrieve information using VCADsPro diagnostic tool.
Service Information

Ground stud - locations 379 Service Information 9/10/2022
Profile:
G780B Volvo
Ground stud - locations


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
A. Rear frame - left side rear
AC condenser fan motors

Fan ECU
D7 ECU housing
D10 alternator
Taillight harness
D7 engine ground strap
B. Rear frame - left side center
Isolation switch
Secondary steering box
D10 engine ground strap
C. Rear frame - right side rear
D7 alternator
D. Rear frame - right side center
Rear harness
E. Cab - lower right side
AC box
Front harness
Extra front headlight
EEC headlight
I-ECU and fuel sensor
AWD front harness
Transmission harness
AWD rear harness
Front float harness
Rear float harness
F. Cab console - panel ground
Console harness
AWD console harness
25 amp converter
60 amp equalizer
G. Cab - upper ground
Upper cab harness
H. Transmission - case ground
Transmission harness
I. Front frame arch - left side
Blade float solenoids
J. Cab ground - left side
Cab ground strap
K. Front frame - rear ground
Cab ground strap

Articulation ground strap
L. Rear frame - front left side
Articulation ground strap
Figure 1
Ground stud locations
GnD = Ground
Wiring diagram 1 - Main diagram/Positive feeds/Chassis connections
Component Ground location

RE3001 Console harness - GnD stud F
Alternator GnD stud A - D10 engine
GnD stud C - D7 engine
Isolation switch GnD stud B
Wiring diagram 2 - Positive feed/Chassis connection I-ECU/E-ECU

I-ECU GnD stud E
E-ECU Rear harness - GnD stud D
Wiring diagram 3 - Engine

RE4201 Console - GnD stud F
SW2101 Console - GnD stud F
HE2101 Grid heater housing
Wiring diagram 7 - Accelerator pedal/Fuel level

SA2701 Front harness - GnD stud E
SE2302 GnD stud E
SE3801 Rear harness - GnD stud D
Wiring diagram 8 - Fan ECU

Fan ECU GnD stud A
Wiring diagram 9 - Headlights/Turn signals/Horn

SA3601 horn Upper cab harness - GnD stud G
LA3502 Upper cab harness - GnD stud G
LA3508 Extra headlight harness- GnD stud E
LA3509 Extra headlight harness - GnD stud E
SW3502 Console harness - GnD stud F
SW3602 Front harness - GnD stud E
Wiring diagram 10 - EEC Headlights and flashers

LA3504 EEC headlight harness - GnD stud E
LA3505 EEC headlight harness - GnD stud E
LA3508 Extra headlight - GnD stud G
LA3509 Extra headlight - GnD stud G
LA3601 EEC taillight harness - GnD stud A
LA3602 EEC taillight harness - GnD stud A
Wiring diagram 11 - Work lights

LA3510 Front harness - GnD stud E
Wiring diagram 12 - EEC Worklights

Wiring diagram 13 - Windshield wiper systems
Component Ground location Notes

MO3601 Upper cab harness - GnD stud G
MO3602 Upper cab harness - GnD stud G
MO3603 Motor GnD's through wiper motor Fixed window wipers
housing
MO3604 Motor GnD's through wiper motor Fixed window wipers
housing
MO3603 Front harness - GnD stud E Vent window wipers
MO3604 Front harness - GnD stud E Vent window wipers
MO3605 Rear harness - GnD stud D
RE3604 Front harness - GnD stud E
Wiring diagram 14 - 25 amp/60 amp converter

PO3901 Console harness - GnD stud F
SO3901 Console harness - GnD stud F
SO3902 Console harness - GnD stud F
Wiring diagram 15 - Rotating beacons/differential lock/MBCS

MA4601 Rear harness - GnD stud D
MA9801 Front harness - GnD stud E
SW9801 Console harness - GnD stud E
Wiring diagram 16 - Transmission ECU

MA4201 Transmission - GnD H, E
MA5501 Rear harness - GnD stud D
SA4201 Taillight harness - GnD stud A
T-ECU Console harness - GnD stud F

AWD-ECU AWD console harness - GnD stud F
SA4401 AWD console harness - GnD stud F
SE4401 AWD console harness - GnD stud F
SE4402 AWD console harness - GnD stud F

MA4401 AWD front harness - GnD stud E
MA4402 AWD rear harness - GnD stud E
SE4403 AWD rear harness - GnD stud E
SW4401 AWD console harness - GnD stud F
SW4402 AWD console harness - GnD stud F

LA3607 Taillight harness - GnD stud A
MO5201 Motor housing
SE5201 Front harness - GnD stud E
SE5202 Brake master cylinder housing
Wiring diagram 21 - Secondary steering

MO6401 Gnd stud B
RE6402 GnD stud B
Wiring diagram 22 - Climate control unit

MA8701 Compressor housing rear harness - GnD stud D
MO8701 GnD stud A
MO8702 GnD stud E
Wiring diagram 23 - Front defroster fans

MO8801 Upper cab - GnD stud G
MO8802 Upper cab - GnD stud G
Wiring diagram 24 - Radio/Dome light/Heated mirrors

HE8901 Upper cab harness - GnD stud G
HE8902 Upper cab harness - GnD stud G
RA3901 Upper cab harness - GnD stud G
SO3903 Upper cab harness - GnD stud G
HM8801 Front harness - GnD stud E
Wiring diagram 25 - Blade float module

Float module Front harness - GnD stud E
MA9101 Blade float harness - GnD stud I
Wiring diagram 26 - Front float module

Float module Front float harness - GnD stud E
LA9101 Front float harness - GnD stud E
MA9105 Front float harness - GnD stud E
MA9106 Front float harness - GnD stud E
Wiring diagram 27 - Rear float module

Float module Console harness - GnD stud F
LA9102 Console harness - GnD stud F
MA9107 Rear float harness - GnD stud E
Wiring diagram 28 - Tire pump/Power outlet

PO9901 Socket case
RE9901 Rear harness - GnD stud D
SW9901 Rear harness - GnD stud D
Wiring diagram 29 - Communication, E-ECU/I-ECU

Service tool Console harness - GnD stud F
Description 2
Diagnostic software 18
Description of tests 19
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Every grader is equipped with the Contronics II warning and information instrument panel located in the pedestal. Many of the
grader's systems are being constantly monitored by sensors positioned in various parts of the machine. Sensors that monitor
speed, temperature, fluid levels, position, pressure and engagement, all send information to the ECU's. This information is then
sent to the display panel and indicator lights.
The display panel can be used for 3 different types of displays.
1. The information display presents the operator with information on machine hours, engine rpm and speedometer
reading (optional). More information on the grader's operation is obtained by selecting a button on the keypad located
below the instrument panel on the pedestal.
2. Warning text is shown on the display panel when any of the machine's monitored operating systems falls out of range.
3. An error text is displayed if a monitoring system within the grader malfunctions.
The instrument panel also contains an indicator light panel that works in conjunction with the display panel. It will light up a red
or amber indicator when a system malfunction occurs and a warning or error is shown on the display panel. Blue and green
lamps light up to act as indicators to the operator.
An optional trip information display screen will provide information on fuel consumption, time and fuel mileage.
Additional information on the distance traveled since the last reset is also available along with the speedometer option. An
information screen that displays total grader hours and engine hours can also be accessed. An independent gauge at the lower
right hand side of the operator also indicates total grader hours.
Figure 1
1. Center instrument panel (display unit, control lamps, gauges)

2. Pedestal head instrument panel (switches, warning lights, gauges)
Figure 2
1. Information (amber)
2. Central warning (red)
3. Charging battery
4. High hydraulic oil temperature
5. Low transmission oil pressure
6. Brake warning
7. Blade control system (MBCS) unlocked
8. Parking brake applied
9. Engine air filter restriction
10. Filter bypass warning
11. Primary steering system pressure
12. High beam headlights
13. Turn signal indicator
14. Differential locked
15. Engine preheat
16. Secondary steering on
17. Display unit (speedometer optional)
18. Engine oil pressure
19. Engine coolant temperature
20. Fuel level
21. (not used)
22. Hydraulic oil level
23. (not used)
General
If red control lamps light up – stop the machine immediately!
If amber lamps light up – an abnormal condition exists and measures may be required depending on the function concerned.
The remaining lamps – indicate that the respective function is engaged/connected.
Figure 3
Figure 4
1 Information (amber)
The amber central warning lamp flashes when system errors occur for less critical warnings. It informs the operator that a
function is engaged/disengaged or that a function needs to be kept under observation (for example, engine air filter). It is
accompanied by another warning lamp and/or message display to clarify the warning/error.
Figure 5
2 Central warning (red)

The central warning lamp flashes when critical warnings or errors occur. It is usually accompanied by a buzzer, another indicator
lamp and/or message on the display unit. It informs the operator that immediate attention is required.
Buzzer
The buzzer sounds at the same time the main central warning lamp is illuminated if any of the following faults are indicated:
Low engine oil pressure

Low transmission oil pressure
Low parking/service brake pressure
Parking brake (if applied in gear)
Low hydraulic oil level
Low steering system pressure
High engine coolant temperature
High hydraulic oil temperature
Pedestal instrument panel

Machine serial number 35061 and up,
including 35050 and 35051
Figure 6
1. Transmission gear display

2. Articulation indicator gauge
3. Keypad, display unit
4. Four-way hazard flasher
5. Differential lock switch
6. MBCS lock pin
7. Secondary steering system test
8. Directional indicator/High beam/Horn
9. Float valves power switch
10. Float valves system indicator lights
11. Parking brake switch
Pedestal instrument panel

Machine serial number 35000 – 35060,
excluding 35050 and 35051
Figure 7

3. Keypad, display unit
4. Four-way hazard flasher
5. Differential lock switch
6. MBCS lock pin
7. Secondary steering system test
8. Directional indicator/High beam/Horn
9. Float valves power switch
10. Float valves system indicator lights
11. Parking brake switch
1 Transmission gear display

The transmission gear display is located in the top left-hand side of the pedestal. It displays the transmission gear selected.
With the shift lever in the FORWARD position, the display shows the number of the forward gear, for example `3'.
With the shift lever in the REVERSE position, the display shows a negative number, for example `-2'.
The gear display can also provide other information:
It indicates a Start code sequence on start-up.

It shows an error code if there is a fault in the transmission or All Wheel Drive electrical system.
Start code sequence
Code Meaning
.8.8 LCD (Liquid Crystal Display)
7.8 T-ECU identification (Electronic Control Unit)
8.4 AWD-ECU identification (All Wheel Drive)
1 Last gear memorized* (example)
-1 Opposite gear* (example)
*Alternating display while in Neutral

When you start the engine, the transmission gear display will show a series of codes called the Start code sequence.
Error codes
The T-ECU continuously monitors the transmission and the AWD electrical system. In the event of a malfunction in either of
these systems, an error code is shown in the gear display.
Record any error codes and have the electrical system repaired by a qualified service technician. Refer to Error codesfor more
information.
Transmission error codes
If a malfunction occurs in the transmission electrical system, the gear display shows the letter `E' followed by a two-digit numeric
code. Multiple error codes are possible. The ECU disables the transmission shifter and places the transmission in NEUTRAL. The
display alternates between `E' and the code until the operator returns the shift lever to the NEUTRAL position.
“1.0” series error codes indicate insufficient power available for transmission solenoids. The transmission will not
operate until this problem has been resolved.
“2.0” or “3.0” series error codes indicate either an open or short circuit in a transmission solenoid. An alternate gear can
be selected by returning the transmission to NEUTRAL. This will allow the grader to be moved.
“2.8” or “3.8” series error codes indicated either an open or short circuit in the parking brake solenoid. The grader will
not operate until this problem is resolved.
“4.2” error code indicates the fault may be corrected by placing the shifter in NEUTRAL then back into gear.
“4.4” error code indicates a multiple shift command error. More than one proximity switch has been energized
simultaneously. The circuit board must be replaced to correct this problem.
“4.6” error code indicates there is a problem with the shift lever. The shift lever is out of neutral with no signal to the
forward or reverse solenoids.
“P” series error codes indicate a malfunction in the parking brake.
All Wheel Drive error codes

The transmission ECU continuously monitors the AWD electrical system. It is able to detect abnormal conditions and alert the
operator of a problem by displaying a code that will aid in correcting the problem.
If a malfunction occurs:
1. The transmission gear display shows the letter “E” followed by a 2-digit alphanumeric code. Multiple error codes are
possible.
2. The display alternates between “E” and the error code until the malfunction is corrected. The transmission is not
disabled.
Record the error codes and have the AWD electrical system repaired by a qualified service technician. Some error codes will
disable the AWD system.
NOTE!
“L1”, “L2” and “L4” Series error codes indicate a serious problem with hydraulic oil temperature, level or pressure. Shut the grader
down immediately and correct the problem.
Figure 8
Articulation gauge
– Machine S/N 35060 and up, including 35050 and 35051
2 Articulation indicator gauge
The indicator needle displays the degree the grader frame is articulated. The frame is straight with the needle in the center
position.
Figure 9
Articulation gauge
– Machine S/N 35000 – 35060, excluding 35050 and 35051
Figure 10
3
Keypad, display unit
The keypad allows access to information in different areas of the grader. The information is organized into systems (function
groups).
Engine
Engine speed, Coolant temperature, Oil pressure, Air inlet temperature, Boost temperature, Boost pressure, Fuel temperature,
Fuel pressure (G740B, G746B and G780B only), Coolant level.
Transmission
Transmission oil pressure, Filter bypass (optional), VHP status.
Figure 11
1. Engine
2. Transmission
3. Hydraulics
4. Hourmeter
5. Electrical system
6. Arrow up
7. Arrow down
8. Setup
9. Select
10. Auxiliary 2
11. Auxiliary 1
12. ESC
Hydraulics
Brake pressure, Hydraulic filter bypass (optional), Hydraulic oil temperature (optional).
Electrical system
System voltage
AUX 1 (Grader information)
Model, Tire size, Distance (only with speedometer option), Instantaneous fuel consumption, Average fuel consumption, Total fuel
consumption, Time to next service, Next service interval.
AUX 2 (Trip measurement information)
Fuel used, Time, Fuel/hour, Distance, Average speed, Fuel/distance, Reset (changes fuel, time and distance values to zero).
The following functions can be controlled from the keypad:
Selecting function group by direct selection (function key)

Browsing within a function group (the arrow keys)
Activating/deactivating functions (on/off)
Setting to zero/acknowledge (time/distance/cycles)
Numerical settings (the arrow keys)
Alpha-numerical settings (the arrow keys)
Simpler settings (e.g. increase/reduce)
Figure 12
Engine, Transmission, Hydraulics, Hourmeter, Electrical, Auxiliary 1 and Auxiliary 2 keys, display information about the respective
function group.
Figure 13
SETUP key displays the menu for making changes to units and language. Refer to Setup, language and units,below.
Figure 14
Arrow Up and Arrow Down keys are used to scroll in a function group menu. Select key is used to change and confirm settings.
Figure 15
ESC key returns the display to “Operating display”, regardless of which menu is showing.
When in the SETUP mode, pressing ESC will bring you back to the top of the selected menu.
Refer to“Setup, language and units”, below.
Display unit
Figure 16
Starting sequence (initial display)

(Ignition key in the “I” position)
The starting sequence takes about 4 to 5 seconds. At this time, a test program runs to verify the system.
The progress of this test is indicated on the display unit by the appearance of black squares from 1 to 7.
During the first part of the test, the control lamps will light up and the gauges will indicate (at twelve o'clock), then return to
actual reading position. The battery lamp, park brake lamp and service brake warning lamp stay on until the grader is started.
Displayed information
Figure 17
Standard operating information display
(without optional speedometer)
The display unit provides information to the operator. This information is divided into three groups:
1. Operating information, etc.

2. Warning displays (low pressure etc.)
3. ERROR displays (sensor and control device check)
Operating information display

This is the default display.
Obtain different information – engine, transmission, hydraulics, hourmeter, electrical, auxiliary 1 and auxiliary 2 – by
selecting buttons on the keypad.
Warning display
Alerts the operator to a malfunction in machine systems (engine, hydraulics, transmission, etc.)
Applies to various areas of the grader.
Error display
Alerts the operator to malfunction in the monitoring system.

Applies to various areas of the grader.
Operating information (default display)
Figure 18
1. Engine speed
2. Machine hours
3. Travel speed
4. Units for travel speed
Operating Information will be displayed after starting (unless the operator had another display screen showing when
the power was switched off).
At a speed above 20 km/h (12 mph) the Operating Information will show the current travel speed (even if another
display screen was selected).
If a display screen other than the Operating Information was selected, the system will revert to that display screen when
the travel speed drops below 20 km/h (12 mph).
Changing the display screen using the keyboard is only possible if the travel speed is below 20 km/h (12 mph).
Changing display screen

Move from one function group to another using the keys on the keypad. When changing function group, the first menu of that
group will be displayed. To return to the Operating Information display, press the ESC key.
Setup
Settings of language and units are done in “Setup, language and units”, below.
Display classes
The information shown on the display for the operator is organized into the following classes:
Class 1: WARNING
Shown regardless of which display is selected. “WARNING” display is shown for 2 seconds, then the previous display for 3
seconds. This is repeated for as long as the malfunction remains.
Generally, the red central warning lamp flashes while the alarm text is shown.
Class 2: INFORMATION
Shown regardless of which display is selected. “INFO” display is shown for 2 seconds, then the previous display for 3 seconds.
This is repeated until the INFO display has been shown 3 times.
Generally, the amber central warning lamp flashes while the INFO display is shown.
The next time the machine is started, the INFO display is repeated if it is still active.
Class 3: ERROR
Shown regardless of which display is selected. “ERROR” display is shown for 2 seconds, then the previous display for 3 seconds.
This is repeated until the INFO display has been shown 3 times.
Generally, the amber central warning lamp flashes while the error display is shown.
Class 4: SERVICE INFO
Shown regardless of which display is selected. “SERVICE INFO” display is shown for 2 seconds, then the previous display for 3
seconds. This is repeated until acknowledged by “reset”.
Generally, the amber central warning lamp flashes while the service INFO display is shown.
Multi-info/warning/error display:
If several info/warning/error displays are active simultaneously, they are shown one after the other.
Machines with the optional speedometer
At vehicle speeds greater than 20 km/h (12 mph), the info/warning/error display is shown first, then “Operating info” is shown,
then the next info/warning/error display, etc. At speeds less than 20 km/h (12 mph), the display information follows the
sequence described in its class, with the “previous” display shown between the alternating multiple displays.
For machines not equipped with a speedometer, the information displayed follows the sequence described in its class above,
with the “previous” display shown between the alternating multiple displays.
Setup, language and units
Figure 19
Language
Depress the SETUP key, then depress the SELECT key to show the language menu. Available languages are English,
French, Spanish, Swedish, and German.
Select the required language with up or down arrow keys.
After the language has been chosen, press SELECT. If no change of the setting is required, just press SELECT.
Units
By pressing the SELECT key, the display will change from the language menu to the menu for “Units”.
Choose the required units with the arrow keys and press SELECT. If no change of the setting is required, just press
SELECT.
Press ESC to return to the main menu
To cancel a setting, press ESC. The SETUP menu will appear. Press ESC again to return to the main menu.
Information display screens
Figure 20
Function groups
Each function group consists of one or more display screens. If there is more than one screen for each function group, an arrow
pointing downward will be displayed in the bottom, right-hand corner of the display. Arrows pointing upward and downward
indicate there are screens above and below the current one.
To browse within a function group, press the down or up arrow keys.
NOTE!
If “Er” is shown for a value in any display screen, it indicates an error in the signal monitoring that information.
NOTE!
Features that are options will not appear in the display unless machine is equipped with that option.
Figure 21
ENGINE I
Speed xxx0 rpm
Water Temp yyy yy
Oil Press zzz.z zzz
x= Engine speed (revolutions per minute).

y= Engine coolant temperature, units are ºC or ºF. Shown down to 0ºC, below that shown as < 0ºC or < 0ºF.
z= Engine oil pressure, units are in bar or psi.
ENGINE II
Inlet Temp xxx xx
Boost Temp yyy yy
Boost Press zzz.z zzz
x= Intake air temperature, units are ºC or ºF. Indicates actual temperature down to 0ºC, below that shown as < 0ºC or
< 0ºF.
y= Charge air temperature, units are ºC or ºF. Indicates actual temperature down to 0ºC, below that shown as < 0ºC or
< 0 ºF.
z= Charge air pressure, units are in bar or psi.
ENGINE III
Fuel Temp xxx xx
Fuel Press yyy yy
Coolant Level zzz.z zzz
x= Fuel temperature, units are ºC or ºF. Indicates actual temperature down to 0ºC, below that shown as < 0ºC or < 0ºF.
y= Fuel pressure, units are bar and psi.
z= Coolant level (normal or low).
Figure 22
TRANSMISSION
Pressure xxxxxx
Filter yyyyyy
VHP Status zzz
x= Transmission oil pressure (indicates normal or low).

y= Transmission oil filter (indicates normal, clogged).[1]
z= VHP status (indicates ON or OFF).
Figure 23
HYDRAULICS
Brake Press xxxxxx
Filter yyyyyy
Temperature zzzzzz
x= Brake system pressure (indicates normal or low).

y= Hydraulic oil filter (indicates normal or clogged).[2]
z= Hydraulic oil temperature (indicates normal or high).
Figure 24
HOURMETER
Grader Hours xxxxx.x
Engine Hours xxxxx.x
x= Time in hours, up to 99999.9.
Figure 25
ELECTRICAL SYSTEM
Voltage xx.x v
x= Electrical system voltage (real time) in volts DC.
Figure 26
INFORMATION I
Motor Grader xxxx
Tire Size yy.yy
Distance yyyyyyy yy
x= Machine model
y= Tire size designation
z= Distance travelled, units in km or mi. Shown up to 999,999 km or 621,372 miles
NOTE!
Values for distance are only shown if the speedometer option is installed on the machine.
FUEL CONSUMPTION
Momentary xxx x/h
Average yyy y/h
Total zzzzzzz z
x= Current fuel consumption, shown in L/h or g/h (liters per hour or US gallons per hour).
y= Average fuel consumption per hour, shown in L/h or g/h (liters per hour or US gallons per hour). Calculated by
dividing total fuel consumed by engine hours.
z= Total fuel consumption, calculated up to 9999999 liters or 2641720 US gal, in one unit increments.
NEXT SERVICE
Remaining xxxx h
Interval yyyy h
Acknowledge Sel.
x= Time remaining to next service interval.

y= Service interval, shown as 250, 500, 1000, 2000. When 8 hours remain to next service, display shows “Time for
service”.
To acknowledge and remove information, press SELECT
NEXT SERVICE
Time to next engine oil change
The bars indicate the total time left until the next service interval. Each one represents 25 hours.
When 8 hours remain to next service, the display shows “Time to change engine oil”.
To acknowledge and remove information, press SELECT.
Figure 27
TRIP MEASUREMENT 1
Fuel xxxxxx x
Time yyyy.y y
Fuel/hr zz.z z
x= Fuel consumption since resetting, in liters or US gal up to 999,999 liters or 264,200 US gal.
y= Time since resetting in hours up to 9999.9
z= Fuel consumption per hour since resetting, up to 99.9 L/h or 26.4 US gal/hr.
NOTE!
To reset, see Trip information reset.
TRIP MEASUREMENT 2
Dist xxxxx.x x
Avg Speed yy.y yyy
Fuel/Dist zz.z z/zz
x= Total distance since resetting in km (or mi) up to 9999.9 km (6213.6 mi), alternatively –
y= Average speed since resetting up to 99.9 kmh (62.1 mph) shown in kmh (kilometre/hour) or mph (miles/hour),
alternatively –
z= Fuel consumption per unit distance since resetting, up to 99.9 in L/km or US mi/gal, alternatively –
NOTE!
Values based on distance only available with speedometer option. If speedometer not available, value displays as “n/a”.
Trip information reset
TRIP RESET
Use Select
Press AUX 2, display shows “TRIP INFORMATION 1”.

Press the down arrow, display shows “TRIP INFORMATION 2”.
Press the down arrow, display shows “TRIP RESET”.
Press SELECT to reset. The display shows “TRIP RESET – RESETTING”.
Trip data is now set to zero.
[1]Optional
[2]Optional
Service Information

Diagnostic software 380 Service Information 9/10/2022
Profile:
G780B Volvo
Diagnostic software

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
VCADsPro (Volvo Computer Aided Diagnostic System) is a PC based service tool that has been developed to facilitate
troubleshooting work. It is able to program control units, download vehicle parameters, read error codes, and carry out testing
and checking of functions or components. The software can activate or deactivate component functions. It displays values with
the test functions and reads error codes.
The VCADsPro software communicates with the grader's software through a PC the technician plugs into the data link port
located in the cab of the grader. This software will then be able to interface with the grader's ECU's through the SAE J1708/1587
bus.
VCADsPro is capable of running tests and retrieving information from 2 main areas: the engine's ECU and sensors, and the entire
machine's sensors and indicators.
Testing of the machine sensors is done with the engine off as well as with the engine running. These tests will indicate whether
the sensors are operating within the specified parameters. If any of the sensors are not sending the intended signal back to the
ECU, the VCADsPro test will notify the technician. From that point on, the proper troubleshooting techniques should be followed.
The monitored sensors include pressure differential sensors for the hydraulic and transmission filters, and transmission oil
pressure.
VCADsPro also communicates with the engine's ECU to determine the status of the sensors that monitor the fuel pressure, fuel
temperature, oil pressure, engine coolant temperature and level, as well as others.
In addition, the software also has the ability to perform cylinder balancing and cylinder compression tests. The software can also
test the response of the accelerator pedal.
Service Information

Description of tests 380 Service Information 9/10/2022
Profile:
G780B Volvo
Description of tests

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The following paragraphs outline the electrical system tests for the grader systems and the engine systems. After the original
login to the VCADsPro system, select the test section from the main menu.
Either stationary engine or running engine options are available.
The next screen displays all possible sensor tests available. When a certain test is desired, select the play button. The software
will then run the test internally and look for information from the I-ECU. If the test indicates normal operation, the test symbols
are green. If any test shows red, additional testing is required.
41 - CLUTCH; TORQUE CONVERTER 2
42 - TRANSMISSION; HYDRAULIC CONTROL 30
44 - HYDROSTATIC DRIVE 69
46 - FRONT AXLE; REAR AXLE 121
Specifications; engine clutch 2
Description and operation; engine clutch 4
Clutch housing; removing 8
Clutch assembly; removing 11
Clutch assembly; installing 13
Clutch housing; installing 15
Bearing support housing; installing 17
Clutch Slave Cylinder and Pedal Free Play; adjusting-1328 19
Clutch Slave Cylinder and Pedal Free Play; adjusting 22
Specifications; clutch master cylinder and booster circuit 24
Description; clutch master cylinder and booster 25
Service Information

Specifications, engine clutch 413 Service Information 9/10/2022
Profile:
G780B Volvo
Specifications, engine clutch


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Engine clutch torque values
Item Torque Value

N•m kgf•m lbf•ft
Drive shaft yoke retaining bolt 149 15 110
Cross shaft arm retaining bolt 32 3 23
Bearing support housing retaining bolts 32 3 23
Clutch housing to flywheel housing bolts 32 3 23
Slave cylinder retaining bolts 149 15 110
Driveshaft bearing cross retaining bolts 47 5 35
Release lever pivot block nut 54 - 61 5,5 - 6 40 - 45
Clutch assembly to flywheel retaining bolts 32 3 23
Clutch plate thickness dimensions
G710B to G730B Qty Maximum Minimum

Four Plate wet mechanical clutch
Friction thickness
Maximum 5,182 mm (0.204 in.) 4 20,726 mm
(0.816 in.)
Minimum 4,928 mm (0.194 in.) 4 19,711 mm
(0.776 in.)
Steel thickness
Maximum 6,401 mm (0.252 in.) 3 19,203 mm (0.756 in.)
Minimum 6,248 mm (0.246 in.) 3 18,745 mm (0.738 in.)
Total 39,929 mm (1.572 in.) 38,456 mm (1.514 in.)
G740B to G780B Qty Maximum Minimum
Five Plate wet mechanical clutch
Friction thickness
Maximum 5,182 mm (0.204 in.) 5 25,908 mm
(1.020 in.)
Minimum 4,928 mm (0.194 in.) 5 24,638 mm
(0.970 in.)
Steel thickness
Maximum 3,581mm (0.141 in.) 4 14,326 mm (0.564 in.)
Minimum 3,454 mm (0.136 in.) 4 13,818 mm (0.544 in.)
Total 40,234 mm (1.584 in.) 38,456 mm (1.514 in.)
Clutch master cylinder fluid

See Recommended lubricants for the specified clutch master cylinder fluid.
Clutch free play
Free play at the slave cylinder adjustment locknuts 3,8 mm ±0,76 mm (0.150 ±0.030 in.)
Pressure plate
Pressure plate machining: not less than 41,6 mm (1.636 in.) from the pressure plate face to the center of the lever pin holes.
Pressure plate warpage: friction face must be flat within 0,13 mm (0.005 in.) TIR (total indicator reading) and parallel with the
plane of the three pin holes within 0,08 mm (0.003 in.)
Pressure plate finish: grind to 32 RMS (root mean square) and hand polish for one minute with 300 grit emery cloth in a circular
motion to create a surface texture compatible with the clutch friction disc material.
Adjusting screw clearance
Set-up distance: 51,7 ±0,4 mm (2.035 ±0.015 in.)
Separator plates
Separator plate warpage: within 0,13 mm (0.005 in.) (also applies to dishing).
Separator plate thickness: minimum after grinding 5,9 mm (0.232 in.)
Separator plate finish: grind to 32 RMS (root mean square) and hand polish for one minute with 300 grit emery cloth in a circular
motion to create a surface texture compatible with the clutch friction disc material.
Friction discs
Wear limit: grooves worn off the friction discs and separator plate stack thickness – new 58,4 mm (2.30 in.)
Clutch springs
Resistance at compressed height 77 kg at 46 mm (170 lbs at 1.81 in.).
Clutch shaft run-out
With the clutch shaft set up on two “V” blocks at the bearing journals, the run-out should be within 0,25 mm (0.010 in.)
Cross shaft bushing free play
Replace the cross shaft bushings if:
a. There is appreciable play between the bushings and the shaft which may affect the clutch free play.
b. The bushings are damaged.
Service Information

Description and operation, 413 Service Information 9/10/2022
engine clutch
Profile:
G780B Volvo
Description and operation, engine clutch


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Description
All G700B motor graders are equipped with a 13.5" diameter wet clutch. The clutch is controlled by a foot pedal and is used
when you start from a complete stop, change direction, and stop the grader. It allows the grader to start moving under high
loads without putting undue force on the drivetrain. You do not need to use the clutch for up or down shifting when the grader
is moving forward or backward.
The clutch assembly is bolted to the engine flywheel and is enclosed by a two-piece clutch housing assembly. The clutch housing
assembly consists of a cast iron bearing support housing attached to an aluminum clutch housing. The aluminum clutch housing,
which is attached to the engine flywheel housing, dissipates heat quickly and is light in weight for easy handling.
The clutch assembly includes four friction discs and three separator plates. The release bearing and sleeve assembly is supported
on the clutch shaft by two needle roller bearings.
System Operation
The engine clutch is activated through a hydraulically operated master cylinder and slave cylinder.
The clutch master cylinder is hydraulically boosted by a priority flow of oil from the transmission pump. The pump is mounted on
the engine. A mechanical linkage connects the clutch pedal to the clutch master cylinder and booster assembly. The force you
apply to the clutch pedal is increased by the clutch booster. The increased force moves the clutch master cylinder piston. The
displaced fluid from the clutch master cylinder reservoir flows through a hydraulic hose to the slave cylinder. The slave cylinder is
attached to the clutch housing and cross shaft arm. The fluid causes the slave cylinder piston to extend and move the cross shaft
arm, which rotates the cross shaft. Inside the clutch housing, a yoke, which is attached to the cross shaft, moves the release
bearing and sleeve assembly toward the clutch release levers. The release bearing contacts the release levers and pushes them
toward the flywheel. The release levers then pull back the pressure plate, which in turn disengages the clutch friction discs and
separator plates.
Oil is used to cool and lubricate the clutch driven members and bearings. Oil flows from the transmission sump, through a
suction screen and the suction hose to the transmission pump. The pump is mounted to an accessory drive on the engine. The
pump divides the oil into priority flow and excess flow. The priority flow supplies a constant 22,7 L/m (6 gpm) first to the clutch
booster and then the brake booster. After the brake booster, the oil joins the transmission lubricating circuit through a fitting at
the transmission pressure regulator valve. The excess flow from the transmission pump circulates through the transmission oil
cooler and the transmission oil filter. The oil continues from the filter to the transmission pressure regulator valve. The pump also
supplies oil to the parking brake valve.
To maintain lockup pressure, most of the oil is discharged internally to the lubrication pressure regulator section of the valve. A
hydraulic hose connected to an additional fitting at the transmission pressure regulator valve supplies lubrication and cooling oil
to the engine clutch assembly. Finally, the oil drains to the bottom of the flywheel housing and returns to the transmission sump
through the drain hose.
The flow rate through the engine clutch assembly is limited by internal restrictors and the lubrication pressure of the
transmission. The flow rate should not exceed 22,7 L/m (6 gpm) at full engine rpm.
Figure 1
Clutch cooling and lubrication
1. Oil cools and lubricates clutch plates

2. Pilot bearing lubrication
3. Oil drains to the transmission sump
4. Lubrication oil from transmission circuit enters here
Oil circuit within the clutch

Oil enters through a fitting at point (4) in the bearing support housing. Most of the oil enters the two cross-drillings and the rifle
drilling in the clutch shaft between the two clutch shaft oil seals. Some oil exits through the orifice plug at the end of the clutch
shaft to lubricate the pilot bearing. The rest of the oil in the clutch shaft leaves the cross drillings at the clutch hub to be
centrifugally forced through the friction discs and separator plates where it cools and lubricates the driven members. On leaving
the driven members and the pilot bearing, the oil lubricates the clutch assembly pivots and splines, the release bearing, and the
needle roller bearings in the release bearing sleeve. The splash action of the oil also lubricates the cross shaft bushings.
A small quantity of oil is diverted when entering the bearing support housing at point (4). The oil passes through a cross-drilled
passage to lubricate the clutch shaft bearing. From the clutch shaft bearing, the oil drains through openings at the bottom of the
bearing support housing to the clutch housing. The oil exits at point (3) in the engine flywheel housing.
Clutch components
Figure 2
Clutch assembly
1. Clutch shaft
2. Output yoke seal
3. Snap ring
4. Clutch shaft bearing
5. Bearing support housing
6. Clutch shaft seals (qty. 2)
7. Cross shaft and yoke
8. Throw-out bearing
9. Clutch fingers
10. Backing plate
11. Pressure plate
12. Adapter drive ring
13. Flywheel
14. Crankshaft
15. Pilot bearing
16. Orifice plug
17. Oil deflector and clutch hub
18. Friction plates
19. Steel spacers
20. Clutch springs (see a)
21. Caging capscrew and washer (for clutch assembly servicing only)
22. O-ring
23. Gasket
24. Output yoke
NOTE!
See slave cylinder assembly items 25 to 35
25. End cap

26. Bleeder screw
27. Bolt
28. O-ring
29. Spring
30. Housing
31. Piston
32. Cup
33. Wiper
34. Rod end
35. Cross shaft arm
NOTE!
a. G710B and G720B - 15 springs 4 plate disc and hub assembly. G726B, G730B, G740B, G746B and G780B - 15 springs 5 plate
disc and hub assembly.
Service Information

Clutch housing, removing 413 Service Information 9/10/2022
Profile:
G780B Volvo
Clutch housing, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 413-011
NOTE!
Place the grader in the Service Position before starting this overhaul procedure. Refer to Service positions.
1. Steam clean the grader. Remove the air intake and muffler stacks. Cover the intake and muffler openings.
2. Remove the engine cowling side panels and hood.
3. Remove the side panels located under both sides of the fuel tank.
4. With the fuel level below the return port, disconnect the diesel fuel return hose from the engine. Promptly plug the
hose and the port to avoid contamination.
5. Remove fuel tank mounted components as they apply to the machine. Examples are: air filter assembly, windshield
washer tank, and air conditioning receiver/dryer.
6. Disconnect the fuel level sender wires at the top of the fuel tank.
7. From the front of the fuel tank stand, remove the U-bolt that retains the hydraulic hoses and wiring harnesses passing
under the fuel tank.
8. Close the fuel tank shut-off tap at the tank sump and disconnect the fuel supply hose. Promptly plug the hose and the
fitting on the shut-off tap to avoid contamination. Remove the bolts and washers retaining the fuel tank stand to the
grader frame.
9. Use a safe lifting device to remove the fuel tank and stand from the grader frame.
10. Identify and tag all hoses connected to the clutch housing. This will help during assembly.
11. Remove the transmission vent hose from the clutch housing port at the two o'clock position (viewed from the front of
the grader).
12. Remove the differential lock valve oil return hose from the bottom of the clutch housing.
13. Disconnect the oil supply hose from the bearing support housing.
14. Promptly plug all hoses and ports to avoid contamination.
15. Cut the tie-wraps and remove the retaining clamps that secure the hoses and wiring harnesses.
16. Move the hoses and wiring harnesses away from the work area.
17. Disconnect and remove the upper driveshaft.
18. Remove the bracket securing the slave cylinder to the clutch housing.
19. Loosen the bolt retaining the arm on the cross shaft. Remove the arm.
20. Move the slave cylinder away from the work area.
21. Remove the output yoke retaining bolt, washers and gasket.
22. Remove the yoke.
23. Remove the bolts and lock washers retaining the support bearing housing to the clutch housing.
24. Remove the bearing support housing, together with the clutch shaft, from the clutch housing and place it on a
workbench.
25. It may be necessary to use a dull, flat chisel to separate the bearing support housing from the clutch housing.
Figure 1
Removing bearing support housing
NOTE!
You can easily damage the aluminum surface of the clutch housing if the chisel is not used carefully.
26. Remove the clutch housing retaining bolts.
27. Remove the clutch housing.
28. If you cannot remove the clutch housing easily, use a rubber mallet to tap around the outside of the housing.
NOTE!
You can easily damage the aluminum clutch and flywheel housings if you use excessive force during removal.
29. Remove and discard the clutch housing gasket.
Service Information

Clutch assembly, removing 413 Service Information 9/10/2022
Profile:
G780B Volvo
Clutch assembly, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 413-012
NOTE!
1. Insert the clutch shaft into the clutch assembly hub.
2. Use three 3/8” x 2 1/4” long bolts (caging bolts) with flat washers to retain the pressure plate to the backing plate.
Insert each bolt through the center hole of the five holes between the release lever pivot block nuts.
Figure 1
Installing clutch assembly caging bolts
3. Remove the clutch assembly bolts at the ten o'clock and two o'clock positions. Install threaded dowel pins in these
positions.
4. Ensure that the pressure plate is retained by the three caging bolts. Remove the remaining bolts from the clutch
assembly.
5. Remove the clutch assembly and the drive ring.
Figure 2
Removing clutch assembly and drive ring
NOTE!
The clutch assembly and drive ring may stick together due to a slight friction fit. They may separate unexpectedly.
Service Information

Clutch assembly, installing 413 Service Information 9/10/2022
Profile:
G780B Volvo
Clutch assembly, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 413-013
NOTE!
1. Install the flywheel to the engine and torque-tighten the bolts according to the engine specifications.
2. Install threaded dowel pins at the ten o'clock and two o'clock positions in the flywheel housing. Install the drive ring.
3. Insert the clutch shaft from the closed side of the hub and clutch assembly.
4. Use the clutch shaft as a pilot tool when installing the hub and clutch assembly into the drive ring. Make sure that the
dished side of the hub faces the flywheel.
5. Engage the separator plates one at a time into the drive ring.
Figure 1
Installing clutch hub with dished side toward flywheel
6. Align the stamped mark of the drive ring with the stamped mark on the backing plate before installing the clutch
assembly onto the dowel pins.
7. Install 10 of the original 3/8 in. x 3 1/4 in. long bolts and lock washers to retain the clutch assembly to the flywheel.
Remove the dowel pins and replace them with the remaining bolts and lock washers.
8. Ensure the backing plate is properly positioned in the locating counterbore of the drive ring.
9. Torque-tighten the 12 bolts evenly and in a diagonal sequence to 32 N•m (3 kgf•m)(23 lbf•ft).
NOTE!
Remember to remove the three caging bolts to release the pressure plate from the backing plate after the clutch
assembly retaining bolts have been torque-tightened.
10. Remove the clutch shaft from the clutch assembly.
Figure 2
Torque-tightening clutch assembly bolts
The installation of the clutch assembly is now complete.
11. Use a proper size seal driver to install the clutch shaft oil seals in their respective bores. Ensure that the cupped sides of
the seals face each other.
Service Information

Clutch housing, installing 413 Service Information 9/10/2022
Profile:
G780B Volvo
Clutch housing, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 413-014
1. Apply petroleum jelly or grease on both sides of a new paper gasket.
2. Install the gasket on the clutch housing.
3. Install two threaded dowel pins in the flywheel housing at the nine o'clock and three o'clock positions.
4. Position the clutch housing correctly on the dowel pins and move it against the flywheel housing (the cross shaft must
be horizontal and underneath the clutch shaft).
5. Install the retaining bolts and lock washers. Install the slave cylinder bracket at the correct location and retain with the
two longer bolts and lock washers.
6. Remove the dowel pins and install the remaining clutch housing retaining bolts and lock washers.
Figure 1
Installing clutch housing and bolts
7. Torque-tighten the clutch housing bolts in a diagonal sequence to 32 N•m (3 kgf•m)(23 lbf•ft).
NOTE!
The clutch housing and the engine flywheel housing are made of aluminum. DO NOT torque-tighten the bolts into the
aluminum housings beyond the specified values. Thread damage to the aluminum housings may occur.
8. Engage the release bearing sleeve into the yoke trunnions ensuring that the oil supply hole points to the top.
Figure 2
Engaging release bearing sleeve into yoke trunnions
9. Temporarily insert the clutch shaft and bearing support housing assembly in the clutch housing and through the release
bearing sleeve. Ensure the cross shaft and yoke assembly moves the release bearing sleeve freely on the clutch shaft.
10. Remove the clutch shaft and bearing support housing assembly.
11. Use a brass drift and hammer to install the woodruff key for the cross shaft arm.
12. Install the arm on the cross shaft and secure it with the woodruff key.
13. Torque-tighten the bolt to 32 N•m (3 kgf•m)(23 lbf•ft).

Service Information

Bearing support housing, 413 Service Information 9/10/2022
installing
Profile:
G780B Volvo
Bearing support housing, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 413-016
1. Coat the clutch housing to bearing support housing mating surfaces with a thin film of RTV silicone, or equivalent.
Make sure there is no oil or debris on surfaces.
2. Lubricate the bearing support housing O-ring with system oil or petroleum jelly.
3. Insert the clutch shaft and bearing support housing assembly in the clutch housing and through the release bearing
sleeve.
Figure 1
Installing clutch shaft and bearing support housing assembly
4. Install the oil inlet fitting at the three o'clock position (viewed from the front of the grader).
5. Install the retaining bolts and lock washers. Torque-tighten the bolts to 32 N•m (3 kgf•m)(23 lbf•ft).
NOTE!
The clutch housing is made of aluminum. DO NOT torque-tighten the bolts into the aluminum housing beyond the specified
value. Thread damage to the aluminum housing may occur.
Service Information

Clutch Slave Cylinder and 413 Service Information 9/10/2022
Pedal Free Play, adjusting
Profile:
G780B Volvo
Clutch Slave Cylinder and Pedal Free Play, adjusting


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 413-017
Final installation and adjustment
1. Measure the clutch free play by moving the cross shaft arm up and down. Use a wrench on the bolt that attaches the
bottom eyebolt of the slave cylinder to the cross shaft arm and move the arm up and down. The free play should be 3.1
to 3.9 mm (1/8 to 5/32 in.)
Figure 1
Measuring release bearing free play
2. Adjust the free play by loosening the bottom locknut and turning the slave cylinder eyebolt. Tighten the locknut after
the adjustment is made.
Figure 2
Adjusting release bearing free play
3. Lubricate the yoke oil seal with system oil or petroleum jelly.
4. Install the yoke, gasket, washer, lock washer and retaining bolt.
5. Torque-tighten the bolt to 149 N•m (15 kgf•m)(110 lbf•ft).
6. Install the upper drive shaft.
7. Torque-tighten the bolts retaining the driveshaft bearing crosses to 47 N•m (5 kgf•m)(35 lbf•ft).
8. Install the elbow fitting at the two o'clock port on the clutch housing (viewed from the front of the grader).
9. Connect the transmission vent hose to this fitting.
10. Connect the differential lock valve return hose to the elbow fitting at the six o'clock position on the clutch housing. If
necessary, install the elbow and breather at the 10 o'clock position on the clutch housing.
NOTE!
Do not use Teflon tape sealer on the pipe thread of the breather and elbow. Use Teflon sealant paste instead.
11. Use a safe lifting device to position the fuel tank and the fuel tank stand on the frame. Install the bolts and washers.
12. Retain the hoses and wiring harnesses passing under the fuel tank with the U-bolt. Install the U-bolt to the front of the
tank stand.
13. Connect any wiring harnesses in the engine area.
14. Secure all hoses and wiring harnesses with the retaining clamps and new tie-wraps to ensure that they do not rub or
contact sharp edges.
15. Connect the fuel supply hose to the fuel tank shut-off tap at the tank sump. Open the shut-off tap.
16. Install fuel tank mounted components as they apply to the machine. Examples are: air filter assembly, windshield washer
tank, air conditioning receiver/dryer, and equipment for cold starting.
17. Connect the fuel level sender wires at the top of the fuel tank.
18. Connect the diesel fuel return hose from the engine.
19. Install the hood, muffler and air intake stacks, rain cap or pre cleaner cap, and side panels under both sides of the fuel
tank.
20. Install the cowling side panels.

NOTE!
Test the grader to ensure that there are no problems with the mechanical function of the engine clutch or hydraulic
leaks.
Service Information

Clutch Slave Cylinder and 413 Service Information 9/10/2022
Pedal Free Play, adjusting
Profile:
G780B Volvo
Clutch Slave Cylinder and Pedal Free Play, adjusting


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The clutch slave cylinder is located on the right-hand side of the clutch housing.
Op nbr 413-017
1. Open the inspection cover on the right-hand side of the fuel tank stand. Open the front right-hand side panel door for
additional access to the clutch housing.
2. Install an appropriate wrench on the bolt retaining the clutch slave cylinder to the cross shaft arm.
Figure 1
1. 3.1 to 3.9 mm (1/8 to 5/32 in.)
3. Press the cross shaft arm downwards. This will rotate the cross shaft.
4. Press until a firm resistance is felt. This means that the release bearing is engaging the lever arms of the clutch.
5. The clutch slave cylinder free play should be 3.1 to 3.9 mm (1/8 to 5/32 in.).
6. Check the clutch pedal free play by depressing the pedal and measuring the deflection. This can be done by hand.
Figure 2
1. 1,5 mm to 3 mm (1/16 to 1/8 in.)

2. Clutch Pedal
7. The clutch pedal free play should be 1,5 to 3 mm (1/16 to 1/8 in.).
Service Information

Specifications, clutch master 413 Service Information 9/10/2022
cylinder and booster circuit
Profile:
G780B Volvo
Specifications, clutch master cylinder and booster circuit


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Priority regulator on the pump is set at 23 L/min (6 gpm)

Each booster contains an integrated pressure relief valve
Brake booster relief valve set to 9,65 MPa (96 bar)(1400 psi)
Clutch booster relief valve set to 2,48 MPa (25 bar)(360 psi)
Pump relief valve is set to 10,34 MPa (103 bar)(1500 psi)
Brake master cylinder capacity 15,16 MPa (152 bar)(2200 psi)
Clutch master cylinder capacity 10,34 MPa (103 bar)(1500 psi)
Service Information

Description, clutch master 413 Service Information 9/10/2022
cylinder and booster
Profile:
G780B Volvo
Description, clutch master cylinder and booster


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
All hydraulic boosters multiply pedal effort and transfer it to a master cylinder. Two boosters are used. One with a dual reservoir
master cylinder for a diagonal brake application circuit and one with a single reservoir master cylinder for a clutch
disengagement circuit. The brake booster features an integral electric back-up pump, designed to provide sufficient boost to
bring the machine to a safe stop, or hold the machine on a slope until the parking brake is applied.
Clutch circuit
The priority outlet of the engine mounted transmission/booster hydraulic pump provides oil for the brake and clutch booster
circuit. A relief valve is incorporated into the pump outlet. Unlike the steering and main hydraulic circuits, this circuit is open
center. Therefore, oil circulates through the boosters until required. Oil passes through the clutch booster first, exits and passes
through the brake booster and then drains back into the transmission case.
Figure 1
Clutch master cylinder and booster circuit
1. Brake master cylinder

2. Brake booster c/w electric back-up pump
3. Clutch master cylinder
4. Clutch booster
5. Transmission/booster hydraulic pump
6. Brake circuit
7. Brake circuit
Clutch master cylinder and booster components

Figure 2
Components
1. Booster
2. Master cylinder
3. Retaining ring
4. Piston
5. Cup
6. Spring
7. Housing
8. Bail hook
9. Cover
10. Diaphragm
11. Washer
12. Connector
13. Bolt
14. Lock washer
15. Cup
16. Decal
17. Ring
18. Warning label
19. Retainer
20. Power booster
21. O-ring
22. Piston ring
23. O-ring
24. Spring
25. Spring
26. Cup
27. Back-up ring
28. Retaining ring
29. Boot
30. Push rod
31. End plug
32. Piston
33. Housing
34. Piston
35. Piston
36. Spring
37. Piston
38. End plug
39. Retainer
40. Snubber
41. Retaining ring
42. Clevis
43. Jam nut
44. Retaining ring
45. Shim
Specifications 2
Description; 8400 transmission 4
Transmission components 7
Transmission ECU and shifter assembly 9
Transmission oil circuit and operation 12
Transmission hydraulic circuit and operation 17
Transmission troubleshooting 19
Error codes 23
Hydraulic system troubleshooting 26
Transmission; removing 32
Transmission; installing 36
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Transmission pump flow

Low engine idle 53 L/min (14 U.S. gpm)
High engine idle 159 L/min (42 U.S. gpm)
Wear limits – clutch friction discs

Disc diameter 133 mm 168 mm
(5 1/4 in.) (6 5/8 in.)
Minimum disc thickness 1,245 mm (0.049 in.) 2,235 mm (0.088 in.)
Torque value N•m kgf•m lbf•ft

Yoke locknut 203 – 271 21 – 28 150 – 200
Bearing retaining locknuts 271 – 339 28 – 35 200 – 250
Oil level check sight glass 7 0,7 5
Solenoid valve cartridges 34 3 25
Solenoid valve conical nuts 7 0,7 5
Collector cap bolts 40 – 47 4–5 30 – 35
Transmission case bolts 108 – 135 11 – 14 80 – 100
Upper driveshaft 74 8 55
- U-joint bolts
Lower driveshaft 109 11 80
- U-joint bolts
Pressure reading kPa bar psi

Clutch pack lock-up pressure 1482– 1620 15 – 16 215 – 235
Maximum lock-up pressure difference between clutches 69 0,7 10
Minimum lubrication pressure at low idle 34 0,3 5
Maximum lubrication pressure at high idle 172 1,7 25
Service Information

Description, 8400 420 Service Information 9/10/2022
transmission
Profile:
G780B Volvo
Description, 8400 transmission


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
All G700B motor graders are equipped with the model 8400 transmission. Its countershaft design was developed specifically for
grader applications as an 8-speed forward, 4-speed reverse, full powershift transmission.
A wide ratio spread of 10.35:1 between first and eighth gears allows for an even increase in road speed with each upshift. Gear
ratios are made possible by seven hydraulically controlled clutch packs mounted onto four of the transmission's five shafts.
Hydraulic flow is distributed to various clutch pack combinations by externally mounted collector caps and drilled passages in
clutch pack shafts. Electric solenoid cartridge valves in the collector caps are activated by the transmission ECU (electronic
control unit) and a shift lever. The ECU utilizes a constant self diagnostic program that monitors and detects electrical
malfunctions. A series of numeric error codes on the transmission gear display report malfunctions to the operator.
An engine mounted, gear-type hydraulic pump draws oil through a suction screen on the transmission sump, an oil cooler and a
7 micron spin-on type oil filter. It supplies the cool, filtered oil to the pressure regulating valve on the back of the transmission
for distribution to the clutches as both actuating and lubrication fluid. The transmission hydraulic circuit also supplies the engine
clutch circuit, differential lock-unlock circuit, HMBCS/MBCS (Moveable Blade Control System) lock pin circuit, and the brake and
clutch actuating systems.
The size of the clutch packs, along with the number of friction discs and separator plates, varies according to the torque loading
of the clutch pack. To provide power flow through the transmission, three of the seven clutch packs must be locked up
(engaged). Power flow passes through four shafts in forward and five when in reverse.
The cast iron housing is vertically split to ease disassembly. This allows complete access to all shafts and clutch packs. Each shaft
is supported by tapered roller bearings to handle the end thrust created by helical gearing. Shims, piloted in the counterbores of
the collector caps, are used to control end float of the tapered roller bearings. The A/B, C/D and R shafts have 0,051 – 0,178 mm
(.002 – .007 in.) end float while the Second intermediate and L/H shafts have 0,000 – 0,127 mm (.000 – .005 in.) The size of the
clutch packs, along with the number of friction discs and separator plates, varies according to the torque loading of the clutch
pack. See Table 1 - Clutch Packs.
To provide power flow through the transmission, three of the seven clutch packs must be locked up (engaged). Power flow
passes through four shafts in forward and five when in reverse. The Table 2 - Clutch Pack Lock up and Gear Ratio shows clutch
packs locked up compared to gear ratio as well as reverse gears corresponding to forward gears.
Table 1*
CLUTCH PACKS DIA. PLATE DISCS
R,A,B 5 1/4” 10 11
C,D 5 1/4” 12 13
L 6 5/8” 10 11
H 6 5/8” 8 9
Table 2*
GEAR FORWARD REVERSE RATIO
F1/R1 A-C-L R-C-L 7.317:1
F2 B-C-L 5.236:1
F3/R2 A-D-L R-D-L 3.777:1
F4 B-D-L 2.703:1
F5/R3 A-C-H R-C-H 1.916:1
F6 B-C-H 1.369:1
F7/R4 A-D-H R-D-H .987:1
F8 B-D-H .707:1
N C C
* Refer to illustration: "Transmission section view"

Transmission pressure warning lamp
The transmission oil pressure is monitored by the machine. If the oil pressure falls below 1379 kPa (13.7 bar)(200 psi), the
Transmission pressure warning lamp in the display panel will light accompanied by the red central warning lamp, a buzzer, and
display message.
Figure 1
A. Transmission pressure warning lamp

B. Central warning lamp
C. Display message
Transmission filter bypass warning lamp (optional)

The pressure differential is monitored between the oil entering and the oil exiting the transmission oil filter. When this
differential reaches 345 kPa (3,45 bar)(50 psi), the filter will begin to bypass and the lamp in the center display will light. The lamp
is accompanied by a message in the center display panel and the yellow central warning.
Figure 2
A. Filter bypass warning lamp

B. Yellow central warning lamp
C. Display message
Figure 3
Transmission section view
1. Reverse shaft
2. Input shaft
3. Intermediate shaft
4. Second intermediate shaft
5. Output shaft
6. Transmission oil sump
7. Lube
NOTE!
The cutaway illustration shows the reverse shaft above the input shaft, when in fact it is not. This has been done for clarity only.
The left-hand illustration shows the location of the cutting plane, pressure test ports and four solenoid cartridge valves.
Service Information

Transmission components 420 Service Information 9/10/2022
Profile:
G780B Volvo
Transmission components

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Transmission exploded assembly
1. Rear case
2. Front case
3. Upper yoke
4. Lower yoke
5. Main control valve
6. Range control valve
7. Reverse control valve
8. Output clutch and shaft
9. Input clutch and shaft
10. Reverse clutch and shaft
11. Second intermediate shaft
13. Piston rings
14. 54 Tooth gear
15. 52 Tooth gear - L.H.
16. 52 Tooth gear
17. 52 Tooth gear - R. H.
18. 24 Tooth gear
19. 70 Tooth gear
20. Spacer
21. Snap ring
Service Information

Transmission ECU and 420 Service Information 9/10/2022
shifter assembly
Profile:
G780B Volvo
Transmission ECU and shifter assembly


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Description
The transmission ECU (T-ECU) is a sealed, non-serviceable solid state component. The transmission shifter assembly contains a 9-
position joystick that relocates a magnet on a replaceable printed circuit board. The circuit board will transmit signals to the ECU
for forward, reverse, upshift or downshift. The ECU will then send 24 volts to the appropriate coils on the transmission for the
gear ratio required. Only 2 or 3 of the 6 coils will be activated for any particular gear.
The ECU also controls Variable Horsepower (VHP) and the backup alarm.
The transmission shifter assembly operates a relay that controls the neutral start safety function and the parking brake warning
light and buzzer in the center display panel.
Figure 1
1. Transmission shift lever

2. Neutral lock button
3. Hand throttle
4. Transmission ECU
5. Transmission shifter assembly
6. Pin connections – see Table 3
7. To AWD harness
8. Transmission harness
The ECU detects electrical failures in the transmission system. Should a failure occur, the pedestal display immediately alerts the
operator by showing an “E” for half a second, followed by a two digit numerical code for half a second. The ECU disables both
actions of the shift lever and places the transmission in neutral. The display will alternate between “E” and the code until the
operator returns the shift lever to the neutral position. To drive the grader with 2.0, 2.6, 3.0 or 3.6 error codes, simply select
another gear not using the failed coil. The pedestal display will show the gear selected and at every 5-second interval, show an
error code for the failed coil or circuit. If the grader is equipped with All Wheel Drive, the transmission and AWD electronics are
combined in a common AWD-ECU. An alphanumeric error code (letter/ number combination) indicates an All Wheel Drive
system error.
See Error codes for explanation of transmission error codes.
See All Wheel Drive system Description, AWD system for explanation of AWD error codes.
The hand throttle is an independently functioning device from the transmission shifter and the ECU. Its purpose is to provide
fixed engine speed during grading.
Table 3 - Pin connections

Pin Description Wire color Circ.
A Power supply Red/Blue 123
B Forward Tan 112
C Downshift Purple 113
D Out of neutral Blue/Yellow 114
E Shifter ground Black SGR
F Upshift Green/Blue 115
G Start relay power Pink 121
H Reverse White/Yellow 116
Operation
When the shift lever is moved into gear, the T-ECU activates the appropriate valve solenoid coils by supplying current. In first
gear forward, the ECU will indicate “1” on the display and activate the A and L coils. This combination of clutches, A-C-L,
provides the lowest gear ratio available and results in first gear forward.
Figure 2
Changing directions
A. Forward
B. Reverse
C. Neutral lock button
In first gear reverse, the controller will indicate “-1” and activate the R and L coils. This combination of clutches, R-C-L, provides
the lowest reverse gear ratio available and results in first gear reverse. The shift lever is pushed away to upshift and pulled in to
downshift. Each movement changes the speed by one gear. The controller automatically activates the correct solenoid coil
combination for the particular gear selected.
Figure 3
Changing transmission gears
A. Shift to higher gear

B. Shift to lower gear
Service Information

Transmission oil circuit and 420 Service Information 9/10/2022
operation
Profile:
G780B Volvo
Transmission oil circuit and operation


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Transmission oil circuit diagram

Figure 1
1. Transmission case
2. Transmission/booster pump
3. Oil/water cooler
4. Filter assembly
5. Filter bypass valve
6. Pressure regulator valve
7. Lock-up pressure spool
8. Lube pressure spool
9. R cartridge valve
10. A/B cartridge valve
11. C/D cartridge valve
12. L/H cartridge valve
13. Reverse shaft
14. Input shaft
16. Output shaft
17. Engine clutch
18. Test port
19. From radiator
20. To engine coolant pump
21. To brake booster
22. Suction
23. Clutch drain
24. Supply
25. Lube
26. Clutch engaged
Overview
A single section gear pump with an integral priority flow valve is mounted on the accessory drive of the engine. The priority flow
output is used for the booster circuit; all excess flow is sent to the pump for the transmission and clutch circuit. A two stage
regulator valve controls clutch pack engagement and lubrication pressures. The transmission case serves as the reservoir for this
circuit.
Circuit
The pump draws oil from the transmission's sump through a suction screen (6 mesh) and passes it through the cooler and filter
assembly. Oil from the excess flow outlet is directed to the two stage transmission regulator valve. Once the first stage spool has
set clutch pack lock-up pressure, it uncovers a passage to the second stage spool which sets lubrication pressure. Should this
pressure be exceeded, the second stage spool uncovers a passage to the transmission case.
Lubrication oil is directed to the center passage of each transmission shaft as well as to the engine clutch to lubricate and cool all
bearings and clutch friction members. The oil then drains back into the transmission case.
Lubrication and lock-up pressure oil is supplied to the four solenoid valve cartridges in the transmission shaft collector caps.
Whenever a clutch pack is not applied, these valves direct lubrication pressure oil to the lock-up cavity, keeping the cavity full of
oil to ensure rapid clutch pack lock-up. The exception is the C clutch pack which is always engaged, even in neutral, until the
controller energizes the D solenoid.
Operation
When the shift lever is moved into gear, the T-ECU activates the appropriate valve solenoid coils by supplying current. In first
gear forward, the ECU will indicate “1” on the display and activate the A and L coils. This combination of clutches, A-C-L,
provides the lowest gear ratio available and results in first gear forward.
Figure 2
Changing directions
A. Forward
B. Reverse
C. Neutral lock button
In first gear reverse, the controller will indicate “-1” and activate the R and L coils. This combination of clutches, R-C-L, provides
the lowest reverse gear ratio available and results in first gear reverse. The shift lever is pushed away to upshift and pulled in to
downshift. Each movement changes the speed by one gear. The controller automatically activates the correct solenoid coil
combination for the particular gear selected.
Figure 3
Changing transmission gears
A. Shift to higher gear

B. Shift to lower gear
Double clutch pack

A double clutch pack is simply two independent clutches mounted onto a common shaft. A clutch pack consists of:
a set of bronze faced friction discs with internal spline teeth mounted onto a hub which is splined to the shaft and;
a set of steel reaction plates retained in a drum and gear assembly by means of external tangs.
The drum and gear assembly is mounted on bearings to enable it to rotate independently of the shaft. The discs and plates are
alternated in the clutch pack, starting and ending with a friction disc. By squeezing these discs and plates together between the
lock-up piston and the backing plate, the gear is locked to the shaft and rotates with it. To perform this function, an assembly
similar to a hydraulic cylinder is used. A solenoid valve, located in the shaft's collector cap, controls the flow of oil to the clutch
pack.
Figure 4
Neutral phase
1. Low gear and drum assembly

2. Backing plate
3. Disc valve (2 parts)
4. Separator plate
5. Lock-up piston
6. Guide pins
7. Drive hub
8. High gear and drum assembly
9. Low clutch oil passage
10. Lubrication oil passage
11. High clutch oil passage
12. Piston centering springs
13. Friction disc
14. Reaction plates
15. Disc valve springs
16. Accelerator piston
Neutral phase
The solenoid valve directs oil at lube pressure to both clutch pack lock-up cavities via the high and low oil passages. Springs
center the lock-up piston between the two clutches, keeping them disengaged. Another set of springs under both disc valves
hold them away from the separator plate. This allows the two lock-up cavities to be joined by a hole in the separator plate.
Independent of the valve, oil at lube pressure flows down the center lubrication passage and through cross drillings to lubricate
the bearings and cool the discs and plates in both clutch packs.
Travel phase
Travel phase begins when the solenoid valve is energized to engage high clutch pack. This delivers oil at lock-up pressure down
the high clutch oil passage into the high gear accelerator piston cavity. Lube oil is fed down the low clutch passages. As pressure
builds within the accelerator piston cavity, the lock-up piston moves to the left while the accelerator piston moves to the right.
The accelerator piston pushes the high gear disc valve against the separator plate while the guide pins hold the low clutch disc
valve away from the separator plate. The movement of the lock-up piston forces oil from the low gear lock-up cavity to transfer
through the separator plate, the outer reed of the high gear disc valve and enter into the high gear lock-up cavity. The oil
transfer between cavities is used to quicken lock-up and eliminate pressure drops while the clutch cavity fills.
Figure 5
Travel phase
1. High gear accelerator piston cavity

2. High gear lock up cavity
3. Low gear lock up cavity
4. Low gear accelerator piston cavity
Apply phase
At the end of the travel phase, pressure builds within the high gear lock-up cavity as oil enters via a small modulating orifice in
the accelerator piston. The disc valve closes and full lock-up pressure is achieved. The clutch pack will remain applied as long as
lock-up oil pressure is directed to it. Very little oil is required to maintain lock-up. During the apply phase, lock-up oil pressure in
(2) is opposed by lubrication oil pressure in (3). Both pressures must be maintained within specifications as the apply force is
dependent upon the difference. Too high or too low of an apply force can lead to friction disc damage.
Figure 6
Apply phase
1. High gear accelerator piston cavity

2. High gear lock-up cavity
3. Low gear lock-up cavity
4. Low gear accelerator piston cavity
Service Information

Transmission hydraulic 420 Service Information 9/10/2022
circuit and operation
Profile:
G780B Volvo
Transmission hydraulic circuit and operation


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Transmission hydraulic circuit diagram

Figure 1
1. Transmission/booster pump
2. Transmission cooler
3. To differential lock circuit
4. Pump suction line
5. Transmission
6. MBCS/HMBCS lock pin circuit (Section 9)
7. Oil filter
8. Pressure regulating valve
9. Clutch booster
10. Vent line
11. Breather
12. Clutch housing
13. Brake booster
14. Clutch drain line
15. Fluid level sight glass
16. Clutch lubrication line
Decsription
The transmission pump (1) contains a priority flow valve that provides a constant flow of 23 L/pm (6 gpm) to the clutch and
brake booster regardless of engine rpm. Oil flow is supplied to the transmission, engine clutch, differential lock/unlock circuit
and the MBCS lock cylinder circuit by the excess flow outlet. The pump is mounted onto the accessory drive of the engine. The
oil in these circuits is completely separate from the oil of the hydraulic system.
Oil is drawn from the transmission sump (4) through a suction strainer into the pump. Oil leaving the pump enters an oil-to-
engine coolant bundle type cooler (2). Coolant exiting the radiator passes through this cooler before entering the engine's water
pump. This type of heat exchanger maintains a consistent temperature regardless of ambient temperature. Oil then flows to the
transmission oil filter (7). This is a special large-capacity, spin-on type filter with a 7 micron rating. A bypass valve is built into the
filter head to allow cold oil to bypass the filter element if the pressure differential between the inlet and outlet exceeds 276 kPa
(3 bar)(40 psi). The bypass valve will also open if the filter is restricted by contamination. This will allow unfiltered oil to continue
to the transmission pressure regulating valve (8). Filter replacement at the recommended intervals is critical to transmission
operation.
Mounted on the front of the transmission is the transmission pressure regulating valve (8). This two stage valve regulates both
lock-up and lubrication pressures. Oil first enters the lockup section where pressure is controlled for use in the clutch pack lock-
up circuits. Lock-up pressure affects the shift characteristics of the transmission. The remainder and majority of the oil enters the
lubrication section where pressure for the lubrication circuit is controlled. Lubrication oil is used to cool and lubricate both the
transmission and engine clutch. Lubrication oil then drains back into the transmission case.
Service Information

Transmission 420 Service Information 9/10/2022
troubleshooting
Profile:
G780B Volvo
Transmission troubleshooting

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
These procedures are intended to help diagnose and repair most electrical and hydraulic malfunctions. In many cases, testing the
electrical and hydraulic systems first can eliminate the need for costly and time-consuming mechanical overhauls. Have proper
tools available and in good working order such as a multimeter, pressure gauges, flow meter rated to at least 150 L/min (40 U.S.
gpm) and standard shop tools.
Visual checks
1. Check the transmission and clutch hydraulic circuits for signs of leaks.
2. Check the transmission oil level, noting the condition of fluid.
Foaming oil can indicate pump aeration.

Milky appearance can indicate the presence of water.
Burnt smell can indicate engine clutch wear caused by slippage due to improper adjustment or operator
misuse.
Start code sequence

When starting the engine or turning the ignition key to “Run”, the transmission gear display in the pedestal shows a start code
sequence. See the table below. If no start code sequence appears, check for a blown fuse. Remove the cover plate on the side
console to access the fuses.
Figure 1
Pedestal
CODE MEANING
.8.8 LCD (Liquid Crystal Display) test
7.8 ECU Identification
8.4 ECU Identification (All Wheel Drive)
1 Last gear memorized* (example)
-1 Opposite gear* (example)
* Alternating display while in neutral
Transmission diagnosis procedure
Correct any of these No Is transmission oil level, type, condition and

faults temperature correct?
Yes
Are transmission error codes present? Yes Repair cause(s) of code(s)
and retest for codes
No
Inspect master clutch No Does upper driveshaft rotate?

for failure
Yes
Does lower driveshaft rotate? Yes Inspect final drive for
failure
No
Test pump flow and No Is transmission lock up pressure within Yes Repair or replace
pressure regulator specification at 1482 – 1620 kPa (15 – 16 bar) transmission
operation (215 – 235 psi) at all clutches?
Is lube pressure within specification at 34 – 172
kPa (0,3 – 1,7 bar)(5 – 25 psi) at all clutches?
Electrical troubleshooting
The electrical schematics for the transmission are found in Section 3 – Electrical system..Wiring diagram 16
Most ECU problems are caused by poor ground connections. Always check for poor ground connection first:
between the cab and the transmission ECU.

between the cab and frame
across the articulation hinge
at the isolation switch
at the battery
Fuse Panel
These are the fuses and relays on the fuse panel that relate to the transmission and starting circuit.
Figure 2
Fuse Panel
1. Transmission shifter
2. Transmission ECU
3. Ignition switch
4. Back-up lights
5. All Wheel Drive
6. Neutral start relay
7. Back-up/alarm lights relay
The fuse panel is located inside the side console and is accessible through the removable fuse access door or by lifting the side
console cover. Thumb screws allow easy removal of both.
Solenoid/clutch engagement
Figure 3
Solenoid/pressure checkpoint locations
1. Lube
Gear Solenoids Energized Clutch engaged

1 A, L ACL
2 B, L BCL
3 A, D, L ADL
4 B, D, L BDL
5 A, H ACH
6 B, H BCH
7 A, D, H ADH
8 B, D, H BDH
Neutral None C
-1 R, L RCL
-2 R, D, L RDL
-3 R, H RCH
-4 R, D, H RDH
Service Information

Error codes 420 Service Information 9/10/2022
Profile:
G780B Volvo
Error codes

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
When the T-ECU detects a fault in the electrical system of the transmission, the error is indicated in the gear display. The display
alternates between and "E" and the two-digit error code. The code may not be displayed until the transmission is taken out of
neutral.
Transmission error codes related to solenoid faults are displayed in several ways, depending on the fault. Short circuit and open
circuit transmission solenoid error codes are displayed in the gear display to orientate the technician to the faulty part. When a
gear is selected that uses the faulty solenoid, the transmission will automatically shift to neutral and intermittently display the
fault code whether the fault is a short circuit or an open circuit. When a gear is selected that does not use the faulty solenoid, the
gear display will show the current gear selected as well as an open circuit code intermittently every 4.5 seconds. This is not
applicable however, to a short circuit code. A short circuit code will only be displayed once a gear is selected that uses the faulty
solenoid.
Reset the T-ECU while troubleshooting error codes by moving the shift lever to NEUTRAL.
For All Wheel Drive error codes, see – AWD error codes and troubleshooting.
Code Malfunction Code series description

1.0 Electric power is below 18.2 Volts Low system voltage
Check:
Charging system
Power supply to controller on pin 23
For loss of main ground
2.0 Open circuit, MA4202 Open circuit in applicable solenoid circuit

2.1 Open circuit, MA4206 *Check resistance of Solenoid coil
2.3 Open circuit, MA4205 *Check continuity of solenoid wiring harness and connectors
2.4 Open circuit, MA4204
3.0 Short circuit, MA4202 Short circuit in applicable solenoid circuit
3.1 Short circuit, MA4206 Check:
3.3 Short circuit, MA4205
Solenoid coil resistance
Solenoid wiring harness and coil resistance
4.2 Neutral restart error Neutral restart error
Shifter lever in gear during start-up attempt

Shifted into gear before completion of start-up sequence
Controller experienced a momentary power or ground loss
while in gear. Return shift lever to neutral to clear.
Check power supply, ground and neutral signal.
4.4 Forward/reverse or upshift/downshift Shifter input error

input error
More than one proximity switch energized simultaneously
Replace circuit board
4.6 Forward/reverse input error Shifter input error

– Out of neutral but neither forward or reverse signal
P3 Malfunction park/start circuit Only valid if displayed AFTER engine has started.
NOTE!
Flashes 3 times after engine start-up or key switch is cycled to the Run
position as part of the diagnostic checks.
Check ignition latch relay RE3302

Check continuity through switch SW5501 (wires 508 – 509).
Pin 18 on T-ECU not receiving signal.
P4 Parking brake signal mismatch error Check parking brake hydraulic pressure sensor SE5501
P5 Parking brake signal mismatch error Only valid if displayed AFTER engine has started.
Check parking brake hydraulic pressure sensor SE5501
Check control valve MA5501 on transmission
P8 Transmission shifted out of neutral with Release the parking brake
the parking brake applied
* When using an ohmmeter, ensure that the battery isolation switch is turned OFF.
Multiple error codes
Shifter wire opens

Code Malfunction
4.2 at end of start up Open circuit - Black
1.0 and 4.2 after fwd or rev shift Open circuit - White/yellow
None, grader does not start Open circuit - pink
None, no upshift Open circuit - Green/blue
4.4, does not recognize fwd or rev Open circuit - Blue/yellow
None, no downshift Open circuit - Purple
1.0 and 4.2 when in fwd Open circuit - Tan
None, does not recognize any shifts Open circuit - Red/blue
None, does not recognize any shifts Open circuit - All
Controller wire opens

Code Malfunction
1.0 and 4.2 Open circuit - GND-1
None, does not recognize any shifts Open circuit - SGR-1
No display, transmission operates Open circuit - DGR-1
None, all functions operate Open circuit - GND-1
No display, transmission operates Open circuit-117-1 Grey
No display, transmission operates Open circuit - 11 8-1 Light blue
2.6 in fwd Open circuit - 125-1 White
None, reverse gear flashes, no back up lights or alarm Open circuit - 35T-1 Green/black
No display, back up alarm on, transmission will not energize Open circuit - 119-1 Red/white
No display, back up alarm on, transmission will not energize Open circuit - 122-1 Purple/white
NOTE!
Check connections and wire locking clips in connectors Breakers
No display, back up alarm sounds and lights No.1 Breaker tripped

None, remains in neutral No.2 Breaker tripped
No display No.3 Breaker tripped
None, reverse gear flashes, transmission recognizes shifts No.13 Breaker tripped
Service Information

Hydraulic system 420 Service Information 9/10/2022
troubleshooting
Profile:
G780B Volvo
Hydraulic system troubleshooting


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
An important point to remember is that hydraulic oil flow rates and pressure settings should be checked first. This will eliminate
unnecessary transmission removal and overhaul. Before making any oil flow or pressure checks, check the transmission oil level
and quality. The oil level is checked with the transmission at operating temperature in neutral with the engine running at low
idle. The transmission oil level should fill three quarters of sight glass. Always use premium quality motor oil in the transmission
hydraulic system. Do not use Dexron or any other brand of automatic transmission fluid. These fluids use friction modifiers that
allow for clutch slippage. See Section 1 – Service and maintenance,Recommended lubricants for exact oil specifications.
If the low lubrication pressure warning light is energized or the transmission is not operating normally, check the lock-
up oil pressure reading at the transmission filter outlet. Record the pressures at idle and rated engine speed. Compare
the results with the specifications listed in Specifications.
If the recorded pressure is lower than the figures listed in the table, remove the transmission filter element and check
for contamination. Drain the transmission oil and check the transmission sump strainer for contamination. Refill the
transmission with the correct type of oil. Make sure the transmission oil is 3/4 up the level check sight glass with the
engine running at idle and at operating temperature. Check all supply hoses for suction leaks or damage.
If the oil flow is at or above the recommended minimum and pressure remains low on graders equipped with a lock/
unlock differential final drive, isolate and plug the line that supplies the differential lock hydraulic circuit. Recheck the
clutch pressure. If the pressure rises there is excessive leakage in the differential lock hydraulic circuit.
Remove and inspect the differential lock valve and cylinder assembly. A malfunctioning assembly may also be the cause
of low lubrication oil pressure.
If the low pressure problem is not corrected by these methods, check the transmission pump oil flow. Install an in-line
type flowmeter (capacity 150 L/min; 40 U.S. gpm) between the transmission oil cooler and the transmission filter.
Record the oil flow at idle and rated engine speed.
If the flow rate is below the specifications listed in Specifications, repair or replace the transmission pump. Look for
defective seals, excessive wear, contamination, cavitation, erosion, or scoring.
If the flow rate is normal and the pressure reading is low, remove and inspect the lock-up pressure regulator valve
spring. If the spring is not collapsed or broken, adding a shim between the spring and spool may raise the transmission
pressure to specification.
If the flow rate and pressure reading are normal, but the low lubrication oil warning light is energized or the
transmission is not working normally, follow the procedures given in Transmission hydraulic test procedure below
and record the results. It may not be necessary to complete the entire sheet.
If the lock-up oil pressure is low in a selected clutch pack, check the mechanical operation of the appropriate solenoid
cartridge valve spool. Remove the coil and cartridge from the valve bore. Inspect the coil and cartridge.
With the engine shut-down, turn the ignition key to the ON position, engage a gear that uses that valve cartridge. The
valve spool should move freely.
Check the screens around the valve for contamination. Check O-rings for damage.
Install the valve cartridge and torque-tighten the hexagon to 34 N•m (3 kgf•m)(25 lbf•ft). If the valve fails to operate,
the collector cap bore is probably distorted. Replace the collector cap.
Torque-tighten the conical nut retaining the coil to 7 N•m (0,7 kgf•m)(5 lbf•ft).
NOTE!
Install the valve cartridge until the O-ring is fully seated.
If the lock-up oil pressure remains low at one clutch pack only, remove the collector cap from that clutch pack. Inspect
seal rings for chipping, cracks or nicks. Inspect the internal bore of the collector cap. The seal ring grooves should be
evenly worn around the inside diameter.
If the flow rate is normal and the pressure reading is low, adding a shim between the spring and spool may raise the
lubrication pressure to specification.
If the transmission still malfunctions with normal flow rates and pressure readings, or lock-up flow to individual clutches
is excessively high, a mechanical problem may exist within the transmission. Refer to the Powertrain component
service manual.
Figure 1
1. Filter by-pass switch

2. Oil pressure switch
Transmission hydraulic schematic

Figure 2
1. Transmission sump
3. To brake circuit
4. Transmission filter
5. Solenoid valve
6. MBCS lock pin cylinder
7. Oil cooler
8. From brake circuit
9. Transmission pressure regulator valve
10. Lube pressure
11. Lock-up pressure
12. To clutches
13. To engine mounted master clutch lubricating circuit
14. Transmission
15. Parking brake valve
16. Accumulator
17. Manual recharge port
18. Hydraulic pressure intensifier
19. Pressure switch
20. Parking brake caliper
21. Solenoid valve
22. Differential lock/unlock cylinder
Transmission hydraulic test port locations
WARNING
Do not remain under the machine when the engine is running.
NOTE!
Ensure that the gauge hoses are long enough to reach beyond the machine wheels.
Figure 3
Test port locations
1. Main supply lock-up pressure
2. Lubrication pressure
Transmission hydraulic test procedure

Fill in the data sheet on the next page. Reproduce sheet as required.
1. Transmission oil must be at full operating temperature: 60ºC (140ºF).

2. Lower the moldboard and all attachments. Block all wheels. Apply parking brake.
3. Install gauges in the test ports as shown on Test port locations above.
4. Run the engine at minimum speed. Depress the clutch pedal and select first gear forward.
5. Record lock-up and lube pressures for all clutches as required (see data sheet).
6. Repeat steps 4 and 5 with the engine at maximum rpm.
7. Repeat steps 4 through 6 for each successive gear.
NOTE!
The difference between the maximum speed pressures and the idle pressures for any open clutch should not exceed 69
kPa (0,7 bar)(10 psi).
8. Check the lube pressures. Refer to Specifications
Transmission hydraulic test sheet
Customer name: Model: Hours Date:
Grader S/N Transmission S/N Tested by:
Forward Clutch Engine idle Lock up pressure Lube pressure

gear engaged speed
1 ACL Low A= C= L=
High A= C= L=
2 BCL Low B= C= L=
High B= C= L=
3 ADL Low A= D= L=
High A= D= L=
4 BDL Low B= D= L=
High B= D= L=
5 ACH Low A= C= H=
High A= C= H=
6 BCH Low B= C= H=
High B= C= H=
7 ADH Low A= D= H=
High A= D= H=
8 BDH Low B= D= H=
High B= D= H=
Clutch Engine idle Lock up pressure Lube pressure

engaged speed
Neutral None Low C=
High C=
Reverse Clutch Engine idle Lock up pressure Lube pressure
gear engaged speed
1 RCL Low R= C= L=
High R= C= L=
2 RDL Low R= D= L=
High R= D= L=
3 RCH Low R= C= H=
High R= C= H=
4 RDH Low R= D= H=
High R= D= H=
Service Information

Transmission, removing 420 Service Information 9/10/2022
Profile:
G780B Volvo
Transmission, removing

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 421-070
Transmission jack: capacity 454 kg (1000 lb)
WARNING
WARNING
1. It is extremely important to support the grader under the tandem cases with proper blocks or stands. Depending on the
model of grader, you may need to raise the machine high enough so that when the transmission is sitting on the jack it
will clear the underside of the frame.
Figure 1
V1023931
2. Remove the transmission guard. Remove the drain plug on the lower left-hand side of the transmission case and drain
the oil into a suitable container—capacity 38 L (10 U.S. gal).
3. Disconnect the transmission hydraulic pump suction hose. Plug the open port and fitting to prevent contamination.
Figure 2
Disconnecting transmission hydraulic pump suction hose
4. Disconnect the oil filler tube and engine clutch drain hose located on the left-hand side of the transmission case. Plug
the open ports and fittings to prevent contamination.
Figure 3
Disconnecting engine clutch drain hose (viewed from below)
5. Disconnect the clutch lubrication hose from the pressure regulator valve. Disconnect the return line from the brake
booster circuit. At the transmission filter discharge port, disconnect the lines for the MBCS control valve and the lock/
unlock shift cylinder control valve. Plug all open ports and fittings to prevent contamination.
Figure 4
Disconnecting transmission plumbing (viewed from below)
6. Disconnect the transmission supply hose at the filter inlet. Plug the open port and fitting to prevent contamination.
7. Disconnect the clutch breather line. Plug the open port and fitting to prevent contamination.
Figure 5
Disconnecting clutch breather line
8. Disconnect the wires from the transmission sending units (i.e., filter, oil temperature and oil pressure).
Figure 6
Disconnecting wire from transmission filter sending unit
9. Disconnect the transmission wiring harness located behind the cab right-hand side panel.
Figure 7
Disconnect transmission wiring harness
10. Disconnect the supply lines to the priority flow valve and the hydraulic filter. Plug the open ports and fittings to prevent
contamination.
11. Disconnect the upper and lower drive shafts at the transmission yoke. Remove the hand brake caliper and bracket from
the transmission case and position them so as not to impede transmission removal.
12. Use a safe transmission jack to support the transmission. Transmission weight: approx. 454 kg (1000 lb).
NOTICE
13. Remove the transmission mounting bolts.
14. Use the jack to lift the transmission off the mounts. Remove the mounts on the transmission case. Make sure nothing
will impede transmission removal. Carefully lower the transmission from the grader.
Service Information

Transmission, installing 420 Service Information 9/10/2022
Profile:
G780B Volvo
Transmission, installing

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 421-072
Transmission jack: capacity 454 kg (1000 lbs)
WARNING
NOTICE
1. Use a safe lifting device to raise the transmission into an upright position. Transmission weight: approx. 454 kg (1000
lb)
Figure 1
2. Apply a bead of gasket eliminator P/N 25303, `Loctite' 515 or equivalent, to the bearing face of both drive shaft yokes
(13). Install the yokes, washers and locknuts (12).
Torque-tighten the locknuts to 203 – 271 N•m (21 – 28 kgf•m)(150 – 200 lbf•ft).
Figure 2
3. Lubricate and install a new O-ring on the suction fitting. Apply teflon paste to the threads of the plug. Install the plug
and sending unit.
4. Carefully place the transmission on a safe jack and maneuver it under the grader. Raise the transmission into position.
NOTICE
5. Install the mounts on the transmission case and ensure they are properly aligned.
6. Install and tighten the transmission mounting bolts on the frame supports.
7. Connect the upper drive shaft.

Torque-tighten the bolts to 74 N•m (8 kgf•m)(55 lbf•ft).
8. Connect the lower drive shaft.

9. Connect the transmission wiring harness behind the cab right-hand side panel.
Figure 3
Connecting transmission wiring harness
10. Connect the supply lines to the priority flow valve and the hydraulic filter.
11. Connect the wires to the transmission sending units (i.e., filter, oil pressure).
Figure 4
Connecting wire to transmission filter sending unit
12. Connect the oil filler tube and engine clutch drain hose located on the left-hand side of the transmission case.
Figure 5
Connecting engine clutch drain hose (viewed from below)
13. Connect the transmission hydraulic pump suction hose.
Figure 6
Connecting transmission hydraulic pump suction hose
14. Connect the clutch breather line.

Figure 7
Connecting clutch breather line
15. Connect the clutch lubrication hose to the pressure regulator valve. Connect the return line to the brake booster circuit.
At the transmission filter discharge port, connect the lines for the MBCS control valve and the lock/unlock shift cylinder
control valve.
Figure 8
Connecting transmission plumbing (viewed from below)
16. Check the positions of the solenoid valve cartridge wires by comparing them to the schematic diagram found on Wiring
diagram 15. Use colors as reference.
17. Install a new transmission filter element. Refill the transmission with clean oil. Refer to Recommended lubricants.
18. Park the grader on level ground. With the engine running at idle and at operating temperature, have an assistant check
the transmission oil level. It should be three quarters up the level check sight glass.
19. Test the grader to ensure that there are no problems with the transmission electrical and mechanical functions. Check
all connections for leaks. When you are satisfied that everything is working properly, install the transmission guard.
Specifications; All Weel Drive system 2
Description; AWD system 3
AWD electrical system 12
AWD hydraulic system 20
All Wheel Drive Operational Checks 29
AWD test procedure and test port locations 31
AWD error codes and troubleshooting 36
All Wheel Drive Pump and Motor Priming Procedure 50
Service Information

Specifications, All Weel 440 Service Information 9/10/2022
Drive system
Profile:
G780B Volvo
Specifications, All Weel Drive system


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Specifications, main drive pumps

Shaft rotation: counter clockwise
Pump displacement: 41 cc/rev (2.5 in/ rev)
Pump input speed: Engine input speed X 1.235
Pump input current: 14 - 85 mA
Maximum charge pressure: 3,44 MPa (34,5 bar)(500 psi)

Minimum charge pressure: 1,89 MPa (19 bar)(275 psi)
Maximum system pressure: 34,47 MPa (345 bar)(5000 psi)
±3,44 MPa (34,5 bar)(500 psi)
Maximum pump case pressure: 344,7 kPa (3,5 bar)(50 psi)
Motor case pressure: Less than 206,8 kPa (2 bar)(30 psi)
Operating Speeds
Top speed 28,6 km/h (17.7 mph)
Creep mode speed 0 – 3,2 km/h (0 – 2 mph)
Service Information

Description, AWD system 440 Service Information 9/10/2022
Profile:
G780B Volvo
Description, AWD system


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
All Wheel Drive (AWD) is a hydrostatic assist system used in the front wheels to increase tractive effort and steering control. Two
electronically controlled, variable-displacement hydraulic pumps power the system in a closed-loop circuit. Each pump supplies
one front wheel motor. The wheel motors are a 2-speed, high torque, radial piston, cam lobe type. The system contains no flow
divider valve, and has two separate speed sensors – one for each pump/motor combination that keep the AWD system driving
around corners. The AWD hydraulic system contains its own oil cooler, pumps, and motors. AWD is available in all gears except
8th gear with equal torque/performance in forward and reverse. Maximum torque is provided in gears 1 to 3. In gears 4 to 7,
torque is reduced to about 25%.
Figure 1
Simplified AWD hydraulic circuit
1. AWD hydraulic tank

2. Charge pump
3. Drive pumps
4. Hydraulic motors
Blue – Charge pump suction

Yellow – Charge oil pressure
Green – Front pump drives right wheel motor
Red – Rear pump drives left wheel motor
The aggression of the AWD system can be controlled with a 16 position manual dial adjustment. This control is used to fine tune
rotational speed differences that may occur between the front and rear wheels when grading in diverse conditions with the All
Wheel Drive system engaged. A lower setting places the AWD in standby until rear wheel slip is encountered. A higher setting
causes the front wheels to turn slightly faster than the rear wheels.
Creep Mode is used for low speed, fine grading using front wheel drive. It will operate at speeds from 0 to 2 mph (0 to 3,2 km/h)
in forward and reverse. Creep Mode eliminates semi-clutching or brake riding when extremely slow speed is required. Creep
Mode is true hydrostatic front wheel drive — the rear wheels are not driving and the moldboard load is being pulled by the front
wheels.
Controls
The control panel is mounted on the right-hand side of the cab in the door post. It contains all the controls and warning lights
needed to operate the All Wheel Drive system. The system is activated by a rocker switch on the front of the control panel. Green
lights indicate system and Creep Mode activation. The control panel has additional lights that warn of excessive oil temperature,
low charge pressure, low oil level and filter bypass. These lights alert the operator that a problem exists. Low oil level and low
charge pressure lights are accompanied by an audible alarm. At the bottom of the control panel is the AWD 16-position
aggression dial. This dial allows the operator to adjust the speed of the front wheels in comparison to the rear.
Figure 2
All wheel Drive control panel
1. System activation lights

2. AWD on/off switch
3. AWD aggression dial
4. Warning lights
5. Creep mode activation switch
The All Wheel Drive and transmission systems are controlled by one ECU.
Error codes
The ECU continuously monitors the All Wheel Drive electrical system. It is able to detect abnormal conditions and alert the
operator of a problem by displaying a code that will aid in correcting the problem.
Figure 3
1. Transmission shift lever

2. Transmission and AWD ECU
If a malfunction occurs:
1. The transmission gear display shows the letter “E” followed by a 2-digit alphanumeric code. Multiple error codes are
possible.
2. The display alternates between “E” and the error code until the malfunction is corrected. Most AWD error codes will
disable the All Wheel Drive system, however the transmission will not be affected.
Circuit
The AWD system can be discussed as 2 circuits consisting of the Charge loop and the Drive loop.
Charge loop
The charge pump is a fixed displacement gear pump mounted externally that supplies flow to both the main (left and right) drive
pumps. It creates a positive inlet pressure at the pump to increase pump life. Charge pump flow is used for the main drive pump
control systems, auxiliary pilot valves and to replenish oil in the main loop that is lost through normal internal component
leakage. Charge pressure aids in keeping the piston shoes in contact with the swashplate in the pumps, and the pistons in
contact with the cams in the motors on the low pressure (or return) side of the main drive loop. Charge pressure acting on pilot
pistons within the main drive pumps is used to vary pump displacement. Charge pressure is also used to change motor
displacement and to switch valves (freewheeling valves) used to engage and disengage the motors.
Figure 4
Charge loop
1. Oil cooler
2. Filter
3. Hydraulic tank
4. Cooler bypass valve
5. Charge pump
6. AWD hydraulic drive pumps
7. Free wheeling solenoid valve
8. To 2-speed valve assembly
Green - Suction
Blue - Oil return to tank
Yellow - Control signal
Orange - Intermediate pressure
Engine running – Front wheels not driving

When the engine is running, the charge pump draws fluid from the reservoir. Exiting from the charge pump, the oil passes
through the charge filter and then tees to enter the RH and LH drive pumps. Internal relief valves in the drive pumps are used to
control the charge pressure. Pressure will fluctuate with engine speed and oil temperature. A pressure switch at the outlet of the
charge pressure filter alerts the operator if pressure drops below 1,72 MPa (17 bar)(250 psi). A test port is available at the filter
outlet to measure charge pressure. Oil passes through the case of the drive pumps and exits to the cooler. A 206,8 kPa (2 bar)(30
psi) check valve (cooler bypass valve) regulates the volume of oil passing through the cooler and also provides pressure spike
protection in cold weather. After exiting the cooler, the oil returns to the reservoir.
Engine running – Front wheels driving
Oil is delivered to the drive pumps as noted above. The drive pump EDC (electric displacement control) receives a signal from
the ECU which in turn initiates a movement of the pump swashplate. The drive pump begins to deliver flow out of one port at
some pressure higher than charge pressure. The drive pump's loop flushing valve is shifted by the high pressure. Oil from the
low pressure side of the loop flows across the loop flushing relief. Charge pump flow is now directed simultaneously across the
charge relief and the loop flushing relief. This lowers charge pressure by approximately 68,9 kPa (0,7 bar)(10 psi). The flow
continues into the case of the drive pump and as noted above.
Drive loop
The drive pumps are variable displacement axial piston pumps with bidirectional swashplates. This means that the swashplate is
capable of going over center. Therefore, the pump is capable of pumping fluid in two directions: one forward, one reverse. The
driveshaft is splined to the rotating group and consequently, the cylinder block and pistons rotate with the driveshaft. The
swashplate does not rotate but tilts back and forth inside the pump housing. Piston shoes attached to the pistons slide on the
swashplate. When the swashplate is on an angle, the pistons are forced to stroke within the barrel and displace oil. When the
swashplate is at 0ºthe pistons do not stroke and oil will not be displaced. Each pump is equipped with an electric displacement
control (EDC). The EDC is the control input that determines the angle of the swashplate. The EDC directs pilot pressure to a
control valve that ports oil to a control piston that strokes the swashplate. The EDC accepts a variable current signal. The angle of
the swashplate (between zero and maximum displacement) is proportional to the input current. Therefore, the oil flow rate
delivered from the pump is also proportional to the input current. The internal relief valve limits the maximum system pressure
to 34,5 MPa (345 bar)(5000 psi).
Figure 5
Drive pump sectional view
1. Swashplate
2. Piston
3. Roller bearing
4. Valve plate
Figure 6
Drive loop – Rear circuit
1. AWD hydraulic oil reservoir

2. Freewheeling solenoid valve
3. Freewheeling valves
4. AWD hydraulic drive pumps
5. Oil flows out the “A” ports of the pump for forward operation
Blue - Return to tank

Red - System pressure
Figure 7
Drive loop – Front circuit. Illustration shows grader with AWD system ON, driving forward.
“A” port is pressurized on right motor and “B” port is pressurized on left motor.
1. Wheel motor
2. Right-hand motor bypass valve assembly
3. Left-hand motor bypass valve assembly
4. Motor displacement solenoid
5. Two-speed valve assembly
Blue - Return to tank

Red - System pressure
From the pump, oil is directed to the freewheeling valves. With the AWD system off, the freewheeling valves are closed and the
main system lines from the pump are blocked. The pump is at zero displacement therefore the flow is zero. The motors two
working ports are joined together with a connection to tank. This allows the motors to mechanically free wheel. When the AWD
system is turned on, the freewheeling valves are piloted open (using freewheeling solenoid DCV2). Pump flow now passes
through them and onto the motor bypass valve assemblies.
Depending on the direction selected by the transmission controller, either the forward or reverse solenoid valve in the motor
bypass valve assembly (i.e. DCV3 and DCV5 or DCV4 and DCV6) is energized. This directs drive pressure to the bypass valve and
determines whether it is opened or closed.
In forward gears 1 to 3 and reverse gears 1 and 2 the motor displacement solenoid (DCV1) is de-energized causing the motors
to function at full displacement. In forward gears 4 to 7 and reverse gears 3 and 4, the motor displacement valve is energized to
cause the motors to function at 1/4 displacement.
Return flow from the motor is directed to the drive pump to complete the closed loop. The charge loop replenishes any fluid lost
due to component leakage or consumed for control functions.
NOTE!
For more information on the AWD electrical system see: AWD electrical system
NOTE!
For more information on the AWD hydraulic system see: AWD hydraulic system
Service Information

AWD electrical system 440 Service Information 9/10/2022
Profile:
G780B Volvo
AWD electrical system


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Electrical system overview

The AWD electrical system centers around a microprocessor based electronic control unit (ECU) with fast processing speed and
high resolution. It receives inputs from the system and provides outputs to control the displacement of the drive pumps and
motors. It will also alert the operator of any conditions that exist which are outside of normal operating parameters.
Function
When the AWD switch is turned on, the ECU energizes the freewheeling solenoid to shift the freewheeling valves. Once the
transmission shifter has been placed in gear and the clutch and brake pedals released, the ECU energizes the appropriate bypass
valve solenoids (forward or reverse) and sets the electric displacement control (EDC) current to a nominal value to suit the
appropriate direction and speed selected. It then samples the front wheel speed and compares it to transmission output speed
(rear wheel speed). It then sets the EDC currents to match wheel speed, based on the setting of the AWD Aggression selection
switch. At setting 1, the pumps will be displacing enough fluid to simply have the front wheels follow the rear. At setting 16, the
front wheels are attempting to overdrive the rear wheels.
During creep mode, the transmission remains in neutral and only the front wheels drive. Once the transmission controller has
been placed in gear, the ECU samples the engine speed input and then sets the EDC currents based on engine speed and
direction.
AWD electrical system components
See Diagram A - AWD Electrical system components
1. AWD control panel

2. AWD on/off switch
3. Creep Mode switch
4. AWD aggression switch
5. Creep Mode switch viewed from rear
6. AWD on/off switch viewed from rear
7. Operator alarm
8. Electrical connectors
9. Fuse panel
10. Connector to electrical harness, rear
11. Connector to electrical harness, front
12. Electrical harness
13. AWD ECU
14. –Black
15. +Red
Figure 1
Diagram A - AWD Electrical system components
See Diagram B - AWD Electrical system components
1. Speed sensor lead

2. EDC, left-hand
3. EDC, right-hand
4. Drive pump, left-hand wheel
5. Drive pump, right-hand wheel
6. Front wheel speed sensor, right-hand
7. Front wheel speed sensor, left-hand
8. Wheel sensor assembly, right-hand/left-hand
9. To pumps
10. Rear connector
11. Front connector
Figure 2
Diagram B - AWD Electrical system components
See Diagram C - AWD Electrical harness installation – Front and rear
1. Fan shroud
2. Charge pressure switch
3. Hydraulic filter switch
4. AWD oil level
5. Hydraulic oil level
6. AWD temperature
7. Oil temperature
8. Drive pump – Left wheel
9. Drive pump – Right wheel
10. Freewheeling valve
11. Ground stud
12. Clutch
13. 23 pin connector
14. Transmission output speed sensor
15. Clutch sensor installation
16. To clutch
17. To slave cylinder
18. Brake sensors
19. 31 pin connector
20. Ground stud
21. Connects to front cab harness
22. Front left-hand wheel speed sensor
23. Front right-hand wheel speed sensor
24. DCV5 – Forward bypass solenoid, right-hand
25. DCV6 – Reverse bypass solenoid, right-hand
26. DCV1 – Motor displacement solenoid
27. DCV3 – Forward bypass solenoid, left-hand
28. DCV4 – Reverse bypass solenoid, left-hand
Figure 3
Diagram C - AWD Electrical harness installation – Front and rear frames
Outputs and inputs
(refer to AWD electrical schematic) see Wiring diagram 16
1. AWD On/Off Switch
A SPDT switch switching 24VDC into the ECU.
2. Aggression select switch
A 16 position binary output switch switching 24VDC into the ECU.

3. Creep mode switch
A normally open momentary push button switching 24VDC into the ECU.
4. Front wheel speed LH and RH
Inductive proximities switching into the ECU @ 92 pulses/revolution of the front wheels.
5. Transmission output speed sensor
A magnetic pickup switching 24VDC into the ECU @ 167.45 pulses/revolution.
6. AWD charge pressure switch
A normally open pressure switch switching 24VDC into the ECU. Closes when the charge pressure rises above
1724 kPa (17,2 bar)(250 psi).
7. AWD filter switch
A normally closed pressure switch switching 24VDC into the ECU. Opens when the pressure differential
between the inlet and outlet of the filter exceeds 172 kPa (1,7 bar)(25 psi).
8. Brake switch 1 and 2
Normally closed pressure switches switching 24VDC into the ECU. Open when output pressure from the brake
master cylinder sections rises above 1034 kPa (10,34 bar)(150 psi) (brake applied).
9. Clutch switch
A normally closed pressure switch switching 24VDC into the ECU. Open when output pressure from the clutch
master cylinder sections rises above 1034 kPa (10,34 bar)(150 psi) (clutch applied).
10. AWD oil level switch
A normally open switch switching 24VDC into the ECU. Open when the oil level in the reservoir falls below the
level of the switch.
11. AWD oil temperature switch
A normally closed switch switching 24 VDC into the ECU. Open when the oil in the reservoir exceeds 88ºC
(190ºF).
12. Engine speed
Alternator “R” terminal signal 16 poles x 2.9 ratio.
13. EDC forward/reverse LH/RH (4 total)
Variable 14±3 to 85±10 ma to pump pilot coil.
14. Motor displacement solenoid (DCV1)
24VDC. Changes motor to minimum displacement.
15. Freewheeling solenoid (DCV2)
24VDC. Pilots directional control valves which allow motors to drive.

16. Forward/reverse bypass solenoid LH/RH (4 total; DCV3 to DCV6)
24VDC. Allows motors to drive forward/reverse.
17. VHP
24VDC. Changes engine to high horsepower.
18. AWD “ON” LED
24VDC. Indicates AWD system ON.
19. AWD oil temperature LED
24VDC. Indicates high oil temperature (> 88ºC; 190ºF).
20. AWD oil level LED
24VDC. Indicates low oil level.
21. AWD oil filter LED
24VDC. Indicates filter in by-pass (differential pressure >172 kPa [(1,7 bar)(25 psi)].
22. AWD charge pressure LED
24VDC. Indicates low charge pressure <1724 kPa (17,2 bar)(250 psi).
23. Creep mode LED
24VDC. Indicates creep mode ON.
24. AWD alarm
24VDC. Indicates loss of charge pressure and/or low oil level.

Service Information

AWD hydraulic system 440 Service Information 9/10/2022
Profile:
G780B Volvo
AWD hydraulic system


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
AWD hydraulic schematic and components
Figure 1
1. Left-hand motor bypass valve assembly

2. Two-speed valve assembly (de-energized, wheel motors are at maximum displacement)
3. Right side motor bypass valve assembly
4. Left-hand wheel motor (oil flows in the motor 'B' port for forward operation)
5. AWD control panel
6. Transmission/AWD ECU
8. Freewheeling solenoid (de-energized, wheel motors free wheel)
9. AWD hydraulic drive pumps (oil flows out pump 'A' port for forward operation)
10. Oil cooler
11. Hydraulic tank
12. Pump gearbox
13. AWD charge pump
14. Hydraulic filter
15. Right side freewheeling valve
16. Left side freewheeling valve
18. AWD oil level switch
19. AWD oil temperature switch
20. Motor displacement solenoid
21. Hydraulic system pump
22. AWD filter switch
23. AWD charge pressure switch
24. Right-hand wheel motor (oil flows in the motor 'A' port for forward operation)
25. Bypass
26. Pump case
DCV3 – Forward bypass solenoid, left-hand
DCV4 – Reverse bypass solenoid, left-hand
DCV5 – Forward bypass solenoid, right-hand
DCV6 – Reverse bypass solenoid, right-hand
DCV3 and DCV5 are energized during forward operation
DCV4 and DCV6 are energized during reverse operation

Figure 2
Wheel motors
The wheel motors are low speed high torque radial piston cam/lobe type motors. Each motor contains 12 pistons at various
stages of power strokes and return strokes. The distributor valve rotates with the housing and ensures the proper timing of oil
flow in and out of the piston bores as the cam rotates. They are dual displacement motors capable of operating at either
maximum displacement or at 1/4 displacement. The motors contain springs that can push the pistons down into their cylinders
and hold them there away from the cam ring. This allows 3/4 or all the pistons to mechanically free wheel.
Figure 3
Wheel motor in operation
NOTE!
12 piston motor used, 8 piston motor shown
1. Cam
2. Cam roller
3. Piston
4. Distributor valve
Yellow - Case pressure

Red - Inlet pressure
Blue - Return pressure
Freewheeling
When the AWD system is off, the motors operate in a mechanical freewheeling mode. In freewheeling mode, the pistons do not
come in contact with the cam. The cam, the motor housing and wheel can rotate freely. Freewheeling mode is achieved by
connecting the main system motor ports (A, B) to tank through the freewheeling valves. This relieves all pressure from top and
bottom of the piston and allows the mechanical springs to push the pistons away from the cam.
Figure 4
Wheel motor freewheeling
1. Spring
Yellow - Case pressure

Green - To tank
Driving – Full displacement

The motors drive at full displacement in forward gears 1 to 3 and reverse gears 1 and 2. Pressurized oil is fed into one of the
motors working ports (A or B) and into the distributor valve. Oil flows into the cylinders that have pistons in power stroke,
pushing the pistons and cam rollers outwards against the cam ring causing the cam ring and motor housing to rotate. When the
pistons reach the end of their stroke, the distributor valve closes the inlet port and opens the outlet port. The next lobe of the
cam ring pushes the piston back to the center and oil from the cylinder exits the motor from the opposite working port (in A and
out B or in B and out A).
Driving – 1/4 displacement
The motors drive at 1/4 displacement in forward gears 4 to 7 and reverse gears 3 and 4. A pilot signal from the motor
displacement solenoid (DCV1) shifts a spool within the motor so that only 1/4 of the pistons receive oil (3 of 12). The 9 non-
working pistons are held away from the cam by the freewheeling springs. At 1/4 displacement, the motor will rotate at four times
the speed of full displacement, but will only develop 1/4 of the torque output if oil flow and pressure to the motor remains
constant.
Figure 5
Wheel motor sectional view
1. Piston
2. Can roller
3. Cam
4. Spring
6. Displacement spool (two-speed spool)
8. Section A-A
Motor bypass valve assembly

The motor bypass valve assembly contains two solenoid-operated valves (the forward bypass solenoid and the reverse bypass
solenoid, DCV3 and DCV4), a pilot operated logic element (bypass valve) and a shuttle valve. The valve assembly controls
whether oil from the pump flows through the motor or bypasses the motor. Simultaneously, oil from the motor can be circulated
through the valve. Bypassing occurs under the following conditions when the AWD is turned on:
Figure 6
ISO schematic - Motor bypass valve
1. Left side motor bypass valve assembly

2. Bypass
3. Forward DCV3
4. Reverse DCV4
the transmission is in neutral

the grader is driving in 8th gear
the clutch or brake pedals are depressed
drive conditions create an overrunning situation
Figure 7
Motor bypass valve assembly
GBL Gauge port motor B port left side

GAL Gauge port motor A port left side
T Tank
MB To motor B port
MA To motor A port
TPL Test port left side
B System port
A System port
NOTE!
Suffix designation R or L on pressure test ports indicate right (R) or left (L) side of valve.
Function
The bypass valve assembly shifts to either an open or closed position depending upon pressure acting on three differential
areas. The “open” pilots are two equally sized areas that sense the pressure at the motor A and B working ports. The “closed”
pilot area is equal to the sum of the two areas on the “open” side. The “closed” pilot receives the motor drive pressure or is
connected to tank. The force exerted by the spring is equivalent to 5,5 bar (80 psi). The two solenoid operated valves in the
motor bypass valve assembly control the switching of pressure to the “closed” pilot. One solenoid valve is used for forward
(DCV3) and the other for reverse (DCV4). A shuttle valve between the two solenoid valves allows the highest pressure to be
sensed at the “closed” pilot.
Ports are available to install test fittings and confirm pressures as required:
GBL/GBR and GAL/GAR to measure the “open” pilot signals.

TPL/TPR to measure the “closed” pilot signal.
During creep mode, both forward and reverse bypass solenoids are energized. This cancels the function of the bypass valve and
allows for hydrostatic braking.
The motor bypass valve assembly also allows for differential action between the front wheels during cornering. Depending upon
traction conditions, some oil will be allowed to bypass the outside motor.
When the AWD system is ON and the grader is shifted from 7th to 8th gear, the pump cannot supply sufficient flow to drive the
motors. The bypass valve assembly allows oil to bypass or re circulate around the motor.
Two-speed valve assembly
The two-speed valve assembly includes the motor displacement solenoid (DCV1) as well as porting for the motor case drain and
the accumulators. The motor displacement solenoid is used to place the motor in either full displacement or 1/4 displacement.
Figure 8
ISO schematic – Two-speed valve assembly
1. Motor displacement solenoids

Figure 9
Two-speed valve assembly
G Gauge port (motor case pressure)

G1 Gauge port (charge pressures, gears 4 to 8)
VT Valve tank
MT Motor tank
ML Motor left side (motor two-speed port)
MR Motor right side (motor two-speed port)
ACL Accumulator left side
ACR Accumulator right side
DRL Drain left side (motor)
DRR Drain right side (motor)
Function
Low speed
In forward gears 1 to 3 and reverse gears 1 and 2, the solenoid is de-energized and charge pressure is blocked at port CP. Ports
ML & MR, which connect to the motors Y ports (two speed), is open to tank through port VT of the valve. The case drain flow
from the motor C2 ports are directed into the valve through ports DRL & DRR and are joined together with a connection to two
accumulators through ports ACL & ACR and then exit to tank through port MT. A test fitting is installed at port G to monitor the
motor case pressure.
High speed
In forward gears 3 to 7 and reverse gears 3 and 4, the solenoid is energized. Charge pressure passes through the valve from port
no.3 to port no.2 and into the motors Y port to shift the 2-speed valve in the motor (this places the motor at 1/4 displacement).
Port G1 allows a test fitting to be installed to confirm the valve has shifted. During the shift from full displacement to 1/4
displacement, 9 out of the 12 pistons become connected to case. The accumulators absorb this sudden surge in case pressure to
prevent over-pressurization.
Freewheeling valve
There are two “freewheeling” valves. One is used with the left drive system and the other with the right drive system. The
freewheeling valves are two position, spring return, pilot operated valves. They either connect the motors to tank (motors free-
wheel) or they connect the motors to the pumps (driving mode).
Figure 10
ISO schematic - Freewheeling valve
1. Left side freewheeling valve
Motors freewheel
In their normal position (no pilot pressure at the X port) the drive motors A and B system ports are open to tank via the C, D, and
T ports while the drive pumps A and B system ports are blocked. In this position the drive motors will be in the “freewheeling”
mode.
Driving (AWD ON) mode
In the shifted position (charge pressure directed to the X ports via the freewheeling solenoid valve – DCV2) the motors A and B
system ports are connected to the pumps A and B system ports via the C, D, E, and G ports. The motors will be in their power (or
driving) mode, the “closed loop” will be completed and AWD system will be engaged.
Figure 11
Freewheeling valve
T Tank
X Pilot port (charge pressure)
C System loop port
D System loop port
E System loop port
G System loop port
Service Information

All Wheel Drive Operational 440 Service Information 9/10/2022
Checks
Profile:
G780B Volvo
All Wheel Drive Operational Checks


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 442-051
AWD system troubleshooting

Before starting any operation or performance tests, perform a visual check of the machine and system for:
1. Loose connections
2. Damage to components
3. Damage to hoses
WARNING
This warning symbol means risk of fatalities or personal injury if the instructions are not followed.
WARNING
Beware of rotating parts. Keep a safe distance.
NOTE!
Wheels may rotate unexpectedly when raised off the ground. Keep clear when engine is running.
NOTE!
Always put the grader in the Service positionsbefore attempting any overhaul, maintenance or inspection procedure.
1. Unlock the differential. Unlocking the differential is very important otherwise the machine is liable to move under power
as all rear wheels are mechanically connected.
2. Lift the front wheels and one tandem off the ground with the moldboard.
3. Turn the AWD on.

4. Set the aggression switch to 7.
5. Depress the clutch, place the transmission shifter in first gear forward and release the clutch.
6. Operate the engine at idle.
7. Both front wheels should turn in the same direction (forward) and at approximately 1/2 the speed of the rear wheels
(due to differential action).
8. Depress the brake pedal and confirm the front wheels stop.
9. Release the brake pedal and confirm the front wheels restart.
10. Depress the clutch pedal and confirm the front wheels stop.
11. Release the clutch pedal and confirm the front wheels restart.
12. Repeat above for reverse.
13. Place the transmission shifter in neutral.
14. Place the AWD system in creep mode.
15. Depress the clutch, place the transmission shifter in forward and release the clutch.
16. The rear wheels should not rotate.
17. The front wheels should not begin rotating until the engine speed reaches 1200 to 1400 rpm (about 1/2 throttle).
18. Once the front wheels begin to rotate, gradually increase the engine rpm up to high free idle and determine whether
the front wheels increase in speed along with engine rpm.
Service Information

AWD test procedure and 440 Service Information 9/10/2022
test port locations
Profile:
G780B Volvo
AWD test procedure and test port locations


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
AWD Test procedure record sheet

Reproduce sheet as required.
Customer: Serial number
Model: Date:
1. Start the grader and warm the oil to normal operating temperatures. Place the grader in the Service Position.
2. Install the gauges as described on the following pages.
3. Start the grader. Allow the engine to idle with the AWD system switched off.
(a) Record Charge 1 pressure
Minimum: 1,9 MPa (19 bar)(275 psi)
(b) Record Pump Case pressure
Maximum: 345 kPa (3.5 bar)(50 psi)
4. Increase engine rpm to high free idle with the AWD switch off.
(a) Record Charge Pressure 1
Maximum: 3,44 MPa (34,5 bar)(500 psi)
(b) Record Pump Case pressure
Maximum: 346 kPa (3,5 bar)(50 psi)
5. Lower engine rpm to idle. Turn AWD switch on.
6. Depress the clutch pedal and select 3rd gear forward.
(a) Record Charge 2 pressure. System 1 and system 2 pressure greater than 2068,4 kPa (20,7
Maximum: 34,5 kPa (0,35 bar)(5 psi) bar) (300 psi)
7. With the clutch pedal depressed, select 4th gear forward by moving the transmission shift lever to the right once.
(a) Record Charge 2 pressure.
Acceptable limit equals charge pressure as in (3a).
8. Select neutral with the transmission shift lever and release the clutch pedal. Turn Creep Mode on. Place transmission shift
lever in forward. Increase engine rpm to maximum speed. This test should not be conducted for more than 15 seconds at a
time.
(a) Record System 1 and System 2 pressures
Acceptable limit: 34,5 ±3,45 MPa (345 ±34,5 bar)(5000 500 psi)
(b) Record Motor Case pressure
Acceptable limit: less than 207 kPa (2 bar)(30 psi)
NOTE!
Lower pressures will not occur if front wheels break traction or if the parking brake does not hold.
Test port locations

Quick disconnect fitting part numbers:
Male #4 SAE - 97712
Male #6 SAE - 97713
Female 1/4” NPT - 97714
System 1
Component Port Gauge range
LH pump forward M1 0 - 50 MPa
(0 - 500 bar)
(0 - 6000 psi)
Figure 1
System 1 at LH pump forward “M1” port
System 2
RH pump forward M1 0 - 50 MPa
(0 - 500 bar)
(0 - 6000 psi)
Figure 2
System 2 at RH pump forward “M1” port
Pump case
LH or RH pump N 0 - 1000 kPa
(0 - 10 bar)
(0 - 100 psi)
Figure 3
Pump case at LH or RH pump “N” port
Motor case
Motor displacement Valve G 0 - 500 kPa
(0 - 5 bar)
(0 - 73psi)
Figure 4
Motor displacement valve at motor case “G” port
Charge 1
Filter head - 0 - 5000 kPa
(0 - 50 bar)
(0 - 725 psi)
Figure 5
Charge 1 at filter head
Charge 2
Motor displacement valve G1 0 - 5000 kPa
(0 - 50 bar)
(0 - 725 psi)
Figure 6
Charge 2 at motor displacement valve “G1” port
Service Information

AWD error codes and 440 Service Information 9/10/2022
troubleshooting
Profile:
G780B Volvo
AWD error codes and troubleshooting


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Error codes – AWD
Code Component Condition Check/action

A1 Front wheel speed LH sensor (check) Signal present Confirms that the front wheel sensor is
positioned properly in the wheel motor.
A2 Front wheel speed RH sensor (check) Signal present Confirms the front wheel sensor is
positioned properly in the wheel motor.
C1 Motor displacement solenoid (DCV1) Open Check:
C2 Motor freewheeling solenoid (DCV2) Open
Solenoid coil resistance
C3 Forward bypass solenoid LH (DCV3) Open
Solenoid wiring harness
C4 Reverse bypass solenoid LH (DCV4) Open continuity
C5 Forward Bypass Solenoid RH (DCV5) Open Harness connection(s)
C6 Reverse bypass solenoid RH (DCV6) Open Controller connection(s) for
corrosion
C7 EDC Forward LH Open
C8 EDC Reverse LH Open
C9 EDC Forward RH Open
C0 EDC Reverse RH Open
H1 Motor displacement solenoid (DCV1) Short Check:
H2 Motor freewheeling solenoid (DCV2) Short
Solenoid coil resistance:
H3 Forward bypass solenoid LH (DCV3) Short
H4 Reverse bypass solenoid LH (DCV4) Short DCV 1 & DCV 2 (39.9 W
H5 Forward bypass solenoid RH (DCV5) Short ±10%)
H6 Reverse bypass solenoid. RH (DCV6) Short DCV 3 to DCV 6 (28.8 W
±10%)
H7 EDC forward LH Short
H8 EDC reverse LH Short Solenoid wiring harness resistance
Harness connection(s)
H9 EDC forward RH Short
Controller connection(s) for
H0 EDC reverse RH Short corrosion
L1 AWD oil level fault Low oil level See info: "Low oil light is ON".
L2 AWD oil temperature fault Reservoir temp >88ºC See info: "High oil temperature light is ON"
(190ºF)
L3 AWD oil filter fault Filter bypassing See info: "Oil filter light is ON"
L4 AWD charge pressure fault Low charge pressure See info: "Low charge pressure light is ON"
J1 Clutch Switch Failure No signal present > 30
J2 Brake Switch 1 Failure secs. and engine signal Continuity through switch
>1200 rpm and right or Continuity through switch wiring
J3 Brake Switch 2 Failure
left wheel or trans output harness
speed signal >5 rpm and Harness Connections
shifter out of neutral Controller connections for
corrosion
P1 Low Voltage Fault <17 VDC

Controller
Charging system
Poor grounds
U1 Front Wheel Speed LH Sensor (fail) No signal present when Check:

right wheel speed & trans.
output speed signal Sensor adjustment (1/4 turn out
present > 30 secs. from bottomed)
Continuity through + and – wires
of sensor
Sensor wiring harness resistance
Sensor wiring harness continuity
corrosion
U2 Front Wheel Speed RH Sensor (fail) No signal present when Check:

left wheel speed & trans.
output speed signal Sensor adjustment (1/4 turn out
present > 30 secs. from bottomed)
Continuity through + and – wires
of sensor
corrosion
U3 Transmission Output Speed Sensor Short low resistance coil Check:
Sensor resistance (1 kW ±10%)

corrosion
U4 Transmission Output Speed Sensor Open high resistance coil Check:
Sensor continuity
corrosion
U5 Transmission Output Speed Sensor No Signal Check:
Sensor adjustment 1,3 mm

clearance (.050”)
U6 Engine (alternator) signal in Creep Mode No Signal Check:
Alternator
Alternator wiring harness
Controller Connections
Off-line checks using the ECU

The following checks are performed when the AWD is not functioning. They ensure that the following components are
communicating with the AWD ECU.
Part designation Description

SE4402 Left front wheel speed sensor
SE4401 Right front wheel speed sensor
SE4404 AWD clutch pressure sensor
SE4405 AWD brake pressure sensor
SE4406 AWD brake pressure sensor
SW4403 AWD aggression switch
Test procedure
1. Place the machine in the service position. Refer to Service positions.

2. Raise the front wheels off the ground.
3. With the ignition switch in the 0 position (OFF), place the transmission shifter in forward or reverse.
4. Turn the AWD switch to the (OFF) position.
5. Turn the ignition switch to the 1 position (ON).
NOTE!
The alarm will energize and error codes E4.2 and L4 will be active on the transmission display.
6. Spin the left front wheel by hand (1 RPM). The expected result should be that the E4.2, L4 and A1 should appear on the
transmission display and the AWD buzzer should beep.
7. Spin the right front wheel by hand (1 RPM). The expected result should be that the E4.2, L4 and A2 should appear on
the transmission display and the AWD buzzer should beep.
8. Turn the ignition switch to the 0 position and leave the transmission shifter in forward or reverse.
9. Turn the AWD switch ON.
10. Turn the ignition switch to the 1 position.
11. Apply the brake firmly and hold. The expected result should be the E4.2, L4, J1, J2 and J3 and aggression switch setting
position.
12. Turn the AWD aggression switch through settings 1 to 16. The expected result should be E4.2, L4, J1, J2 and J3 and
aggression switch setting position.
13. Release the brake pedal.
14. Apply the clutch pedal firmly and release. The expected result should be that J1 is eliminated from the transmission
display.
15. Apply the brake pedal firmly and release. The expected result should be that J2 and J3 are eliminated from the
transmission display.
16. Carefully, lower the front wheels of the machine.
NOTE!
The off - line check using the AWD ECU procedure is now complete.
Low charge pressure light is ON:

Charge pressure is monitored with a Normally Open pressure switch located at the outlet of the charge pressure filter. The switch
will be closed, completing the electrical circuit, when charge pressure is normal.
There are two main reasons for the Charge Pressure light to remain ON.
1. Charge pressure is low and the charge pressure switch is “open”.

2. The electrical system has malfunctioned.
Charge pressure is low:

If the proper type of fluid and the level of fluid are correct, three conditions will cause low charge pressure.
1. The volumetric efficiency of the charge pump is below acceptable limits. Charge pump flow is insufficient and the drive
loop and control systems consume oil faster than the pump can supply oil.
2. A substantial external leak exists that allows oil to drain from the main drive loop.
3. There is excessive internal leakage within the drive loop and oil is drained back to tank faster than the charge pump can
supply oil. This “leakage” can occur at a number of locations.
Location Possible cause(s)

Drive pump
Charge relief valve(s) malfunction
System relief valve(s) malfunction
High leakage between rotating/moving surfaces (valve
plate, cylinder block, piston shoes, pistons) swashplate
Seal failure
Drive motor
High leakage between rotating/moving surfaces (distributor
valve, pistons)
Seal failure
Sealing rings worn
Freewheeling solenoid
Seal failure
Freewheeling valves
Seal failure
Motor displacement solenoid

Seal failure
Motor bypass valve

Seal failure
High internal leakage within the drive pumps and/or the drive motors will often result in other symptoms other than low charge
pressure. The system may operate at higher temperatures than normal and system performance may be reduced.
Charge pump flow and pressure varies with engine speed. Typically, a weak charge pump or excessive internal component
leakage will start to become evident at low engine speeds.
Electrical system malfunction:
There are three possible electrical failures.
1. The AWD charge pressure switch has failed.

2. There is a loose or broken electrical connection.
3. The ECU is faulty.
Figure 1
High oil temperature light is ON

Oil temperature is monitored with a Normally Closed temperature switch located in the AWD hydraulic tank. The switch will
remain closed, completing the electrical circuit, when the oil temperature is normal.
There are two main reasons for the Oil Temperature Light to remain ON.
1. The oil temperature is high and the oil temperature switch is open.
Oil temperature is high:

There are a number of conditions that will cause high oil temperature.
1. The duty cycle and ambient air temperature are high and system cannot be cooled.
2. AWD cooler efficiency is reduced due to restricted airflow.
3. The AWD hydraulic system is not operating efficiently.
Location/defect Possible cause(s)

Reduced oil flow through AWD cooler
30 psi bypass check valve is stuck open.
System is contaminated and cooler flow is restricted.
High internal drive pump leakage

Charge relief valve(s) malfunction.
System relief valve(s) malfunction. High leakage between
rotating/moving surfaces (valve plate, barrel face, piston shoes,
pistons). Seal failure.
High internal motor leakage

High leakage between rotating/moving surfaces (distributor
valve, pistons). Seal failure. Sealing rings worn.
Operates continuously at a high pressure

System relief valve(s) malfunction. Pump(s) will not de-stroke.
Reduced system performance

High internal component leakage. Typically pumps and/or
motors.
A system operating at increased temperature due to poor efficiency of the hydraulic components will tend to display other
symptoms.
The overall performance of the system will typically be reduced. For example, full system pressure and/or wheel speeds cannot
be achieved. Low charge pressure may also be experienced.
1. The AWD oil temperature switch has failed.

Figure 2
Oil filter light is ON

The condition of the AWD filter is monitored with a Normally Closed pressure switch located in the filter head. The switch will be
closed, completing the electrical circuit, when the condition of filter is okay.
There are three possible reasons for the filter light to remainON.
1. The filter element is restricted, increasing the pressure drop across the filter, and the switch opens.
2. The oil viscosity is high, increasing the pressure drop across the filter, and the switch opens. This may be typical during
a cold start and will correct itself when oil temperature increases.

1. The AWD filter switch has failed.

Figure 3
Low oil light is ON

AWD oil level is monitored with a Normally Open float switch located in the AWD hydraulic tank. The switch will be closed,
completing the electrical circuit, when the oil level is okay.
There are two main reasons for the low oil level light to remain ON.
1. The oil level is low and the switch is open.


1. The AWD oil level switch has failed.

Figure 4
The AWD system will not drive in forward or reverse (both wheels)
The following conditions will shut the AWD system OFF:
1. Low charge pressure.

The charge pressure light and alarm should be ON.
2. Low oil level.
The low oil level light and alarm should beON.
3. High oil temperature.
The high oil temperature light should be ON.
Check the gear display for Error Codes if these conditions are normal.
See table below.
Possible error codes Effect Possible causes

C2 or H2 Freewheeling solenoid valve (DCV2) will Check solenoid.
not shift. Freewheeling valves will not shift Check for broken or loose wires/
and motors remain in freewheeling mode. connections.
C3, C4, C5, C6 or H3, H4, H5, H6 The forward and reverse bypass solenoids ECU may be faulty.
(DCV3, DCV4, DCV5, DCV6) will not shift.
Oil bypasses the motors.
C7, C8, C9, C0 or H7, H8, H9, H0 The pumps will not stroke. Oil will not be
supplied to the motors.
U3, U4, U5 There may not be a signal from the Check the sensor
transmission output speed sensor. The Check for broken or loose wires/
pump is not commanded to stroke. Oil will connections.
not be supplied to the motors. ECU may be faulty.
P1 Low voltage Check charging system,
grounding, for broken or loose connection/
wires. ECU may be Faulty.
J1, J2, J3 No signal present >1 min. and engine Continuity through switch
signal >1200 rpm and right or left wheel or Continuity through switch wiring harness
trans output speed signal >5 rpm and Harness connections
shifter out of neutral ECU connections for corrosion
Check the AWD ON/OFF Switch:

The AWD ON/OFF switch may have failed. Check for any broken or loose connections/wires.
Check the AWD Aggression Select Switch:
The aggression switch may have failed. Check for any broken or loose connections/wires.
Check the Clutch Switch, Brake Switch 1 and Brake Switch 2:
The clutch and brake switches are Normally Closed pressure switches. The clutch switch opens when the clutch is
applied and the brake switches open when the brakes are applied. When these switches are open the forward and
reverse bypass solenoids (DCV3, DCV4, DCV5, DCV6) are all de-energized. This allows oil to bypass the motors and
stops the AWD from driving when the clutch/brake pedals are depressed. The AWD will not drive if any one of these
switches fails in the open position.
Check hydraulic components
Check for malfunctioning hydraulic components if the above conditions and switches are all normal.
Possible component failure Effect

Freewheeling solenoid valve (DCV2) The valve is stuck open. The freewheeling valves will not shift (no
pilot pressure) and the motors will remain in freewheeling mode.
Restricted or broken hydraulic line No pilot pressure available for freewheeling valves. The valves
will not shift and the motors will remain in freewheeling mode.
Figure 5
The AWD system will not drive in forward and/or reverse (one wheel)
Check the gear display for Error Codes
C3, H3
Forward Bypass Solenoid LH (DCV3) will not 1. Check for broken or loose
shift. The left wheel will not drive in forward. wires/connections.
Creep mode will not work. 2. Check solenoids/coils.
3. ECU may be faulty.
C4, H4
Reverse Bypass Solenoid LH (DCV4) will not
shift. The left wheel will not drive in reverse.
Creep mode will not work
C5, H5
Forward Bypass Solenoid RH (DCV5) will not
shift. The right wheel will not drive in forward.
Creep mode will not work.
C6, H6
Reverse Bypass Solenoid RH (DCV6) will not
shift. The right wheel will not drive in reverse.
Creep mode will not work.
C7, H7
EDC Forward LH. The left pump will not stroke
properly in forward. The left wheel will not
drive properly in forward.
C8, H8
EDC Reverse LH. The left pump will not stroke
properly in reverse. The left wheel will not
drive properly in reverse.
C9, H9
EDC Forward RH. The right pump will not
stroke properly in forward. The right wheel
will not drive properly in forward.
C0, H0
EDC Reverse RH. The right pump will not
stroke properly in reverse. The right wheel will
not drive properly in reverse.
Check for malfunctioning hydraulic components if there are no error codes displayed.
Possible component failure Effect Possible cause

Forward bypass solenoid Valve will not shift. Left wheel will not drive Valve stuck.
LH (DCV3) in forward. Internal leakage.
Reverse bypass solenoid Valve will not shift. Left wheel will not drive Valve stuck.
LH (DCV4) in reverse. Internal leakage.
Forward bypass solenoid Valve will not shift. Right wheel will not Valve stuck.
RH (DCV5) drive in forward. Internal leakage.
Reverse bypass solenoid Valve will not shift. Right wheel will not Valve stuck.
RH (DCV6) drive in reverse. Internal leakage.
Motor bypass valve assembly Will not shift to closed position. Left motor Valve stuck.
will not drive in forward or reverse. Internal leakage.
LH Bypass valve Forward or reverse bypass solenoids
(DCV3, DCV4) not operating properly
Motor bypass valve assembly Will not shift to closed position. Right Valve stuck. Internal leakage. forward
motor will not drive in forward or reverse. or reverse bypass solenoids (DCV5,
RH Bypass valve DCV6) not operating properly.
Freewheeling valve LH The valve will not shift. The left motor will The freewheeling valve is stuck in the
remain in freewheeling mode. The left normal position. Restricted or broken
wheel will not drive in forward or reverse. hydraulic line not allowing pilot
pressure.
Freewheeling valve RH The valve will not shift. The right motor will The freewheeling valve is stuck in the
remain in freewheeling mode. The right normal position. Restricted or broken
wheel will not drive in forward or reverse. hydraulic line not allowing pilot
pressure.
Drive pump LH Will not stroke. Left wheel will not drive. High internal leakage within pump
control circuit. EDC pilot valve has
failed. Pump has failed.
Drive pump RH Will not stroke. Right wheel will not drive. High internal leakage within pump
control circuit. EDC pilot valve has
failed. Pump has failed.
Drive motor LH Left motor will not drive Check error codes. Forward or
reverse bypass solenoid(s) valves LH
(DCV3, DCV4) have failed. Bypass
valve LH has failed. Left freewheeling
valve will not shift. Left pump does
not supply oil. Left motor has failed.
Drive motor RH Right motor will not drive Check error codes. Forward or
reverse bypass solenoid(s) valves RH
(DCV5, DCV6) have failed. Bypass
valve RH has failed. Right
freewheeling valve will not shift.
Right pump does not supply oil.
Right motor has failed.
Creep mode will not function (normal AWD still operates)

Check the gear display for Error Codes:

U6 Engine (alternator R-terminal) has failed Check for broken or loose wires/
connections. Check alternator.
ECU may be faulty.
C3, C4, C5, C6, H3, H4, H5, H6 Any one of these error codes will disable the Check solenoid.
creep mode function. Check for broken or loose wires/
NOTE! connections
Normal AWD will be allowed but will not be ECU may be faulty.
fully functional.
Check the creep mode switch:

The Creep Mode switch may have failed. Check for any broken or loose connections/wires.
Service Information

All Wheel Drive Pump and 440 Service Information 9/10/2022
Motor Priming Procedure
Profile:
G780B Volvo
All Wheel Drive Pump and Motor Priming Procedure


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 442-052
After replacing an All Wheel Drive hydraulic pump or wheel motor, the following procedure must be performed to remove any
air from the pump or motor case and connecting hydraulic lines. Follow these steps to prevent dry start-up damage:
1. In the event of a hydraulic pump or motor failure, thoroughly flush the AWD hydraulic system. Be sure to flush all lines
and control valves.
2. Thoroughly clean out the hydraulic tank to remove any contaminants or particles.
3. Refill the hydraulic tank with clean filtered oil to the full level.
4. Using an air regulator and a controllable fitting, pressurize the tank to 14 – 20 kPa (2 – 3 psi).
5. Open the main control valve supply line to the hydraulic drive motors at the front of the grader and let oil flow from the
lines until no air bubbles are present in the oil. Reinstall these supply lines to the motors.
6. Refill the hydraulic tank to the correct level and re-pressurize to 14 – 20 kPa (2 – 3 psi).
7. Open the return lines on the hydraulic motors. Bleed off until there are no bubbles in the oil. Reconnect these lines.
Open the following 4 quick disconnect fittings to atmosphere:
1. Case drain test port (N) for the left-hand AWD drive pump.
Figure 1
1. Left drive pump – case pressure test port (N)

2. Right drive pump – case pressure test port (N)
2. Case drain test port (N) for the right-hand AWD drive pump.
Figure 2
1. AWD charge pressure
3. Test port downstream of AWD charge pressure filter.

Figure 3
1. LS pressure test port
4. Test port connected to LS (load sense) port of main hydraulic pump.
Let the oil flow until all the air bubbles disappear and there is a steady stream of oil.
NOTE!
Failure to open the quick disconnect fittings to atmosphere while pressurizing the reservoir may result in pump damage.
Specifications; SR final drive 2
Description; SR final drives 3
Operation; SR final drive 4
Lock_unlock function 6
Final drive assembly; removing 7
Tandem; removing 9
Final drive assembly; installing 10
Specifications; G780B - DR final drive 12
Description; G780B - DR final drive 13
Operation; G780B DR final drive 14
Lock_unlock function 16
Lubrication circuit 17
Final drive assembly; removing 18
Final drive assembly; installing 23
Specifications; tandems 28
Tandem assembly 29
Tandem; removing 31
Differential Lock; G710B - G746B 37
Differential Lock; G780B 39
Service Information

Specifications, SR final drive 463 Service Information 9/10/2022
Profile:
G780B Volvo
Specifications, SR final drive


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
G710B to G746B - Single reduction final drive
Model Weight
SR 30 – G710B to G726B 565 kg (1246 lb)
SR 40 – G730B to G746B 680 kg (1500 lb)
Gear ratio
SR 30 and SR 40 6.14:1
Service Information

Description, SR final drives 463 Service Information 9/10/2022
Profile:
G780B Volvo
Description, SR final drives


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The SR 30 final drive is used on models G710B to G726B while the SR 40 final drive is used on models G730B to G746B. Both SR
final drives use a hypoid gear set that positions the drive pinion shaft below the center line of the ring gear. The weight of the
grader is transferred directly to the tandem from the final drive housing through flanged sleeves. Therefore, the drive axle carries
no weight. Each flanged sleeve oscillates in 2 Teflon coated bushings pressed into the final drive housing, but cannot move
laterally due to a split ring which clamps the final drive to the tandem. Teflon thrust plates transmit thrust loads from the split
rings and the flanged sleeves to the final drive housing when the tandems oscillate. A lock/unlock differential allows both
maximum traction when locked and minimum turning radius when unlocked.
Service Information

Operation, SR final drive 463 Service Information 9/10/2022
Profile:
G780B Volvo
Operation, SR final drive


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
A drive shaft connects the transmission output shaft to the final drive input shaft. The pinion shaft gear transfers power to the
ring gear which rotates the differential housing. Tapered roller bearings support the differential housing. There is no movement
of the spider gears and pinions relative to the differential housing unless differential action occurs between the two axles. The
axle shafts are splined to the spider gears and supported at the outer end by a double row spherical roller bearing.
Figure 1
Single reduction final drive – G710B to G746B
1. Ring gear
2. Pinion shaft/gear
3. Lock/Unlock switch
4. Shift cylinder
5. R.H. axle shaft
6. Thrust plates
7. Seal
8. Seal
9. Level check plug
10. Shift collar
11. Final drive housing
12. Differential housing
13. Breather
A. Shift cylinder oil pressure port

B. Shift cylinder oil pressure port
Service Information

Lock/unlock function 463 Service Information 9/10/2022
Profile:
G780B Volvo
Lock/unlock function

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The differential lock is operated by a hydraulic shift cylinder assembly that is mounted on the differential housing. A solenoid
valve is used to direct oil from the output side of the transmission filter to the final drive shift cylinder. An electric switch on the
pedestal activates the solenoid valve. An indicator light, mechanically switched by the shift fork, energizes when the differential is
unlocked. The light operates independent of the switch and therefore reflects the true position of the differential lock shift collar.
To lock the differential, the valve is energized and directs oil pressure to port “A” on the shift cylinder. The piston moves the
shift fork against a spring until the shift collar engages the splines on the differential housing. The right-hand axle shaft is now
locked to the differential assembly. No differential action can occur between the tandems.
To unlock the differential, the solenoid valve is de-energized and directs oil pressure to port “B” on the shift cylinder. The
cylinder moves forcing oil out the “A” port through the valve and back to tank. The spring pushes the shift fork and shift collar
away from the differential housing to unlock the differential.
Service Information

Final drive assembly, 463 Service Information 9/10/2022
removing
Profile:
G780B Volvo
Final drive assembly, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 463-055
1. Park the grader on level ground. Place the transmission in neutral. Centralize the circle, drawbar and moldboard
assembly using the circle shift and blade lift cylinders. Lower the moldboard onto wooden blocks. Shut down the
engine and place the machine in the Service Position. Refer to Service positions.
Figure 1
2. Place a container (capacity: 23 L; 6 U.S. gal) under the final drive drain plug. Remove the plug and drain the oil. Clean
and install the plug.
3. Disconnect all brake lines between the rear frame and tandems. Identify the lines to prevent confusion during assembly.
Immediately plug the lines and connectors to prevent dirt and moisture entering the brake fluid system. Remove any
spilled brake fluid to prevent paint damage.
4. Disconnect the lower drive shaft universal joint from the final drive yoke. Secure the slip yoke and drive shaft with lock
wire.
Figure 2
5. Disconnect the hydraulic hose at the differential lock cylinder cover. Plug the open ports. Disconnect the sensor switch
wiring harness from the main wiring harness.
6. Make a visual safety check around the grader. Ensure that all personnel are away from the area. Signal your intention
and start the engine when it is safe to do so. Position the moldboard at 90ºto the frame. Apply down pressure to the
moldboard and lift the front wheels about 60 cm (2 feet) off the ground. Shut down the engine. Remove and retain the
ignition key. Turn the battery isolation switch to the OFF position. Place a safe, adequate stand under the nose plate.
7. Open the battery box and disconnect the battery cables. Remove one battery and pass the cables through the
grommet.
8. Attach a safe lifting device to the rear of the grader frame. Remove the bolts and special washers retaining the final
drive assembly to the frame brackets. Remove the nose plate stand. Raise the rear end of the grader clear of the final
drive by pivoting on the moldboard. Roll out the final drive and tandem assembly from under the grader. Lower the
rear end of the grader onto a safe, adequate stand.
Service Information

Tandem, removing 463 Service Information 9/10/2022
Profile:
G780B Volvo
Tandem, removing

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 463-056
1. Install wheel chocks in front and behind the tandem tires. Place a container under the tandem drain plug.
Oil disc brake capacity: 38 L (10 US gal)
Tandem capacity:
G710B to G746B – 100 L (26.5 US gal)
G780B – 105 L (27.7 US gal)
2. Remove the plugs and drain the oil. Clean and reinstall the magnetic plugs. If the oil and magnetic plugs are
contaminated with metal particles, completely disassemble the tandem to remove defective parts.
3. If applicable, disconnect and remove the transverse brake line. Immediately plug the line and connector. Remove any
spilled brake fluid to avoid paint damage.
4. Remove the bolts securing the tandem side cover plate and remove the plate. Remove all traces of silicone sealant.
5. Remove the bolts, tab washer and end cap securing the drive sprocket to the axle shaft. Discard the tab washer.
6. Support the final drive assembly on safe, adequate stands. Attach a safe lifting device to the tandem. Remove the bolts
and lock washers retaining the final drive assembly to the tandem.
7. Carefully remove the tandem. Remove the drive sprocket and chains from the axle shaft using a pry bar. Repeat steps 2
to 7 for the other tandem.
Service Information

installing
Profile:
G780B Volvo
Final drive assembly, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 463-057
1. Apply a uniform bead of silicone sealant P/N 56427 to the tandem mounting surface and the drive sprocket bearing
surface.
2. Attach a safe lifting device to the final drive assembly. Position the assembly and align the splines of the axle shaft and
drive sprocket.
3. Apply thread locking compound P/N 40945 to the bolts retaining the final drive split rings to the tandem. Install the
bolts and lock washers that fasten the final drive to the tandem case.
Torque-tighten the bolts to 407 – 447 N•m (41 – 46 kgf•m) (300 – 330 lbf•ft).
4. Install the end cap, new tab washer and bolts securing the drive sprocket.
Torque-tighten the bolts to 108 – 136 N•m (11 – 14 kgf•m)(80 – 100 lbf•ft).
Bend the tab washer corners to secure the bolt heads.
5. Apply a uniform bead of Loctite 587 blue to the side cover plate mounting surface. Install the side cover plate and
secure with the bolts. Repeat steps 1 to 5 for the other tandem.
6. If applicable, install and connect the transverse brake lines. Remove any spilled brake fluid to avoid paint damage.
7. Attach a safe lifting device to the rear of the grader frame. Raise the end of the grader and remove the stands. Roll the
final drive and tandem assembly under the grader. Lower the grader until the frame brackets rest on the final drive
mounting plates. Install the bolts and special washers.
Torque-tighten the bolts to983 – 1085 N•m
(100 – 110 kgf•m)(725 – 800 lbf•ft).
8. Remove and discard the lock wire securing the slip yoke and drive shaft together. Connect and retain the lower drive
shaft to the final drive yoke.
9. Connect all brake lines between the rear frame and tandems. Ensure that all connections are clean and tight. Remove
any spilled brake fluid to prevent paint damage.
10. Connect the sensor switch wiring harness to the main wiring harness. Install the hydraulic hoses to the differential lock
cylinder cover.
11. Pass the battery cables through the grommet. Install one battery and connect the battery cables. Close and secure the
battery box.
12. Refer to Recommended lubricants for the capacities and recommended tandem and final drive lubricating oils. Remove
the upper pipe plug from the final drive housing. Fill the final drive until oil reaches the bottom of the plug hole. Clean
the plug. Apply pipe sealant P/N 19167 to the plug threads and install the plug.
13. Remove and clean the tandem filler plugs and level check plugs. Fill both tandems to the bottom of the check plug
hole. Apply pipe sealant P/N 19167 to the plug threads and install the plugs.
Service Information

Specifications, G780B - DR 463 Service Information 9/10/2022
final drive
Profile:
G780B Volvo
Specifications, G780B - DR final drive


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Model Weight
Volvo twin bull gear 821 kg (1810 lb)
Gear ratio 8.97:1
Service Information

Description, G780B - DR 463 Service Information 9/10/2022
final drive
Profile:
G780B Volvo
Description, G780B - DR final drive


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The double reduction final drive is used in the model G780B. This final drive uses a spiral bevel gear set and two spur gear sets.
The weight of the grader is transferred directly to the tandem from the final drive housing through flanged sleeves. Therefore,
the drive axle carries no weight. Each flanged sleeve oscillates in two Teflon lined bushings pressed into the final drive housing,
but cannot move laterally due to a split ring which clamps the final drive to the tandem. Teflon thrust plates transmit thrust loads
from the split rings and the flanged sleeves to the final drive housing when the tandems oscillate. A lock/unlock differential
allows both maximum traction when locked and minimum turning radius when unlocked.
Service Information

Operation, G780B DR final 463 Service Information 9/10/2022
drive
Profile:
G780B Volvo
Operation, G780B DR final drive


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
A drive shaft connects the transmission output to the final drive input. The pinion shaft gear transfers power to the ring gear
which rotates the differential housing. There is no movement of the spider gears and pinions relative to the differential housing
unless differential action occurs between the two axles. The cross shaft is splined to the differential housing and is supported by
tapered roller bearings. Two spider pinions on the cross shaft mesh with two bull gears which are supported by roller bearings.
The axle shafts are splined to the bull gears and supported at the outer end by double row spherical roller bearings.
Figure 1
Double reduction final drive – G780B
1. Oil pump
2. Tapered roller bearing
3. Spider pinion
4. Ring gear
5. Cross shaft
6. Shift clutch gear
7. Shift fork
8. Shift clutch
9. Spider gear
10. Shift piston
11. Shift cylinder body
12. Switch
13. Seal rings
14. Spring
15. Half ring
16. Pinion shaft
17. Sleeve bushings
18. Uni-ring seal
19. Drive axle
20. Lip seal
21. Thrust plates
Service Information

Lock/unlock function 463 Service Information 9/10/2022
Profile:
G780B Volvo
Lock/unlock function

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The differential lock is operated by a hydraulic shift cylinder assembly that is mounted on the differential housing. A solenoid
valve is used to direct oil from the output side of the transmission filter to the shift cylinder. An electric switch on the pedestal
activates the solenoid valve. An indicator light, mechanically switched by the shift cylinder piston, energizes when the differential
is unlocked. The light operates independent of the switch and therefore reflects the true position of the differential lock shift
collar.
To lock the differential, the valve is energized and directs oil pressure to port “A” on the shift cylinder. The piston compresses
the spring and pushes the shift rail and shift fork until the shift collar engages the splines on the differential housing. The left-
hand axle shaft is now locked to the differential assembly. No differential action can occur between the tandems.
To unlock the differential, the solenoid valve is de-energized and now directs oil pressure to port “B” on the shift cylinder. The
piston pulls the shift rail and shift fork backwards, disengaging the shift collar from the differential housing.
Service Information

Lubrication circuit 463 Service Information 9/10/2022
Profile:
G780B Volvo
Lubrication circuit

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
To lubricate the spider pinions and spider gear bearings, a small bi-directional oil pump is mounted on the right end of the cross
shaft. Oil travels through the center of the cross shaft and to the bearings and gears through small cross drilled passages. The
pump is a positive displacement internal gear type and can supply oil in forward or reverse direction. An external suction line
runs from the top of the final drive case to the pump cap.
Service Information

removing
Profile:
G780B Volvo
Final drive assembly, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 463-055
1. Park the grader on level ground. Place the transmission mode lever in Neutral. Centralize the circle, drawbar and
moldboard assembly using the circle shift and blade lift cylinders.
2. Lower the moldboard onto wooden blocks. Shut down the engine and place the machine in the Service Position. Refer
to Service positions.
Figure 1
3. Drain the differential final drive lubricating oil —34 L (9 US gal). Clean and install the magnetic drain plug.
4. Drain the lubricating oil from both tandem cases. Clean and install the magnetic drain and long-reach plugs.
5. Remove the filler pipe and hose from the frame.

6. Disconnect the brake lines from the tee fittings on the frame. Plug the lines and fittings and wipe away any spilled brake
fluid.
7. Disconnect the lower driveshaft from the front of the differential final drive.
Figure 2
8. Disconnect the three hose fittings from the lock/unlock cylinder. Plug the ports and hoses. Identify the fittings to avoid
confusion during assembly.
9. Disconnect the wires from the lock/unlock switch terminals.
10. Remove the nuts and bolts from the final drive hanger bracket half-clamps. Identify the halves to ensure that you install
them in the same locations during assembly.
Figure 3
11. Remove the nuts, bolts, lock washers, and rear mounting plate (133).
Figure 4
12. Start the engine and raise the front wheels just off the ground using the moldboard. Shut down the engine.
13. Disconnect the battery cables and remove the battery box.
14. Attach the lifting device to the rear of the grader frame. Raise the frame until it is clear of the differential final drive.
Make sure that the emergency brake disc does not interfere with the mounting brackets.
Figure 5
15. Roll the differential final drive and tandem assembly out from under the frame.
Figure 6
16. Lower the frame onto a secure stand.
17. Remove the capscrews retaining the tandem cover plates. Remove the plates and discard the gaskets. If gasket
eliminator compound has been used, remove all traces of the sealant.
18. Release the tabs and remove the capscrews (139), lockplate (138) and sprocket retainer (137). Remove and discard the
lockplate.
Figure 7
19. Remove the capscrews (54) and lock washers (55) retaining the half-rings (73) to the tandem.
Figure 8
20. Attach the lifting device to the tandem case.
Figure 9
21. Support the weight of the differential final drive on proper blocks.
Figure 10
22. Remove the tandem case from the differential final drive assembly using the lifting device. Make sure that the flanged
sleeve separates from the tandem and remove the tandem. Discard the gasket. If gasket eliminator compound has been
used, remove all traces of the sealant.
23. Lower the tandem on blocks.

Service Information

installing
Profile:
G780B Volvo
Final drive assembly, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 463-057
1. Before installing the tandem on the differential apply gasket eliminator P/N 25303, to the mounting surfaces of the
flanged sleeve.
Figure 1
2. Install the differential onto the tandem while aligning the axle splines with those of the tandem sprocket. Take care not
to damage the oil seal when installing the sprocket onto the drive axle.
3. Install the capscrews and lock washers that retain the half-rings to the tandem case.
Torque-tighten the capscrews to 407 – 447 N•m
(41 – 46 kgf•m)(300 – 330 lbf•ft).
Figure 2
4. Support the weight of the differential final drive on proper blocks or stands. Repeat the procedures described in steps
1, 2 and 3 to install the other tandem.
5. Install the sprocket retainer (137), new lockplate (138) and capscrews (139) for each drive sprocket.
Torque-tighten the capscrews to 108 – 135 N•m (11 – 14 kgf•m)(80 – 100 lbf•ft).
Bend the lock plate corner tabs to secure the capscrew heads.
Figure 3
6. Apply gasket eliminator compound P/N 25303, around the tandem cover plate opening.
7. Install the tandem cover plates and fasten them with the capscrews. Remove the blocks supporting the differential final
drive assembly.
8. Raise the frame using the lifting device. Remove the stand.
Figure 4
9. Roll the differential final drive and tandem assembly into position under the frame.
10. Carefully lower the frame onto the differential final drive housing using the lifting device. Make sure that the parking
brake disc does not interfere with the mounting brackets.
Figure 5
11. Install the hanger bracket half-clamps (be sure to check the matching identification marks). Retain with the nuts and
bolts, but DO NOT torque tighten.
Figure 6
12. Install the mounting plate (133) and retain with the nuts, bolts (132) and lock washers.
Torque-tighten the hanger bracket half-clamp nuts to1424 – 1593 N•m (145 – 162 kgf•m)(1050 – 1175 lbf•ft), and
torque-tighten the mounting plate nuts to 407 – 447 N•m (41 – 46 kgf•m)(300 – 330 lbf•ft).
Figure 7
13. Reconnect the lower driveshaft to the differential final drive brake flange yoke.
Torque-tighten the capscrews to 122 – 136 N•m (12 – 14 kgf•m)(90 – 100 lbf•ft).
Figure 8
14. Identify and reconnect the three hydraulic hoses to the lock/unlock cylinder.
15. Reconnect the wires to the lock/unlock switch terminals.
16. Reconnect the brake lines at the tee fittings on the frame. Be sure to wipe up any spilled fluid immediately.
17. Install the battery box and connect the battery cables to the proper terminals.
18. Install the battery box cover.
19. Install the filler pipe and hose on the frame.
20. Fill the differential final drive to the correct level using the lubricant recommended in Recommended lubricants.
21. Fill the tandem cases to the correct level using the lubricant recommended in Recommended lubricants.
22. Purge the brake system as described in the brakes section.

23. Removal and installation of the lock/unlock differential final drive is now complete. Road test the grader to make sure it
is working properly. Check all connections for leaks.
Service Information

Specifications, tandems Service Information 9/10/2022
Profile:
G780B Volvo
Specifications, tandems

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Oil capacity
Tandems – G710B to G746B 100 L (26.4 U.S. gal) each
Tandems – G780B 105 L (27.7 U.S. gal) each
Service Information

Tandem assembly Service Information 9/10/2022
Profile:
G780B Volvo
Tandem assembly

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Tandem assembly
1. Bolts
2. Lock washers
3. Brake line shield
4. Breather
5. Oil level dipstick
6. Retainer plate bolts
7. Retainer plate
8. Shim pack
9. Drain plug
10. Drive chain
11. Driven sprocket
12. Tandem case
13. Connector link
14. Cotter pin
15. Bolt
16. Lock washer
17. Retainer plate
18. Tab washer
19. Bolt
20. Side cover plate
21. Side cover plate bolts
22. Oil disc brake
23. Bolt
24. Lock washer
25. Step
26. Cover plate
27. Bolt
28. Drive sprocket
29. Oil disc brakes
Service Information

Tandem, removing Service Information 9/10/2022
Profile:
G780B Volvo
Tandem, removing

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 463-056
NOTE!
1. Loosen the wheel retaining bolts on the tandem that will be removed. DO NOT remove the bolts.
2. Turn the battery isolation switch to the ON position. Place the final drive in the unlocked position. Start the engine
when it is safe to do so. Position the moldboard centrally on the circle and 90º to the frame. Operate the blade lift
cylinders and raise the tandem. Shut down the engine.
3. Place a safe, adequate stand under the frame on the same side as the tandem to be removed. The stand should be high
enough to prevent both tandem wheels touching the ground. Position the stand under the midpoint of the frame. Start
the engine when it is safe to do so. Operate the blade lift cylinders and lower the grader onto the stand. Shut down the
engine. Remove and retain the ignition key. Turn the battery isolation switch to the OFF position.
4. Remove the wheel rim bolts and lock washers and roll the rims and tires away from the tandem case.
Figure 1
5. Remove the drain plug (22) from one end of the tandem case and drain the oil into a suitable container—capacity 100 L
(26.4 US gal) – G710B to G746B; 105 L (27.7 US gal) – G780B. Clean the drain plug and apply a bead of Teflon¯ pipe
thread sealant. Fully install the drain plug.
Figure 2
6. Remove the drain plug from the final drive housing and drain the oil into a suitable container (capacity 23 L (6 US gal),
G710B to G746B; 34 L (9 US gal), G780B). This is to prevent oil leakage when the flanged sleeve is removed. Clean the
drain plug and apply a bead of Teflon ¯ pipe thread sealant. Fully install the drain plug.
Figure 3
1. Drain plug
7. Remove the bolts (34), lock washers (33), and flat washers (32) securing the cover plates (30) and brake line shields (31).
Remove the cover plates and brake line shields. Remove the tool box and battery box.
Figure 4
8. Remove the bolts and side cover plate (39).
Figure 5
9. Disconnect the brake lines at the brake housings. Immediately plug the open ports and fittings to prevent
contamination.
Figure 6
10. Working through the inspection port on top of the tandem, turn the driven sprocket until the connector link (37) of the
drive chain is accessible. Remove and discard the cotter pins. Remove the connector link from the drive chain. Repeat
this step for the other drive chain.
WARNING
Risk of cuts! Wear safety glasses and use protective gloves.
NOTE!
For removal of G780B tandem drive chains with press fit chain connector links refer to: Service Bulletin 463GRD3 and
Installation Instructions document ref. No. 21A1000920.
Figure 7
11. Use a safe lifting device to remove the drive chains through the inspection port. Make sure the chains do not foul within
the tandem case.
Figure 8
12. Attach a safe lifting device to the brake housing. Remove the brake housing mounting bolts and lock washers. Remove
the brake assembly from the tandem case.
Figure 9
13. Attach a safe lifting device to the tandem case. Remove the bolts and hardened washers retaining the split ring and
flanged sleeve to the tandem case. Use an appropriate pry bar to release the tandem case from the flanged sleeve. Take
care to support the tandem case during this operation. Move the tandem case to a clean work area.
NOTE!
You may have to use a modified wrench due to restricted access of the split ring bolts.
Figure 10
14. Remove the nuts and bolts securing the split ring halves. Separate the split ring halves and remove them from the final
drive housing.
NOTE!
The split ring halves are a matched pair. Keep them temporarily bolted together during the overhaul procedure.
Remove all traces of gasket eliminator from the split ring flanges.
15. Release the tabs and remove the bolts, tabwasher and sprocket retainer plate. Discard the tabwasher. Remove the
driving sprocket.
WARNING
16. Use a safe lifting device to remove the flanged sleeve and drive axle assembly from the final drive housing.
17. Remove and discard the oil seals from the flanged sleeve and final drive housing. Check the condition of the drive axle
splines, bearing and bushings.
Service Information

Differential Lock, G710B - 468 Service Information 9/10/2022
G746B
Profile:
G780B Volvo
Differential Lock, G710B - G746B


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Differential lock/unlock circuit

Oil is taken from a tee fitting on the outlet of the filter head (1) to operate the differential lock/unlock circuit. A switch on the
pedestal controls the flow of oil through the valve (3) to the lock/unlock shift cylinder (4). All models use a double acting
cylinder with spring assist.
Figure 1
1. Transmission oil filter

2. Clutch housing
3. Solenoid valve
4. Double acting lock cylinder
5. From transmission pump
6. To MBCS lock valve
7. To park brake control
8. To transmission
Service Information

Differential Lock, G780B 468 Service Information 9/10/2022
Profile:
G780B Volvo
Differential Lock, G780B


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Differential lock/unlock circuit

Oil is taken from a tee fitting on the outlet of the filter head (1) to operate the differential lock/unlock circuit. A switch on the
pedestal controls the flow of oil through the valve (3) to the lock/unlock shift cylinder (4). All models use a double acting
cylinder with spring assist.
Figure 1
G780B Differential lock circuit

2. Clutch housing
3. Solenoid valve
4. Double acting lock cylinder
5. From transmission oil cooler
6. To MBCS lock valve
7. To park brake control
8. To transmission
50 - GENERAL 2
51 - WHEEL BRAKE 7
52 - HYDRAULIC BRAKE SYSTEM 53
55 - PARKING BRAKE 80
Overview 2
Service Information

Overview 500 Service Information 9/10/2022
Profile:
G780B Volvo
Overview

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Oil disc service brakes are standard on all models. Two hydraulic power boosters are used: one with a dual reservoir brake
master cylinder; and one with a single reservoir clutch master cylinder. The brake power booster includes an integral electric
back-up pump. The back-up pump provides sufficient boost to either bring the machine to a safe stop or hold it on a slope until
the parking brake is applied.
Oil for the brake and clutch power booster circuit comes from the priority outlet of the engine mounted hydraulic pump. The
priority regulator valve on the pump is set to 23 L/min (6 US gpm). The pump outlet incorporates a relief valve. The pump's relief
valve is set to 103 bar (1500 psi) to provide protection in the event one of the brake or clutch relief valves fail.
Figure 1
Clutch and brake booster hydraulic circuit

2. Brake booster c/w electric back-up pump
4. Clutch booster
6. Brake circuit
7. Brake circuit
8. Tuning hose
A. Brake master cylinder pressure test location

B. Brake booster pressure test location
Unlike the steering and main hydraulic circuits, this circuit is an open center type. Therefore, oil circulates through the power
boosters until required. Oil passes through the clutch power booster first, then passes through the brake power booster before
draining into the transmission case.
The oil disc service brakes are designed as a modular assembly and can be removed intact without performing any disassembly
on the machine. A threaded hole for a hoisting eyebolt is located at the top of the brake housing. Most parts are common
between models. The main differences are the quantity of friction discs and reaction plates used, and the axle shaft design. The
tandem oil is used to cool and lubricate the friction pack and bearings. Check the oil level by using the dipstick on the tandem
case.
Brake circuit
The outlet ports on the master cylinder are connected in a diagonal pattern to the four brake units. This provides two
independent brake circuits. If a failure occurs in one of the two circuits, a differential pressure switch activates when the brake
pedal is depressed. This switch energizes a warning lamp and alarm to alert the operator. Braking remains effective on all four
drive wheels through the tandem chains.
A flow switch mounted in the outlet port of the brake power booster monitors the flow of oil through the booster. This switch
controls the electrical circuit that activates the back-up pump. The circuit is designed to operate the back-up pump with the
ignition key in either the on or off positions.
Ignition key in the on or running “I” position:
If the engine stalls or there is an oil flow interruption, the flow switch activates the back-up pump to provide boost at a reduced
level. A warning lamp in the center display and a separate alarm alert the operator that the back-up pump is working. The pump
automatically shuts down when main hydraulic flow is restored.
Ignition key in the off “O” position:
The brake light switch takes the place of the ignition key switch in supplying power to the back-up pump electrical circuit. With
the engine off, the flow switch on the power booster is closed to complete the electrical circuit. The back-up pump will operate
as long as the brake pedal is depressed. As the ignition key is off, the warning lamp and alarm will not energize to alert the
operator.
Figure 2
1. Master cylinder
2. Booster
3. Pump and motor assembly
4. Master cylinder differential pressure switch
5. Power switch
6. Boot
7. Brake mounting bracket
8. Adjusting nut
9. Clevis
10. Outer pivot
11. Inner pivot
12. Pivot plate
13. Rod
14. Adjusting nut
15. Clevis
16. Brake light switch
17. Switch bracket
18. Shaft
19. Grease fitting
20. Set screw
21. Spring
22. Spring lug
23. Rubber boot
24. Mounting flange
25. Adhesive tape
26. Brake pedal assembly
27. Pedal
General 2
Description 3
Brake circuit hydraulic schematic 7
Electrical schematic 9
Electric motor_pump troubleshooting 12
Oil disc brake assembly; removing 15
Oil disc brakes; disassembling 18
Oil Disc Brake - Cleaning and Inspection 24
Brake housing; pre-assembling 26
Tandem axle oil seal installation 28
Tandem axle seal; installing 30
Oil disc brakes ; assembling 36
Oil Disc Brakes - Bench Adjustment 41
Oil disc brake; installing 43
Service Information

Profile:
G780B Volvo
General

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

Inboard bearing retainer plate bolts (shim setup) 54 5 40
Inboard bearing retainer plate bolts (final value) 230 23 170
Back-up plate to brake housing bolts 136 14 100
Brake housing to tandem case bolts 237 24 175
Driving sprocket retainer plate bolts 108 11 80
Side cover plate and inspection cover plate bolts 34 3 25
Wheel rim to axle shaft bolts 650 66 480
Thickness mm in.
Friction disc (new) 3,38 – 3,53 0.133 – 0.139
Friction disc (minimum) 2,62 0.103
Reaction plate (new) 3,05 – 3,18 0.120 – 0.125
Reaction plate (minimum) 2,92 0.115
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Oil disc brake assembly
1. Axle
2. Duo-cone seal
3. Outboard bearing cup
4. Outboard bearing cone
5. Brake housing bolts
6. Lock washers
7. Brake housing
8. Inner back-up ring
9. O-rings
10. Outer back-up ring
11. Piston
12. Friction discs
13. Reaction plates
14. Outer snap ring
15. Hub
16. Inner snap ring
17. Back-up plate
18. Washers
19. Back-up plate bolts
20. Inboard bearing cup
21. Inboard bearing cone
22. Drain plug
23. Shim pack
24. Retainer plate
25. Tabwasher
26. Retainer plate bolts
27. Tandem case
28. Breather
29. Driven sprocket
30. Inspection cover
31. Brake line shield
32. Washer
33. Lock washer
34. Bolts
35. Drive chain
36. Cotter pin
37. Connector link
38. Side cover plate bolts
39. Side cover plate
40. Oil level dipstick
41. Bleeder screw
42. Adjusting pin
43. O-ring
44. Jam nut
45. Piston travel limiting screw
46. Blanking plug
Construction
Two tapered roller bearings support the axle shaft in the brake housing. The outboard bearing is a press fit and the inboard
bearing is a slide fit on the axle shaft. The assembly contains shims to exert a slight preload on the bearings. The oil disc brake
friction pack consists of:
A set of organic faced friction discs with internal spline teeth. The friction discs mount onto a hub splined to the axle
shaft.
A set of steel reaction plates. External spline teeth retain the reaction plates in the brake housing.
The discs and plates are alternately installed in the brake housing; starting and ending with a reaction plate. The number of discs
and plates varies between models as follows:
G710B: 3 Discs / 4 Plates

G720B, G726B, G730B: 4 Discs / 5 Plates
G740B, G746B, G780B: 5 Discs / 6 Plates
The difference in the number of plates and discs is compensated by using backing plates of different thicknesses. All axle shafts
are hardened; one axle shaft is used for models G710B to G746B and another for model G780B. The G780B axle shaft has a bolt
pattern for rims with larger tires.
A Duo-cone seal is used at the outboard bearing. A breather maintains a slight pressure to prevent dust and dirt entering the
tandem case. Make sure the breather does not become clogged as over-pressurizing the tandem case can cause seal leakage.
Application circuit
System fluid enters one of two inlets on the top of the brake housing. Rear mounted brake assemblies use the rear port; front
mounted brake assemblies use the front port. The system fluid moves the piston away from the piston travel limiting screw
towards the friction pack. Braking action occurs as the piston compresses the discs and plates against the backing plate. When
the brake pedal is released, the system fluid returns to the brake master cylinder and the friction pack disengages. The grooves
in the friction discs allow oil to enter between the discs and the reaction plates. This allows the discs and plates to separate
slightly, moving the piston toward the piston travel limiting screw. Once the piston has released its clamping force, the axle
rotates freely.
Service Information

Brake circuit hydraulic 510 Service Information 9/10/2022
schematic
Profile:
G780B Volvo
Brake circuit hydraulic schematic


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
1. Transmission sump
3. To transmission
4. Clutch master cylinder/booster
5. Clutch slave cylinder
6. Brake master cylinder/booster
7. To transmission
8. Left-hand front disc brake
9. Right-hand front disc brake
10. Left-hand rear disc brake
11. Right-hand rear disc brake
Service Information

Electrical schematic 510 Service Information 9/10/2022
Profile:
G780B Volvo
Electrical schematic

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation
NC
3 RE5202 Brake No Flow relay Std. One pole, single throw Convenience center
NC
sensor corner on brake booster
5 SE5202 Brake delta pressure Std. NO, closed with a pressure Under cab, right-hand side, rear
sensor difference between the dual corner on brake master cylinder
brake circuits
motor 2. Ground
7 SW5201 Electrical brake Std. NC, closed when brake is Under cab at brake pedal linkage
switch engaged.
8 LA3607 Light pod, rear right- Std. Backup light bulb – 21W Rear of grader
Figure 1

Figure 2

Service Information

Electric motor/pump 510 Service Information 9/10/2022
troubleshooting
Profile:
G780B Volvo
Electric motor/pump troubleshooting


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Trouble Possible causes Check and remedy

(Ignition switch off in the “O” position)
Brake tail lights do not operate Brake switch on linkage out of Test for continuity.
adjustment or defective. Switch is normally closed.
Adjust brake linkage so that switch is
depressed and held open.
Electric back-up pump does not operate No power from ignition switch to brake Test for 24 volts from the key switch
relay coil. ignition post to brake relay coil.
Key switch fuse blown or diodes fail.
No ground from flow switch on power Test for ground from the flow switch to
booster to brake relay coil. brake relay coil.
No power from Accessory relay to Test for 24 volts from the Accessory
brake relay contact relay post to brake relay post.
Test for 24 volts at the Accessory relay
post or broken wire.
No power from brake relay contact to Test for 24 volts from the brake relay
electric back-up pump. post to electrical back-up pump.
Test for 24 volts at the brake relay or
broken wire.
Electric back-up pump motor defective Replace electric back-up pump and
motor.
Electric back-up pump does not operate Defective pressure flow switch Replace pressure flow switch
(Ignition switch on in the “R” position;
engine operating)
Electric back-up pump does not shut off. Flow switch is not receiving hydraulic Check for hydraulic flow through hose
flow or is defective. at power booster.
Inspect the piston, spring, and switch
contact.
Hard pedal Binding pedal linkage Check brake pedal linkage
Low booster supply flow Repair/replace hydraulic pump
Fluid contamination Drain, flush and refill system. Replace
booster and master cylinder as
appropriate.
Master cylinder Repair/replace master cylinder
Booster Replace booster
Hose passages are blocked shut Replace parts containing blocked
passages
Excessive pedal travel Improper pedal adjustment Adjust brake linkage
(pedal goes to the floor) External leak in brake fluid system Check all fittings and connections for
the master cylinder and brake unit.
Check seals, hoses and replace as
necessary
Internal master cylinder leak Repair/replace master cylinder
Air in brake fluid system Bleed system
Brake friction disc Inspect and replace friction disc if
necessary
Excessive pedal travel (continued) Master cylinder Repair/replace master cylinder
Weak brake hoses that expand under Replace defective hoses
pressure
Poor quality brake fluid (low boil point) Drain the system. Flush and refill with
the recommended fluid
Brake piston out of adjustment Adjust piston travel limiting screw
Soft, spongy brakes Air in hydraulic brake system Bleed brake system
Poor quality brake fluid (low boil point) Drain system. flush and refill with
recommended fluid
Weak brake hoses that expand under Replace defective hoses
pressure
Pedal does not return Binding pedal linkage Check brake pedal linkage
Fluid contamination Drain, flush and refill system. Replace
booster or master cylinder as
appropriate
Binding booster Replace booster
Self-applied booster (transmission Repair or replace transmission
pump fluid flow too high) hydraulic pump
Pulsating brake pedal Variable transmission hydraulic pump Repair or replace transmission
fluid flow through booster hydraulic pump/booster
Non-concentric brake unit plates Replace brake unit plates
Brake self apply Self-applied booster (fluid flow too Repair or replace transmission
high) hydraulic pump
Constricted master cylinder reservoir Clean vent passage in reservoir cap
vent
Dragging brake Self-applied booster (fluid flow too Repair or replace transmission
high) hydraulic pump
Binding booster Replace booster
Binding pedal linkage Verify pedal linkage is returning
properly
Return spring tension Check spring tension and verify with
Volvo Product Support
Soft or swollen seal due to brake fluid Repair/replace master cylinder, flush
contamination out old brake fluid and replace with
new
Hydraulic pressure present in brake Replace the parts containing the
lines, passages restricted restriction
Hydraulic pressure present in brake Monitor pressure, separate master
lines when pedal is released cylinder and booster by 3 mm (1/8 in.),
if pressure drops, check/replace
booster
Leakage Master cylinder Repair/replace master cylinder
Booster Replace booster
Master cylinder reservoir vent caps Replace vent caps
Fluid contamination/incorrect brake Drain, flush and refill system. Repair/
fluid replace master cylinder as appropriate.
Back-up pump mounting seals Replace seals
Flow switch seals Replace O-ring
Hydraulic fittings and connections Tighten and replace as necessary
Brake loose in left front and right rear or left Low brake master cylinder fluid level Add fluid as required
rear and right front brake circuits Fluid loss in master cylinder primary or Replace hoses, seals to repair fluid
secondary circuits leakage
Service Information

Oil disc brake assembly, 517 Service Information 9/10/2022
removing
Profile:
G780B Volvo
Oil disc brake assembly, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 517-071
NOTE!
1. Loosen the retaining bolts on the wheel that will be removed. DO NOT remove the bolts.
2. Turn the battery isolation switch on. Place the differential in the unlocked position. Start the engine when it is safe to do
so. Position the moldboard centrally on the circle and 90º to the frame. Operate the blade lift cylinders and raise the
tandem. Shut down the engine.
3. Place a safe, adequate stand or blocking under the tandem on the same side as the wheel to be removed. The blocking
should be high enough to prevent both tandem wheels from touching the ground. Start the engine when it is safe to
do so. Operate the blade lift cylinders and lower the grader onto the blocks. Shut down the engine. Remove and retain
the ignition key. Turn the battery isolation switch off.
4. Remove the wheel rim bolts and lock washers. Roll the wheels away from the tandem case.
Figure 1
5. Remove the drain plug from one end of the tandem case. Drain the oil into a suitable container. Clean the drain plug
and apply a bead of Teflon¯ pipe thread sealant. Fully install the drain plug.
6. Remove the bolts, lock washers, and flat washers securing the cover plates and brake line shields. Remove the cover
plates and brake line shields.
7. Remove the bolts and side cover plate.
8. Disconnect the brake lines at the brake housings. Immediately plug the open ports and fittings to prevent
contamination.
9. Working through the inspection port on top of the tandem, turn the driven sprocket until the connector link (37) of the
drive chain is accessible. Remove and discard the cotter pins. Remove the connector link from the drive chain. Repeat
this step for the other drive chain.
WARNING
Risk of cuts! Wear safety glasses and use protective gloves.
NOTE!
For removal of G780B tandem drive chains with press fit chain connector links refer to: Service Bulletin 463GRD3 and
Installation Instructions document ref. No. 21A1000920.
Figure 2
10. Use a safe lifting device to remove the drive chains through the inspection port. Make sure the chains do not foul within
the tandem case.
Figure 3
11. Attach a safe lifting device to the brake housing. Remove the brake housing mounting bolts and lockwashers. Remove
the brake assembly from the tandem case.
Figure 4
Service Information

Oil disc brakes, 517 Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Oil disc brakes, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 517-072
1. Place the oil disc brake assembly, with the wheel mounting flange down, onto a level work surface. Remove the 3
retainer plate bolts (26).
Figure 1
2. Remove the bolts, retainer plate (24) and shims (23). Keep the original shims for installation.
3. Use a safe lifting device to remove the sprocket. Note the proper orientation of the sprocket flange to prevent incorrect
installation.
Figure 2
4. Remove the back-up plate retaining bolts and hardened washers. Install an appropriate puller to remove the inboard
bearing cone and back-up plate. (It may be necessary to tap the inner housing if sealant leaked between the housings.)
Remove the bearing cone and place to one side for cleaning and inspection.
Figure 3
5. Place the back-up plate (17) in a hydraulic press and remove the inboard bearing cup. Place the bearing cup to one side
for cleaning and inspection.
Figure 4
6. Remove and discard the inner snap ring (16) from the axle shaft (1).
Figure 5
7. Remove the hub (15) from the axle shaft (1).
8. Remove the friction discs and the reaction plates (13) from the brake housing (7). Be sure to keep them in order. Place
each plate and disc to one side for cleaning and inspection.
9. Use a safe lifting device to remove the brake housing from the axle shaft. Remove the corresponding Duo-cone seal
halves from the axle shaft and the brake housing.
NOTE!
Do not touch the lapped seal mating surfaces. The natural acidity of the skin may etch the delicate metal surfaces.
Figure 6
10. Remove and discard the outer wire snap ring (14) from the axle shaft.
Figure 7
11. Use an appropriate puller to remove the outboard bearing cone (4) from the axle shaft (1). Place the bearing cone to
one side for cleaning and inspection. If installed, remove and discard the wear sleeve from the axle shaft.
WARNING
Compressed air. Never direct to bare skin. Use protective equipment.
Figure 8
12. Place the brake housing (with the large opening down) on a sturdy, level work surface. Use a rubber tipped air nozzle to
carefully apply shop air pressure until the piston releases from the bore.
Figure 9
13. Remove and discard the O-rings (9) and back-up rings (8 and 10) from the piston (11).
Figure 10
14. Place the housing in a hydraulic press. Remove the outboard bearing cup. Place the bearing cup to one side for
cleaning and inspection.
Figure 11
15. Remove the adjusting pin. Remove and discard the O-ring.
Figure 12
Service Information

Oil Disc Brake - Cleaning 517 Service Information 9/10/2022
and Inspection
Profile:
G780B Volvo
Oil Disc Brake - Cleaning and Inspection


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 517-073
WARNING
Risk of personal injury! Wear safety glasses and use protective gloves.
For tolerances and other specifications, check General. A careful and thorough inspection of all parts is extremely important. If
there is evidence of damage or wear, replace all defective items with genuine Volvo parts.
Check for the causes of defective components. Replacing parts may not necessarily correct the problem.
Carefully inspect all bearing rollers, cages and cups, for wear, nicks, and chipping. When replacing bearings, always install new
mating cups and cones.
Retain O-rings and back-up rings only for inspection and troubleshooting purposes. Replace all O-rings and back-up rings when
overhauling the oil disc brake assembly.
Cleaning
Wear cotton gloves when handling bearings. This prevents skin acids and perspiration transferring onto the bearing races.
Immerse bearings and small parts in fresh cleaning solvent. Use a hot tank system and a mild alkali solvent. Agitate the parts to
remove all foreign matter.
Parts should remain in the solvent long enough to be thoroughly cleaned. In the hot tank system, heated parts help to evaporate
the solvent and rinse water. Thoroughly rinse parts to remove all traces of dirt and solvent.
NOTE!
Do not clean the friction discs.
After rinsing, immediately dry the parts using moisture-free compressed air. Lint-free, uncontaminated wiping rags can be used.
Ensure all oil passages are unblocked.
Rinse cleaned bearings and dry with moisture-free compressed air while rotating them slowly by hand. DO NOT spin bearings
when drying. Lubricate all bearings with system oil. Wrap in clean, lint-free cloth or paper. Store in a cool, dry place.
Brake housing
Remove the remnants of silicone sealant and any other contaminants before inspection. The mating surfaces must be free of
nicks and burrs. Inspect the surface finish of the housing that is in contact with the Duo-cone rubber toric. It must be free of
damage and corrosion.
Friction discs and reaction plates
Check the thickness and condition of all friction discs and reaction plates. Compare with the specifications listed at the back of
this publication. Discard all warped plates.
Axle shaft
Small nicks can be removed using an appropriate grinding stone. Inspect for signs of bent or twisted splines and replace any
deformed axle shafts. Inspect the contact surface of the Duo-cone seal rubber toric. It must be cleaned to remove corrosion and
other contamination.
Service Information

Brake housing, pre- 517 Service Information 9/10/2022
assembling
Profile:
G780B Volvo
Brake housing, pre-assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 517-074
1. Remove any nicks and burrs from the piston and the inside of the brake housing. Give special attention to the
chamfered edges and openings of the oil passages.
2. Place the brake housing (7) (with the large opening down) on a sturdy, level work surface. Lubricate the bearing cup (3).
Install the outboard bearing cup using a hydraulic press and a piloted bearing driver with the same outside diameter as
the cup. Alternatively, place the cup in a deep freeze unit or dry ice to shrink it for easier assembly. DO NOT freeze
below –54ºC (–65ºF).
Figure 1
3. Turn the brake housing over. Lubricate and install a new O-ring on the adjusting pin. Install the pin into the small hole
in the brake housing.
Figure 2
4. Lubricate and install new O-rings (9) and back-up rings (8 and 10) on the piston (11). The back-up rings are installed on
the outside and the O-rings are installed on the inside.
5. Install the piston (11) in the piston bore. Both the piston and the bore must be well lubricated with system oil.
Figure 3
Service Information

Tandem axle oil seal 517 Service Information 9/10/2022
installation
Profile:
G780B Volvo
Tandem axle oil seal installation


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Tandem axle and oil disc brake assembly
1. Tandem axle
2. Duo-cone oil seal
3. Brake housing
Overview
Correct assembly of Duo-cone Seals reduces leaks and field failures. There are five reasons for failure:
1. Oil leakage
2. Galling
3. Toric failure
4. Pumping mud past the toric
5. Seal ring breakage
Many of the Duo-Cone Seal failures are the direct result of one or more mistakes made during assembly or installation of seal
components.
It is most important that correct assembly and installation procedures are followed when Duo-Cone Seals are used.
Figure 2
Terminology
1. Seal ring
2. Rubber toric
3. Housing retaining lip
4. Housing ramp
5. Seal ring housing
6. Seal ring face
7. Seal ring ramp
8. Seal ring retaining lip
9. Installation tool
Service Information

Tandem axle seal, installing 517 Service Information 9/10/2022
Profile:
G780B Volvo
Tandem axle seal, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 517-075
89405 Assembly tool

Assembly lubricant required: Isopropyl alcohol
1. Remove any oil film, dust, or other foreign matter from the rubber torics (2), and from the ramps (4 and 7) and lips (3
and 8) of both the seal rings (1) and housings (5).
Use isopropyl alcohol as the assembly lubricant and a clean lint-free cloth or paper towel for wiping. All components
should be completely dry prior to proceeding.
Do not permit oil to get on the rubber torics (2) or ramps (4 and 7) before both seal rings (1) are put together in their
final assembled position (Step 8).
Figure 1
2. Put the toric (2) on the seal ring (1) at the bottom of the seal ramp (7) and against the retaining lip (8).
Make sure that the rubber toric (2) is straight on the seal ring (1) and is not twisted.
Be careful when working on the rubber toric. Nicks, cuts and scratches can cause leaks.
Figure 2
3. Put the installation tool (9) onto the seal ring (1) with the rubber toric (2).
Lightly dampen all surfaces of the rubber toric (2) with Isopropyl Alcohol.
Techniques to dampen the toric include wiping with lint free towel or dipping in a container with towels that are
saturated with Isopropyl Alcohol (10).
NOTE!
Do not use "Stanosol" or any other liquid that leaves an oil film or does not evaporate quickly.
WARNING
Explosion hazard.
Figure 3
4. Ensure that all surfaces of the rubber toric (2) are still wet.
Use the installation tool (9) to position the seal ring (1) and the rubber toric (2) squarely against the housing (5) as
shown.
Use sudden and even pressure to pop (push) the rubber toric under the retaining lip (3) of the housing (5).
Figure 4
11 Seal ring locator

12 Toric ring locator
5. Check assembled height (A) in at least four places 90 degrees apart using either a caliper, tool-makers ruler or any other
calibrated measuring device.
The difference in height around the ring must be 1 mm (0.04"). A = 7,62 0,5 mm (0.30 0.02 in.).
If small adjustments are necessary, do not push or pull directly on the seal ring (1).
Use the installation tool (9) to push down, and fingers to pull up uniformly on the rubber toric (2) and seal ring (1).
NOTE!
Rubber toric (2) can twist if it is not wet all around during installation, or if there are burrs or fins on the retaining lip (3)
of the housing (5).
Misalignments, twists and bulges of the rubber toric will cause Duo-cone Seal failures.
If correct installation is not obvious, remove seal from housing and repeat steps 3 through 5.
Rubber torics (2) must never slip on the ramps of either seal rings (1) or seal ring housings (5).
Allow adequate evaporation time for the lubricant before proceeding with further assembly. This will prevent slippage.
The rubber toric must roll on the ramps only.
Figure 5
Figure 6
Figure 7
Figure 8
6. Wipe the seal faces (6) of the seal rings (1) clean using a lint-free cloth or paper towel.
No particles of any kind are permissible on the sealing surfaces. Even a small piece of paper towel can hold the seal
faces apart and cause leakage.
Figure 9
7. Put a thin film of clean oil on the seal ring faces (6).
Use applicator, a disposable tissue or a clean finger to distribute the oil evenly.
Do not get any oil on the rubber torics.
8. Make sure the brake housings and axle are in correct alignment and are concentric.
Move the parts slowly and carefully toward each other.
Do not slam the sealing faces together. High impact can scratch or break the seal components. Once in place, fasten all
parts tightly.
Figure 10
Results of incorrect assembly
Figure 11
Examples of incorrect assembly
If the rubber toric slips at one location, but not all around, it twists. This can cause the seal rings to lock.
Cocked seals cause uneven pressure on the seal face, resulting in a wobbling motion of the seal.
Uneven pressure on the seal faces causes galling, scoring and leakage.
Wobbling seals can cause dirt to enter by pumping mud past the rubber torics.
Figure 12
Figure 13
This shows an incorrectly assembled seal in it's “as assembled” position. The upper housing is stationary; the lower is rotating.
Figure 14
This shows the same seal after the lower housing has rotated 180º. In this position, there will be high pressure at the points “B”
and “X”. This could result in galling of the seal rings. At points “A” and “Y” there will be low pressure, and possible leakage.
Service Information

Oil disc brakes , assembling 517 Service Information 9/10/2022
Profile:
G780B Volvo
Oil disc brakes , assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 517-076
73817 Wear sleeve installation tool
NOTE!
Avoid damaging the bearing cage and rollers. Always use a tubular driver with the same inside diameter as the bearing cone.
1. Use a safe lifting device to stand the axle on its wheel flange end. Make sure machined surfaces are free of oil and
contaminants. Lubricate the outboard bearing cone (4). Use a hydraulic press and tubular driver to install the bearing
cone. The bearing is easier to install when heated. Use only an oven or oil bath type heater and DO NOT exceed 121ºC
(250ºF). Install the cone on the shaft (1).
2. Use a safe lifting device to lower the brake housing onto the axle shaft. A second person must guide the housing as it is
lowered to it's final position.
Use a flashlight to illuminate the Duo-cone bearing contact surfaces just before they contact (less than 10 cm). The light
will reveal any contamination that may have accumulated on the lapped seal surfaces during this procedure. This also
provides an opportunity for final cleaning.
Great care must be taken in the final descent to ensure that the seal halves contact square and concentric.
Figure 1
3. Install a new outer snap ring (14) onto the axle shaft (1).
Figure 2
4. Lubricate the splines and install the hub (15) onto the axle shaft (1).
5. Install a new inner snap ring (16) onto the axle shaft (1).
Figure 3
6. Install a reaction plate (13) first, followed by a friction disc.
Install the remainder of the reaction plates and friction discs, alternating plates and discs. Finish with a reaction plate.
Be sure to use the correct number of reaction plates and friction discs. All models use the same reaction plates and
friction discs. However, refer toGeneral for the proper number of reaction plates and friction discs required for the
grader model being repaired.
7. Place the back-up plate (17) (with the webbed side uppermost) on the work surface.
Lubricate the bearing cup (20).
Install the inboard bearing cup using a hydraulic press and a piloted bearing driver with the same outside diameter as
the cup. Alternatively, place the cup in a deep freeze unit or dry ice to shrink it for easier assembly.
DO NOT freeze below –54ºC (–65ºF).
Figure 4
8. Install the back-up plate on the brake housing and tap into place with a plastic mallet.
Install the retaining bolts (19) and hardened washers.
Torque-tighten the bolts in a diagonal pattern to 136 N•m (14 kgf•m; 100 lbf•ft).
9. Lubricate the inboard bearing cone (21) and install on the axle shaft (1). This should be a slide fit.
10. Use a safe lifting device to install the driven sprocket on the axle shaft. This should be a slide fit. Make sure the sprocket
flange is in the correct orientation.
Figure 5
11. Install the retainer plate without shims.
Install the bolts and torque-tighten to 54 N•m (5 kgf•m)(40 lbf•ft).
Rotate the housing (7) during the tightening process to seat the bearings properly. It may be necessary to retighten the
bolts several times.
Remove the bolts and retainer plate. DO NOT turn the housing. The bearings are now set at zero preload.
Figure 6
12. Measure the distance from the step in the driven sprocket to the end of the axle shaft. Record the measurement.
Repeat the procedure in three separate places.
Calculate the average of the three measurements.
Subtract the following:
0,225 0,025 mm (0.009 0.001 in.) models G710B to G746B 0,275 0,025 mm (0.011 0.001 in.) model G780 from the
average measurement and make up a shim pack (23) to this thickness.
Check shim pack thickness with a micrometer.
Figure 7
13. Install the shim pack (23).

Install the retainer plate (24), and the bolts (26). Use loctite 243 on the bolts.
14. Torque-tighten the bolts in 68 N•m (0,7 kgf•m)(50 lbf•ft) increments to a maximum of 230 N•m (23 kgf•m)(170 lbf•ft).
15. Rotate the brake housing (7) to ensure that it moves freely and to confirm a slight preload on the bearings.
Figure 8
Service Information

Oil Disc Brakes - Bench 517 Service Information 9/10/2022
Adjustment
Profile:
G780B Volvo
Oil Disc Brakes - Bench Adjustment


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 517-077
1. Before adjusting the piston travel, ensure the O-ring plug is installed in the unused inlet port.
Install the jam nut (44) onto the piston travel limiting screw (45).
Install the limiting screw assembly into the adjusting hole in the brake housing (7).
Figure 1
2. Using a rubber tipped air nozzle, apply shop air pressure at the brake line port on the brake housing to move the discs
into the clamped position.
With air pressure applied, turn the piston travel limiting screw (45) inwards until it touches the back of the piston. Turn
the limiting screw outwards one complete turn, release the air pressure. Tighten the jam nut.
WARNING
Figure 2
3. Pressure test the assembly. Install a pressure hand pump to the brake line port on the brake housing (7).
Apply 345 kPa (3 bar)(50 psi) for two minutes and check the assembly for leaks. Increase the pressure to 17 237 kPa
(172 bar)(2,500 psi), and again check for leaks. The assembly can now be installed onto the tandem case.
NOTE!
There should be zero leakage during both tests. If the brake assembly fails either test, disassemble and check for faulty
piston O-rings and back-up rings. Replace parts as appropriate.
Figure 3
Service Information

Oil disc brake, installing 517 Service Information 9/10/2022
Profile:
G780B Volvo
Oil disc brake, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 517-078
25303 Gasket eliminator

47298 Silicone sealant
1. Apply a bead of 25303 gasket eliminator (`Loctite' 515 or equivalent) to the tandem opening for the brake housing.
Apply the gasket eliminator inside and to both sides of the bolt holes.
Figure 1
2. Attach an eyebolt to the threaded hole in the brake housing mounting flange.
Use a safe lifting device to position the brake unit against the tandem opening.
Make sure the threaded hole is at the top.
WARNING
The parts are heavy. Take appropriate safety cautions when handling them.
Figure 2
3. Install the bolts (34) and lock washers.

Torque-tighten the bolts in a diagonal pattern to 237 N•m (24 kgf•m)(175 lbf•ft).
4. Use a safe lifting device to install the tandem drive chains into the tandem case.
Position the drive chains to install the connector links at the top of the driven sprockets.
Figure 3
5. Install the connector link (37) and secure it with new cotter pins. Repeat this step for the other drive chain.
6. Apply a bead of 47298 sealant to the tandem side opening and side cover plate (39).
Install the side cover plate, and retain with the bolts.
Install the toolbox or battery box.
Figure 4
7. Check the security of the tandem drain plugs. Refill the tandem with fresh lubricant. Refer to General.
8. Connect the brake lines to the brake housings.

Apply a bead of 47298 sealant to the mating surface of the inspection covers and openings. Install the inspection covers
(30) and the brake line shields (31).
Install the bolts (34), lock washers (33) and flat washers (32).
9. Check the oil level in the top front cover plate by removing the oil level dipstick. The oil level should be between the
two bends in the dipstick.
Figure 5
10. Install the rims and tires and install proper retaining bolts and lock washers.
Torque-tighten the wheel bolts in a diagonal pattern to 644 – 712 N•m (66 – 73 kgf•m)(475 – 525 lbf•ft).
11. Turn the battery isolation switch on. Start the engine when it is safe to do so. Operate the blade lift cylinders to raise
the tandem. Shut down the engine. Remove the supports (or blocks).
Start the engine and operate the blade lift cylinders to lower the machine onto its wheels.
Place the final drive in the locked position. Shut down the engine. Remove and retain the ignition key.
12. With the grader parked on a level surface, recheck the tandem oil level. Add oil if necessary.
Oil disc brakes – Bleeding procedure

The final procedures are bleeding the brakes and the brake function test. Refer to Brake master cylinder – Bleeding procedure
and Service brakes – Brake function check, Brake master cylinder and power booster, installing
The oil disc brake overhaul is now complete.
Test the grader to ensure there are no problems with the mechanical functions of the tandems or hydraulic leaks.
Specifications- 2
Description- 3
Brake master cylinder and power booster; removing 13
Power booster; disassembling 14
Power booster; assembling 16
Brake master cylinder; disassembling 18
Brake master cylinder; assembling 21
Brake master cylinder and power booster; installing 24
Adjustment checks 26
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Description Pressure readings[1]

kPa bar psi
Brake power booster pressure relief valve 9 653 96 1000
Hydraulic pump pressure relief valve 10 342 103 1500
Brake master cylinder 15 168 152 2200
Description Torque value

N•m kgf•m lbf•in./lbf•ft
Flow switch contact to booster housing 2–4 0,2 – 0,5 20 – 40 lbf•in.
Electric motor pump to booster housing bolts 24 – 34 2,5 – 3,5 18 – 25
lbf•ft
Reservoir to brake master cylinder body bolts 19 – 24 1,9 – 2,4 170 – 210 lbf•in.
Booster housing to brake master cylinder body locknuts 34 – 41 3,5 – 4,1 25 – 30 lbf•ft
Brake master cylinder assembly to mounting bracket bolts 22 – 34 2,2 – 3,5 16 – 25 lbf•ft
Push rod adjustable clevis nuts 122 12 90 lbf•ft
End plug 27 – 33 2,7 – 3,3 240 – 290 lbf•in.
Pressure differential switch 2–4 0,2 – 0,5 20 – 40 lbf•ft
[1]Refer to Clutch and brake booster hydraulic circuit,Overview for pressure test locations.
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Brake master cylinder and power booster assembly
1. Diaphragm (internal)
2. Brake master cylinder body
3. Locknut
4. Power booster
5. Boot
6. Electric motor pump
7. Reservoir cap
8. Reservoir
9. Flow switch contact
10. Snap ring
11. Primary piston assembly
12. Primary piston return spring
13. Secondary piston assembly
14. O-ring
15. Secondary piston return spring
16. Compensating valve seal
17. O-ring
18. Tube seat
19. Pressure differential switch
20. End plug
21. Plastic insert
22. Pressure differential spool
Overview
Description and operation
The following description is written with permission from Ford Motor Company of Canada Limited.
Brake master cylinder
The brake master cylinder and power booster assembly is installed under the cab on the right-hand side of the grader.
In the released position, both primary and secondary piston actuators contact compensating valve stems that project into the
master cylinder bore. This keeps the valves open and allows system fluid in the reservoir to replenish any fluid displaced from the
master cylinder.
Initial forward travel of the primary piston moves the primary actuator away from its compensating valve. The valve closes and
shuts off the passage between the reservoir section and primary pressure chamber.
Further movement of the primary piston creates a pressure in the primary pressure chamber causing the secondary piston and
actuator to move. The secondary actuator moves away from its compensating valve, which closes and shuts off the passage
between the reservoir section and secondary pressure chamber. Further movement of the primary piston causes both chambers
to build pressure.
When the load on the primary piston is removed, the combined return spring force and fluid pressure in each chamber cause the
primary and secondary pistons to return to their original positions. The actuators contact both compensating valve stems and
open the passages between the reservoir sections and pressure chambers.
Should the rate of release be great enough to cause a partial vacuum in a pressure chamber, the open compensating valve
allows system fluid replenishment in the cylinder bore.
Any excess system fluid remaining at the end of the stroke (due to `pumping' and/or volume change due to temperature
fluctuation) is released as the compensating valve ports open.
Power booster
The power booster receives hydraulic fluid pressure through the inlet port. This pressure forces the power piston to move the
output push rod against the primary piston and actuator in the master cylinder.
Under normal conditions, depressing the brake pedal forces the input pedal rod against the valve rod and reaction piston. The
reaction piston moves forward and closes the pressure valve. Closing the pressure valve reduces the fluid flow into the area in
front of the power piston (low pressure chamber). The pressure acting on the large diameter power piston increases and forces
the power piston and output push rod forward.
The area between the output push rod O-ring and the primary piston O-ring is vented to the atmosphere. This venting prevents
hydraulic fluid mixing with oil disc brake petroleum base fluid (PBF) should either or both O-rings start leaking.
Figure 2
Brake master cylinder and power booster assembly
1. Secondary compensating valve and seal

2. Secondary reservoir section
3. Primary reservoir section
4. Primary compensating valve and seal
5. System fluid reservoir
6. Flow switch
7. Inlet pressure port
8. Check balls
9. Pressure regulator assembly
10. Input pedal rod
11. Reaction piston
12. Pressure valve
13. Power piston
14. Check ball
15. Electric motor pump assembly
16. Vented area
17. Output push rod
18. Primary piston and actuator sub-assembly
19. Primary pressure chamber
20. Primary return spring
21. Secondary piston and actuator sub-assembly
22. Secondary pressure chamber
23. Secondary return spring
Engine running – No brake application

System function when hydraulic fluid is supplied to the brake master cylinder and power booster assembly:
1. Hydraulic fluid pressure holds the booster inlet check valve open.
2. Hydraulic fluid passes freely through the pressure valve and into the low pressure chamber.
3. Hydraulic fluid returning to tank holds the flow switch open. Electric motor pump is not energized.
4. No pressure is applied to the power piston and the output push rod is at rest.
5. No action takes place in the brake master cylinder and no brake application is experienced.
Figure 3
Engine running – No brake application
1. Flow switch (open)

2. Fluid return
3. Fluid flow
4. Inlet check valve
5. Pressure valve (open)
6. Full fluid flow to return
7. Low pressure chamber
8. Output push rod (at rest)
Engine running – Light brake application

System function when brake pedal is depressed slightly and power assist action begins:
2. The brake pedal push rod begins to close the pressure valve. The restricted fluid flow creates a pressure build up in the
high pressure chamber. Pressure build up acting on the power piston becomes power boosted movement to the brake
master cylinder through the output push rod.
4. The forward movement of the output push rod forces the primary piston and actuator away from its compensating
valve.
5. Hydraulic pressure builds up in the primary braking system and the primary brakes are applied.
Figure 4
Engine running – Light brake application
1. Primary compensating valve (seated)

3. Fluid return
4. Fluid flow
5. Inlet port
7. Pressure valve (partially closed)
8. Brake pedal push rod (partially applied)
9. Pressure regulator spring
10. High pressure chamber
11. Power piston (begins to move)
13. Output push rod (begins to move)
14. Primary piston (moves past compensation)
Engine running – Normal brake application

System function when normally applying the brakes (firm pedal, but not panic):
2. The brake pedal push rod continues to close the pressure valve.
3. Pressure to the power piston is high.
4. The output push rod moves further into the brake master cylinder.
6. Both primary and secondary piston and actuators move past the compensating valves. The primary and secondary
braking systems are pressurized.
Figure 5
Engine running – Normal brake application
1. Secondary compensating valve (seated)

3. Atmospheric pressure
5. Fluid return
6. Fluid flow
8. Pressure valve (partially open)
9. Brake pedal push rod (not quite fully applied)
12. Power piston (extensive movement)
14. Output push rod (further movement)
15. Primary piston
16. Secondary piston
Engine running – Maximum brake application

System function when brake pedal is fully depressed during an emergency stop:
2. The brake pedal push rod moves inward to virtually fully restrict fluid flow through the pressure valve. Maximum rated
pressure build up now acts on the power piston and the movement is transferred to the brake master cylinder through
the output push rod.
3. When the maximum rated pressure is exceeded, the pressure regulator spring compresses. This allows the pressure
valve to open slightly and by-pass hydraulic fluid through the pressure valve orifice.
5. Both the primary and secondary piston and actuators move to the maximum braking position.
Figure 6
Engine running – Maximum brake application
1. Secondary compensating valve (seated)

3. Atmospheric pressure
5. Fluid return
6. Fluid flow
7. Inlet check ball
8. Pressure valve (almost totally closed)
9. Brake pedal push rod (fully applied)
12. Power piston
14. Output push rod (maximum output force)
15. Primary piston
16. Secondary piston
Hydraulic boost malfunction – Normal brake application

System function when brake boost is demanded and there is no hydraulic fluid flow due to engine shut down or some other
condition that interrupts fluid flow:
1. The booster inlet check valve closes as a result of no fluid flow entering the booster assembly.
2. The flow switch closes since there is no flow to keep it open. This completes the electric circuit to the electric motor
pump mounted on the bottom of the power booster housing.
3. The electric motor pump supplies system fluid at a somewhat lower pressure for power braking assist. Therefore,
increased pedal effort is required to stop the grader within a specified distance. The brake system is faulty if the brake
warning lamp and alarm energize.
The brake system must be repaired by a qualified service technician. DO NOT drive the grader.
4. The brake master cylinder operates as described in Engine running - normal brake application, above.
Figure 7
Hydraulic boost malfunction – Normal brake application
1. Flow switch (closed)

2. Return port (no flow)
3. Inlet port (no flow)
4. Check valve (closed)
5. Pressure valve (partially closed)
6. Brake pedal push rod (partially applied)
7. Pressurized chamber
8. Power piston (begins to move)
9. Check valve (open)
10. Electric motor pump (operating)
12. Output push rod
Complete boost malfunction – Manual brake application

Should a complete loss of all power assist occur when operating the grader, it is still possible to bring the machine to a
controlled stop by manually actuating the brake master cylinder pistons. However, brake pedal effort will be greatly increased
and the effective stopping distance will be significantly longer.
The brake system must be repaired by a qualified service technician. DO NOT drive the grader.
The brake master cylinder operates as described in Engine running - normal brake application, above.
Figure 8
Complete boost malfunction – Manual brake application
1. Direct mechanical force from brake pedal

2. Flow switch (closed)
3. Return port (no flow)
4. Inlet port (no flow)
5. Check valve opens (to relieve hydraulic fluid trapped in the low pressure chamber)
6. Brake pedal push rod
7. Electric motor pump (not operating)
9. Output push rod
Service Information

Brake master cylinder and 521 Service Information 9/10/2022
power booster, removing
Profile:
G780B Volvo
Brake master cylinder and power booster, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 521-011
NOTE!
1. Remove clevis pin retaining the push rod clevis to the pivot plate. Discard cotter pin. Disconnect the flow switch,
pressure switch, and electric pump and motor wires.
2. Remove inlet and return hoses from booster. The return hose is installed on a barbed fitting. It may be necessary to slit
the hose lengthways to remove it. Remove and discard damaged part of hose and plug ports. Remove the two brake
fittings from master cylinder body and immediately plug ports.
3. Remove bolts retaining the assembly to mounting bracket and place master cylinder in vise with soft jaws, to prevent
damage to aluminum housing.
Service Information

Power booster, 521 Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Power booster, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 521-012
1. Remove power booster from master cylinder and discard nuts. Carefully remove power booster and place on a clean
workbench.
Figure 1
2. Place the power booster, with electric pump and motor uppermost, in a vise with soft jaws. Using a felt-tip marker, mark
which side of the mounting flange the motor is placed. Remove electric pump and motor and discard oval O-rings.
NOTE!
Approximately three cups of oil will drain from the power booster housing when the electric motor pump is removed.
Avoid damaging the mating surfaces during removal.
3. Remove the locknut and adjustable clevis from the push rod. Remove the boot.
Figure 2
4. Remove the flow switch contact. Remove and discard the O-ring. Use a small magnet to remove the flow switch piston
and spring.
Cleaning and inspection

Immerse parts into a cleaning solvent. Agitate the parts to remove all foreign matter. Parts should remain in the solvent long
enough to be thoroughly cleaned. Thoroughly rinse parts to remove all traces of dirt and solvent.
Ensure all oil passages are unblocked. Wrap in clean, lint-free cloth or paper. Store in a cool, dry place.
A careful and thorough inspection of all parts is extremely important. If there is evidence of damage or wear, replace all defective
items with genuine Volvo parts.
Check for the causes of defective components, as replacing parts may not necessarily correct the problem.
Service Information

Power booster, assembling 521 Service Information 9/10/2022
Profile:
G780B Volvo
Power booster, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 521-013
1. Install the flow switch spring. Lubricate and install the flow switch piston. Install flow switch contact with new lubricated
O-ring.
Torque-tighten to 2 – 4 N•m (0,2 – 0,5 kgf•m)(20 – 40 lbf•in.).
Figure 1
2. Inspect the electric motor pump to verify that the motor pump check ball and retainer are in place.
NOTE!
The electric motor pump can be incorrectly installed. Check the orientation arrow for the proper position of the electric
motor.
Lubricate and install two new oval O-rings into the recesses of the electric motor pump mounting flange. Carefully
install the electric motor pump onto the power booster housing and secure with the bolt.
Torque-tighten the bolts to 24 - 34 N•m (2,5 - 3,5 kgf•m; 18 - 25 lbf•ft).
Figure 2
3. Install boot, clevis and locknut.

Assembly of the power booster is now complete.
Service Information

Brake master cylinder, 521 Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Brake master cylinder, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 521-014
1. Remove the reservoir caps. Drain and discard system fluid from reservoir. To ensure correct reservoir positioning during
assembly, use a felt tip marker and draw identification marks on reservoir and corresponding side of brake master
cylinder body. Remove reservoir.
Figure 1
2. Remove and discard the two compensating valve seals from the bottom of the reservoir. Remove and discard the piston
stop O-ring.
WARNING
3. Remove end plug and plastic insert (use Allen key for insert). Re-install end plug. Use low-pressure compressed air 172
kPa (1,7 bar)(25 psi) to remove the pressure differential piston. Plug the front top port. Apply compressed air to the
front brake port until the sound of the piston hitting the end plug is heard. Remove compressed air, end plug, and
piston.
Figure 2
4. Use an appropriate tool and depress the primary piston assembly approximately 25 mm (1 in.). Spring compression
load is between 41 and 59 kg (90 and 130 lb). Take care not to scratch the bore surface. Remove the piston stop pin
from the master cylinder body.
Figure 3
5. Remove and discard the snap ring from the brake master cylinder bore.
6. Slowly relieve the compression on the primary piston. Remove the primary and secondary piston assemblies from the
brake master cylinder body bore.
WARNING
7. Re-install the compression tool. Use low-pressure compressed air 172 kPa (1,7 bar)(25 psi) to remove the secondary
piston assembly. Plug all outlet ports except for rear compensating valve port. Do not place hands between the cylinder
body and compression tool. Apply compressed air to rear compensating valve port.
Figure 4
8. Place the master cylinder on its side in a vice with soft jaws. Using an easy out, tap into tub seat and unscrew.
Disassembly is now complete.
Figure 5

Immerse parts in fresh cleaning solvent. Agitate the parts to remove all foreign matter. Parts should remain in the solvent long
Ensure all oil passages are unblocked. Wrap in a clean, lint-free cloth or paper. Store in a cool, dry place.
A careful and thorough inspection of all parts is extremely important. If there is evidence of damage or wear, replace all defective
items with genuine Volvo parts.
Check for the causes of defective components, as replacing parts may not necessarily correct the problem.
Retain O-rings only for inspection and troubleshooting purposes. Replace all O-rings when overhauling the brake master
cylinder.
Service Information

Brake master cylinder, 521 Service Information 9/10/2022
assembling
Profile:
G780B Volvo
Brake master cylinder, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 521-015
1. Lubricate the brake master cylinder body bore, primary and secondary piston assemblies and all parts in the repair kit.
NOTE!
Use only mineral oil. DO NOT use hydraulic fluid.
2. Install the large diameter of the primary piston return spring into the primary piston actuator.
3. Place secondary piston return spring into secondary piston actuator.
WARNING
Spring tension.
Danger of objects released under spring compression. Serious injury can result. Wear appropriate face and hand protection.
4. Carefully install the secondary piston assembly, spring end first. Carefully install the primary piston assembly, spring end
first. Using same compression tool, depress both piston assemblies approximately 25 mm (1 in.). Spring compression
load is between 41 and 59 kg (90 and 130 lb). Take care not to scratch the bore surface. Lubricate and install piston stop
pin.
Figure 1
5. Install a new snap ring into the body bore. Remove the spring compression tool.
6. Install 2 new compensating valve seals into their recesses in the reservoir. Install a new piston stop O-ring.
7. Install new O-rings on pressure differential piston, lubricate and install with plastic insert.
Figure 2
8. Install the two tube seats with an appropriate tool.
Figure 3
9. Place the reservoir into position on the brake master cylinder body as marked during disassembly. Ensure that the
compensating valves are free to move. Insert an appropriate clean, metal probe through the reservoir ports and check
that the valves can move up and down by 1,5 mm (1/16 in.).
Figure 4
10. Install the bolts and torque-tighten to 19 - 24 N•m (1,9 - 2,4 kgf•m)(170 - 210 lbf•in.).
Install short, flexible tubes from the outlet ports at the branch tee fittings into the reservoir sections.
Secure the master cylinder with the front end tilted slightly down. Fill the reservoir sections with mineral oil.
Depress and release the primary piston several times using any tool with a smooth, rounded end.
Secure the master cylinder with the front end tilted slightly up. Again, depress and release the primary piston several
times.
Remove the tubes and install the reservoir caps.
NOTE!
Once all air is expelled from the master cylinder, the primary piston cannot be depressed.
Assembly of the master cylinder is now complete.
11. Carefully install the power booster onto the master cylinder and retain with new locknuts.
Torque-tighten the locknuts to 34 – 41 N•m (3,5 – 4,1 kgf•m)(25 – 30 lbf•ft).
Service Information

Brake master cylinder and 521 Service Information 9/10/2022
power booster, installing
Profile:
G780B Volvo
Brake master cylinder and power booster, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 521-016
1. Install assembly to mounting bracket. Torque-tighten bolts to 34 N•m (3,5 kgf•m)(25 lbf•ft)
2. Connect the two brake hoses to the master cylinder. Connect the inlet and return hoses to the power booster housing.
3. Install clevis pin retaining the push rod clevis to the pivot plate.
Install and secure a new cotter pin.
Torque-tighten nuts to 122 N•m (12 kgf•m) (90 lbf•ft).
Connect flow switch, pressure switch and electric pump and motor wires.
NOTE!
Make proper contact with electric pump and motor wire, and flow and pressure switch connectors.
Brake master cylinder – Bleeding procedure

The grader should remain in the Service Position. Refer to Service positions.
Always wear face protection when working over the bleed fittings. DO NOT use the electric motor pump for the bleeding
procedure.
Connect a flexible tube from the bleed fitting on the front left oil disc brake housing into a transparent container half full of fresh
petroleum base fluid (PBF). Immerse the tube.
Release the bleed fitting. Slowly depress the brake pedal and wait for five seconds; slowly release the brake pedal and wait for
five seconds. Ensure the tube remains immersed in the fluid.
Repeat this procedure until the air bubbles stop flowing into the container. Tighten the bleed fitting. Check the level in the
reservoir sections and replenish with fresh PBF (Petroleum Base Fluid) if required. Install the reservoir caps.
Repeat the bleeding procedure at the rear right, front right and rear left oil disc brake housings in that sequence. After each
bleeding procedure step, check the level in the reservoir sections and replenish with fresh system fluid if required. Install the
reservoir caps.
Do not exceed 241 kPa (2.4 bar)(35 psi) when using pressure bleeding equipment. Follow the pressure bleeding equipment
manufacturer's instructions.
When everything is working properly, perform a brake function test.
Service brakes – Brake function check
Perform this brake function check once every week.
Check the parking brake operation. Refer to the G700B Operator's Manual.
Make a visual check around the machine. Ensure all personnel are clearly away from the area. Signal before starting the engine.
Start the engine when it is safe to do so.
Back the grader up a slight incline where it is safe to allow the machine to roll forward without power.
Stop the grader, place the transmission in NEUTRAL, and apply the parking brake. Shut down the engine. Cycle the ignition
switch to position III (crank position) momentarily. Release and return the switch to position I (running position). Ensure engine
does not start.
Release the parking brake when it is safe to do so. Allow the grader to roll ahead at about 3 to 5 km/h (2 to 3 mph). Apply the
service brakes. The grader must stop abruptly.
If the grader does not stop, use the parking brake to stop the machine. Immediately have the brake system repaired by a
qualified service technician.
NOTE!
Unless braking action is required, do not depress brake pedal when ignition key is off. The service brake electric motor
pump will energize using battery power only. Subsequent loss of braking effectiveness could result in personal injury or
death. Apply the parking brake before shutting down the engine.
The brake master cylinder and power booster assembly overhaul is now complete.
Service Information

Adjustment checks 521 Service Information 9/10/2022
Profile:
G780B Volvo
Adjustment checks

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
1. Piston travel limiting screw
As the friction discs wear, the system fluid displacement may not move the piston enough to fully compress the discs and plates.
This wear is sensed as a circuit problem. When the brake pedal is depressed, the brake warning light in the center display
energizes. Adjust the piston travel limiting screw to decrease the volume necessary to obtain the full force of the piston. With the
brakes lightly engaged, turn the screw in until it contacts the piston, then back it off one complete turn. Secure the screw with
the jam nut. No other adjustments are required until a complete overhaul is performed.
Figure 2
1. Brake pedal freeplay

2. Brake light switch adjustment
Brake pedal free play adjustment

Brake pedal free play must be 3 ±1,5 mm (1/8 ±1/16 in.).
Brake light switch adjustment
Brake light switch setup dimension must be 5 – 6 mm (3/16 – 1/4 in.).
Check brake master cylinder pressure
1. Place the grader in the service position. Refer to Service positions.

2. Tee into a brake line between master cylinder and brake unit. Refer toOverview.
3. Connect a pressure gauge with the capacity of 0 – 400 bar (0 – 6000 psi) into the tee fitting.
4. Start the engine and apply the brakes.
5. The pressure gauge should read approximately 152 bar (2200 psi).
Check brake booster pressure
1. Place the grader in the service position. Refer to Service positions.

2. Tee into the brake booster pressure line (hydraulic line between the brake booster and transmission pump). Refer to
Overview.
3. Connect a pressure gauge with the capacity of 0 – 400 bar (0 – 6000 psi) into the tee fitting.
4. Start the engine and apply the brakes.
5. The pressure gauge should read approximately 69 bar (1000 psi).
Specifications- 2
Description 4
Parking brake; manually releasing 6
Hydraulic diagram 8
Electrical schematic 11
Parking brake troubleshooting 13
Parking brake overhaul procedure 14
Parking brake assembly; removing 17
Parking brake; disassembling 18
Parking brake; pre-assembling 20
Parking brake; assembling 21
Parking brake; installing 23
Parking brake; adjusting 25
Parking brake intensifier 27
Parking brake valve assembly 29
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Pressure switch Configuration: Single pole, normally closed. Closes at 6895

±55 kPa
(69 ±0,5 bar)(1000 ±8 psi)
Parking brake hydraulic pressure downstream of intensifier 1482 – 1620 kPa

(15 – 16 bar)(215 – 235 psi)
Parking brake hydraulic pressure at brake unit (upstream of 17 – 19 MPa
intensifier) (171 – 186 bar)
(2473 – 2702 psi)
Tightening torques
Description Torque
Jam nut/sleeve to mounting surface 271 N•m
(28kgf•m)(200 lbf•ft)
Plug 61 – 68 N•m
(6,2 – 6,9 kgf•m)(45 – 50 lbf•ft)
Nut for socket head adjusting bolt 41 – 47 N•m
(4,1 – 4,8 kgf•m)(30 – 35 lbf•ft)
Coupling nut 68 – 75 N•m
(6,9 – 7,6 kgf•m)(50 – 55 lbf•ft)
Bleeder screw 23 – 28 N•m
(2,4 – 2,9 kgf•m)(17 – 21 lbf•ft)
Tolerances
Description Tolerance
Parking brake lining (pad) minimum thickness 0,790 mm (0.031 in.)
Running clearance each side of disc 0,254 – 0,396 mm
(0.010 – 0.015 in.)
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Parking brake system

2. Intensifier
3. Accumulator
5. Manual recharge fitting
6. Parking brake disc
7. Pressure switch
Figure 2
A. Parking brake switch

B. Parking brake applied warning lamp (red)
C. Central warning lamp (red)
D. Display message
The parking brake is a spring applied/hydraulic release brake. The parking brake unit is driveline mounted to the transmission
output shaft. The brake unit is electrically controlled by the parking brake switch located on the right-hand side of the pedestal.
The parking brake should only be applied when the machine is stopped. However in an emergency situation, the parking brake
may be used as an emergency brake.
The brake is hydraulically operated. Oil under pressure is supplied by the transmission pump to the parking brake valve and from
there to the intensifier and out to the high pressure caliper brake unit. The parking brake is applied by spring pressure every time
the ignition key is turned off or when the parking brake switch on the pedestal is applied (pushed in). When the parking brake is
applied, the transmission cannot be shifted out of neutral. The red indicator lamp (B) and red central warning lamp (C) on the
center instrument panel are illuminated. Therefore, the parking brake must be applied to start the grader. Pull the parking brake
knob out to release the brake.
The parking brake switch is a normally closed switch; the brake is applied when the switch is closed.
Service Information

Parking brake, manually 550 Service Information 9/10/2022
releasing
Profile:
G780B Volvo
Parking brake, manually releasing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 550-015
If the engine and hydraulic system are inoperable, proceed as follows:
1. If the engine is inoperable, use a hand pump to recharge the parking brake accumulator through the test port on the
top of the valve. Pressure is limited to 1724 kPa (17 bar)(250 psi) with a relief valve
Figure 1
2. Return to cab, and push in the parking brake switch to the applied position.
3. Cycle the key switch to the crank position (III) momentarily and release.
4. Pull the parking brake switch out to the release position.
5. If a hand pump is not available, place the machine in the Service Position. Refer toService positions then remove the
lower driveshaft.
Figure 2
A. Lower driveshaft between the transmission and final drive

Service Information

Hydraulic diagram 550 Service Information 9/10/2022
Profile:
G780B Volvo
Hydraulic diagram

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
1. From transmission sump

3. To brake circuit
4. Transmission filter
5. To differential lock/unlock valve
6. To MBCS lock cylinder
7. From brake circuit
8. Transmission pressure regulator valve
9. To transmission clutch packs
10. To transmission sump
11. Manual recharge port
12. Accumulator
14. Hydraulic pressure intensifier
15. Pressure switch
Service Information

Electrical schematic 550 Service Information 9/10/2022
Profile:
G780B Volvo
Electrical schematic

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Part Description Std./Opt. Specification Location
designation
SW3301 Starter/ignition switch Std. 5 pole, single throw Console switch plate
SW5501 Parking brake switch Std. Double pole, double throw Pedestal
NO
SW4201 Transmission gear Std. 1. Triple pole, single throw Side console
shifter switch 2. Double pole, single throw
Momentary, normally neutral
(off)
RE3301 Start relay Std. Single pole, single throw Console side wall
RE4201 Neutral start relay Std. Single pole, single throw Console convenience center
MO3301 Starter motor Std. Output: Front of engine, right-hand side
G710B to G730B – 5.4 kW
G740B to G780B – 8.0 kW
Service Information

Parking brake 550 Service Information 9/10/2022
troubleshooting
Profile:
G780B Volvo
Parking brake troubleshooting


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Condition Cause Corrective action

Grader will not start Parking brake not applied prior to Turn ignition key off (“O” position),
starting the grader apply parking brake and start grader
Parking brake lamp illuminated on center – Parking brake applied – Release parking brake (pull brake
instrument panel – Low hydraulic parking brake pressure switch out)
– Check pressure switch and system
pressure
Parking brake lamp illuminated in center Parking brake applied when transmission Place transmission shifter in the neutral
display panel, accompanied by red central is in gear position, release brake
warning lamp, buzzer and display
message
Parking brake will not release – Defective parking brake switch – Replace parking brake switch
(brake applied) – Defective solenoid – Replace solenoid
– Open/short circuit in wire – Check wiring for breaks. Check
ground and terminal connections
Error code “P” in the transmission gear Malfunction in the parking brake Check system electrical and system
display parking brake hydraulic pressure
Cracked or chipped linings (pads) Worn linings Replace linings
Fluid leakage – Defective seal, O-ring – Replace seal, O-ring
– Loose fitting – Tighten fitting
– Cracked brake housing – Replace brake housing
Service Information

Parking brake overhaul 550 Service Information 9/10/2022
procedure
Profile:
G780B Volvo
Parking brake overhaul procedure


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Parking brake assembly
1. Torque plate
2. Bolt
3. Jam nut/sleeve
4. Spring housing
5. Plug
6. Socket set screw
7. Shim
8. Disc spring
9. Piston
10. O-ring
11. Back-up ring
12. Piston
13. O-ring
14. Back-up ring
15. O-ring
16. Wiper
17. Bolt
18. Nut
19. Brake lining
20. Bleeder
21. Urethane spring
22. Flat washer
23. O-ring
24. Roll pin
25. Coupling nut
26. O-ring
Tool list
Spanner wrench (Two 5/16 in. dia. pins on a 3.25 in. dia. hole circle)
Small screwdriver
5/16 in. Allen wrench
15/16 in. Socket
1-1/8 in. Crows foot
Torque wrench capable of 270 N•m (28 kgf•m)(200 lbf•ft)
7/16 in. combination wrench
13/16 in. Spark plug socket or 13/16 in. drop neck box-end wrench
Parking brake operation

Ten disc springs (8) are used to hold the park brake in the actuated state. The springs (8) push the pistons (9,12) into the lining
and carrier assembly (19) which squeezes a driveline mounted disc. The brake is released by fluid entering a threaded inlet (SAE
7/16-20) in the side of the caliper (torque plate) (1) which pushes the pistons back and compresses the springs (8).
The parking brake caliper also contains a pressure switch. The switch confirms that the brake has been released. The switch is
designed to close at 6,9 MPa (69 bar)(1000 psi) falling. Once the pressure at the brake unit is below 6,9 MPa (69 bar)(1000 psi), it
sends a signal to the central instrument panel and illuminates the parking brake lamp, indicating that the parking brake is
applied.
Service Information

Parking brake assembly, 550 Service Information 9/10/2022
removing
Profile:
G780B Volvo
Parking brake assembly, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 550-018
Place the grader in the Service Position. Refer toService positions.
1. Apply hydraulic pressure to the brake and remove plug (5) and socket head bolt (17).
2. With pressure applied, loosen coupling nut (25) and back-off set screw (6) until the end of piston (12) that contacts the
front lining carrier is flush with the exposed end of piston (9).
3. Release hydraulic pressure from the brake and remove lining and carrier assemblies (19).
4. Loosen brake line and cap inlet port.
5. Loosen jam nut/sleeves (3) and back mounting bolts (2) out of mounting holes.
Service Information

Parking brake, 550 Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Parking brake, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 550-019
Figure 1
Mandrel assembly and press
A. Mandrel – Female end

B. Mandrel – Male end
C. Fixture
D. Spring compression range[1]
1. Remove plug (5).
2. Using a press and mandrel assembly, compress springs (8) to depth shown in illustration (maximum 3400 kg; 7500 lb)
to eliminate the force on the spring housing (4). Use a spanner wrench to remove the spring housing (4) (counter-
clockwise direction). The disc springs (8) will be accessible when the spring housing is removed. See Fig. 87.
NOTE!
The spring housing (4) may be removed without compressing the springs (8); however, it is not recommended due to
the high torque required.
3. The preferred method for removal of the pistons (9 and 12) is to press the pistons out from the lining and carrier (19)
side of the torque plate (1). If the brake is mounted on the vehicle and accessibility to the pistons cannot be achieved
from the lining and carrier side of the torque plate, then the set screw (6) and coupling nut (27) combination may be
threaded into the piston (9) to assist in removal.
NOTICE
New seal(s) must be installed.
4. Piston (12) may be removed from piston (9) by pushing on piston (12) through set screw hole with a small nut-driver or
similar device.
[1]Do not compress springs past the spring compression range

Service Information

Parking brake, pre- 550 Service Information 9/10/2022
assembling
Profile:
G780B Volvo
Parking brake, pre-assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 550-020
1. Clean all metal parts prior to assembly.
2. Blow excess cleaning solution off of all parts and out of all fluid passages.
Service Information

Parking brake, assembling 550 Service Information 9/10/2022
Profile:
G780B Volvo
Parking brake, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 550-021
1. Apply a thin coat of fluid (compatible with mineral oil based hydraulic fluid) to seals (10, 13, 15, 25), back-up rings (11,
14) and the wiper (16).
2. Install seal (15) in seal groove on piston (12).
3. Assure that roll pin (24) is inserted into hydraulic piston (9). roll pin must protrude from surface of hydraulic piston a
maximum of 9,754 mm (0.384 in.) and a minimum 8,992 mm (0.354 in).
4. Slide the Adjustment piston (12) into the bore located in the hydraulic piston (9) until it hits the bottom of the bore.
5. Install Wiper (16), back-up ring (14) and O-ring (13) in the grooves located in the small hole in the torque plate (1).
Install in the order as shown in Parking brake overhaul procedure.
6. Install O-ring (10) and back-up ring (11) in larger grooves in torque plate (1). Install in the order as shown in Parking
brake overhaul procedure.
7. Install piston assembly into torque plate (1).

NOTE!
Ensure that roll pin (26) in hydraulic piston (9) aligns with hole in torque plate (1).
8. Place the male end of mandrel assembly into inside diameter of piston (9). Stack disc springs (8) around the mandrel.
(See illustration.) Springs should be placed in an alternating cupped face to cupped face orientation. The springs on the
outside ends of the stack should be oriented cupped face out.
If the brake contained a shim (7) when it was disassembled, place the shim (7) so it will be in the bottom of the spring
housing (4) when it is installed. (See illustration 4.) Apply a thin coat of Loctite type 570 thread sealant to the spring
housing (4) threads. Thread spring housing (4) clockwise into torque plate (1) about 3 turns until it makes contact with
the disc springs (8).
NOTE!
Springs are matched and pre-tested. If new springs are being installed, add a shim only if the new springs are shipped
with one.
Figure 1
A. Springs
B. Shim
9. Place female end of mandrel assembly over male end of mandrel assembly. Using a press and mandrel assembly,
compress disc springs (8) to depth shown in Parking brake, disassembling(3400 kg; 7500 lb) to eliminate the force on
the spring housing (4). Use a spanner wrench to tighten the spring housing until the face bottoms out on the
counterbore face in the torque plate (1).
Tighten to 56,5 – 68 N•m (5,8 – 6,9 kgf•m)(500 – 600 lbf•in).
10. Thread screw (6) and coupling nut (25) into the hydraulic piston (9) until the set screw contacts the adjustment piston
(12).
11. Install O-rings (23) in back counterbores of the torque plate (1).
12. Assemble washer (22) and the urethane spring (21) on the mounting bolt (2), then slide mounting bolts through bolt
holes in the torque plate (1). Thread jam nut/sleeve (3) onto mounting bolt. The cylindrical part of the jam nut/sleeve
should extend into the torque plate, past the O-rings (25). See Parking brake overhaul procedure.
13. Install lining and carrier Assemblies (19). Install socket head bolt (17) into torque plate (1) and thread it into the hex
nuts (18) located in the slot in the back side of the torque plate (1). See Fig. Parking brake overhaul procedure.
Torque the 2 hex nuts (18) against each other to 41 – 47 N•m (4 – 4,9 kgf•m)(30 – 35 lbf•ft).
14. Install the bleeder (20) in the port located on the top side of the torque plate (1).
Torque-tighten to 24 – 28 N•m (2 – 3 kgf•m)(200 – 250 lbf•in).
15. After brake is mounted and adjusted, screw plug (5) onto spring housing (4).
NOTE!
Plug must be torqued to 61– 68 N•m (6,2 – 6,9 kgf•m)(45 – 50 lbf•ft).
Service Information

Parking brake, installing 550 Service Information 9/10/2022
Profile:
G780B Volvo
Parking brake, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 550-022
1. Slide brake over disc and into the mounting position.
2. Start mounting bolts (2) into mounting surface far enough to just support the brake.
3. Remove plug (5) and tighten set screw (6) and coupling nut (25) combination until linings (19) are clamped to the disc.
This locates and holds the brake in the proper position to set the mounting bolts and Jam-nuts.
4. Tighten mounting bolts (2) until they make contact with the urethane springs (21), then tighten 4 flats (about 1-1/2 mm;
1/16 in.) more. This puts the proper amount of pre-load on the urethane springs.
5. Tighten jam nut/sleeve(3) against mounting surface.

Torque to 271 N•m (28 kgf•m)(200 lbf•ft).
NOTE!
Brake linings are susceptible to contamination. When installing or servicing brakes, keep all oil and fluids away from the
linings. Poor brake performance may result.
6. Attach brake line to inlet port located on the side of the torque plate (1).
7. Bleed brake system to remove trapped air as follows:

NOTE!
Use bleeder hose on bleeder screws (preferably clear tubing) to route fluid away from the brake and linings.
WARNING
Bear in mind that bleeding takes place at high pressure. Use safety equipment.
Open the bleeder screw very slowly when performing the bleeding procedure.
1. Apply pressure to brake and slowly open the bleeder screw (20) observe any air bubbles that flow from the
brake.
2. Repeat the previous step until no air is observed in the fluid from the bleeder screw (20).
Torque-tighten the bleeder screw to 24 – 28 N•m (2 – 3 kgf•m)(200 – 250 lbf•in).
Service Information

Parking brake, adjusting 550 Service Information 9/10/2022
Profile:
G780B Volvo
Parking brake, adjusting


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 550-002
1. Apply hydraulic pressure to the brake.
2. With plug (5) removed, loosen coupling nut (25) and set running clearance between the disc and lining surface by
adjusting until a 0.020 – 0.030 in. thick shim just fits between the lining and disc surface when the opposite lining is in
contact with the disc.
Torque the coupling nut (25) to 68 – 75 N•m (7 – 7, kgf•m)(50 – 55 lbf•ft).
3. Replace plug (5).

Torque plug to 61 – 68 N•m (6 – 7 kgf•m)(45 – 50 lbf•ft).
4. Even up running clearance 0,254 – 0,381 mm (0.010 – 0.015 in.) on each side of the disc by adjusting the carrier
retaining socket head bolt (17). Loosen the outer nuts (18) and place a 0.010 – 0.015 in. thick shim between the lining
and the disc surface. Adjust the socket head bolt (17) until the clearance between the shim is eliminated. Tighten the
outer nuts (18) to complete the centering operation.
Torque the 2 nuts (18) against each other to 41 – 47 N•m (4 – 4,9 kgf•m)(30 – 35 lbf•ft).
5. Re-adjust the brake when running clearance reaches a total of 2,540 mm (0.100 in.).
Figure 1
Running clearance
6. Check the parking brake function by performing the following:
1. Apply parking brake.

2. With the engine at high idle (2300 rpm), depress the clutch pedal and engage third gear. Slowly release the
clutch pedal. The machine should remain stationary and the engine should stall.
Service Information

Parking brake intensifier 550 Service Information 9/10/2022
Profile:
G780B Volvo
Parking brake intensifier


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The parking brake intensifier function takes the inlet pressure and increases the outlet pressure by approximately 8.3:1 ratio. The
intensifier is located on the back of the transmission, mounted below the transmission input shaft yoke. The minimum required
input pressure is 793 kPa (7.9 bar)(115 psi) and maximum input pressure is limited to 1482 – 1620 kPa (15 – 16 bar)(215 – 235
psi), therefore intensifier outlet pressure is limited to 17 – 18,6 MPa (170 – 186 bar)(2473 – 2703 psi).
Figure 1
Parking brake Intensifier
1. Small cylinder tube

2. Snap ring
3. Snap ring
4. Cylinder plate
5. Cylinder tube assembly
6. O-ring
7. Back-up ring
8. Small piston
9. Spring
10. O-ring
11. Large piston
12. O-ring
13. Check valve
14. Roll pin
15. Snap ring
16. Inlet port
17. Outlet port
Intensifier function test
1. To verify that the check valve is open in the released position, pressurize outlet port to 34 – 69 kPa (0.35 – 0.70 bar)(5 –
10 psi).
2. Pressurize the inlet port to 793 ±48 kPa (7.9 ±0.5 bar)(115 ±7 psi) for a 1.5 minute period. Outlet port pressure must be
7929 ±138 kPa (79.3 ±1.4 bar)(1150 ±20 psi). No leakage is permitted.
3. Pressurize inlet port to 1868 ±48 kPa (18.7 ±0.5 bar)(271 ±7 psi) for a 1.5 minute period. Outlet port must be 20,7 ±0,1
MPa (20,7 ±1.4 bar)(3000 ±20 psi). No leakage is permitted.
Service Information

Parking brake valve 550 Service Information 9/10/2022
assembly
Profile:
G780B Volvo
Parking brake valve assembly


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Parking brake valve assembly
1. Accumulator
2. Manual recharge fitting
3. Valve body
4. Solenoid valve
5. Relief valve
The parking brake valve is located on the back of the transmission below the transmission input shaft yoke. The valve directs
pressure to the brake to release it, or allows the hydraulic oil at the brake to vent to tank so that the brakes can be applied.
The valve houses an accumulator pre-charged to 1200 kPa (12 bar)(174 psi). The accumulator stores hydraulic pressure in the
circuit allowing the parking brake to be released if there is a loss of system pressure. Once the stored pressure is depleted, the
parking brake will be applied automatically. When hydraulic pressure is restored, the brake can be released.
The valve also houses a 1724 kPa (17.2 bar)(250 psi) relief valve. The relief valve function is to protect the accumulator during
manual recharge so that it cannot be over-pressurized.
Figure 2
Parking brake valve ISO schematic
PB – Pressure intensifier
ACC – Accumulator
MOV – Manual recharge port
SV1 – Solenoid valve
CV1 – Check valve
RV1 – Relief valve
T – Tank
P – Pressure
60 - GENERAL 2
62 - STEERING AXLE 16
64 - STEERING 69
Steering system; description 2
Tightening torques 5
Front axle toe-in 6
Description 7
Tightening torques- 12
Front axle toe-in 13
Front axle pivot (G710B to G746B) 14
Service Information

Steering system, description 600 Service Information 9/10/2022
Profile:
G780B Volvo
Steering system, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Overview – G780B
The heavy-duty front axle performs all the functions that the standard front axle does: steering, axle pivot, and wheel lean. The
fundamental differences between the heavy-duty axle and the standard axle are its size and the types of bearings used. The
heavy-duty axle has a more rugged construction to withstand the stresses exerted in rigorous applications.
Steering
A king pin passes through the entire length of the spindle and is retained by a setscrew. Needle roller bearings support the king
pin in the knuckle. Thrust loads are transmitted between the spindle and the knuckle by a thrust bearing.
Pivoting axle
The axle pivot pin is a separate part. It is clamped to the main frame by split mounting blocks. Needle roller bearings support the
axle frame on the pivot pin. The axle frame end float is limited to 0,076 – 0,127 mm (0.003 – 0.005 in.) and is shim adjustable.
Thrust washers underneath the pivot pin end caps handle the thrust and torsional forces generated between the axle frame and
the pivot pin. Minimal force should be required to pivot the front axle when the axle is raised off the ground. Stop blocks restrict
axle pivot to 16º on each side of the grader's center line.
Wheel lean
Two hydraulic cylinders pivot the knuckles on pivot pins in the axle frame to a maximum of 18º on each side. A lock valve
prevents cylinder drift under load. The tie bar keeps both wheels parallel so that they lean together. Knuckle pivot pins are
retained by setscrews and supported in the axle frame by needle roller bearings. End float (shim adjustable) is 0,000 - 0,102 mm
(0.000 – 0.004 in.). Slightly preloaded bushings and thrust washers are used in the pivot block.
Wheel group
The heavy-duty front axle has a wider stance between the front tires than the standard front axle to allow full mobility with 20.5 x
25 tires. Two tapered roller bearings support the wheel hub. The spindle locknut tightness determines preload. With the front
axle raised, the wheel can be turned with a torque force of 11 – 16 N•m (1 – 2 kgf•m)(8 – 12 lbf•ft). This is measured at one of
the hub cap bolts. A V-ring seal prevents bearing cavity pressurization and dirt ingress.
Toe-in
The toe-in measurement for the heavy-duty front axle is 3 - 6,5 mm (1/8 – 1/4 in.). It is the same as the standard front axle. Toe-
in is altered by adjusting the drag link length.
Figure 1
Front axle – G780B
1. Wheel hub
2. Hub cap
3. Spindle nuts
4. Tabwasher
5. Lock washer
6. Wheel bearings
7. V-ring seal
8. Spacer
9. Dust shield
10. Spindle
11. Lock screw
12. King pin
13. Thrust bearing
14. King pin bearing
15. L.H. knuckle
16. Pin and bearing
17. Toe-in adjustment locknut
18. L.H. steering yoke
19. Pivot block assembly
20. Mounting block - frame
21. Mounting block - matched halves
22. Pivot pin
23. Pivot needle bearings
24. Shims
25. Thrust washer
26. Thrust cap
27. Leaning wheel tie bar
28. Leaning wheel cylinders
29. Steering cylinders
30. Drag link
31. Axle frame
32. Lock screw
33. Knuckle pivot pin
34. Dust seals
35. Knuckle pivot bearings
36. Pivot block pin
37. Bushing
38. Radius arm pin
39. Thrust washer
Service Information

Tightening torques 600 Service Information 9/10/2022
Profile:
G780B Volvo
Tightening torques

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Description N•m kgf•m lbf•ft

Front axle pivot cap retaining bolts 108 11 80
Knuckle bearing cap retaining bolts 47 5 35
Tie bar bearing pin lock plate retaining bolts 47 5 35
Wheel lean cylinder bearing pin lock plate retaining bolts 47 5 35
Upper and lower king pin retaining setscrews 108 11 80
Pivot block pin slotted nut 68 – 102 7 – 10 50 – 75
Drag link pivot pin slotted nut 68 – 102 7 – 10 50 – 75
Steering cylinder anchor pin lock plate retaining bolts 47 5 35
Steering cylinder piston rod cap retaining bolts 12 1 9
Wheel hub bearing preload 11 – 16 1–2 8 – 12
(rolling torque at hub cap bolt)
Wheel hub bearing outer locknut 271 – 305 28 – 31 200 – 225
Hub cap retaining bolts 24 2 18
Service Information

Front axle toe-in 600 Service Information 9/10/2022
Profile:
G780B Volvo
Front axle toe-in


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
G710B, G720B, G730B and G740B 3 – 6.5 mm 1/8 – 1/4 in.

Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Overview – G710B to G746B

The front axle of a motor grader performs several functions: steering, axle pivot, and wheel lean. It must also be capable of
carrying heavy front mounted attachments.
Tandem drive and AWD (All Wheel Drive) grader front axles share a group of common parts. What differentiates the two axles is
the “wheel group” that attaches to the knuckle. A tandem drive grader uses a spindle to mount a wheel hub. An AWD grader
uses a cradle to mount a hydraulic motor.
Steering
Two hydraulic cylinders pivot the spindles or cradles on king pins in the knuckle. Bushings support the king pins in the knuckle
frame. The drag link makes both sides turn together. On tandem drive graders, the king pins are retained by square head
setscrews. On AWD graders, however, socket head setscrews are used to provide clearance for hoses. Thrust loads are
transmitted between the knuckle and spindle or cradle by a special thrust washer.
Pivoting axle
The pivot of the front axle allows the front wheels to travel over uneven ground with minimal main frame movement. The axle
frame mounts onto a pivot pin welded to the main frame. Angular contact bushings, which are pre-loaded and shim adjustable,
support the axle frame on the pivot pin. With the front axle raised off the ground, a person weighing 68 – 82 kg (150 – 180 lb)
should be able to move the axle on the pivot pin. Stop blocks restrict axle pivot to 16º on each side of the grader's center line.
Wheel lean
Leaning the wheels reduces the turning radius, braces against moldboard imposed side loads, and gives better stability while
grading on slopes. Setscrews retain the pivot pins in the knuckles. The pivot pins are supported in the axle frame by spherical
bushings. End float is 0,000 – 0,102 mm (0.000 – 0.004 in.) and is shim adjustable. One or two hydraulic cylinders pivot the
knuckles and pins to a maximum of 18º each side of center. A lock valve prevents cylinder drift under load. The tie bar keeps
both wheels parallel so that they lean together. The pivot block, like a universal joint, allows movement in two directions during
wheel lean and steering. Slightly pre-loaded bushings and thrust washers are used in the pivot block.
Wheel hub – Tandem drive wheel group
Two tapered roller bearings support the wheel hub. The spindle locknut tightness determines preload. A V-ring seal prevents
bearing cavity pressurization and dirt ingress.
Wheel hub – AWD Wheel group
A hydraulic motor is mounted directly onto the AWD hub. The hub mounts into the knuckle the same as the tandem drive axle. A
hose guard is mounted to the back of the hub to protect the hydraulic hoses.
Toe-in
The term “toe-in” means that the distance between the front (toe) of the tires is less than the distance between the rear of the
tires. On tandem drive models, toe-in is 3 – 6,5 mm (1/8 – 1/4 in.). On AWD models there is no toe-in as front wheels are also
driving wheels. Toe-in is altered by adjusting the drag link length.
Figure 1
Front axle – G710B to G746B
1. Expansion ring
2. Back-up washer
3. Bearing pin
4. Bearing
5. Bearing
6. Bearing cap
7. Pivot pin
8. Tie bar
9. King pin
10. Shim
11. Spacer
12. Bearing
13. Knuckle - R.H and L.H.
14. Gasket - hub cap
15. Front axle
16. Hub cap
17. Bushing
18. Roll pin
19. Grease fitting
20. Thrust washer
21. Cap
22. Shim - 0.010 in.
23. Shim - 0.005 in.
24. Pin
25. Hub and spindle - L.H.
26. Hub and spindle - R.H.
27. Shim - 0.007 in.
28. O-ring
29. Cotter pin
30. Roll pin
31. Snap ring - internal
32. Grease fitting
33. Grease fitting
34. Bolt
35. Bolt
36. Lock washer
37. Bolt
38. Lock washer
39. Locknut
40. Tabwasher
41. Washer - wheel bearing
42. Flat washer
43. Slotted nut
44. Setscrew
45. Lock plate
46. V-ring seal
47. Back-up ring
48. Cup - inner bearing
49. Cone - inner bearing
50. Cup - outer bearing
51. Cone - outer bearing
52. Bolt
53. Lock washer
54. Setscrew
55. Grease fitting
56. Front bearing mount
57. Lug - wheel lean cylinder
58. Anchor lug - steering cylinder
59. Pin and lug assembly
60. Pin
61. Lug
62. Hub - wheel
63. AWD models
64. AWD hub - RH and LH
65. AWD wheel motor
66. Hose guard
Figure 2
Drag link – G710B to G746B
1. Cap
2. Bearing pin
3. Bearing pin
4. Bearing
5. Lock plate
6. Bushing
7. Thrust washer
8. Anchor pin
9. Grease fitting
10. Jam nut - L.H.
11. Yoke - L.H.
12. Yoke - R.H.
13. Pivot block
14. Pivot pin
15. Drag link
16. Bushing
17. Cotter pin
18. Roll pin
19. Lock washer
20. Snap ring - internal
21. Snap ring - external
22. Grease fitting
23. Bolt
24. Bolt
25. Lock washer
26. Flat washer
27. Slotted nut
28. Jam nut
29. Lock plate
30. Bolt
Service Information

Profile:
G780B Volvo
Tightening torques

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

Front axle pivot pin thrust cap retaining bolts 49 5 36
Mounting block matched halves retaining bolts 393 40 290
Wheel lean cylinder bearing pin lock plate retaining bolt 108 11 80
Tie bar bearing pin lock plate retaining bolts 108 11 80
Wheel hub bearing outer locknut 271 28 200
Drag link adjusting collar locknut 746 76 550
Wheel hub bearing preload 11 – 16 1–2 8 – 12
Wheel hub bearing outer locknut 271 28 200
Hub cap retaining bolts 12 1 9
Wheel rim retaining bolts 624 64 460
Service Information

Front axle toe-in 600 Service Information 9/10/2022
Profile:
G780B Volvo
Front axle toe-in


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
All models 3 – 6,5 mm 1/8 – 1/4 in.

Service Information

Front axle pivot (G710B to 600 Service Information 9/10/2022
G746B)
Profile:
G780B Volvo
Front axle pivot (G710B to G746B)


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Torque the pivot cap bolt until a small amount of force at the wheel is required to pivot the axle when the front end of the
grader is off the ground. The axle must stay in the new position when the force is removed.
Wheel hub; removing 3
Wheel hub; installing 5
Steering axle – Disassembly 7
Preparation and wheel; removing 8
Tie bar; removing 10
Tie bar; installing 11
Steering cylinder; removing 12
Steering cylinder; installing 14
Knuckle; removing 15
Knuckle; installing 16
Drag link; removing 17
Drag link; installing 19
Pivot block; removing and disassembling 20
Pivot block; assembling and installing 21
Wheel lean cylinder; removing 22
Wheel lean cylinder; installing 24
Front axle frame; removing 25
Front axle frame; installing 27
Wheel; installing 29
Axle disassembly and assembly - G780B 30
Front Axle Pivot Pin Bearings; disassembling 31
Front Axle Pivot Pin Bearings; assembling 33
King Pin Bearings and Spindle Thrust Bearing; disassembling 36
King Pin Bearings and Spindle Thrust Bearing; assembling 38
Wheel bearings; disassembling 40
Wheel bearings; assembling 42
Pivot Block Adjustments 44
Wheel Bearing; cleaning and inspecting 45
Spindle; removing and disassembling 47
Spindle; assembling and installing 49
Toe - in; adjustment_{019-28} 51
Toe - in; adjustment_{019-10} 52
Service Information

Wheel hub, removing 622 Service Information 9/10/2022
Profile:
G780B Volvo
Wheel hub, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-052
18516 Socket wrench
1. Attach a safe lifting device to the wheel hub. Remove the hub cap. Remove and discard the hub cap gasket.
2. Bend back the tabs of the tabwasher. Using the special tool P/N 18516, remove the outer locknut, tabwasher and inner
locknut. Discard the tabwasher. Remove the wheel bearing washer.
3. Pull the wheel hub out slightly on the spindle and remove the outer bearing cone. Remove the wheel hub from the
spindle.
Figure 1
4. Remove the inner bearing cone. Remove and discard the back-up ring and V-ring seal.
5. Inspect the bearing cups for signs of damage or wear. If necessary, use a hammer and soft metal drift to remove them.
If replacing the bearing cups, place them in a freezer to shrink them for easier installation.
Service Information

Wheel hub, installing 622 Service Information 9/10/2022
Profile:
G780B Volvo
Wheel hub, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-069
18516 Socket wrench
1. Use a hammer and soft metal drift to install the inner and outer bearing cups into the wheel hub. Alternatively, place
cups in a freezer to shrink them for easier assembly.
2. Pack the inner bearing cone with grease and install the cone. Carefully install a new back-up ring. Apply 2 cups of
grease to the inside of the wheel hub. Lubricate and install a new V-ring seal onto the spindle.
3. Attach a safe lifting device to the wheel hub. Slide the wheel hub onto the spindle.
Figure 1
4. Pack the outer bearing cone with grease and install it on the spindle. Install the wheel bearing washer and the inner
locknut.
NOTE!
Always install the inner and outer locknuts with the chamfer facing outwards from the wheel hub.
NOTE!
Do not over-lubricate the wheel bearing cones. Excess grease can damage the hub cap gasket.
5. Set the wheel preload by first installing one of the hub cap bolts. Use tool P/N 18516 to tighten the locknut. When
tightening the locknut, rotate the wheel hub and periodically take a rolling torque reading using a torque wrench
attached to the hub cap bolt.
Stop tightening when the rolling torque reaches 11 – 16 N•m (1 –2 kgf•m)(8 – 12 lbf•ft).
Figure 2
Determining wheel bearing preload
6. Install a new tabwasher and the outer locknut. Use tool P/N 18516 and torque-tighten the locknut to 271 – 305 N•m
(28 – 31 kgf•m)(200 – 225 lbf•ft).
Bend the tabs so they engage into the slots of both locknuts.
7. Install a new hub cap gasket. Install the hub cap and secure with the bolts and lock washers.
Service Information

Steering axle – Disassembly 622 Service Information 9/10/2022
Profile:
G780B Volvo
Steering axle – Disassembly


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The following pages describe how to overhaul the front axle for Models G710B to G746B. Overhaul instructions for the heavy-
duty front axle (installed on the Model G780B) are described later in this section. Before starting the overhaul procedure, make
sure work area is clean and safe. Make sure proper tools, including a safe lifting device, are available and in good working order.
Read all warnings and act accordingly.
NOTE!
Service Information

Preparation and wheel, 622 Service Information 9/10/2022
removing
Profile:
G780B Volvo
Preparation and wheel, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-051
1. Start the engine when it is safe to do so. Position the moldboard centrally on the circle and 90º to the frame. Lower the
moldboard onto wooden blocks. Shut down the engine.
WARNING
2. Loosen the wheel rim bolts with the tires on the ground. Start the engine and operate the blade lift cylinders to raise
the front end of the grader. Place a safe stand under the nose of the grader. Operate the blade lift cylinders and lower
the front end of the grader onto the stand. Shut down the engine. Remove and retain the ignition key.
3. Remove the wheel rim bolts and lock washers and roll the rims and tires away from the front axle.
Figure 1
Service Information

Tie bar, removing 622 Service Information 9/10/2022
Profile:
G780B Volvo
Tie bar, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-058
1. Remove the bolts, lock washers and lock plates securing the bearing pins. Use a hammer and drift to remove the
bearing pins. Remove the tie bar from the front axle.
Figure 1
2. Place the tie bar on a clean workbench. Remove and discard the internal snap rings. Use a hammer and appropriate
drift to remove the bearings.
NOTE!
The bearings can only be removed in one direction.
3. Examine the bearings for signs of damage or wear and replace if necessary.
Service Information

Tie bar, installing 622 Service Information 9/10/2022
Profile:
G780B Volvo
Tie bar, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-063
1. Secure the tie bar in a vise. Use a hammer and appropriate drift to install the bearings. Install new snap rings.
Figure 1
2. Install the tie bar onto the front axle. Install the bearing pins. Install the lock plates and secure them with bolts and lock
washers.
Service Information

Steering cylinder, removing 622 Service Information 9/10/2022
Profile:
G780B Volvo
Steering cylinder, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-053
WARNING
NOTE!
Residual pressure may remain in hydraulic circuits containing lock valves.
1. Identify the hydraulic hoses to prevent confusion during assembly. Disconnect the steering cylinder hoses.
Plug the open ports and fittings to prevent contamination.
2. Remove the bolts and lock washers retaining the piston rod end cap. Remove the end cap. Remove and discard the
external snap ring.
3. Use a suitable puller to remove the piston rod end from the yoke pivot stud.
Figure 1
4. Remove the bolts, lock washers and lock plate from the cylinder barrel end.
5. Use a bottle jack under the cylinder barrel anchor pin and remove the pin. Remove the steering cylinder from the front
axle. Remove the bearing from the anchor lug.
NOTE!
The bearing can only be removed in one direction.
Figure 2
6. Place the steering cylinder on a clean workbench. Remove and discard the internal snap ring. Use a hammer and
appropriate drift to remove the bearing.
8. Repeat the removal procedure for the other steering cylinder.

Service Information

Steering cylinder, installing 622 Service Information 9/10/2022
Profile:
G780B Volvo
Steering cylinder, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-068
1. Remove the grease fitting and secure the rod end of the steering cylinder in a vise. Be sure to align the grease groove
and grease fitting hole.
Use a hammer and appropriate drift to install the bearing.
2. Install a new internal snap ring. Install the grease fitting.
3. Use a hammer and appropriate drift to install the steering cylinder bearings into the front axle.
NOTE!
The steering cylinder bearings can only be installed from the top of the anchor lug counterbores.
4. Install the steering cylinder onto the anchor lug and pivot block. Remove the grease fitting from the steering anchor
pin. Be sure to align the anchor pin lock plate groove with the cylinder lug bolt holes.
5. Use a bottle jack to push the steering anchor pin into position. Use an assistant to align the holes for easier installation
of the anchor pin.
Once the anchor pin is in position, install the grease fitting, lock plate, bolts and lock washers.
6. Use a hammer and appropriate drift to install the rod eye and bearing onto the yoke pivot stud. Secure the rod eye with
a new external snap ring.
7. Install the cap, bolts and lock washers.

8. Connect the hydraulic hoses.
9. Repeat the installation procedure for the other steering cylinder.

Service Information

Knuckle, removing 622 Service Information 9/10/2022
Profile:
G780B Volvo
Knuckle, removing

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-059
1. Remove the setscrew securing the pivot pin.
2. Use a safe lifting device to support the knuckle. Remove the bolts and lock washers retaining the bearing cap. Remove
the bearing cap and shims.
3. Use a hammer and drift to remove the pivot pin. Remove the knuckle from the front axle.
Figure 1
4. Use a hammer and appropriate drift to remove the bearings from the axle frame. Examine the bearings for signs of
damage or wear and replace if necessary.
NOTE!
The rear bearings can only be removed in one direction.
Service Information

Knuckle, installing 622 Service Information 9/10/2022
Profile:
G780B Volvo
Knuckle, installing

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-062
1. Use a hammer and appropriate drift to install the bearings into the axle frame counterbores. Attach a safe lifting device
to the knuckle and slide it into place on the axle frame. Align the holes and install the pivot pin.
NOTE!
The rear bearings can only be installed in one direction.
2. To adjust the knuckle pivot pin end play, first remove any dirt or paint on the machined surfaces of the bearing cap and
the axle frame. Install the bearing cap without any shims and secure with two bolts and lock washers. Pivot the knuckle
back and forth; at the same time, torque-tighten the bolts in an opposing sequence to 47 N•m (5 kgf•m)(35 lbf•ft).
3. Use feeler gauges to measure the gap between the bearing cap and axle frame surfaces. Two measurements are
required. Calculate the average of the two measurements. This method determines the number of shims needed.
4. Use a micrometer to measure the correct shim pack thickness. Remove the bearing cap. Install the shim pack and
bearing cap. Install the bolts and lock washers.
Torque-tighten the bolts in a diagonal sequence to 47 N•m (5 kgf•m)(35 lbf•ft).
5. Apply `Loctite' 243 thread-locking compound (or equivalent) onto the setscrew. Install the setscrew to secure the
knuckle pivot pin.
Service Information

Drag link, removing 622 Service Information 9/10/2022
Profile:
G780B Volvo
Drag link, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-054
1. Use a safe lifting device to support the drag link. Remove and discard the cotter pin securing the slotted nut that retains
the pivot pin. Remove the slotted nut, flat washer and pivot pin.
Figure 1
2. Repeat the disassembly procedure for the other pivot pin. Remove the drag link from the front axle. Remove the thrust
washers.
Figure 2
Service Information

Drag link, installing 622 Service Information 9/10/2022
Profile:
G780B Volvo
Drag link, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-067
1. Align the dowels and dowel holes. Install the drag link thrust washers. To ease thrust washer installation, apply a small
amount of grease to hold them in place.
2. Use a safe lifting device to support the drag link. Tap the drag link into place and align the thrust washers.
3. Install the pivot pin, flat washer and slotted nut.

Torque-tighten the nut to 68 – 102 N•m (7 – 10 kgf•m) (50 – 75 lbf•ft).
Install a new cotter pin.
Repeat the assembly procedure for the other pivot pin.
Figure 1
Service Information

Pivot block, removing and 622 Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Pivot block, removing and disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-055
1. Remove and discard the cotter pin securing the slotted nut that retains the pivot block pin. Remove the slotted nut, flat
washer and pivot block pin. Slide the pivot block out of the spindle clevis and remove the thrust washers.
2. Place the pivot block in a vise. Use a hammer and soft metal drift to remove the bushings. Discard the bushings.
3. Repeat the disassembly procedure for the other pivot block.

Service Information

Pivot block, assembling and 622 Service Information 9/10/2022
installing
Profile:
G780B Volvo
Pivot block, assembling and installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-066
1. Secure the pivot block in a vise. Use a hammer and soft metal drift to install new bushings. Be sure to align the grease
holes and grease fittings.
2. Align the dowels and dowel holes. Install the pivot block thrust washers. To ease thrust washer installation, apply a
small amount of grease to hold them in place.
3. Use a soft-faced hammer to force the pivot block pin into position. Install the slotted nut and flat washer.
Torque-tighten the nut to 68 – 102 N•m (7 – 10 kgf•m)(50 – 75 lbf•ft) until the pivot block moves with a small amount
of preload. Install a new cotter pin.
Service Information

Wheel lean cylinder, 622 Service Information 9/10/2022
removing
Profile:
G780B Volvo
Wheel lean cylinder, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-057
1. Identify the hydraulic hoses to prevent confusion during assembly. Disconnect the wheel lean cylinder hoses. Plug the
open ports and fittings to prevent contamination.
WARNING
NOTE!
Residual pressure may remain in hydraulic circuits containing lock valves.
2. Support the wheel lean cylinder with a block of wood. Remove the bolts, lock washers and lock plates securing the
bearing pins.
Use a hammer and drift to remove the bearing pins. Remove the wheel lean cylinder from the front axle.
Figure 1
3. Place the wheel lean cylinder on a clean workbench. Remove and discard the internal snap rings. Use a hammer and
appropriate drift to remove the bearings.
5. Repeat the removal procedure for the other wheel lean cylinder if installed on the machine.
Service Information

Wheel lean cylinder, 622 Service Information 9/10/2022
installing
Profile:
G780B Volvo
Wheel lean cylinder, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-064
1. Secure the wheel lean cylinder in a vise. Use a hammer and appropriate drift to install the bearings. Install new snap
rings.
2. Install the wheel lean cylinder onto the front axle. Install the bearing pins. Install the lock plates and secure them with
bolts and lock washers.
Connect the hydraulic hoses.
3. Repeat the installation procedure for the other wheel lean cylinder if installed on the machine.
Service Information

Front axle frame, removing 622 Service Information 9/10/2022
Profile:
G780B Volvo
Front axle frame, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-060
1. Remove the bolts and lock washers retaining the bearing cap to the axle frame. Remove the cap and shims.
2. Use a safe lifting device to support the axle frame. Force the axle frame back as far as possible. (It may be necessary to
use a chain hoist attached to the rear of the drawbar.)
3. Remove the front bearing cup and the O-ring. Discard the O-ring.
4. Use a suitable bearing puller to remove the front bearing cone and back-up washer from the pivot pin.
Figure 1
5. Lower the rear of the axle frame until it is below the pivot pin. Pull the axle frame forward. Lower the axle frame to the
ground as soon as it clears the front portion of the pivot pin.
6. Remove and discard the rear O-ring. Use a suitable bearing puller to remove the rear bearing cone and back-up washer
from the pivot pin. Remove the rear bearing cup from the axle frame.
Service Information

Front axle frame, installing 622 Service Information 9/10/2022
Profile:
G780B Volvo
Front axle frame, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-061
1. Apply grease to the axle frame rear counterbore. Use a hammer and soft metal drift to install the rear bearing cup into
the axle frame. Alternatively, place cups in a freezer to shrink them for easier assembly. Lubricate and install a new O-
ring.
2. Install the rear back-up washer on the pivot pin. Heat the rear bearing cone evenly to a maximum of 121ºC (250ºF) and
install it on the pivot pin. Make sure that it seats properly.
3. Use a safe lifting device and raise the axle frame off the ground. Engage the front of the axle frame with the pivot pin.
Pull the axle frame back far enough to clear the rear portion of the pivot pin. Raise the rear of the axle frame until it
aligns with the pivot pin.
Figure 1
4. Position the axle frame ahead to fully engage the rear bearing cup and cone. Install the front back-up washer. Lubricate
the back-up washer and pivot pin. Heat the front bearing cone evenly to a maximum of 121ºC (250ºF) and install it on
the pivot pin. Make sure that it seats properly. Lubricate and install a new O-ring. Lubricate and install the front bearing
cup.
5. Install the pivot cap without any shims and secure with two bolts and lock washers. Tighten the bolts evenly until the
axle frame stays in place when moved and released.
6. Use feeler gauges to measure the gap between the pivot cap and the axle frame. Four measurements are required.
Calculate the average of the four measurements. This method determines the number of shims needed.
7. Use a micrometer to measure the correct shim pack thickness. Remove the pivot cap. Install the shim pack and pivot
cap. Install the bolts and lock washers and torque-tighten the bolts in a diagonal sequence to 108 N•m (11 kgf•m)(80
lbf•ft).
Service Information

Wheel, installing 622 Service Information 9/10/2022
Profile:
G780B Volvo
Wheel, installing

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-070
1. Position the wheels onto the wheel hubs and retain them with the bolts and lock washers. Start the engine when it is
safe to do so.
Operate the blade lift cylinders to raise the front end of the grader. Remove the stand.
Operate the blade lift cylinders and lower the front of the grader.
Tighten the rim bolts in a diagonal sequence to 624 N•m (64 kgf•m)(460 lbf•ft).
2. Re-check the preload of the axle pivot pin. Stand on one of the front wheel rims and hold onto the tire. An average
person weighing 68 – 82 kg (150 – 180 lb) should just make the axle pivot on the pin. If the preload is incorrect, add or
remove shims under the pivot pin cap.
Service Information

Axle disassembly and 622 Service Information 9/10/2022
assembly - G780B
Profile:
G780B Volvo
Axle disassembly and assembly - G780B


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The following pages describe how to overhaul the front axle for the model G780B. Overhaul instructions for the standard front
axle (models G710B to G746B) are described earlier in this section. Before starting the overhaul procedure, make sure the work
area is clean and safe. Make sure proper tools, including a safe lifting device, are available and in good working order. Read all
warnings and act accordingly
NOTE!
Service Information

Front Axle Pivot Pin 622 Service Information 9/10/2022
Bearings, disassembling
Profile:
G780B Volvo
Front Axle Pivot Pin Bearings, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-072
moldboard onto wooden blocks.
WARNING
2. Operate the blade lift cylinders to raise the front end of the grader until the tires are just touching the ground. Place a
safe stand under the nose plate. Shut down the engine. Remove and retain the ignition key.
3. Identify the steering and leaning wheel hydraulic hoses to prevent confusion during assembly.
4. Disconnect the steering cylinder hoses. Plug the open ports and fittings to prevent contamination.
5. Disconnect the left-hand leaning wheel cylinder hoses. Plug the open ports and fittings to prevent contamination.
6. Disconnect the right-hand leaning wheel cylinder hoses. Plug and cap all open ports and fittings to prevent
contamination.
7. Remove the bolts and flat washers securing the tie bar bearing pins. Use a hammer and metal drift to remove the
bearing pins. Remove the tie bar. Attach a safe lifting device to the drag link.
8. Use a hammer and center punch to mark the pivot pin mounting blocks. The marks will help identify the upper and
lower mounting block matched halves during assembly.
9. Remove the bolts and lock washers retaining the lower mounting block halves. Remove the lower mounting block
halves.
10. Start the engine when it is safe to do so. Operate the blade lift cylinders and raise the front end of the grader until it is
clear of the front axle frame. Remove the safety stand.
11. Lower the lifting device and allow the front axle to roll over slowly. Remove the lifting device and roll the front axle
away from the grader.
Figure 1
Allowing front axle to roll over and stabilize
12. Lower the front end of the grader and place the safety stand under the nose plate. Shut down the engine. Remove and
retain the ignition key.
13. Remove the bolts and lock washers retaining the front and rear thrust caps. Remove the thrust caps, thrust washers, and
any shims from the axle frame bosses.
14. Remove the pivot pin out of the bearings.
Figure 2
Removing pivot pin
15. Use a hammer and appropriate tubular drift to remove the needle roller bearings and seals. Discard the seals.
16. The front axle pivot pin bearing disassembly is now complete. Place the parts to one side for cleaning and inspection.
Refer to Wheel Bearing, cleaning and inspecting
Service Information

Front Axle Pivot Pin 622 Service Information 9/10/2022
Bearings, assembling
Profile:
G780B Volvo
Front Axle Pivot Pin Bearings, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-073
1. Lubricate the needle roller bearings with grease. Use a hammer and appropriate tubular drift to install the bearings into
the axle frame front and rear bosses. Lubricate and install new seals. The seal lips should face outward.
Figure 1
Installing front axle pivot pin bearings
2. Lubricate the pivot pin with grease. Use a soft-faced mallet to install the pivot pin into the bearings. Take care not to
damage the seals.
3. Install the thrust cap, thrust washer and three shims onto the rear boss face of the axle frame. Retain the thrust cap with
Torque-tighten the bolts in a diagonal sequence to 49 N•m (5 kgf•m)(36 lbf•ft).
4. Install the thrust cap and thrust washer onto the front boss face of the axle frame. Do not install any shims. Retain the
thrust cap with bolts and lock washers. Do not torque-tighten the bolts.
clear of the safety stand. Remove the stand.
6. Roll the axle assembly under the grader front end. Attach a safe lifting device to the drag link. Use the lifting device to
slowly turn the axle over. Be careful the axle does not turn over-center.
Figure 2
Using safe lifting equipment to turn over front axle
7. Make sure the mounting block mating faces are clean. Place the safety stand under the nose plate and lower the front
end of the grader onto the axle frame.
Align the pivot pin with the mating groove of the upper pivot blocks.
Shut down the engine. Remove and retain the ignition key.
8. Align the match marks and install the lower mounting block halves. Retain the mounting block halves with bolts and
lock washers.
Figure 3
Torque-tightening front axle mounting bolts
9. Install the tie bar. Lubricate and install the bearing pins. Retain the bearing pins with bolts, lock washers and flat
washers.
10. Connect the left-hand leaning wheel cylinder hydraulic hoses. Connect the right-hand leaning wheel cylinder hydraulic
hoses. Connect the steering cylinder hydraulic hoses.
clear of the safety stand. Remove the stand.
12. Set the end float by tightening the front thrust cap bolts until the thrust cap is snug against the pivot pin. Do not over-
tighten the bolts. This can damage the thrust cap.
Lower the grader front end. Shut down the engine. Remove and retain the ignition key.
13. Use feeler gauges to measure the gap between the front thrust cap and the axle frame boss face in three or four places.
The average of these measurements determines the number of shims needed.
Figure 4
Measuring gap to determine shim pack thickness
14. Remove the thrust cap and thrust washer. Now install the thrust cap, thrust washer, required number of shims, and
another shim equal to the end float specification of 0,076 – 0,127 mm (0.003 – 0.005 in.). Retain the thrust cap with
15. Torque-tighten the bolts until 68 kg (150 lb) of weight at the wheel is required to pivot the front axle with the front end
of the grader off the ground.
16. Lubricate both front axle thrust caps through the grease fittings. Road test the grader to make sure there are no
problems with the mechanical function of the front axle or hydraulic leaks.
Service Information

King Pin Bearings and 622 Service Information 9/10/2022
Spindle Thrust Bearing,
disassembling
Profile:
G780B Volvo
King Pin Bearings and Spindle Thrust Bearing, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-074
1. Many components are duplicated on both sides of the grader. The following steps describe the disassembly and
assembly procedures for the left-hand side only. These procedures can be used for both sides.
WARNING
2. Loosen the wheel nuts. Start the engine when it is safe to do so. Position the moldboard centrally on the circle and 90º
to the frame. Lower the moldboard onto wooden blocks.
3. Operate the blade lift cylinders and raise the front end of the grader until the tires are just touching the ground. Place a
safe, adequate stand under the nose plate. Shut down the engine. Remove and retain the ignition key.
4. Remove the wheel. Attach a safe lifting device onto one of the wheel studs.
5. Remove the cotter pin, slotted nut and flat washer retaining the pivot block pin. Use a hammer and appropriate metal
drift to remove the pin. This disconnects the drag link from the pivot block.
6. Remove the bolts and lock washers retaining the king pin caps. Remove the caps. Remove the setscrew from the
spindle.
7. Use a jack and appropriate drift to remove the king pin. Use the lifting device to remove the spindle/wheel hub
assembly. Remove the thrust bearing.
Figure 1
Using jack and appropriate drift to remove king pin
8. Use a hammer and appropriate tubular drift to remove the two needle roller bearings from the top bore of the knuckle.
Figure 2
Using hammer and appropriate drift to remove bearings
9. Use a jack and appropriate tubular drift to remove the two needle roller bearings and seal from the bottom bore of the
knuckle. Discard the seal.
Figure 3
Using jack and appropriate drift to remove bearings
10. The left-hand king pin bearing and spindle thrust bearing disassembly is now complete. Place the parts to one side for
cleaning and inspection. Refer to Wheel Bearing, cleaning and inspecting.
Service Information

King Pin Bearings and 622 Service Information 9/10/2022
Spindle Thrust Bearing,
assembling
Profile:
G780B Volvo
King Pin Bearings and Spindle Thrust Bearing, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-075
1. Place the king pin in a freezer or dry ice. Freezing causes the king pin to shrink and makes installation easier.
2. Lubricate the needle roller bearings with grease. Use a hammer and appropriate tubular drift to install the bearings into
the upper and lower bores of the knuckle. Lubricate and install a new seal at the top face of the knuckle lower bore. The
seal lip should face upward.
Figure 1
Using hammer and appropriate drift to install bearings
3. Use the lifting device to position the spindle/wheel hub assembly into position at the knuckle. Install the thrust bearing
between the spindle and the knuckle upper boss.
4. Carefully install the king pin. Be sure to align the slot in the king pin with the tapped hole for the setscrew. As previously
stated, freezing the king pin helps make the installation easier. Install the setscrew to secure the king pin. Check to see
that the spindle pivots freely on the king pin.
Figure 2
Installing king pin and aligning setscrew locking slot
5. Apply a bead of silicone sealant (P/N 56427 or equivalent) to the king pin caps. Install the caps and retain them with
bolts and star washers. Lubricate both king pin caps through the grease fittings.
6. To install the pivot block pin, first remove the pivot block from the spindle. Remove the slotted nut and flat washer from
the bottom of the radius arm pin, then remove the pin. Remove the pivot block assembly from the spindle.
7. Check the pivot block bushings. Replace parts as necessary.
8. Install the pivot block into the yoke of the drag link and retain with the pivot block pin. Secure the pin with the flat
washer, slotted nut, and cotter pin.
9. Install the pivot block between the spindle radius arms. Install the radius arm pin and retain with the flat washer, slotted
nut, and cotter pin.
Lubricate the pivot block and pivot block pin through the grease fittings.
10. Install the wheel on the wheel hub.

Torque-tighten the wheel nuts in a diagonal sequence to 644 – 712 N•m (66 – 73 kgf•m)(475 – 525 lbf•ft).
Road test the grader to make sure there are no problems with the mechanical function of the front axle.
Service Information

Wheel bearings, 622 Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Wheel bearings, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Many components are duplicated on both sides of the grader. The following steps describe the disassembly and assembly
procedures for the left-hand side only. Use these steps for the right side as well.
WARNING
Op nbr 622-076
1. Loosen the wheel nuts. Start the engine when it is safe to do so. Position the moldboard centrally on the circle and 90º
to the frame. Lower the moldboard onto wooden blocks.
2. Operate the blade lift cylinders and raise the front end of the grader until the tires are just touching the ground. Place a
safe, adequate stand under the nose plate. Shut down the engine. Remove and retain the ignition key.
3. Remove the wheel. Attach a safe lifting device onto one of the wheel studs.
4. Remove the bolts and lock washers retaining the hub cap. Remove the hub cap.
5. Use a hammer and appropriate drift to disengage the tabs of the tab washer. Remove the outer locknut. Remove and
discard the tab washer. Remove the inner locknut. Remove the lock washer.
Figure 1
Disengaging tabs of tab washer
6. Pull the wheel out slightly on the spindle. Remove the outer bearing cone. Remove the wheel. Remove the inner
bearing cone.
7. Remove and discard the V-ring seal from the deflector spacer. Remove the deflector spacer and dust seal. Discard the
dust seal.
8. Use a hammer and appropriate soft metal drift to remove the inner and outer bearing cups.
9. The front axle wheel bearing disassembly is now complete. Place the parts to one side for Wheel Bearing, cleaning and
inspecting.
Figure 2
Using hammer and soft metal drift to remove bearing cups
Service Information

Wheel bearings, assembling 622 Service Information 9/10/2022
Profile:
G780B Volvo
Wheel bearings, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-077
1. Lubricate the outside diameter of the inner and outer bearing cups with oil. Use a hammer and soft metal drift or
appropriate bearing driver to install the inner and outer bearing cups into the wheel hub. Alternatively, place cups in a
freezer to shrink them for easier assembly.
Lubricate the wheel bore and inside diameter of the bearing cups with a generous amount of grease.
Figure 1
Using hammer and bearing driver to install bearing cups
2. Install a new dust seal, deflector spacer and new V-ring seal. Apply grease onto the spindle.
3. Pack the inner bearing cone with grease and install it onto the spindle. Fill the wheel hub with 3 1/2 cups of grease.
Attach a safe lifting device to the wheel hub and install it onto the spindle. Pack the outer bearing cone with grease and
install it onto the spindle.
4. Install the lock washer. Install the inner locknut.

NOTE!
Always install the inner and outer locknuts with the chamfer facing outwards from the wheel hub.
5. Install one of the hub cap bolts to help determine the wheel bearing preload.
Tighten the inner locknut until 11 – 16 N•m (1 – 2 kgf•m) (8 – 12 lbf•ft) of torque (applied at the hub cap bolt) is
needed to turn the wheel.
Figure 2
Determining wheel bearing preload
6. After setting the wheel bearing preload, install a new tab washer. Install the outer locknut and tighten to 271 N•m (28
kgf•m) (200 lbf•ft).
Bend the tab washer tabs until they engage into the slots of both locknuts.
7. Apply a bead of silicone sealant (P/N 56427 or equivalent) to the hub cap. Install the hub cap and retain it with bolts
and lock washers. Lubricate the hub cap until the wheel bearings are full of grease.
8. Install the wheel on the wheel hub.

Torque-tighten the wheel nuts in a diagonal sequence to 644 – 712 N•m (66 – 73 kgf•m) (475 – 525 lbf•ft).
9. Recheck the wheel bearing preload by pushing the wheel. It should rotate 1 1/2 turns before stopping. Road test the
grader to ensure there are no problems with the mechanical function of the front axle.
Service Information

Pivot Block Adjustments 622 Service Information 9/10/2022
Profile:
G780B Volvo
Pivot Block Adjustments


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-078
1. Proper pivot block and toe-in adjustments are essential to ensure reduced tire wear and stable operation of the grader.
2. Start the procedure with the left-hand pivot block.
3. Tighten castle nut hand tight or until all play is gone.
4. Tighten nut 1 flat or until the hole in the pivot block pin lines up with the castle nut.
5. Install the cotter pin.
6. Repeat steps 3 to 5 for the other side.

Service Information

Wheel Bearing, cleaning and 622 Service Information 9/10/2022
inspecting
Profile:
G780B Volvo
Wheel Bearing, cleaning and inspecting


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-079
Cleaning
WARNING
Risk of serious corrosive injuries!
NOTE!
Wear goggles, protective clothing and a respirator. Handle chemicals according to manufacturer's instructions. Severe personal
injury or death could result.
Use a cleaning solvent to clean ground or polished parts or surfaces. Kerosene or diesel fuel oil can be used. Do not use
gasoline.
Use a flat-bladed tool to remove silicone sealant residue.
Do not clean ground or polished parts in water, steam, alkaline solutions or a hot solution tank.
Immediately dry parts after cleaning. Use soft, clean paper or cloth rags. Parts can also be dried (except bearings) using moisture
free compressed air.
NOTE!
Do not dry bearings with compressed air. Spinning bearings with compressed air can damage the races and rollers.
Apply grease or system oil to undamaged parts that are ready for assembly. If storing parts for some time, apply a rust inhibitor
to all surfaces. Wrap parts in rust inhibitor impregnated paper before storing.
Inspection
Inspect all tapered roller bearing cups and cones. Replace the bearing if the following defects are visible:
1. Center of the large diameter end of the roller worn level with or below the outer surface of the roller.
2. Radius of the large diameter end of the roller worn to a sharp edge.
3. Visible roller grooves in the cup or cone inner race surfaces.
4. Deep cracks in the cup, cone inner race or roller surfaces.
5. Bright wear marks on the roller cage outer surface.
6. Etched and pitted rollers or cup and cone inner race surfaces that touch the rollers.
7. Cup and cone inner race surfaces that touch the rollers damaged by spalling and flaking.
Replace worn or damaged front axle assembly parts. These are examples of what to check, repair or replace:
1. Replace any fasteners if the corners of the head are worn.

2. Replace damaged washers.
3. Replace all oil seals, O-rings, V-rings and cotter pins.
4. Clean parts and apply new silicone sealant (P/N 56427 or equivalent) where required when front axle is assembled.
5. Use emery cloth to remove nicks, scratches and burrs from machined or ground surfaces.
6. Clean and repair threads. Use a die or tap of the correct size or a fine file.
NOTE!
Threads must be clean and undamaged to ensure correct values when fasteners are torque-tightened.
Service Information

Spindle, removing and 622 Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Spindle, removing and disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-056
1. Remove the setscrews securing the upper and lower king pins.
Figure 1
2. Cut a slot in the upper and lower expansion plugs. Remove and discard the plugs.
3. Use a safe lifting device to support the spindle. Use a slide hammer to force the upper and lower king pins out of the
spindle.
4. Carefully slide the spindle out of the knuckle. Remove the thrust washer and upper and lower spacers.
Use a hammer and soft metal drift to remove the king pin bushings. Discard the bushings.
Figure 2
Service Information

Spindle, assembling and 622 Service Information 9/10/2022
installing
Profile:
G780B Volvo
Spindle, assembling and installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-065
1. Use a hammer and appropriate soft metal drift to install new king pin bushings. Be sure to align the grease holes and
grease fittings.
2. Attach a safe lifting device to the spindle. Insert the spacer for the lower king pin, and the thrust bearing and spacer for
the upper king pin. Fully install the spindle in the knuckle.
NOTE!
Ensure the grease channel for the upper king pin thrust bearing faces upward.
3. Use a hammer and appropriate drift to install the upper king pin. Use a bottle jack to install the lower king pin.
4. Apply `Loctite' 243 thread-locking compound (or equivalent) onto the upper and lower setscrews and install them.
Torque-tighten the setscrews to 108 N•m (11 kgf•m)(80 lbf•ft).
Figure 1
5. Install new upper and lower expansion plugs. Indent the plugs to properly secure them.
Service Information

Toe - in, adjustment 622 Service Information 9/10/2022
Profile:
G780B Volvo
Toe - in, adjustment


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-071
1. Check the toe-in adjustment of the front wheels by making a mark on the tires behind the front axle and level with the
centerline of the spindle.
Measure the distance between the inside walls of the tires at these marks. Record this measurement.
2. Operate the blade lift cylinders and raise the front axle. Turn the wheels and position the marks on the centerline of the
spindles in front of the axle.
Measure the distance between the inside walls of the tires at these marks. Record this measurement.
The front measurement should be 3 – 6,5 mm (1/8 – 1/4 in.) less than the measurement made behind the front axle.
3. To adjust the toe-in, first loosen the jam nut at the right hand drag link yoke.
NOTE!
The jam nut has left hand threads.
4. Turn the drag link to alter its length. When the toe-in measurement is correct, tighten the jam nut to secure the drag
link.
5. Lubricate all grease fittings. Road test the grader to ensure there are no problems with the mechanical function of the
front axle, or hydraulic oil leaks.
Service Information

Toe - in, adjustment 622 Service Information 9/10/2022
Profile:
G780B Volvo
Toe - in, adjustment


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 622-071
1. Before starting the toe-in check, ensure that the wheels are straight and are not leaning to the left or right. If necessary,
move the grader forward and backward to remove any tread distortions.
2. Start the toe-in check by making a mark on the tires behind the axle frame and at the same level as the center line of
the spindle. Measure the distance between the tires at these marks.
3. Start the engine when it is safe to do so. Slowly drive the grader forward so the marks on the tires are in front of the
axle frame and are at the same level as the center line of the spindle. Shut down the engine and retain the ignition key.
Figure 1
Measuring distance between tires and rear to determine toe-in
4. Measure the distance between the tires at the marks again. The front measurement should be 9 - 13 mm (3/8 - 1/2 in.)
less than the rear measurement.
Figure 2
Measuring distance between tires and front to determine toe-in
5. To adjust the toe-in, loosen the setscrew and locknut on the drag link. Use a wrench to turn the adjusting collar.
Turning the adjusting collar varies the length of the drag link and changes the toe-in measurement.
Figure 3
Turning drag link collar to adjust toe-in
6. After completing the toe-in adjustment, retain the adjusting collar with the locknut. Torque-tighten the locknut to 746
N•m (76 kgf•m) (550 lbf•ft) and tighten the setscrew. Re-check the toe-in measurement.
7. The toe-in adjustments are now complete.

Wheel lean hydraulic schematic - Image 3
Secondary steering hydraulic schematic - Image 4
Steering hydraulic schematics - Image 5
Specifications 6
Description 7
Steering column; disassembling 9
Steering column; assembling 11
Steering Column - Cleaning and Inspection 12
Steering control unit; removing 13
Steering control unit; installing 14
Specifications- 15
Description - 16
Steering hydraulic schematics 17
Steering system troubleshooting guide 19
Steering control unit troubleshooting 21
Specifications . 24
Components. 25
Steering control unit overhaul procedure 27
Steering control unit; disassembling 28
Steering control unit; assembling 33
Steering Control Unit - Bleeding Procedure 39
Specifications. 40
Description. 41
Function. 43
Specifications-. 45
General description 47
Secondary steering; specifications 48
Secondary steering; description 49
Secondary steering; component location 51
Secondary steering hydraulic schematic 54
Secondary steering troubleshooting 56
Hydraulic cylinder specifications 57
Description -. 59
Wheel lean hydraulic schematic 61
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Steering wheel nut 54 N•m 5,5 kgf•m 40 lbf•ft

Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Steering column
1. Steering control unit

2. Steering wheel cap
3. Nut
4. Steering wheel
5. Snap ring
6. Flange
7. Boot
8. Steering column
9. Mount plate
10. Support
11. Washer
12. Nut
13. Bolt
14. Bolt
15. Washer
16. Nut
17. Locknut
18. Steering hydraulic circuit
Service Information

Steering column, 641 Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Steering column, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 641-022
400424 Steering wheel puller
1. Remove the steering wheel cap. Remove the nut securing the steering wheel to the steering column. Use 400424 puller
to remove the steering wheel.
NOTE!
Use the threaded holes in the steering wheel collar as an anchor.
Figure 1
Removing steering wheel
2. Remove and discard the external snap ring from the steering column.
3. Remove the bolt, nuts and flat washers securing the steering control unit (Orbitrol) and steering column to the support.
4. Remove the four bolts and lock washers securing the mount plate and steering column to the steering control unit. You
can now remove the steering column from the steering control unit.
5. Remove the steering column from the grader (the column will slide through the dust boot).
Figure 2
Removing steering column
Service Information

Steering column, 641 Service Information 9/10/2022
assembling
Profile:
G780B Volvo
Steering column, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 641-024
1. Use tape to temporarily secure the universal joint on the steering column. This prevents the dust boot from being
damaged when you install the steering column. From outside the cab, carefully install the steering column through the
dust boot.
2. Install the four bolts and lock washers securing the mount plate and steering column to the steering control unit
(Orbitrol). Install the bolt, nuts and flat washers securing the steering control unit and steering column to the support.
3. Install a new external snap ring onto the steering column. Install the steering wheel and nut.
Torque-tighten the nut to 54 N•m (5 kgf•m)(40 lbf•ft).
Install the steering wheel cap.
Figure 1
Torque-tightening steering wheel nut
Service Information

Steering Column - Cleaning 641 Service Information 9/10/2022
and Inspection
Profile:
G780B Volvo
Steering Column - Cleaning and Inspection


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Clean and inspect all components. Pay special attention to the universal joint bearings. If you see evidence of damage or wear,
replace all defective items with genuine Volvo parts.
Service Information

Steering control unit, 645 Service Information 9/10/2022
removing
Profile:
G780B Volvo
Steering control unit, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 645-031
1. Identify the hydraulic hoses to prevent confusion during assembly.
2. Disconnect the hoses from the steering control unit fittings. Immediately plug the open ports and fittings to prevent
contamination.
3. Remove the four bolts and hardened washers securing the mount plate (3) and steering column (2) to the steering
control unit (1). Remove the steering control unit from the grader. See Components.
Service Information

installing
Profile:
G780B Volvo
Steering control unit, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 645-035
Figure 1
1. Steering control unit assembly

2. Steering column assembly
3. Support
1. Install the four bolts and washers securing the steering control unit (1) to the mount plate (3) and steering column (2).
2. Connect the hoses to the steering control unit (1).

Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Relief setting 8274 ±690 kPa 83 ±7 bar 1200 ±100 psi

Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The steering circuit is supplied with oil from the main hydraulic pump. The steering control unit is a closed center, load sensing
component like the control valves in the main hydraulic circuit. Therefore, no oil flows through the steering valve until the
steering wheel is turned. A priority flow valve maintains consistent steering response throughout the engine rpm range. This
valve operates similar to the pump's load sense module. It's purpose is to provide priority flow to the steering circuit ensuring
consistent steering response regardless of engine rpm or main hydraulic requirements. All excess flow is available for use in the
main hydraulic control valve through port “EF”. A relief valve built into the priority flow valve limits steering circuit pressure
independently of the main hydraulic relief valve. Oil exiting from the steering valve returns to the left side of the main hydraulic
control valve and enters the return to tank passage.
The steering control valve features a dynamic signal circuit. The load sense port of the priority flow valve is connected to the
steering valve. An orifice is located in the steering control unit. With the steering valve in the neutral position, a small amount of
oil flows through the orifice in the steering control unit. This oil flow continues through the main control valve return passage
and then back to tank. The purpose of the dynamic signal circuit is to improve steering response by charging the load sense line
with warm oil under low pressure and to warm the steering valve in cold climates thus preventing thermal shock to the steering
control valve.
Service Information

Steering hydraulic 645 Service Information 9/10/2022
schematics
Profile:
G780B Volvo
Steering hydraulic schematics


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
A Main hydraulic pump

C Priority flow control valve
D Steering control unit
D1 Pressure test port
E Crossover relief valve
G Steering cylinders
1 Pressure, to main directional control valve
2 Pressure, to fan control valve
3 Load sense, fan control valve
4 Load sense, main directional control valve
5 Set to limit the maximum pressure at the CF port to 8274 kPa (82.8 bar)(1200 psi)
6 Priority valve control pressure 1690 kPa (16.9 bar)(245 psi)
Figure 1
Steering hydraulic circuit
Service Information

Steering system 645 Service Information 9/10/2022
troubleshooting guide
Profile:
G780B Volvo
Steering system troubleshooting guide


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Condition Possible cause

Front wheels vibrate when steering
Air in the steering cylinders and/ or the hydraulic hoses from
the steering control unit to the steering cylinders.
Defective steering control unit.
Steering wheel kicks back when reaching stop

Air in the steering cylinders
and/or the hydraulic hoses from the steering control unit to
the steering cylinders
Defective or missing check valve at the steering control unit
pump pressure port.
Steering wheel oscillates (rotates back and forth)

more than three times when it is released. Steering pressure in the priority flow valve is set too high and
allows steering oil to relieve at the crossover relief valve.
Crossover relief pressure is set too low.
Steering cylinder internally bypassing oil.
Defective steering control unit.
Steering does not work, but other hydraulic functions

operate. Pump is not receiving a load sense signal from the steering
control unit.
Priority flow valve spool stuck and not allowing pump flow to
the steering circuit.
The steering circuit is blocked or damaged.
The front axle is blocked and binding.
Incorrect number of turns of the steering wheel.
Wrong steering control unit.
Internal leakage of the steering control unit.
Internal leakage of the steering cylinders.
Service Information

Steering control unit 645 Service Information 9/10/2022
troubleshooting
Profile:
G780B Volvo
Steering control unit troubleshooting


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Trouble Possible cause Check and remedy

Hard or slow steering. Pump not receiving LS (load sense)
signal. Install a pressure gauge on a male
quick-disconnect coupling at the load
sense pump discharge line.
∆P = 1724 kPa (17 bar)(250 psi).
Priority flow relief valve malfunction.

Check relief pressure setting 8274 kPa
(83 bar)(1200 psi). Inspect for
contamination or damage.
Priority flow valve sticking.

If main hydraulic functions are normal,
inspect the spool and bore for
contamination or damage. Replace as
necessary.
Worn pump.
Check the pump flow rate at 284 L/
min (75 U.S. gpm) and high idle with
all hydraulic functions activated.
No emergency steering. Malfunctioning electrical circuit.

Check the fuse, relays, pressure switch
and electrical circuit for continuity.
Malfunctioning hydraulic circuit.
Check the main hydraulic pump
suction and discharge hoses for
kinking or obstructions.
Check the valve at the test fitting on
the pump discharge side.
Wander – grader will not hold a Air in the system.

straight line. Check for leaks, low oil level or
cavitating pump.
Severe wear in the steering control

unit. Check for contamination. Repair or
replace the steering control unit.
Worn or damaged steering linkage.

Repair or replace the steering linkage.
Worn steering cylinder(s).

Perform leak-by test. Repair the
steering cylinder(s).
Slow movement of the steering Worn steering cylinder(s).

wheel does not cause the front Perform leak-by test. Repair the
wheels to move. steering cylinder(s).
Worn steering control unit meter.

Repair or replace the steering control
unit.

Free wheeling – steering wheel turns Defective steering column.
freely with no feeling of pressure and Repair or replace steering column.
no movement in the front wheels.
Lack of oil in the steering control unit after
service. Wait for the steering control unit
to fill with oil after starting.
Lack of flow to the steering control unit.

Check for low oil level or leaks.
Check flows from the main

hydraulic pump and priority flow
valve.
Binding – steering wheel does not Steering column damaged or misaligned.

centralize. Repair or replace steering column.
Serious contamination.
Clean the steering control unit
and purge the system. Repair or
replace if damaged.
Steering wheel oscillates or turns by Steering control unit improperly

itself. assembled, timing wrong. Reassemble the steering control
unit correctly.
Hoses connected improperly.

Reconnect the hoses.
Broken centering springs.

Repair the steering control unit.
Front wheels turn opposite to Hoses from the steering control unit to the
steering wheel direction. steering cylinders are connected in reverse. Reconnect the hoses.
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Torque N•m kgf•m lbf•in.

Endcap capscrews 17 1,7 150
Service Information

Components 645 Service Information 9/10/2022
Profile:
G780B Volvo
Components

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Steering control unit
1. Steering control unit assembly
2. Steering column assembly
3. Mount plate
4. End cap
5. Housing
6. Meter gear housing
7. Meter gear
8. Spacer
9. Drive coupling
10. Spacer plate
11. Retaining ring
12. Seal gland
13. Quad ring seal
14. Oil seal
15. Thrust bearing
16. Control sleeve
17. Control spool
18. Drive pin
19. Centering springs
20. Setscrew
21. Check ball seat
22. Check ball
23. O-ring
24. Check ball retainer
25. O-ring
26. O-ring
27. O-ring
28. End cap capscrews
Service Information

Steering control unit 645 Service Information 9/10/2022
overhaul procedure
Profile:
G780B Volvo
Steering control unit overhaul procedure


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Steering control unit ISO schematic
NOTE!
Thoroughly clean the steering control unit before disconnecting the hoses. This minimizes the possibility of contaminating the
hydraulic system with dirt or moisture. The steering control unit is a precision assembly and can be easily damaged by very small
contaminants or by the effects of thermal expansion.
Service Information

disassembling
Profile:
G780B Volvo
Steering control unit, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 645-032
1. Place the steering control unit housing (5) into a vise. The meter gear end of the control unit should be pointing up.
Tighten the vise sufficiently enough just to hold the steering control unit in place.
2. Remove the cap screws retaining the end cap (4). Remove the end cap from the meter gear housing (6).
3. Carefully lift off the meter gear housing (6), meter gear (7), spacer, drive coupling and spacer disc (10) and set them
aside. Remove and discard the three O-rings.
Figure 1
4. Turn the assembly over and remove the retaining ring (11).
Figure 2
5. Remove the seal gland (12).
6. Remove and discard the quad ring seal and oil seal (14).
Figure 3
7. Remove the O-ring from the housing (5). Discard the O-ring.
Figure 4
8. Remove the thrust bearing (15).

Figure 5
9. Loosen the jaws of the vise. Rotate the control assembly (16 and 17) while pulling it from the housing (5). Take care not
to force the components.
NOTE!
The heat of your hand can cause enough expansion to affect the clearance between the control assembly and housing.
If the parts become tight, allow them to cool off. Lubricate and try again.
Figure 6
10. Remove the drive pin (18).
Figure 7
11. Carefully separate the control sleeve (16) and control spool (17).
Figure 8
12. Compress and remove the centering springs (19).
Figure 9
13. Remove the setscrew and the check ball seat (21).
Figure 10
14. Remove and discard the O-rings.
15. Remove the check ball (22).

Figure 11

Ensure all oil passages are unblocked. Wrap in clean, lint-free cloth or paper and store in a cool, dry place.
A careful and thorough inspection of all parts is extremely important. If you see any evidence of damage or wear, replace all
defective items with genuine Volvo parts.
Check for the causes of defective components as replacing parts may not necessarily correct the problem.
Retain O-rings and seals only for inspection and troubleshooting purposes. You must replace all O-rings and seals when
overhauling the steering control unit.
Inspect each part for scoring, wear or pitting. Remember that the control assembly components are matched. If one of the parts
is damaged, you must replace all of them.
You can dress the mating surfaces of the body components and the meter gear using #600 grit paper laid on a flat surface or an
equivalent stone. After 6 to 10 strokes, wash the components thoroughly in fresh cleaning solvent and dry them with
compressed air. After inspection, dip all parts in system oil and set them to one side.
Service Information

assembling
Profile:
G780B Volvo
Steering control unit, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 645-034
1. Lubricate and install new O-rings on the check ball seat (21).
2. Install the check ball (22) and seat (21) in the housing (5). This procedure can be made easier if you install a machine
screw in the end of the seat.
Figure 1
3. Install the setscrew (20) and torque-tighten to 17 N•m (1,7 kg•m)(150 lbf•in.).
Figure 2
4. Install the centering springs (19) into the control spool (17).
NOTE!
The fit of the control components is critical and can be affected just by the heat of your hands.
Figure 3
5. Apply lubricant to the control spool (17) and rotate it as you install it in the control sleeve (16).
NOTE!
The fit of the control components is critical and can be affected just by the heat of your hands.
Figure 4
6. Compress the centering springs (19) into their slot.

Figure 5
7. Install the drive pin (18).
Figure 6
8. Apply lubricant to the control assembly (16 and 17). Rotate the control assembly as you install it in the control housing
(5).
NOTE!
Do not force the control assembly. If the components jam during the installation, you may permanently damage them.
Figure 7
9. Install the thrust bearing (15).

Figure 8
10. Lubricate and install a new O-ring into the housing.
11. Lubricate a new oil seal (14) and quad ring seal and install them in the seal gland (12).
12. Install the seal gland (12) and secure it with the retaining ring (11).
Figure 9
13. Turn the housing (5) over. Lubricate a new spacer disc O-ring and spacer disc (10) and install them.
Figure 10
14. Install the drive coupling (9) in the meter gear (7) so that the slot aligns with the valleys in the gear.
Figure 11
Figure 12
15. Install the coupling and gear on the spacer disc (10) so that the drive coupling (9) engages the drive pin.
16. Lubricate a new O-ring and install it on the meter gear housing (6).
17. Install the meter gear housing (6) and align the bolt holes.
Figure 13
18. Install the spacer (8).
19. Lubricate a new O-ring and install it on the end cap (4). Install the end cap and torque-tighten the cap screws to 17
N•m (1,7 kg•m) (150 lbf•in).
Install plugs into the open ports to prevent contamination.
Service Information

Steering Control Unit - 645 Service Information 9/10/2022
Bleeding Procedure
Profile:
G780B Volvo
Steering Control Unit - Bleeding Procedure


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 645-036
1. Place the grader in the Service positions. Remove the rear cover plate under the radiator grille to uncover the load
sense line quick-disconnect fitting. Start the engine when it is safe to do so and bring it up to operating temperature.
Centralize all hydraulic control levers (neutral position).
2. Connect a long hose to the load sense line quick-disconnect fitting. Place the other end of the hose in a clean container
— capacity 7,5 L (2 U.S. gal.) - partially filled with fresh hydraulic oil. Immerse the hose in the oil.
3. Bleed the steering circuit by turning the steering wheel in one direction for 5 seconds; then in the other direction for 5
seconds.
4. When the service technician is operating the steering wheel, have an assistant observe the hydraulic oil and air bubbles
flowing out of the hose immersed in the container. Continue operating the steering wheel until air bubbles cease
coming out of the hose.
5. At the end of the bleeding procedure, shut down the engine. Remove the hose at the load sense line quick-disconnect
fitting.
6. Refill the hydraulic tank to the proper level with fresh lubricant Refer toRecommended lubricants .
The steering control unit overhaul is now complete.

Test the grader to ensure there are no problems with the steering control unit functions. Check all connections for leaks.
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Torque Value N•m kgf•m lbf•ft

Cartridge 45 4,5 33 lbf•ft
Cracking pressure settings
Cracking pressure 12 MPa (117 bar)(1700 psi)

Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Crossover relief valve
The crossover relief valve is found in the steering hydraulic circuit. It contains two relief valves in one body and protects both
sides of the hydraulic circuit from high pressure spikes created by shock loads. As the pressure reaches the preset level of the
valve, the poppet pushes against the spring and moves from its seat. This allows oil to by-pass to the opposite low pressure side.
During normal operation, oil flows straight through the valve and the poppets remain seated.
Typically, the crossover relief valve pressure setting is higher than the relief valve which protects the circuit. Therefore, the
crossover relief valve must be removed from its circuit for testing. Increasing or decreasing the spring pressure on the poppet
with the adjustment screw will alter the pressure setting.
Service Information

Function 645 Service Information 9/10/2022
Profile:
G780B Volvo
Function

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The steering circuit cross over relief valve is located in the nose of the grader frame. Its function is to limit the steering system
shock load.
Figure 1
Crossover relief valve ISO schematic
Figure 2
Crossover relief valve components
1. Body
2. Adjustment Screw
3. Locknut
4. Poppet
5. Relief valve cartridge
6. To valve
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

Cylinder nut – 75 mm (3 in.) diameter cylinder 407 41 300
0.75 in. NC Piston retaining bolt – 75 mm (3 in.) diameter cylinder 461 47 340
Figure 1
- 75 mm (3 in.) hydraulic cylinder
1. Piston retaining bolt

2. Piston (includes nylon/Teflon¯ rings)
3. Cylinder barrel
4. Cylinder head
5. Wear ring
6. O-ring
7. Back-up ring
8. Rod seal
9. Rod wiper
10. Piston rod
11. Cylinder nut
12. Flat washer
Service Information

General description 645 Service Information 9/10/2022
Profile:
G780B Volvo
General description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
All models incorporate two steering cylinders for the hydraulic steering system. All models have a cylinder size of 76 mm (3 in.)
diameter cylinder barrel and 35 mm (1.38 in.) cylinder rod.
G710B to G746B
Cylinder retracted length is 536.5 mm (21.12 in.)
Cylinder extended length is 847.6 mm (33.37 in.)
G780B
Cylinder retracted length is 565.2 mm (22.25 in.)
Cylinder extended length is 876.3 mm (34.50 in.)
To check for cylinder leaks, pressure test cylinder to 19 MPa (186 bar)(2700 psi). Refer to Section 9 for hydraulic cylinder
overhaul.
Service Information

Secondary steering, 647 Service Information 9/10/2022
specifications
Profile:
G780B Volvo
Secondary steering, specifications


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Secondary steering pressure switch Configuration: NC

Setting: open at 1551 kPa (15.5 bar)(225 psi)
Relief valve setting 689 kPa (69 bar)(1000 psi)
Pump flow 18 Lpm @ 689 kPa (69 bar)
(4.8 US gpm @ 1000 psi)
Pump relief pressure 8273 kPa (82.8 bar)(1200 psi)
Service Information

description
Profile:
G780B Volvo
Secondary steering, description


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
This auxiliary hydraulic system is optional on G710B to G746B models and standard on G780B and EEC models. It allows the
operator to make steering corrections more easily in the event of loss of hydraulic flow to the steering unit. This system supplies
extra hydraulic pressure to the steering system when the pressure drops below 1551 kPa (15.5 bar)(225 psi).
Figure 1
A. Control lamp (red) primary steering system

B. Control lamp (amber) secondary steering system
C. Message display
D. Central warning lamp (red)
The secondary steering box contains the pump and motor assembly, relief valve, power relay, pressure switch and other
components. It is located at the right rear side of the grader, close to the main hydraulic tank.
The ignition key must be in the “I” position to operate the system.
NOTE!
Do not operate the secondary steering system longer than two minutes. Equipment damage will result.
Operate the system long enough only to make a steering correction - maximum two minutes.
In the event of low steering oil pressure, the Primary steering system warning lamp (A) and the Secondary steering system status
lamp (B) will illuminate, accompanied by a buzzer, message display (C), and the red central warning lamp (D).
To test the Secondary steering system:
Figure 2
Insert and turn the ignition key to the “I” position (running position).
Do not start the engine.
Depress and hold the Secondary steering test button located on the pedestal.
The Secondary steering warning lights and alarm should energize.
Check the system by turning the steering wheel. If it does not turn easily, there is a fault in the system. Have the system
repaired by a qualified Volvo service technician.
Depress and hold the Secondary steering test button only long enough only to check the system.
Start the engine. The warning lights and alarm will de-energize, indicating the system is ready if the engine stalls.
If the warning lights and alarm remain energized with the engine running, do not drive the grader. The system is faulty
and must be repaired by a qualified service technician.
Service Information

component location
Profile:
G780B Volvo
Secondary steering, component location


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
1. Secondary steering box

2. Hydraulic pump
3. Electric motor
4. Relief valve
5. Check valve
6. Pressure switch
7. Power relay (solenoid)
Secondary steering system plumbing diagram

Figure 2
1. Main hydraulic pump

2. Priority flow valve
3. Pressure test port
4. Check valve
5. Secondary steering box
6. Hydraulic tank
7. To steering control unit
Service Information

Secondary steering 647 Service Information 9/10/2022
hydraulic schematic
Profile:
G780B Volvo
Secondary steering hydraulic schematic


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1

2. Priority flow valve
4. Secondary steering unit
5. To fan control valve
6. From fan control valve
Service Information

Secondary steering 647 Service Information 9/10/2022
troubleshooting
Profile:
G780B Volvo
Secondary steering troubleshooting


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
NOTE!
For the Secondary steering electrical schematic, refer to Wiring diagram 21.

Pump will not operate – Defective relay – Check warning and power relay if energized
(Ignition switch in ON position and – Open circuit – Check fuse and all ground connections
engine off) – Faulty pressure switch – Check pressure switch
– Defective motor – Check motor and connections
Secondary steering motor and – Defective secondary steering – Replace pressure switch
warning light on during normal pressure switch – Check main hydraulic pump
grader operation – Low system hydraulic
pressure
Service Information

Hydraulic cylinder 648 Service Information 9/10/2022
specifications
Profile:
G780B Volvo
Hydraulic cylinder specifications


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

Figure 1
– 102 mm (4 in.) hydraulic cylinder shown
For 75 mm (3 in.) cylinder, refer to Specifications

2. Piston seals
3. Piston
4. Cylinder barrel
5. Cylinder head
6. Wear ring
7. O-ring
8. Back-up ring
9. Rod seal
10. Rod wiper
11. Piston rod
12. Cylinder nut
13. Flat washer
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The front wheels on a motor grader lean to counter the “side draft” which results from cutting material at one end of the
moldboard and discharging it at the other. Wheel lean is also used in steering, bank slope work and in cutting and cleaning
ditches. The wheel lean system leans the wheels 18º to the left or right from the vertical position.
G710B and G720B
These models are equipped with a single wheel lean cylinder and counterbalance valve as standard equipment. Cylinder size is
102 mm (4 in.) diameter barrel and 50.6 mm (2 in.) diameter cylinder rod.
Cylinder retracted length is 536.5 mm (21.12 in.).
Cylinder extended length is 847.6 mm (33.37 in.).
G726B, G730B, G740B, and G746B
These models are equipped with two wheel lean cylinders and counterbalance valve. Cylinder size is 76 mm (3 in.) barrel and 35
mm (1.38 in.) diameter cylinder rod.
Cylinder retracted length is 416 mm (16.38 in.).
Cylinder extended length is 614 mm (24.13 in.)
G780B
This model is equipped with two wheel lean cylinders and counterbalance valve. Cylinder size is 102 mm (4 in.) diameter barrel
and 50.6 mm (2 in.) diameter cylinder rod.
Cylinder retracted length is 511.8 mm (201.15 in.).
Cylinder extended length is 639.3 mm (25.17 in.).
To check for cylinder leaks, pressure test cylinder to 19 MPa (186 bar)(2700 psi). Refer to Section 9 for Hydraulic Cylinder
Overhaul Procedure.
It is recommended to use the wheel lean system to check main hydraulic system relief pressure. To achieve system relief, set
engine speed to low idle and bottom out wheel lean cylinders (tilt wheels to maximum position, to the left or right). Refer to
Section 9 for Specifications.
Figure 1
Wheel lean plumbing diagram
1. Main directional control valve

2. Counterbalance valve
3. Left-hand wheel lean cylinder
4. Right-hand wheel lean cylinder
5. Dual wheel lean – G726B to G780B
6. Counterbalance valve location
Service Information

Wheel lean hydraulic 648 Service Information 9/10/2022
schematic
Profile:
G780B Volvo
Wheel lean hydraulic schematic


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
See Fig. 1.
A Main hydraulic pump

B7 Main directional control valve – Section 8, wheel lean
C Priority flow control valve
F Counterbalance valve
O Wheel lean hydraulic cylinders
1. To steering control unit

2. Load sense line from steering control unit
3. Load sense from fan control valve
4. Return from circuit
Figure 1
71 - FRAME 2
74 - FRAME LINK 5
77 - WHEELS; TRACKS; TYRE; HUB; DRUM 28
Description 2
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The front frame is a fully welded box section. It carries the cab and transmission. The cab and transmission are mounted on
rubber isolators.
The rear frame is a full perimeter welded box section. The rear frame permits modular powertrain mounting for ease of service
and simplifies attachment mounting. Attachments are mounted to the frame and are not supported by a powertrain component.
Figure 1
1. Full perimeter rear frame
2. Front frame
Tightening torques 2
Articulation hinge 3
Articulation hinge – Preparation for disassembly 6
Articulation hinge; disassembling 8
Cleaning and inspection 12
Articulation Hinge; assembling 13
Articulation hydraulics 17
Articulation Indicator - Setup and Adjustment 20
Service Information

Profile:
G780B Volvo
Tightening torques

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

Upper driveshaft U-joint bolts 74 8 55
Lower driveshaft U-joint bolts 109 11 80
Upper and lower articulation hinge pin bolt 339 35 250
Service Information

Articulation hinge 740 Service Information 9/10/2022
Profile:
G780B Volvo
Articulation hinge

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Articulation hinge
1. Bearing retainer bolt

2. Upper bearing retainer
3. O-ring
4. Upper and lower pin bearing
5. Lower bearing retainer
6. Articulation cylinder bearing
7. Locking plate bolt
8. Lock washer
9. Locking plate
10. Grease fitting
11. Front pin
12. Articulation cylinder
13. Rear pin plug
14. Rear pin
15. Stop block shim
16. Nut
17. Flat washer
18. Rear frame pivot lug
19. Rear frame pivot lug
20. Lower pin bolt
21. Lower pin
22. Sleeve
23. Lower pin washer
24. Locknut
25. Upper pin washer
26. Upper pin
27. Upper pin bolt
28. Spacer
29. Spacer
30. Front frame pivot lug
31. Locking pin
Service Information

Articulation hinge – 740 Service Information 9/10/2022
Preparation for disassembly
Profile:
G780B Volvo
Articulation hinge – Preparation for disassembly


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Fabricated frame support
1. Thickness of rear frame section

2. Distance between tandem pivot stop block and bottom of frame
It is necessary to fabricate frame supports before disassembling the articulation hinge. These supports are imperative to the
safety of the technician repairing the grader and are used to prevent the rear section of the frame from tipping backward. The
following illustration shows how they are made.
The following items also are required:
Two safe stands for the front section of frame are required
Appropriate jacks and chock blocks to maneuver the frame and prevent the frame sections from moving out of position
Measure the distance between the tandem pivot stop blocks and the bottom of the frame. This is the total length of frame
support that will be required. Measure thickness of the rear frame section. This is required for width of frame support.
Installation of frame support stands
Figure 2
Installing stands under front articulation plate
moldboard onto wooden blocks. Operate the blade lift cylinders to raise the front end of the grader sufficiently enough
to place safe stands under the front articulation plate. Shut down the engine. Place two safe stands under the front
articulation plate.
Figure 3
Installing special fabricated frame support
2. Install the frame supports between the tandem pivot stop blocks and frame.
3. Start the engine when it is safe to do so. Operate the blade lift cylinders to lower the grader onto the stands. Shut down
the engine.
Service Information

Articulation hinge, 742 Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Articulation hinge, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 742-051
Tools:
Fabricated frame support
9/32 in. Socket driver
NOTE!
1. Remove the cab steps, transmission guard, cab side covers and side covers under the fuel tank.
2. Remove the drain plug on the lower left-hand side of the transmission case. Drain the oil into a suitable container with
a capacity of 38L (10 U.S. gal).
3. Disconnect the upper and lower driveshafts at the transmission yoke. It may be necessary to tie the universal joints
together to prevent them from falling apart.
4. Disconnect the articulation indicator cable from the ball joint.
5. Remove the U-bolts from under the fuel tank and at the back of the cab. Cut and remove any tie-wraps that secure the
hoses and wiring harnesses.
6. Place a container beneath the water valve. Disconnect the hoses from the valve and allow the coolant to drain out. Plug
the open ports to prevent contamination.
7. Disconnect the clutch slave cylinder line. Plug the open fittings to prevent contamination.
8. Disconnect the transmission pump supply hose and oil pressure gauge line. Plug the open fittings to prevent
contamination.
9. Disconnect the electrical junction block from under the side console. (A 9/32 in. socket driver is required for this
procedure.)
Disconnect the engine electrical harness to allow separation at the articulation hinge.
10. Open the left-hand rear access door. Disconnect the load sense line at the main hydraulic pump. Plug the open fittings
to prevent contamination. Pull the load sense line through to the front frame section.
11. Disconnect windshield washer hoses. Plug the hoses to prevent contamination. Pull the washer hoses through to the
front frame section.
12. Disconnect the differential lock/unlock solenoid valve supply hose. Plug the open fittings to prevent contamination.
Disconnect the clutch supply and vent hoses. Plug the open fittings to prevent contamination.
13. Disconnect transmission suction and clutch drain hoses. Plug the open fittings to prevent contamination.
14. Identify and disconnect the filter head and priority flow valve hoses. Plug the open fittings to prevent contamination.
15. Identify the articulation cylinder hoses and disconnect them at the counterbalance valve. The counterbalance valve is
located on the right-hand side of the frame under the cab.
16. Install a C-clamp over the ends of the articulation cylinder piston rod clevis. Remove the articulation cylinder pin locking
plate and hardware. To make the job easier, remove all paint and rust from the bottom of the articulation cylinder pins.
Using a jack and appropriate drift, push the articulation pin up and out of the pivot lug. (The purpose of the C-clamp is
to prevent the clevis spreading and binding the articulation cylinder pin or possibly breaking the clevis. Repeat this step
for the other articulation cylinder.)
Figure 1
Installing C-clamp onto piston rod clevis
17. Remove the bolts, washers and locknuts from the upper and lower pins. Discard the locknuts.
NOTE!
The lower pin uses a thick washer and the upper pin uses a thin washer. Measure the distance between the top and
bottom of the front and rear articulation frame plates (dimensions A and B in illustration). Keep this distance constant
for easier pin removal.
Figure 2
Reference dimensions between articulation frame plates
18. Place two 13 mm (1/2 in.) thick steel plates on the lower articulation frame plate, each side of the lower pin sleeve. Place
a 25 mm (1 in.) thick steel plate on top of the two plates. Place a jack on top of the 25 mm (1 in.) thick plate. Position an
appropriate drift between the jack and the upper pin. Remove the upper pin.
NOTE!
Position the jack so that jack handle protrudes out from the articulation hinge towards the tandem.
Figure 3
Hydraulic jack
19. Place an appropriate drift on top of the lower pin. DO NOT place the drift onto the lower pin sleeve. Place the jack on
top of the drift. Place a 25 mm (1 in.) thick steel plate between the jack and the upper articulation frame plate.
When the drift begins to move, check the distance between the top and bottom of the front and rear articulation frame
plates.
Use an appropriate jack under the front frame plate to keep dimensions A and B constant. Shim the safety stands if
necessary.
20. Remove the lower pin. Use an appropriate drift to remove the sleeve.
21. With both upper and lower pins removed, make sure the bearing retainers (or spacers) are not preventing the front and
rear frame sections from pulling apart. Use an appropriate, safe method to separate the front and rear sections.
22. Remove the bearing retainers and O-rings from the upper articulation plate. Remove the bearing. Remove the spacers,
bearing retainers, O-rings and bearing from the lower articulation plate. Discard the O-rings.
NOTE!
It may be necessary to heat the bearing retainer bolt heads for 10 to 15 seconds. Applying heat breaks down the
thread-locking compound resistance. This prevents the bolt heads from possibly shearing off.
Figure 4
Removing spacers from lower articulation plate
Disassembly of the articulation hinge is now complete.

Service Information

Cleaning and inspection 742 Service Information 9/10/2022
Profile:
G780B Volvo


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Clean and inspect all components. Pay special attention to bearings, spacers and any other parts that appear worn or damaged.
Replace all defective items with genuine Volvo parts. Steam clean the pivot area to remove all debris from the upper and lower
articulation plates. Use an appropriate solvent to remove residual thread-locking compound from the bearing retainer bolt
threads.
Service Information

Articulation Hinge, 742 Service Information 9/10/2022
assembling
Profile:
G780B Volvo
Articulation Hinge, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 742-053
For easier assembly, shrink the upper and lower bearings and pins. Place the bearings and pins in a deep freeze unit or dry ice.
DO NOT freeze below –54ºC (–65ºF).
1. Use an appropriate drift to install the bearings in the upper and lower articulation plates of the front frame section.
Apply grease to the bearings.
2. Apply a bead of silicon sealant (P/N 32338, `Rhodorsil' 3B or equivalent) to the mounting surfaces of the bearing
retainers. Lubricate and install new O-rings into the retainer counterbores. Install the retainers onto the articulation
plates. Apply thread-locking compound (`Loctite' 243 or equivalent) onto the retainer bolt threads. Install the bolts to
secure the retainers.
Figure 1
Installing bearing retainers onto articulation plate
WARNING
Do not remain under the machine when the engine is running.
NOTE!
Pinch zone. Do not stand between front and rear frame sections.
3. Use an appropriate, safe method to move the rear frame section close enough so that the front and rear articulation
plates overlap by 25 mm (1 in.). Block the wheels to prevent the rear frame section from moving. Install the lower pin
spacers.
4. After the lower spacers are installed, remove the blocks and slowly guide the rear frame section to align the pin holes.
Take care when moving the rear section forward to prevent “hooking” the spacers on the articulation plates.
5. Once the articulation plates are properly aligned, install the lower pin. Freeze-shrink the pin and install it using a jack
and appropriate drift. During installation, be careful to properly align the pin, spacers and bearing.
Figure 2
Installing lower pin into articulation plate
6. After installing the lower pin, check the distance between the top and bottom of the front and rear articulation frame
plates. Use an appropriate jack under the front frame plate to keep dimensions A and B constant.
Shim the safety stands if necessary.
7. Place the upper pin in the top articulation plate. Freeze-shrink the pin and install it using an appropriate hammer.
During installation, be careful to properly align the pin and bearing.
8. Install the upper and lower bolts and washers. Install the thick washer and spacer on the lower pin. Install the thin
washer on the upper pin. Install and fully tighten new locknuts.
9. Install a C-clamp over the ends of the articulation cylinder piston rod clevis. Use a hammer and appropriate drift to
install the articulation cylinder pin. (The purpose of the C-clamp is to prevent the clevis spreading and binding the
articulation cylinder pin or possibly breaking the clevis.)
Install the articulation cylinder pin locking plate and hardware. Repeat this step for the other articulation cylinder.
Figure 3
Installing articulation cylinder pin
10. Connect the articulation cylinder hoses to the counterbalance valve.
11. Connect the filter head and priority flow valve hoses.
12. Connect the transmission suction and clutch drain hoses.
13. Connect the differential lock/unlock solenoid valve supply hose. Connect the clutch supply and vent hoses.
Figure 4
Connecting differential solenoid valve and clutch lube hoses
14. Pull the load sense line through the rear frame section. Connect the line to the main hydraulic pump.
15. Pull the windshield washer hoses through the rear frame section. Connect the hoses.
16. Connect all engine electrical harnesses. Connect the electrical junction block under the side console. A 9/32 in. socket
driver is necessary for this procedure.
NOTE!
The wire tips on the junction block will bend if the harness is installed crooked.
17. Connect the transmission pump supply hose and oil pressure gauge line.
18. Connect the clutch slave cylinder line.
19. Connect the heater hoses to the heater core tubes.
20. Connect the articulation indicator cable to the ball joint.
Figure 5
Connecting articulation indicator cable to ball joint
21. Gather all hoses and wiring harnesses through two U-bolts. Install the U-bolts under the fuel tank and at the back of the
cab.
Secure the hoses and wiring harnesses with new tie-wraps. DO NOT pinch hoses.
Figure 6
Gathering hoses and wiring harnesses under fuel tank
22. Connect the upper driveshaft.

23. Connect the lower driveshaft.

Torque-tighten the bolts to 110 – 134 N•m (11 – 14 kgf•m)(81 –99 lbf•ft).
24. Refill the transmission with fresh lubricant. Refer to Recommended lubricants.
25. Start the engine when it is safe to do so. Operate the blade lift cylinders to raise the front end of the grader sufficiently
enough to remove the stands from under the front articulation plate. Shut down the engine. Remove the stands from
under the front articulation plate. Remove the safety supports from between the rear frame and the tandem pivot stop
blocks.
26. Start the engine when it is safe to do so. Operate the blade lift cylinders to lower the grader. Check for any loose
fittings, leaks, disconnected hoses or wires.
Articulate the grader to the maximum angle and check for proper routing of hoses and wires.
27. When everything is working properly, shut down the engine and place the machine in the Service positions. Install the
steps, transmission guard, cab side covers and side covers under the fuel tank.
Service Information

Articulation hydraulics 742 Service Information 9/10/2022
Profile:
G780B Volvo
Articulation hydraulics

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Specifications – Articulation cylinder
Tightening torque N•m kgf•m lbf•ft

Cylinder nut for both 813,5 83 600
114 mm (4.5 in.) and
127 mm (5 in.) diameter cylinders
Piston retaining bolt 1844 188 1360
(1.25 in. NC, both cylinders)
Cylinder specifications G710B to G726B G730B to G780B

Barrel diameter 114,3 mm 127 mm
(4.5 in.) (5 in.)
Rod diameter 50,6 mm 50,6 mm
(2 in.) (2 in.)
Retracted length 536,5 mm 536,5 mm
(21.13 in.) (21.13 in.)
Extended length 759,2 mm 759,2
(29.89 in.) (29.89 in.)
Description
All models incorporate twin articulation cylinders and a counterbalance valve for the hydraulic articulation system. To check for
cylinder leaks, pressure test cylinder to 18,6 MPa (16 bar)(2700 psi). Refer to Hydraulic Cylinder Overhaul Procedure.
The counterbalance valve relief setting is 18,6 MPa (16 bar)(2700 psi).
The articulation directional control valve section in the main directional control valve is a “motor” spool type. Flow rate is 64 L/
min (17 gpm). For overhaul procedure, refer to Main control valve overhaul procedure.
Figure 1
Articulation cylinder

2. Piston seals
3. Piston
4. Cylinder barrel
5. Cylinder head
6. Wear ring
7. O-ring
8. Back-up ring
9. Rod seal
10. Rod wiper
11. Piston rod
12. Cylinder nut
13. Flat washer
Figure 2
Articulation hydraulic circuit
1. Main directional control valve

2. Articulation valve section
3. Counterbalance valve
4. Right-hand articulation cylinder
5. Left-hand articulation cylinder
Service Information

Articulation Indicator - 742 Service Information 9/10/2022
Setup and Adjustment
Profile:
G780B Volvo
Articulation Indicator - Setup and Adjustment


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 742-054
This operation applies to machine serial numbers 35000 to 35060, excluding 35050 and 35051.
Articulation electrical schematic

designation
SE3802 Articulation sensor Std. 10 4 ohms to 18 +4, -3 ohms Front of the left-hand side
articulation hinge
Figure 1
Figure 2
The articulation indicator is basically a potentiometer that adjusts a voltage signal received directly by the articulation gauge on
the instrument panel. The signal is transferred through wires in the machine's wiring harness. The manipulation of the signal to
the gauge is controlled by the position of the indicator arm.
The gauge and indicator can be adjusted to ensure that they are relaying an accurate reading. The grader must first be parked
on a flat surface and the front and rear frames must be in straight alignment with each other. To ensure this, the distance
between the front and rear hinge plates must be the same on either side of the grader. Take measurements with a tape measure
to properly adjust the machine.
Once the grader is in proper alignment, the indicator arm must be adjusted. The needle in the instrument panel gauge must be
centered and show no degree of articulation. The positioning of the indicator arm takes place resulting from the adjustment of
the length of the linkage arm. The linkage arm is connected to the indicator arm and to the frame pivot. As the length of the
linkage changes, the indicator position changes accordingly.
The indicator arm should be adjusted to between 75 – 100 mm (3 – 4 in.) in distance between the linkage connection point and
the arm's pivot point. This must be done to ensure that the range of the indicator position falls within the actual articulation of
the machine. The longer this length is adjusted to, the greater the articulation angle limits become.
Fine-tune the setting by adjusting the indicator's mounting plate position. Loosen the mounting bolts so that the plate can be
adjusted until the gauge needle in the instrument panel is perfectly centered.
Figure 3
1. Sender – Position indicator

2. Sender mounting plate
3. Articulation indicator linkage
4. Articulation indicator electrical harness
5. Front articulation hinge plate
Wheels; specifications 2
General description – Wheels 3
Tire troubleshooting guide 5
Service Information

Wheels, specifications 770 Service Information 9/10/2022
Profile:
G780B Volvo
Wheels, specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Wheel rim bolt torque N•m kgf•m lbf•ft

All models 624 64 460
Maximum tire pressure

Maximum pressures shown are only a guideline for typically equipped machines. Consult your tire manufacturer for further
details.
Bias ply tires Radial tires

Tire size Ply Maximum pressure Tire size Maximum pressure
kpa psi kpa psi
13.00 X 24 12 241 35 13.00R24 310 45
14.00 X 24 12 241 35 14.00R24 310 45
14.00 X 24 16 301 45 16.00 X 24 310 45
15.50 X 25 12 248 36 15.5R25 248 36
16.00 X 24 12 206 30 16.00R24 310 45
16.00 X 24 16 275 40 17.50R25 310 45
17.50 X 25 12 206 30 20.50R25 310 45
20.50 X 25 12 172 25
Service Information

General description – 770 Service Information 9/10/2022
Wheels
Profile:
G780B Volvo
General description – Wheels


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The rims are a 10-hole, bolt-on type steel rim. Rims are interchangeable between the front wheels and the rear. They are
available in different sizes and types: 1-piece, 3-piece, and with offset.
Model One-piece rim Three-piece rim 25 mm 50 mm

(1 in.) Offset (2 in.) Offset
G710B – G746B Yes Yes Yes N/A
G780B N/A Yes N/A Yes
Generally, the front tires are factory mounted with the tread facing the opposite direction of the rear tires. This promotes self-
cleaning of the tire. However, the driving front wheels of an All Wheel Drive grader must have the tire tread facing the same
direction as the rear tire tread.
Figure 1
1. One-piece rim
2. Tire
3. Three-piece rim
4. Side ring
5. O-ring (tubeless tires only)
6. Lock ring
Wheel weights
Figure 2
1. Inner wheel weight

2. Outer wheel weight
Optional cast iron wheel weights are available in 2 different weights:

– Inner wheel weight is 45,4 kg (100 lb)
– Outer wheel weight is 67 kg (148 lb)
Wheel weight bolt torque N•m kgf•m lbf•ft

Inner wheel weight 583 – 651 59 – 66 430 – 480
Outer wheel weight 624 64 460
Service Information

Tire troubleshooting guide 770 Service Information 9/10/2022
Profile:
G780B Volvo
Tire troubleshooting guide


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

Tire noise, vibration of cab Tire tread hitting the road at certain Install tires with smoother tread design and
components speeds with a greater number of tread lugs
Tire bounce “Loping” Flat spot in the tire from sitting for an “Massage” flat spot out by rotating the tire 1/4
extended period of time of a turn and let sit. Repeat for 1 full rotation
before roading machine.
Incorrect tire pressure Check tire pressure when tires are cold. Add
air in 35 kPa (5 psi) increments until ride is
acceptable. Do not exceed maximum pressure.
Tire mounted improperly Check alignment of the tire bead with rim
flange. If they are not concentric, remount the
tire following the manufacturer's and safety
instructions.
Tire and rim runout Check:
Maximum acceptable radial runout of the tire
is 6 mm (1/4 in.). The acceptable lateral runout
of the tire measured at the base of the tread
lugs is also 6 mm (1/4 in.).
Radial runout is more critical to machine
vibration. Perform the following
measurements after the tires have reached
operating temperatures:
If a tire is found to have radial runout in excess
of 6 mm (1/4 in.), the rim should also be
checked for runout. Maximum acceptable rim
runout is 3 mm (1/8 in.)
If both the tire and the rim have maximum
runout, the value can reach 9,5 mm (3/8 in.).
To minimize machine bounce, mark the
position of each runout, remove the tire and
reinstall with the marks opposite to each
other.
Center wear Over inflation Measure and adjust pressure
Shoulder wear Under inflation Measure and adjust pressure
Feathered edge Incorrect toe-in; incorrect toe-out Adjust draglink toe-in. Adjust draglink toe-out.
Replace worn pivot block, bushings and
thrustwashers.
Inside tire wear Incorrect toe-out Adjust draglink. Replace pivot block bushings
and thrust washers. Repair/replace front axle
parts, worn bearings.
Outside tire wear Incorrect toe-in – Adjust draglink
– Replace pivot block bushings and
thrustwashers
– Repair/replace front axle parts
– Replace worn bushings
Scalping Combination of: Measure and adjust pressure. Use proper type
– Over inflation tire for working application.
– Wrong tire type for application
– One front tire on paved road and the
other on non-paved road
87 - AIR CONDITIONING UNIT 2
88 - INTERIOR EQUIPMENT 29
Specifications 2
Description 4
Operating principle 5
HVAC system components 7
Cab air distribution_{55-15} 12
Cab air distribution_{54-55} 14
Basic operational checks 16
Air conditioning system 17
Climate control unit electrical schematic 18
Troubleshooting guide Low pressure gauge shown on left; high pressure
gauge shown on right. 20
HVAC routine maintenance 23
Air conditioner service 25
Air Conditioning System Repairs 26
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
NOTE!
All G700B model motor graders use an R134a (non-Freon¯ refrigerant) air conditioning system. This is the only refrigerant
approved for use in these systems.
Output 7308 gram-calories (29,000 Btu)

Refrigerant charge capacity 1,7 kg (3.75 lb), R134a type
Compressor 6 cylinder, swashplate design
Compressor clutch Electromagnetic single plate dry clutch
Cylinder capacity 163 cm (10 in)
Refrigerant oil PAG oil (polyalkyleneglycol)
Compressor capacity 180 mL (6 fl oz)
System capacity 140 mL (5 fl oz) + compressor capacity
Drive belt tension
New belt (<30 min of use) 533 N (16,6 kgf)(120 lb)
Used belt (>30 min of use) 400 N (12,4 kgf)(90 lb)
Evaporator thermostat Cut out: –3ºC (26ºF)
Cut in: 2ºC (35ºF)
Pressure switch settings High: 3137 kPa (31 bar)(455 psi)
Low: 193 kPa (2 bar)(28 psi)
System refrigerant pressures

NOTE!
Use these pressure specifications for verification purposes. Charge the system by refrigerant weight only, do not use these
pressures. Extremely low system pressure indicates low refrigerant charge. Extremely high pressure indicates a blockage in the
system.
At 21ºC (70ºF)
Low 0 to 69 kPa (0 to 0,69 bar)(0 to 10 psi)
High 827 to 1068 kPa (8,27 to 10,68 bar)(120 to 155 psi)
At 30ºC (86ºF)
Low 0 to 103 kPa (0 to 1,03 bar)(0 to 15 psi)
High 1034 to 1275 kPa (10,34 to 12,75 bar)(150 to 185 psi)
Tightening torques
Compressor oil filler plug 13 – 15 N•m 1,3 – 1,5 kgf•m 9.6 – 11 lbf•ft
Compressor oil drain plug 13 – 15 N•m 1,3 – 1,5 kgf•m 9.6 – 11 lbf•ft
Center bolt, magnetic clutch 12 – 14 N•m 1,2 – 1,5 kgf•m 8.7 – 10.5 lbf•ft
Compressor mounting fasteners 47 N•m 4,8 kgf•m 35 lbf•ft
Hose fittings
No. 6 (3/8 in.) 15 – 18 N•m 1,5 – 1,8 kgf•m 11 – 13 lbf•ft
No. 8 (1/2 in.) 20 – 27 N•m 2 – 2,8 kgf•m 15 – 20 lbf•ft
No. 10 (5/8 in.) 29 – 37 N•m 2,9 – 3,7 kgf•m 21 – 27 lbf•ft
No. 12 (3/4 in.) 38 – 45 N•m 3,9 – 4,6 kgf•m 28 – 33 lbf •ft
Pressure switch 8 – 10.8 N•m 0.83 - 1.1 kgf•m 6 - 8 lbf •ft
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The G700B cab is heated and pressurized with filtered air. Air conditioning is available as an option. Outside air is drawn in
through the intake vents on the outside of the cab above the left-hand side door. This air passes through a filter, the air
conditioning evaporator, and a heater core. It then enters the cab through 6 upper and 4 lower adjustable air vents. The HVAC
(Heating, ventilation and air conditioning) unit is located below the operator's seat.
Cab pressurization is controlled by 1 single-speed fan, located between the filter and the evaporator core. It draws fresh air into
the cab and pressurizes the operator's compartment. The variable speed fans direct the temperature controlled air through the
air vents. Cab air is recirculated by drawing it back through a filter screen under the front of the operator's seat. It enters the
HVAC unit and is mixed with filtered fresh air before re-entering the cab.
The cab heating system consists of a heater core, a water valve, and a potentiometer. Turning the potentiometer controls the
motorized water valve to increase or decrease the coolant flow to the heater core, thus increasing or decreasing the heat output.
The fans, switches and adjustable air vents are common to both the heater and air conditioning systems.
The air conditioning system is a five component expansion valve design. It includes a compressor, a condenser coil, a receiver-
dryer, an expansion valve, and an evaporator coil. System controls include a fan speed switch, an air conditioning on/off switch,
and a temperature control dial. A pressure switch on the receiver-dryer protects the compressor from extreme high and low
system pressures. A thermostat and capillary tube assembly senses evaporator icing. The thermostat cycle the clutch-controlled
compressor.
Service Information

Operating principle 870 Service Information 9/10/2022
Profile:
G780B Volvo
Operating principle

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Typical air conditioning circuit
1. Thermostat
2. Evaporator
3. Blower motors
4. Expansion valve
5. Receiver - dryer
6. Desiccant
7. Pressure switch
8. Sight glass
9. Condenser fan
10. Condenser
11. Compressor
12. Low pressure vapor
13. Low pressure liquid
14. High pressure vapor
15. High pressure liquid
A. Pressure rise
B. Heat loss yields phase change (gas condenses)
C. Water removal and reserve R134a
D. Pressure drop
E. Heat gain yields phase change (liquid evaporates)
Air conditioning/refrigeration cycle

During air conditioning operation, the fixed displacement compressor pressurizes vaporized refrigerant against the restriction
created by the block-style expansion valve. The high pressure vapor (A) travels to the condenser via the pump discharge line
where air flow created by the cooling fan causes the refrigerant to become liquid (B). The high-pressure liquid travels through
the liquid line to the receiver-dryer where it is filtered and reserve R134a is stored (C). It then passes through another liquid line
to the expansion valve. The expansion valve creates a pressure drop across a variable orifice (D). The now low-pressure liquid
expands into the larger volume of the evaporator. Large quantities of heat from the air forced across the evaporator by the
blower motors cause the refrigerant to become a low-pressure vapor (E) before returning to the compressor.
G700B Refrigerant system operation
The evaporator and condenser are heat exchangers within the HVAC system. The evaporator is located inside the HVAC unit
under the operator's seat deck. The condenser unit is located below the cooling module hood. An engine-mounted compressor
circulates refrigerant between the two heat exchangers within a sealed circuit.
The air conditioning system removes heat from the air in the operator's cab and disperses it into the surrounding atmosphere.
As cab temperature is lowered, the humidity level in the cab is reduced as moisture from the air condenses on the cold fins of
the evaporator. Three drain hoses direct condensation out of the cab.
The HVAC unit draws air through the cold evaporator (where the refrigerant is under low pressure) and removes heat energy by
absorption. Heat energy is then dispersed into the atmosphere by the condenser, which receives air flow from the electric fans.
Service Information

HVAC system components 870 Service Information 9/10/2022
Profile:
G780B Volvo
HVAC system components


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Right-side console
1. Ignition switch
2. Accessory relay
3. Temperature control switch (potentiometer)
4. Heater switch
5. Air conditioning switch
1. Ignition switch
The ignition switch is found on the right-hand console. It provides battery voltage to activate the accessory relay in the
on “I” or “R” (radio) position.
2. Accessory relay
The accessory relay is found in the right-hand console. It provides fuse controlled battery voltage to the heater switch
and high speed fan relay.
3. Temperature control switch potentiometer
– The potentiometer is a variable 10K ohm resistor.
– The center terminal is the potentiometer slider.
– The blue wire is the 24 volt +
– The black wire is the 24 volt –
– A variable resistance of 0 to 10 K ohm can be measured across the center terminal and either outside terminal for
operational value check.
– A maximum 10K ohm value will be measured across the outside (blue and black) wire terminals.
4. Heater switch
The heater switch provides fused battery voltage to:
– The air conditioning on/off switch, in all fan speed positions.
– The cab pressurizer fan, in all fan speed positions.
– The recirculating fans, in all fan speed positions.
– The potentiometer assembly, in all fan speed positions.
5. Air conditioner switch
The air conditioning switch provides fused battery voltage to:
– The temperature switch.
- The condenser fans.
– The low/high pressure switch.
– The air conditioning compressor clutch coil.
The temperature switch (evaporator thermostat) and low/high pressure switch are connected in series with the A/C
compressor clutch.
Figure 2
Cab heater and air conditioner
1. Casing assembly
2. Evaporator coil cover
3. Heater coil cover
4. Filter assembly
5. Blower holder
6. Cover
7. Inside cover
8. Bracket
9. Cover
10. Relay cover
11. Heater hose
12. Straight splicer
13. Cab air distribution fan
14. Cab air distribution fan
15. Pressurizer fan
16. Evaporator coil
17. Block valve
18. O-ring
19. Heater coil
20. Motorized water valve
21. Heater hose
22. Band clamp
23. Thermostat
24. 24V relay
25. 24V resistor
26. Drain hose
27. Drain Valve
1. HVAC unit
The HVAC unit is located under the operator's seat floor plate. It contains the following components:
– single-speed pressurizer fan and resistor
– two variable speed distribution fans and resistors
– high speed fan relay, wiring junction bar and wiring
– evaporator temperature thermostat
– evaporator core
– heater core
– air filter
2. Evaporator thermostat
The evaporator thermostat is located inside the HVAC unit, near the right-hand end of the evaporator coil.
The thermostat is used to prevent icing of the evaporator coil by cycling the compressor clutch. Temperature settings
are -3ºC (26ºF) cut-out and 2ºC (35ºF) cut-in.
Battery voltage is supplied from the air conditioning switch. Battery voltage “out” feeds the pressure switch. With the
switch open, the voltage supply to the pressure switch is interrupted and the compressor clutch is disengaged.
Figure 3
Motorized water valve (top view)
1 Clockwise to OPEN position

2 Counter clockwise to CLOSE position
A To engine
B From engine
C From heater coil
D To heater coil
3. Motorized water valve

The motorized water valve is mounted externally at the right, rear of the heater/air conditioner assembly. It controls the
flow of hot engine coolant to the heater core by rotation of an internal butterfly valve. Movement of the valve allows
engine coolant to circulate through or to bypass the heater core.
The valve position is indicated by the external slots in the valve shaft actuator hub relative to the four reference marks
on the side cover.
Verify valve operation as follows:
– Turn the ignition key on to the “R” or “I” position.
– Turn the heater fan switch to the low speed position.
– Turn the temperature control dial to the maximum cold position, the valve shaft should rotate counterclockwise to
position 2.
– Turn the temperature dial to the maximum heat position, the valve shaft should rotate clockwise to position 1.
4. Pressurizer fan
The pressurizer fan is mounted inside the heater/air conditioner box between the internal air filter and the evaporator
core.
It draws fresh outside air through the cab air filter(s) and pressurizes the cab. The resistor is a 4.5 ohm value to maintain
fan speed at a constant low speed.
5. Cab air distribution fans and resistors
The cab air distribution fans are mounted inside the heater/air conditioner box assembly between the heater core and
front heater box panel.
The air distribution fans draw a mixture of fresh outside air and recirculated cab air through the evaporator core, heater
core and then supply it to the cab through distribution vents.
For low speed operation, the fan switch supplies 24 volts to the 4.5 ohm circuits of the resistors and on to the fan
distribution motors.
For medium speed operation, the fan switch supplies 24 volts to the 1.4 ohm circuits of the resistors and on to the fan
distribution motors.
For high speed operation, the fan switch supplies a 24 volt signal feed to the high speed fan relay. The relay closes and
fused voltage from the accessory relay is supplied to the distribution fans.
Pressure switch
The pressure switch is installed on the receiver/dryer. It safeguards the compressor against extreme high and low pressures.
The pressure switch is closed when pressures are within the limits and open when pressures are out of range. With the switch
open, the voltage supply to the compressor clutch is interrupted and the compressor will not be driven.
Magnetic clutch
The magnetic clutch is mounted on the air conditioning compressor. It operates on 24 Volts, 3.75 amperes (maximum draw).
When energized, it connects the drive pulley to the compressor.
Service Information

Cab air distribution 870 Service Information 9/10/2022
Profile:
G780B Volvo
Cab air distribution


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
– Machine S/N 35061 and up, including 35050 and 35051

Upper level vents
Figure 1
1. Upper level vents

2. Recirculation vents
On cabs that have the pressurized system, vents are mounted in the upper door posts. The high profile cab has three vents, one
facing forward and two facing center/rearward. The low profile cab has two vents, one facing forward and one facing center/
rearward.
Recirculation vent louvers should be closed for defrosting.
Figure 2
1. Mid-level vents
2. Floor level vents
3. Recirculation vent and screen
Mid level vents

These vents are mounted on the seat deck (1). They face forward and rearward.
If the system has the pressurized option installed, the left-hand mid level vent is replaced by the side console (2). One vent is
mounted on the inner facing console wall, and another is mounted on the rear cab wall.
Recirculation vents and screen
The recirculation vents and screen (3) provide an intake for cab air to be recirculated through the evaporator and heater cores.
The vent below the seat has a washable electrostatic filter mounted in the inlet screen.
Air can also be recirculated through the intake tube vents on the left-hand door post (see illustration above). With the vents
closed, more outside air is drawn into the cab. This position is used for normal winter and summer operation. With the vents
open, intake air is a mix of inside and outside air. This allows more cab air to be recirculated through the evaporator to cool the
cab quicker.
Service Information

Cab air distribution 870 Service Information 9/10/2022
Profile:
G780B Volvo
Cab air distribution


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
– Machines S/N 35000 to 35060, excluding 35050 and 35051

Upper vent louvers
Figure 1
These louvers are mounted in the upper door post vents. The high profile cab has three louvers: one facing forward and two
facing center/rearward. All louvers are installed to close in the downward position. The low profile cab has two louvers, one
facing forward and one facing center/rearward. Both louvers are installed to close in the downward position.
Figure 2
1. Mid-level vents
2. Floor level vents
3. Recirculation vent and screen
Mid level vents

These vents are mounted on the seat floor (1). Both of these vents face rearward and close towards the outside of the cab.
If the left-hand side console option is installed, the L.H. louver is mounted on the inner facing console wall. The louver closes in
the upward position.
Floor level vents
These vents are mounted in the seat riser panel, one per side (2). The two louvers for the floor level vents close towards the
outside of the cab.
Recirculation vent and screen
The recirculation vent and screen provide an air intake for cab air to be recirculated through the evaporator and heater cores (3).
A washable foam filter is mounted in the inlet screen.
Service Information

Basic operational checks 870 Service Information 9/10/2022
Profile:
G780B Volvo
Basic operational checks


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Before attempting any service procedure or performance check, follow these operational checks:
1. The machine will be operated during system evaluation. Ensure engine fluid levels and condition will support testing.
2. Operate the engine to ensure it will reach operating temperature for normal heating system operation.
3. Inspect the fresh air filter(s) before proceeding with any operational test to ensure adequate air flow to the cab.
4. Perform a thorough visual inspection of air conditioning refrigerant system components for signs of refrigerant oil
leakage or physical damage.
5. Heater only systems: operate blower fans at all speeds; slowly cycle temperature potentiometer from cold to hot to
check heater valve operation.
6. Heater/Air conditioning systems: operate blower fans at all speeds; slowly cycle the temperature potentiometer from
hot to cold to check heater valve operation.
7. Visually identify compressor clutch engagement. If suction line (refrigerant return) is not cold to the touch within 1 to 2
minutes of compressor operation, shut system down to avoid component damage.
Service Information

Air conditioning system 870 Service Information 9/10/2022
Profile:
G780B Volvo
Air conditioning system


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Checking performance
WARNING
Beware of rotating parts. Keep a safe distance.
NOTE!
Take care to avoid moving any levers and controls by accident and make sure to warn persons in the area. Put the machine in
the Service positions before starting any of these procedures.
Required tools and equipment:

– Stick-type dial thermometer or digital thermometer.
Test the system performance at least once a year.
1. Operate the engine to bring it to its normal operating temperature.

2. Park the grader with the cab in the shade and leave the engine running. Measure and record the ambient air
temperature and relative humidity.
3. Set the cab fan speed to the maximum setting and the temperature selector to maximum cooling setting.
4. Close all windows and doors on the machine.
5. Turn on the air conditioning system and check to see that the compressor clutch engages.
6. With the engine at high idle, operate the system for ten minutes and measure the temperature of the cooling air at the
seat deck riser vent.
7. Inspect for any evidence of leakage, repairing the system immediately if a leak is found.
8. If the performance test results are not satisfactory, refer to Troubleshooting guide Low pressure gauge shown on left;
high pressure gauge shown on right.
9. During measuring, the lower vent temperature should drop to the range of 1ºC to 14ºC (34ºF to 58ºF).
NOTE!
The vent temperature will vary with humidity and ambient temperature readings.
NOTE!
Shut off the air conditioning system immediately if the clutch engages but the suction line to the compressor is not cold in 1 to 2
minutes. Continued operation in this condition can damage the compressor.
Service Information

Climate control unit 870 Service Information 9/10/2022
electrical schematic
Profile:
G780B Volvo
Climate control unit electrical schematic


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

designation
FU10 Condenser fan fuse Opt. 20 A Fuse panel, convenience center
FU11 Heater fuse Opt. 25 A Fuse panel, convenience center
FU12 Air conditioner fuse Opt. 25 A Fuse panel, convenience center
MA8701 Compressor solenoid Opt. Single plate dry clutch Right-hand side, rear of engine
24 VDC, 3.75 A max. compartment at compressor
CW/CCW
MA8702 Climate unit valve Opt. Motor: 12V nominal, 0.5 amps Climate control box unit
Pinout: 7 - ground
8 - Input
10 - Ignition
5, 6, 9 not used
MO8701 Condenser fan Opt. Current = 17 A at 27V At condenser, rear of grader
Capacity: 30,000 Btu/h at 38 ºC
(100ºF) air temperature. Ball
bearings and long life brushes
RE8701 Condenser relay Opt. Single pole, single throw
RE8702 Climate control unit Opt. Single pole, single throw Inside climate control box,
high speed fan relay underneath operator seat
SW8701 Heater fan speed Opt. 4 position, 3 pole Side console switch plate
switch single throw, NO (off)
SW8702 Heater temperature Opt. Potentiometer Side console switch plate
control 10 kohms
SW8703 AC on/off switch Opt. Single pole, single throw, double Side console switch plate
LED
SE8701 AC temperature Opt. Cold cut out: –3.3ºC (26º F) Inside climate control box unit
SE8702 AC pressure sensor Opt. Limiting high pressure: 2648 kPa Front left-hand side of engine
(26.5 bar)(384 psig) compartment at receiver/dryer filter
Limiting low pressure: 193 kPa (1.9
bar)(28 psig)
MO8702 Climate control box Opt. 2, 3-speed recirculation fan Inside climate control box unit
1 pressurizer fan motor – 24 V, 5 A
Wiring diagram 22 - Climate control system
Figure 1
Service Information

Troubleshooting guide Low 870 Service Information 9/10/2022
pressure gauge shown on
left; high pressure gauge
shown on right.
Profile:
G780B Volvo
Troubleshooting guide Low pressure gauge shown on left; high pressure

gauge shown on right.

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
System pressure relationships
Figure 1
Normal system
Condition Action
Normal system Touch test. High side components should feel hot to touch.
Low side line at compressor should feel cold.
Figure 2
System empty, both gauges at 0
Condition Action
System empty Pressurize system to 1379 kPa (14 bar)(200 psi) with inert gas (nitrogen). Listen for
leaks. Use soap solution on accessible areas. Repair leaks before proceeding.
IMPORTANT! Do not use shop air.
Figure 3
Internal compressor mechanical fault. Both gauges at equal pressure. Compressor clutch energized with air conditioner switch.
Condition Action
Internal compressor mechanical fault Replace compressor, receiver-dryer, and expansion valve.
Flush, discharge liquid lines and condenser with approved solvent.
Dispose of solvent in an approved manner.
Figure 4
Air in system. Both gauges reading high.
Condition Action
Air in system Occurs usually after system service.
Evacuate for at least 30 minutes. If possible, recharge system from virgin source.
Perform air purge on recovery equipment.
System pressure relationships
Figure 5
System overcharge; condenser air flow restricted. Both gauges read high.
Condition Action
1. System overcharge Recover refrigerant from system. Use recovery machine weigh scale to confirm
charge.
2. Condenser air flow restricted Clean condenser fins. Ensure no debris exists between condenser and radiator.
Figure 6
System undercharge; system restricted. Both gauges read low.
Condition Action
1. System undercharge Visual inspection. Leak test with approved leak detector. MInimum 345 kPa (3,4 bar)
(50 psi).in system at rest at minimum 15.5ºC (60ºF).
2. System restricted Use touch test. All high pressure side components should feel hot to touch.
Usual causes: expansion valve, receiver-dryer restriction.
Figure 7
Expansion valve stuck open. High side gauge reads low; low side gauge reads high.
Condition Action
Expansion valve stuck open Replace expansion valve. Replace receiver-dryer as preventive maintenance.
Service Information

HVAC routine maintenance 870 Service Information 9/10/2022
Profile:
G780B Volvo
HVAC routine maintenance


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Compressor seals can dry out and leak if the compressor is not used periodically. To prevent the seals from drying out, operate
the air conditioner at least five minutes at each engine oil change (or once a month) – even in the winter months.
Perform a visual inspection for:
1. Loose electrical connections

2. Damage to components
3. Damage to refrigerant or coolant hoses
Figure 1
Internal cab air filter

This filter is found on the external left-hand side of the cab behind the door. Remove the panel. Turn the wing nuts to open the
filter compartment.
To service the internal cab air filter, remove the lower left-hand side panel, unlatch the access door and pull the filter outward.
Clean or replace the filter as required. Check weekly, or more often in dusty environments.
Vacuum the filter area as required, reassemble.
Figure 2
External cab air filter

The optional external cab air filter is mounted on the outside of the cab above the left side door.
Remove the two grill retainer bolts, lower the grill and remove the filter assembly. Clean, inspect and replace the filter as
necessary.
Figure 3
Recirculation vent filter

Remove the recirculation vent screen to remove the foam filter. Wash or clean as necessary. Inspect for damage or tears. Replace
as necessary.
Drain hose valves
The drain hose valves are located on the bottom of the HVAC unit. They are accessible from underneath the cab.
Check drain hose valves for restriction, sticking or sealing. Clean or replace the valves and hoses as necessary.
Service Information

Air conditioner service 870 Service Information 9/10/2022
Profile:
G780B Volvo
Air conditioner service


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The most common air conditioning problems are caused by moisture in the refrigerant and refrigerant leakage. Moisture in the
refrigerant will cause ice to form and block the expansion valve. Working in a clean, dry environment and completing repairs
quickly can reduce the risk of introducing moisture into the system. Store compressor PAG (polyalkyleneglycol) oil in a sealed
container to prevent it from absorbing moisture. Do not remove plugs and caps from new components until they are ready for
connection. Do not clean components with compressed air.
1. Inspect lines and fittings for leakage and external damage.

2. Check the operation of the cab switches and controls.
3. Inspect the electrical connections and wiring for damage and poor connections.
4. Make sure there is no restriction in the evaporator drain tube.
5. Check to see that the cab air filter is not plugged. Remove the filter and clean it if necessary. Replace the filter if it is
damaged.
6. Carefully inspect all components if there has been damage from a collision. Pay special attention to soldered joints.
Replace any bent or cracked pipes, do not attempt to repair them. If there is evidence that a component has become
contaminated, it must be thoroughly cleaned and inspected before it is reused.
NOTE!
Replace the receiver-dryer unit whenever major repairs are made, components are changed, or if there is evidence of moisture in
the system.
Service Information

Air Conditioning System 870 Service Information 9/10/2022
Repairs
Profile:
G780B Volvo
Air Conditioning System Repairs


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 870-002
Tools
11666070 Volvo charging/discharging station
11666072 Volvo 4-way pressure gauge
11666074 Volvo electronic weigh scale
The following procedures are written using the above tools. Procedures for equipment other than those listed may differ. Refer
to specific equipment instructions.
Refer to Safety when working with air-conditioning refrigerantin the Safety section of this manual.
WARNING
R134a is moderately dangerous to one’s health. When handling refrigerant, wear close-fitting goggles and protective
gloves. In liquid form refrigerant can cause frost-bite and when in the form of a gas at high concentration it has an
anaesthetising effect and at lower concentration it primarily affects the nervous system.
NOTE!
R134a refrigerant was developed as a less environmentally damaging alternative to the R12 Freon¯-type used on earlier systems.
While R134a does not harm the earth's ozone layer, it does contribute to the greenhouse effect. Like R12, it must not be
intentionally released into the atmosphere.
WARNING
Equipment intended for use on R12 systems must not be used for R134a systems, except for the vacuum pump.
Refrigerants R12 and R134a must never be mixed as this will cause compressor breakdown.
WARNING
R134a is hazardous to personal health
NOTICE
Refrigerant under pressure. Do not disconnect any hoses or connections on the air conditioning, thereby involuntary
releasing refrigerant.
WARNING
R134a will easily cause frostbite if it comes into contact with bare skin. Therefore, the following safety instructions must
be followed whenever handling refrigerant.
In case of exposure to R134a refrigerant:

If it is suspected refrigerant has escaped, all persons in the area should move away into the fresh air. Avoid inhaling R134a
refrigerant. In case of skin contact with R134a liquid, rinse the frostbitten area immediately with lukewarm water. If the contact
area was extensive, warm clothing should be used along with lukewarm water to reduce frostbite damage to the skin. Seek
medical attention. In case of eye contact with R134a liquid, rinse the eyes with clean, lukewarm water until the irritation is
relieved. Seek medical attention.
Recharging
NOTE!
If the system must be recharged in cold weather, use warm water at a temperature of no more than 40ºC (104ºF) to pour over
refrigerant cylinders. Never heat refrigerant containers directly. Do not put the charge valve in the warm water. Do not use
refrigerant containers that have been damaged or dented. Never store refrigerant containers in direct sunlight or where
temperatures can exceed 40ºC (104ºF).
1. Operate the grader and bring the engine to its normal operating temperature.
2. Park the grader in safe location, free of obstructions. Place it in the Service positions.
3. Install the Volvo charging/discharging station and evacuate and reclaim the existing refrigerant from the system.
4. Check all air conditioning hoses for kinks or tight bends, especially at the compressor and correct any plumbing
problems before proceeding.
5. Pressure test the system with dry nitrogen to verify that it will hold a pressure of 1380 kPa (13,8 bar)(200 psi) for at least
15 minutes (or longer if that is practical). Use a digital pressure gauge that is capable of reading 0.69 kPa (0,007 bar)(0.1
psi) and an electronic leak detector.
6. Evacuate the system and verify that it will hold a vacuum for at least 30 minutes (one hour in high humidity).
7. Recharge the system with the specified amount of new R134a refrigerant.
8. Install the Volvo 4-way pressure gauge. Start the engine and air conditioning system.
9. Operate the engine at maximum rpm and record the low and high system pressures (see Specificationsfor specific
ambient temperatures).
10. Operate the engine and air conditioning system for 10 minutes to stabilize the refrigerant in the system.
11. Test the operation of the system and verify that it is cooling properly.
Description 2
Control levers; disassembling 6
Control Levers - Cleaning and Inspection 9
Control levers; assembling 10
Pedestal Locking Strut - Setup 12
Locking Strut - Troubleshooting 13
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
The pedestal design allows it to tilt 20º from vertical towards the operator. A locking strut permits movement of the pedestal for
fore and aft adjustment. The tilt pedal is located at the bottom of the pedestal between the clutch and the brake pedals.
Depressing the pedal opens the lock valve in the tip of the locking strut cylinder rod allowing the strut to adjust. Releasing the
pedal locks the valve to engage and hold the pedestal in the selected position.
Short-throw hydraulic control levers are mounted on the pedestal and move with it as it is adjusted. The jointed control rods
connect directly to the main hydraulic control valve outside of the cab.
Figure 2
Pedestal control levers and linkage
1. Locknut
2. Control lever shaft
3. Thrust bearing - thin
4. Bushing - control lever
5. Control lever
6. Knob - control lever
7. Jam nut
8. Rod nut
9. Bolt
10. Thrust bearing - thick
11. Jam nut
12. Upper control rod
13. Lower control rod
14. Bolt
15. Flat washer
16. Shaft - bell crank
17. Thrust bearing
18. Bushing - bell crank
19. Bell crank
20. Rod nut
21. Jam nut
22. Shoulder bolt
23. Clevis end
24. Locknut
Figure 3
Pedestal locking strut and foot pedal
1. Shoulder bolt
2. Locknut
3. Flat washer
4. Pedestal locking strut
5. Pedestal
6. Foot pedal
7. Rear support frame
8. Locking strut valve actuator pin
9. Jam nut
10. Bottom of actuator groove
11. Bottom of pedal lever
Service Information

Control levers, 881 Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Control levers, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 882-001
NOTE!
1. If any control lever knobs are damaged, loosen the jam nut and remove the knob.
2. Remove the bolts connecting the rod ends to the control levers. Remove and discard the control lever shaft locknut.
Remove the thrust bearings and control levers. Inspect the control lever bushings.
Figure 1
Inspecting control lever bushing
3. Loosen the jam nuts and remove the rod ends.
4. Remove the brake and clutch pedals. Remove the floor mat and floor plates. Remove the upper and lower front covers.
5. On the base side plates, remove the four upper bolts and lock washers. Loosen the two lower bolts.
Figure 2
Removing base side plate bolts
6. Remove the shoulder socket head bolts connecting the lower control rods to the control valve spools. Discard the lock
nuts. Remove the two rod grommet covers.
Figure 3
Disconnecting lower control rods from control valve spool
7. Use pry bars to move the base side plate and pedestal assembly out of the cab mount far enough to install bolts and
flat washers into the bell crank shaft. Using a piece of wood (to slide the assembly on), lift the assembly and move it
toward the operator's seat. This should be sufficient to reach the lower control rod retaining rings.
8. Move the steering column to its most extended position. There is now enough room to work on the lower control rod
bell cranks.
9. Loosen the bolts and flat washers that were installed on the bell crank shaft. Using an appropriate tool, remove the
retaining rings from each bell crank. Discard the retaining rings. Disconnect both the upper and lower control rods from
the bell cranks. Remove the control rods.
NOTE!
Keep the control rods in their sequence during disassembly. The control rods fit only one way.
Figure 4
Removing retaining rings from bell cranks
10. Use a plastic mallet to remove the base side plates and shims. Remove the bell cranks and thrust bearings. Inspect the
bell crank bushings and all contact surfaces.
Figure 5
Control rod sequence
Service Information

Control Levers - Cleaning 881 Service Information 9/10/2022
and Inspection
Profile:
G780B Volvo
Control Levers - Cleaning and Inspection


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Clean and inspect all components. Pay special attention to bushings. If there is evidence of damage or wear, scratching or
pitting, replace all defective items with genuine Volvo parts.
Service Information

Control levers, assembling 881 Service Information 9/10/2022
Profile:
G780B Volvo
Control levers, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 882-003
1. Install the bell cranks and thrust bearings. Install two bolts and washers to compress the bell crank and thrust washer
assemblies onto the shaft. Position the shaft as best as possible so that an equal length appears on both sides of the
pedestal centerline.
2. Position the base side plates and shims onto the pedestal assembly. Remove the bolts and washers compressing the
bell crank and thrust washer assemblies. Maneuver the pedestal assembly to roughly align the attachment bolt holes.
Figure 1
Compressing bell crank and thrust washer assemblies
3. Use an appropriate drift to align the upper bolt holes with the holes in the base side plates (align one side at a time).
Install the four bolts and washers. Tighten the six bolts to secure the base side plates.
Figure 2
Aligning pedestal assembly and base side plate bolt holes
4. Working from the center to the outside, install the upper and lower control rods. Secure the control rods with new
retaining rings.
5. Connect the lower control rods with the control valve spools. Install the shoulder socket head bolts and new lock nuts.
Install the two rod grommet covers.
6. Install the control levers and thrust bearings in their proper sequence on the shaft. Install a thick thrust bearing,
followed by a control lever and a thin thrust bearing.
7. Install a new locknut on the control lever shaft. Tighten the nut, then back it off two flats.
8. Install the rod ends. Do not tighten the jam nuts. Install the bolts connecting the rod ends to the control levers. Install
the control lever knobs in their proper sequence. Tighten the jam nuts.
9. Align the control arm levers in line with one another. To do this, turn the rod end clockwise (to lower) or
counterclockwise (to raise). Tighten the jam nuts.
NOTE!
The control levers must move freely.
Figure 3
Adjusting rod ends to align control levers
10. Install the upper and lower front covers. Install the floor plates and floor mat. Install the brake and clutch pedals.
Service Information

Pedestal Locking Strut - 881 Service Information 9/10/2022
Setup
Profile:
G780B Volvo
Pedestal Locking Strut - Setup


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 882-004
1. Place the pedal into the actuator head as shown.
2. The bottom of the pedal lever should be flush with the bottom face of the actuator head groove.
3. Screw the locking strut into the actuator head until the actuator pin makes contact with the bottom of the pin capture
section of the pedal lever.
4. When this position is achieved, rotate the locking strut toward the pedal 1/2 turn maximum, so the upper lug will be in-
line with the mounting lug on the rear support beam.
5. Apply a drop of Loctite to the threads just above the actuator head and tighten the jam nut. Ensure the Loctite does not
enter the pedal lever groove as this will affect proper pedal function.
Service Information

Locking Strut - 881 Service Information 9/10/2022
Troubleshooting
Profile:
G780B Volvo
Locking Strut - Troubleshooting


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 882-005
If the pedestal will not tilt, the following conditions indicate the locking strut has failed. In both cases the locking strut must be
replaced:
1. Pedestal will not move (locking strut valve will not open).
2. Pedestal can be adjusted to new position, but will not stay there (locking strut valve opens but will not lock).
90 - GENERAL 2
91 - WORKING HYDRAULIC; SERVO HYDRAULICS 30
92 - MECHANICAL EQUIPMENT_ATTACHMENT 184
98 - FUNCTION FOR ROAD CONSTRUCTION 206
Main hydraulic schematic; EEC float valves – Sheet 4 - Image 2
Main hydraulic schematic; EEC – Sheet 3- Image 3
Main hydraulic schematic; float valves – Sheet 2 - Image 4
Main hydraulic schematic - sheet 1 - Image 5
Main hydraulic schematic - sheet 1 6
Main hydraulic schematic; float valves – Sheet 2 10
Main hydraulic schematic; EEC – Sheet 3 13
Main hydraulic schematic; EEC float valves – Sheet 4 16
Specifications- 19
Description- 20
Hydraulic components; location 22
Hydraulic system troubleshooting guide 25
Service Information

Main hydraulic schematic - 900 Service Information 9/10/2022
sheet 1
Profile:
G780B Volvo
Main hydraulic schematic - sheet 1


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
A. Main hydraulic pump

B. Main directional control valve
B1 Left blade lift

B2 A-frame
B3 Blade slide
B4 Blade tilt
B5 Circle turn
B6 Circle side shift
B7 Articulation
B8 Wheel lean
B9 Scarifier
B10 Right blade lift
C. Priority flow control valve

D. Steering control unit
E. Counterbalance valve
F. Steering cylinders
G. Fan control valve
H. Fan hydraulic motor
I. Load sense relief valve
J. Secondary steering (optional on G710B to G746B; standard on G780B and EEC machines)
K. Hydraulic filter
L. Cooler
M. Circle turn valve
N. Swivel valve
O. Hydraulic oil tank
P. Auxiliary valve pressure connection
Q. Float valve drain connection
R. Auxiliary valve return connection
S. Return line filter
TP = Test port
TO = Optional
TC = Required with secondary steering
1. Left-hand blade lift cylinder

2. A-frame lift cylinder
3. Blade slide cylinder
4. Blade tilt cylinder
5. Circle turn cylinder
6. Circle shift cylinder
8. Wheel lean cylinder
9. Scarifier cylinder
10. Right-hand blade lift cylinder
Main hydraulic schematic - Sheet 1

Figure 1
Service Information

Main hydraulic schematic, 900 Service Information 9/10/2022
float valves – Sheet 2
Profile:
G780B Volvo
Main hydraulic schematic, float valves – Sheet 2


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

B1 Left blade lift

B2 A-frame
B3 Blade slide
B4 Blade tilt
B5 Circle turn
B7 Articulation
B8 Wheel lean
B9 Scarifier

E. Crossover relief valve
F. Counterbalance valve
G. Steering cylinders
H. Fan control valve
I. Fan hydraulic motor
J. Load sense relief valve
K. Secondary steering (optional on G710B to G746B; standard on G780B)
L. Hydraulic filter
M. Hydraulic oil cooler
N. Circle turn valve
O. Swivel valve
P. Hydraulic oil tank
Q. Auxiliary valve pressure connection
R. Float valve drain connection
S. Auxiliary valve return connection
T. Float valve (optional; replaces F on sections B1, B2, and B10)
TP = Test port
TO = Optional
TC = Required with Secondary steering

Main hydraulic schematic, float valves – Sheet 2

Figure 1
Service Information

EEC – Sheet 3
Profile:
G780B Volvo
Main hydraulic schematic, EEC – Sheet 3


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

B1 Left blade lift

B2 A-frame
B3 Blade slide
B4 Blade tilt
B5 Circle turn
B7 Articulation
B8 Wheel lean
B9 Scarifier

F. Counterbalance valve (EEC version)
K. Secondary steering
L. Hydraulic filter
O. Swivel valve
TP = Test port
TO = Optional

Main hydraulic schematic, EEC – Sheet 3

Figure 1
Service Information

EEC float valves – Sheet 4
Profile:
G780B Volvo
Main hydraulic schematic, EEC float valves – Sheet 4


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

B1 Left blade lift

B2 A-frame
B3 Blade slide
B4 Blade tilt
B5 Circle turn
B7 Articulation
B8 Wheel lean
B9 Scarifier

F. Counterbalance valve (EEC version)
K. Secondary steering
L. Hydraulic filter
O. Swivel valve
T. Float valve (optional; replaces F on sections B1, B2, and B10)
TP = Test port
TO = Optional

Main hydraulic schematic, EEC float valves – Sheet 4

Figure 1
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
General
Type of system Closed-center, load sensing

Maximum system pressure 17,2 MPa (172 bar)(2500 psi)
Type of hydraulic pump Pressure and flow compensating (load sensing) variable
displacement piston pump
Pump displacement 130 cc (7.93 in) per revolution
Available pump flow@2200 rpm 284 Lpm (75 gpm)
Pressure compensator setting 18,6 MPa (186 bar)(2700 psi)
Differential pressure setting 2413 kPa (24 bar)(350 psi)
Standby pressure (varies with fan speed)
Fan speed at 550 rpm 3447 – 4137 kPa (500 – 600 psi)
Fan not connected 2413 kPa (350 psi)
External load sense relief valve setting 17,2 MPa (172 bar)(2500 psi)
Fan motor Fixed displacement, vane motor
Fan motor displacement 45 cc (2.75 in) per revolution
Minimum fan speed 550 rpm (nominal)
Maximum fan speed 1750 rpm (nominal)
Hydraulic filter 10 micron absolute – 2 micron nominal
Capacities
Hydraulic system, total 210 L (55.5 US gal)

230 L (60.8 US gal) AWD models
Hydraulic tank 134 L (35.4 US gal)
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The G700B Model motor graders use a closed center, open loop hydraulic system that senses load requirements and maintains
system pressure at 2413 kPa (24 bar)(350 psi) above load.
Hydraulic oil tank
The hydraulic oil tank is the reservoir for all hydraulic oil requirements of the grader. It is mounted at the back of the grader
below the cooling module to supply the main hydraulic pump and the optional All Wheel Drive system. The angled tank floor
maximizes ground clearance, speeds up oil draining, and allows settling of metal contaminants close to the magnetic drain plug.
A breather and level dipstick are incorporated into the filler cap. A temperature sensor is mounted on the front of the tank to
provide a signal for the cooling fan controller. The optional high hydraulic oil temperature sender is also mounted on the front
of the tank.
Hydraulic pump
The main hydraulic pump is mounted on top of the hydraulic tank. Oil is drawn directly into the variable displacement piston
pump assisted by tank pressure (maximum pressure 0.3 bar, 5 psi) created by the check valve in the filler cap of the hydraulic
tank.
The pump has built in pressure and flow compensator control valves. The flow compensator control valve controls the stand by
pressure which is also the pump bias pressure. The pressure compensator control valve limits maximum pump pressure. The
hydraulic system pressure is not regulated by the pump's pressure compensator. Instead, an external load sense relief valve is
used. The internal pressure compensator valve is set at a pressure higher than the external load sense line relief valve to prevent
it from opening. The external load sense pressure regulation is required to ensure that the system pressure and load sense
pressure are never equal. If these pressures would become equal, then the flow compensators in the hydraulic control valves
would shut and any movement of hydraulic functions would stop.
The pump maintains a standby pressure of 2413 kPa (24 bar)(350 psi) when the hydraulic controls and the steering valve are not
actuated (no demands on the pump). The cooling fan control valve always supplies oil to the cooling fan motor even if cooling
air is not required. In the “neutral” mode, the fan motor will turn at approximately 550 rpm. This demand on the pump raises the
standby pressure to a level of 3447 – 4137 kPa (34.5 – 41,4 bar)(500 to 600 psi). The actual standby pressure depends on the
temperature and viscosity of the hydraulic oil and the fan speed.
The steering system, cooling fan drive system, main control valve and any auxiliary hydraulic control valves are supplied by the
main hydraulic pump.
Oil flow from the pump directly supplies the priority flow valve from which the priority flow “CF” port is directed to the steering
control valve. Oil from the excess flow “EF” port of the priority flow valve is available to the main control valve, the fan control
valve, and other optional valves.
Priority flow valve
The priority flow valve maintains consistent steering response throughout the engine rpm range. It's purpose is to provide
priority flow to the steering circuit through port “CF” ensuring consistent steering response regardless of engine rpm or main
hydraulic requirements. All excess flow is available for use in the main hydraulic control valve through port “EF”. A relief valve
built into the priority flow valve limits steering circuit pressure independently of the main hydraulic relief valve. Oil exiting from
the steering valve returns to the left side of the directional control valve and enters the return to tank passage.
Main control valve
The function of 10 section main control valve is to distribute oil to the working (implement) hydraulics for the moldboard
positioning, frame articulation, A-frame, scarifier, and front wheel tilt. Each valve spool is specially machined to provide the
correct flow and reaction required by each individual application. No port relief valves are installed in any main valve section.
Relief, float, oil crossover and other special oil control functions are performed by special function valves. The number 2 and 9
valve sections are available to operate attachments, such as a ripper or dozer blade. If additional circuits are required, an auxiliary
3 or 5 section control valve is available as an option.
Counterbalance valves
Counterbalance valves are incorporated into the blade lift, A-frame, blade tilt, circle turn, side shift, wheel lean, articulation and
scarifier circuits to prevent cylinder drift. The control levers are a short throw type located on an adjustable steering pedestal.
Service Information

Hydraulic components, 900 Service Information 9/10/2022
location
Profile:
G780B Volvo
Hydraulic components, location


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Hydraulic components
1. Wheel lean circuit lock valve

2. Steering circuit crossover relief valve
3. Blade lift circuit accumulators (optional)
4. Circle shift counterbalance valve
5. Circle side shift circuit accumulators (optional)
6. Blade lift circuit counterbalance valves or electric float valves
7. Moldboard tilt circuit lock valves (G710B has only one)
8. Articulation counterbalance valve
11. 3 or 5 section auxiliary control valve (optional)
12. Lock/unlock differential circuit solenoid valve
13. Transmission hydraulic pump
14. Fan control valve
15. Load sense shuttle valve
16. Hydraulic oil cooler
17. Load sense relief valve
18. Fan motor
19. Hydraulic tank
21. Priority flow divider valve
22. Hydraulic system filter
23. Load sense shuttle valve
24. 10 - section main control valve
25. MBCS lock pin cylinder solenoid valve
26. Hydraulic swivel joint
27. Circle turn valve
28. Circle turn circuit counterbalance valve
29. Scarifier circuit lock valve (optional)
30. Auxiliary return line filter
Service Information

Hydraulic system 900 Service Information 9/10/2022
Profile:
G780B Volvo
Hydraulic system troubleshooting guide


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Condition Possible cause Solution

System standby pressure too high
1. One or more controls (including 1. Check and adjust control to
steering) is not in neutral, thereby neutralize the affected spool
sending a load sense signal to the 2. Check the fan control valve, fan
pump. motor and fan electrical circuit
2. Defect in fan control circuit (or 3. Adjust pressure differential to 350
settings). psi ( 24.13 bar; 2413.16 kPa)
3. Pump stand by LS differential
adjustment set too high
No main pressure
1. Hydraulic oil level too low. 1. Fill tank to correct level
2. Defective pump or connection to 2. Replace pump
engine has failed.
Pressurize tank to 10 psi
Pump not receiving a load (0.69 bar; 68.95 kPa)
sense signal. Adjust compensator to
Pump control valve in the 2700 psi (186.17 bar;
pump is defective or 18615.84 kPa) - see pump
contaminated adjustment
Remove compensator
valve and check for debris
and seating
System pressure too low

1. External load sense relief valve 1. Adjust external relief valve to 2500
defective or set too low. psi (172.38 bar; 17236.89 kPa)
2. Pump control valve contaminated 2. Clean or replace 4 way valve on
or defective. pump
3. Load sense signal system is 3. Check and repair leak
leaking.
System pressure too high

External load sense relief valve set See hydraulic pump adjustments
wrong or defective. for solutions
Pump control valve set wrong or
defective.
Noisy pump and erratic cylinder

movement. 1. Incorrect oil viscosity. 1. Drain hydraulic tank, cylinders and
2. Aerated oil or low oil level in the hoses and refill with the correct
tank. Check for leaks on the pump type of oil as per the Operator's
supply tubes and connections. Manual
3. Defective or worn out pump 2. Check all hoses, clamps and O-
rings on the inlet side of the pump
for leakage
3. Replace pump
Condition Possible cause Solution

Large amounts of air in the oil
1. Leak in the pump inlet tubes and 1. Check and repair inlet leak
connections. 2. Bleed air from system
2. Hydraulic system not properly bled 3. Reseal leaking cylinders
of air.
3. Cylinder seals leaking.
Hydraulic oil temperature too high

1. Incorrect oil viscosity. 1. Flush the tank and system , and
refill with Volvo approved hydraulic
Standby (low unload) oil
pressure is too high. 2. Replace pump
3. Check for leaks on suction lines
2. The pump is worn out. and bleed system
An oil passage is Check cooler relief valve

restricted. and circuit
The system is overloaded
4. Clean the cooler and check fan for
3. Aerated oil. proper operation
4. Air flow and oil flow through the oil
cooler is restricted.
Hydraulic cylinder moves with the
control lever in neutral position. 1. Defective lock valve or counter- 1. Check and adjust the cracking
balance valve. pressure of cartridges in
2. Defective cylinder piston seals. counterbalance valve or replace the
3. Spool in the control valve section valve and / or cartridges as
bore has too much clearance. required
4. Blade lift cylinder optional detent 2. Reseal the cylinder
activated; float switches stuck in 3. Replace valve section
position. 4. Check and repair the electrical
circuit and valve section
Single hydraulic function responds

too slow. 1. Binding lever linkage: valve spool 1. Check and adjust linkage for full
cannot travel to its full extent. spool travel
2. Wrong valve section installed in the 2. Replace the spool and / or valve
main control valve bank. section
3. Shuttle disc in the valve section not 3. Replace the shuttle disc or
sealing. complete valve section
4. Line or hose restriction. 4. Clear restriction and reseal cylinder
5. Defective or contaminated 5. Check/replace/adjust
counterbalance valve or lock valve counterbalance lock valve/
if used in the circuit. cartridge
6. Defective valve section. 6. Replace valve section
7. Hydraulic cylinder by-passing oil. 7. Reseal cylinder
Several hydraulic functions do not

respond or respond too slow. 1. Defective external load sense relief 1. Check and adjust external relief
valve. valve to 2500 psi (172.38 bar;
2. Pump main control valve defective 17236.89 kPa) or replace the valve
or contaminated. 2. Adjust compensator to
3. Air in the main control valve bank specifications or replace with kit
load sense signal system. part number 12738956
4. Leaking load sense shuttle disc seat 3. Bleed load sense signal circuit
in the valve section. 4. Replace the valve section
5. Priority valve is not shifting to 5. Remove the priority valve and
excess flow (EF) position inspect spool and orifices for
contaminants
All hydraulic functions do not

respond or respond too slow. 1. Air in the load sense signal system. 1. Bleed load sense signal circuit
2. Leaking load sense signal shuttle
block seats, or leaking load sense Adjust compensator to
shuttle discs in the valve sections. specifications
3. Pump control valve contaminated
or defective. 2. Replace the valve section
4. External load sense relief valve is
defective. Priority valve is not
5. Priority valve is not shifting shifting to excess flow (EF)
position
3. Replace the compensator with kit

part number 12738956
4. Check and adjust external relief
valve to 2500 psi (172.38 bar;
17236.89 kPa) or replace the valve
5. Remove the priority valve and
inspect spool and orifices for
contaminants
All hydraulic functions are

unstable. 1. Hydraulic oil is too thick: oil is not 1. Flush hydraulic tank and system
warmed up or incorrect viscosity and fill with Volvo approved oil
for the operating temperatures. 2. Replace pump control valve
2. Defective pump control valve.
Control lever effort is too high.

1. Lever linkage is binding or bent. 1. Repair, replace and adjust the lever
linkage and ball joints
Defective pivots or ball 2. Install the correct valve section
joints in lever linkage. 3. Replace affected valve sections
2. Wrong valve section installed in the

main control valve bank.
3. Sticking valve spools. Check a)
torque of tie bolt nuts, b) oil
temperature, c) chrome finish on
valve spool, d) contamination in
the oil.
Hydraulic functions do not work,

but steering functions properly. 1. Defective or contaminated load 1. Replace the shuttle block
sense shuttle block. 2. Remove and clean the priority
2. Spool stuck in the priority flow valve
valve and does not allow flow to
the hydraulic function circuits
through the “EF” (Excess Flow) port.
Hydraulic function response is too

fast. Wrong valve section and spool Replace with the correct valve
installed in the main control valve section and spool
bank.
Auxiliary control valves – Sheet 5 4
Hydraulic Oil Filler Cap - Prevention of Contaminants 6
Hydraulic oil cleanliness 8
Specifications- 14
Description- 16
Main control valve spool flow rates 17
Main control valve section 19
Main control valve troubleshooting 23
Main control valve overhaul procedure 25
Main control valve; removing 26
Main control valve; disassembling 27
Valve section; disassembling 29
Valve section; assembling 32
Main control valve; assembling 34
Main control valve; installing 37
Main Control Valve Bleeding Procedure 38
Specifications 40
Description 41
Hydraulic swivel joint; removing 43
Hydraulic swivel joint; disassembling 46
Hydraulic swivel joint; assembling 49
Hydraulic swivel joint; installing 52
Specifications. 55
Description. 56
Components 57
Circle Turn Valve Overhaul Procedure 60
Circle turn valve; removing 61
Circle turn valve; disassembling 63
Circle turn valve; assembling 67
Circle turn valve; installing 70
Circle Timing 72
Specifications.. 75
Description... 77
Specifications 78
Test procedures 79
Description 81
Function 82
Specifications-2847 83
Test procedures 84
Description-2803 86
Function-2740 87
Description-2648 91
Preventive maintenance 92
Accumulator precharge pressure; checking 93
Accumulator -Charging 95
Accumulator precharge adjustment chart 97
Hydraulic Cylinder Overhaul Procedure 100
Hydraulic cylinder; disassembling 102
Hydraulic cylinder; assembling 108
Special tools 113
General-2230 115
Function-2146 117
Description-2102 119
Function 120
Auxiliary load sense shuttle valve 122
Counterbalance valve for attachments-1948 123
Counterbalance valve for attachments 124
Single attachment valve with relief (EEC) 126
General-1842 127
General 128
Description-1639 135
Principle of operation; main hydraulic pump 138
Principle of operation; pressure compensator control 141
Hydraulic system; bleeding air 145
Main hydraulic pump troubleshooting guide 147
LS (load sense) pressure; checking 149
Compensator Valve Pressure Setting - Checking 151
LS (load sense) Differential Pressure - Checking 152
Service Information

Auxiliary control valves – 910 Service Information 9/10/2022
Sheet 5
Profile:
G780B Volvo
Auxiliary control valves – Sheet 5


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
A. Main directional control valve

B. Five section auxiliary control valve
C. Three section auxiliary control valve
D. Counterbalance valve
1. Return from steering control unit

2. To fan control valve
3. From priority flow valve EF port
4. Return to tank
5. Float valve drain connection
6. From steering LS circuit
7. To pump LS port
8. From fan control valve LS port
Auxiliary control valves – Sheet 5

Figure 1
Service Information

Hydraulic Oil Filler Cap - 911 Service Information 9/10/2022
Prevention of Contaminants
Profile:
G780B Volvo
Hydraulic Oil Filler Cap - Prevention of Contaminants


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Affected serial numbers 35000 to 36242.

The purpose of this repair is to prevent oil seepage around the neck of the hydraulic oil tank filler cap. During operation, the
pressure within the hydraulic oil tank may vary between 0 and 5 psi (0 and 35 kPa; 0 and 0,3 bar). At higher tank pressures, oil
may seep through the holes of the six screws and create a damp area around the filler cap.
Before performing this repair, thoroughly clean and dry the area around the flange of the filler neck to prevent the entry of
debris into the hydraulic oil tank.
Tools:
Standard hand tools and shop towels

Loctite silicone sealant
Op nbr
1. Remove the filler cap

Figure 1
Hydraulic Filler Tank Cap Assembly
2. Remove the six screws and filler strainer.
3. Thoroughly clean the screws, filler neck flange, threaded holes and two rubber gaskets.
4. Apply a thin bead of "Loctite" product #587 or equivalent silicone sealant, around the flange of the filler neck and
threads of the six screws. Install the gaskets. Install and retain the filler strainer with the six screws. Install the filler cap.
Service Information

Hydraulic oil cleanliness 911 Service Information 9/10/2022
Profile:
G780B Volvo
Hydraulic oil cleanliness


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The following provides detailed procedures on the method and tooling required to filter the oil in the main hydraulic system to
meet the cleanliness standards of ISO 4406 18/13. The process may be used whenever there has been a major component failure
in the hydraulic system or oil analysis reports indicate a contaminated main hydraulic system.
This two-part number is an International Standards Organization Code to illustrate the level of cleanliness of the hydraulic fluid
in the machine. The numbers are logarithmic representations of the total number of particles greater than Five (5) microns (first
number) and greater than Fifteen (15) microns (second number) in a one-milliliter sample. The larger the ISO code, the more
contaminants and the more potential for wear.
For this purpose you are recommended to take oil samples before and after the flushing procedure. This will be a good
indication on the success of the work performed and the efficiency of the filter cart and filtration procedure.
Special Tools
1. A filter cart with a pump flow rate of 10 gpm (38 L/min) capability (Fig. 1). The filter cart must have a 10-micron and 3-
micron filter plumbed in series. The 10-micron filter must be ahead of the 3-micron filter. Both filter housings must have
by-pass valves set to 30 psi (207 kPa; 2 bar) with 0 to 50 psi (0 to 345 kPa; 0 to 3,4 bar) pressure gauges. A suitable
suction strainer / filter that complies with the pump manufacturer's specifications is recommended to prevent damage
to the hydraulic pump on the filter cart.
Figure 1
Commercial filter cart
2. Vacuum pump
3. 1 inch swivel nut tee-fitting part No. 112C-16 with a 1/8 in. external seat drain cock. Drill and tap the hole to install the
1/8 in. drain cock.
Figure 2
Filter cart hydraulic schematic
1. 0.5 hp (0,4 kW) motor

2. 0-50 psi (0 - 345 kPa; 0 - 3, 4 bar) pressure gauge
3. 10µ filter
4. 3µ filter
5. 30 psi (207 kPa; 2 bar) relief valve
6. Hydraulic tank
7. 10µ strainer
8. 10 gpm (38 L/min) hydraulic pump
Inspecting Magnetic Drain Plug Procedure
Op nbr
Place the grader in the Service positions.
1. Remove the hydraulic oil tank filler cap and breather assembly.
2. Connect and operate a vacuum pump to the top of the hydraulic oil tank to prevent oil escaping when the tank's
magnetic drain plug is removed.
NOTE!
Modulate the amount of vacuum on the hydraulic oil tank to reduce the possibility of oil from being removed from the tank.
3. Remove and inspect the magnetic drain plug for metallic particles.
4. If the particles attracted to the magnet are "light", proceed to filter the hydraulic system oil.
Figure 3
Light magnetic particles
5. If the particles on the magnet are "heavy", the system is highly contaminated and a serious failure may already have
occurred. Major components in the circuit such as the pump, valves and cylinders must be examined and the problem
must be rectified before filtering the oil.
Figure 4
Heavy magnetic particles
6. Thoroughly clean the magnetic plug and replace the O-ring.
Inspecting the main relief (piston pump)
Op nbr
1. Remove the load sense external relief valve cartridge and inspect for scoring and debris.
Figure 5
Piston pump main relief valve and plumbing
1. Pump outlet pressure test port (P2) (2500 psi [17 237 kPa; 172 bar])
2. External relief valve
3. External relief valve cartridge (2500 psi [17 237 kPa; 172 bar])
4. To tank
5. Load sense line from control valve
6. Pump compensator (2700 psi [18 616 kPa; 186 bar]) at pump outlet
7. Pump standby regulator
Connecting the filter cart to the grader
Op nbr
1. Place the grader in the Service positions.
2. With the vacuum pump still in place, remove the return line to the tank and install a 1 in. JIC swivel tee fitting at the
tank. Adjust the JIC swivel tee fitting so the drain cock is pointing downward or sideways.
NOTE!
Modulate the amount of vacuum on the hydraulic tank to reduce the possibility of oil being removed from the tank.
3. Connect the hydraulic system return line and the vacuum pump suction line to the JIC swivel tee fitting.
4. Disconnect and remove the vacuum pump.
5. Insert the discharge side hose of the filter cart into the top of the hydraulic oil tank (filler cap). Ensure the hoses are
secured.
Flushing the hydraulic oil tank
Op nbr
NOTE!
The engine must be run at idle during the entire filtration process.
1. Start the filter cart pump and check for leaks.
2. Check the pressure gauges on the filter cart and ensure the pressure is below the opening of the filter by-pass valves.
3. Run the filter cart pump for twenty minutes.
Flushing individual circuits (cylinders and steering)
Op nbr
1. With the filter cart in operation, cycle each of the grader's hydraulic circuits one at a time. Continue the filtering
process for 5 minutes between the different functions. Keep a close watch on the pressure gauges and replace the
filters if the pressure readings are approaching the by-pass pressure setting.
2. Flush the hydraulic oil tank for 15 minutes.
3. Repeat the process of flushing the individual circuits.
4. Take an oil sample and send it to a Volvo approved oil laboratory for analysis.
Removing the flushing equipment
Op nbr
1. Reconnect the vacuum pump to the hydraulic oil tank filler cap and disconnect the filter cart.
NOTE!
Modulate the amount of vacuum on the hydraulic oil tank to reduce the possibility of oil from being removed from the tank.
2. Reconnect the hydraulic return line to the grader hydraulic oil tank.
3. Disconnect the vacuum pump.
4. Clean and reassemble the oil filler and cap.
5. Check the oil level in the hydraulic oil tank before returning the grader to service.
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Compensator spring:
Free length 21 mm (0.827 in)
Outside diameter 7 0,1 mm (0.276 0.004 in)
Length @ maximum load 11 mm (0.433 in)
Maximum load 1,5 kg (3.21 lb)
Length @ minimum load 18 mm (0.709 in)
Minimum load 0,5 0,09 kg (1.10 0.2 lb)
Spring, valve center spool:
Free length 46 mm (1.811 in)
Outside diameter 21 mm (0.827 in)
Length @ maximum load 18 mm (0.709 in)
Maximum load 6 0,6 kg (14.1 1.4 lb)
Length @ minimum load 28 mm (1.102 in)
Minimum load 4 kg (9.15 lb)
Figure 1
Torque specifications
1. Lower tie rod nuts (pre-torque) 9 3 N•m
(1 0,3 kgf•m)(7 2.5 lbf•ft)
1. Lower tie rod nuts (final) 19 N•m
(2 kgf•m)(14 lbf•ft)
2. Upper tie rod nuts (pre-torque) 9 3 N•m (1 0,3 kgf•m)(7 2.5 lbf•ft)
2. Upper tie rod nuts (final) 45 N•m (5 kgf•m)(33 lbf•ft)
3. O-ring plugs 65 7 N•m
(6,6 0,7 kgf•m)(48 5 lbf•ft)
4. Spring cap screws 9 1,3 N•m
(1 0,13 kgf•m)(7 1.0 lbf•ft)
5. Spool end assembly 9 1,3 N•m
(1 0,13 kgf•m)(7 1.0 lbf•ft)
6. Seal plate screws 5 1,3 N•m
(0,5 0,13 kgf•m)(4 1.0 lbf•ft)
7. Control valve to support nuts 31 N•m (3 kgf•m)(23 lbf•ft)
8. Load sense check valve 32-33 N•m
(3,1-3,3)(23-24 lbf•ft)
9. Connector fittings 65 7 N•m
(6,6 0,7 kgf•m)(48 5 lbf•ft)
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The main hydraulic directional control valve assembly consists of 10 directional control valve sections connected in parallel and a
set of end sections. It's purpose is to direct metered flow to the individual functions and transmit a load sense signal to the
pump.
The flow rating of a valve section is dependent on the width of the valve spool's center land and/or the design of the feathering
grooves. This controls the size of the orifice at full spool stroke. A wide center land with narrow feathering grooves opens to a
small orifice producing a low flow rate. A narrow center land with wide feathering grooves opens to a large orifice producing a
high flow rate. A valve section's flow rating and neutral configuration is matched to the circuit it operates. This takes into
consideration any accessory valve that may be used between the directional control valve section and the hydraulic cylinder. Two
different neutral configurations are used in the valve sections:
1. A “motor” spool opens the work ports to tank through restricting orifices. This bleeds off pressure between the
directional control valve and the accessory valve enabling the accessory valve to relieve properly.
2. A “cylinder” spool blocks the work ports from tank. Oil is trapped between the directional control valve section and the
hydraulic cylinder.
3. The 10 section directional control valve is located on the front of the cab and above the frame goose neck of the
grader.
Service Information

Main control valve spool 912 Service Information 9/10/2022
flow rates
Profile:
G780B Volvo
Main control valve spool flow rates


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
G710B, G720B, G726B
Spool No. Description Flow rates Type

L/min (gpm)
1 Blade lift 57/38 (15/10) motor
2 A-frame 64/64 (17/17) motor
3 Slide shift 45/68 (12/18) cylinder
4 Blade tilt 38/38 (10/10) motor
5 Circle turn 76/76 (20/20) motor
6 Circle shift 38/57 (10/15) motor
7 Articulation 64/64 (17/17) motor
8 Wheel lean 38/38 (10/10) motor
9 Scarifier 64/64 (17/17) motor
G730B to G780B
Spool No. Description Flow rates Type

L/min (gpm)
2 A-frame 64/64 (17/17) motor
3 Slide shift 76/76 (20/20) cylinder
4 Blade tilt 38/38 (10/10) motor
5 Circle turn 76/76 (20/20) motor
6 Circle shift 64/64 (17/17) motor
7 Articulation 64/64 (17/17) motor
8 Wheel lean 38/38 (10/10) motor
9 Scarifier 64/64 (17/17) motor
Service Information

Main control valve section 912 Service Information 9/10/2022
Profile:
G780B Volvo
Main control valve section


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
A. Typical to sections 1, 4, 5, 6 and 10

B. Typical to sections 2, 7, 8 and 10
1. Compression washer
2. Nut
3. Inlet end cap
4. Left-hand blade lift section
5. A-frame section
6. Moldboard slide shift section
7. Moldboard tilt section
8. Circle turn section
9. Circle shift section
10. Articulation section
11. Front wheel lean section
12. Scarifier section
13. Right-hand blade lift section
14. Outlet end cap
15. Lower tie rod
16. Upper tie rod
17. Socket head screw
18. Spring cap
19. O-ring
20. Wiper seal
21. Spring seats
22. Spring - spool
23. Spool end
24. Spool stop
25. O-ring
26. Seal plate
27. Screw
28. Spool
29. Housing
30. Piston - compensator
31. Spring - bias
32. Shuttle disc
33. O-ring
34. Load check poppet
35. Load sense check valve
Figure 2
Float switch module

Figure 3
Overview – Main control valve section

The individual directional control valve sections feature:
built in pressure compensation so light loads do not take precedence over heavy loads with multiple functions activated
built in load sense shuttle between valve sections
low effort directional spools
The illustration above, shows a sectioned view of a single valve section. The following text describes four different operating
conditions and how the valve performs its function by using its features.
Valve in neutral
The centering springs keep the valve in neutral. Standby pressure is present in the pressure passage. The bridge is connected to
tank through cross drillings in the spool. No load sense signal is sent to the pump. The center land of the spool blocks all flow to
the work ports. The work ports are isolated from the bridge.
Single section activated
Oil flows across the spool's center land, lifting the compensator and entering the bridge. One work port is connected to the
bridge and the other is connected to tank. A load sense signal is transmitted from the bridge, through the internal shuttle to all
compensators and to the pump. The pump reacts to the load sense signal by directing the required flow to the pump's discharge
port to obtain load sense pressure plus bias pressure.
Two or more functions activated
The internal load sense shuttles transmit the highest load sense signal to the top side of all compensators and to the pump. The
pump reacts by directing the required flow to the pump's discharge port to obtain load sense pressure plus bias pressure. Oil
flow entering the control valve must be prevented from favoring a light load over a heavy load. Oil passing through every active
valve must overcome the compensators which are being held closed by the load sense signal of the highest acting load. Effective
flow dividing occurs as all valves are exposed to the same load regardless of the actual load at the workport.
Multiple functions activated – Pump flow limited
The valves operate similar to above. Flow demand of the valve sections exceed the pump's capacity. This results in a lower
pressure drop across the valve spool. The pump's bias pressure drops as it cannot discharge sufficient flow to meet the demand.
Since the pressure differential between system pressure and load sense pressure is less than pump bias, the compensators move
down to further restrict flow and divide the available flow proportionally. The pump's flow compensator maintains maximum
flow output in an attempt to achieve rated bias pressure.
Service Information

Main control valve 912 Service Information 9/10/2022
troubleshooting
Profile:
G780B Volvo
Main control valve troubleshooting


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

Hydraulic functions do not work, Defective or contaminated load sense
but steering functions properly. shuttle block or load sense (LS) valve Inspect the load sense shuttle block
ball and seats. Clean or replace as
necessary.
Replace the main hydraulic filter and
inspect the hydraulic tank for
contamination.
Check tank then change filter
Priority flow valve spool stuck and does

not allow oil flow to the hydraulic Inspect the priority flow valve spool
function circuits through the “EF” (excess and bore for contamination or
flow) port. damage. Clean or replace the priority
flow valve.
Replace the main hydraulic filter and
inspect the hydraulic tank for
contamination.
Hydraulic function response is too 1 Wrong valve section installed for the
fast. particular hydraulic function. Remember, Attach a flow meter to the “A” work
spools can have 2 flow rates for extend port and check the flow rate at low
and retract. idle. If the reading is different to the
specified flow rate, determine if other
valve section(s) have been incorrectly
installed.
Disassemble the control valve and
reassemble as specified on the
hydraulic schematic diagram.
Service Information

Main control valve overhaul 912 Service Information 9/10/2022
procedure
Profile:
G780B Volvo
Main control valve overhaul procedure


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
NOTE!
Place the grader in the Service Position. Refer to Service positionsbefore starting this overhaul procedure.
1. Thoroughly clean the control valve assembly before disconnecting the hoses. This minimizes the possibility of
contaminating the hydraulic system with dirt or moisture.
2. If the valve assembly is being removed because of oil leaks, try to isolate the valve section where the leak originates.
Make sure that the oil leak does not originate from a faulty fitting or hose.
Service Information

Main control valve, 912 Service Information 9/10/2022
removing
Profile:
G780B Volvo
Main control valve, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-091
1. Remove the shoulder socket head bolts connecting the control rods to the valve spools. Discard the locknuts.
2. Identify all hoses to prevent confusion during assembly. Disconnect the hoses from the valve section fittings.
Immediately plug the open fittings to prevent contamination.
Figure 1
Removing control valve assembly from support
3. Attach a safe lifting device to the valve assembly. Remove the three bolts, nuts, flat washers and lock washers securing
the control valve assembly to the support. Carefully lift the valve assembly off the support and place on a clean work
bench.
Service Information

disassembling
Profile:
G780B Volvo
Main control valve, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-088
NOTE!
Use a scriber or oil-proof method to mark the sequence of valve sections in the valve assembly. Each valve section is designed
specifically for the function it controls and cannot be interchanged.
1. Remove the special nuts and compression washers from the tie rods on the outlet end cap. Keep the tie rods in the
valve assembly. The outlet end cap is identified by a load sense signal port. Discard the nuts.
Figure 1
Removing compensator piston from valve section housing
2. Carefully place the valve assembly on its end, resting on the three tie rod ends of the inlet endcap.
3. Remove the outlet end cap.
4. Remove the O-ring, bias spring and compensator piston or load check valve. Discard the O-ring. Store the bias spring
and compensator piston or load check valve in a safe, clean place and identified by the valve section from which they
originated.
NOTE!
The valve section next to the outlet end cap does not have a load sense shuttle disc. It may be necessary to use small
straight nosed external snap ring pliers or similar small expanding tool to remove the compensator piston or load check
valve.
Figure 2
Removing load sense shuttle disc
5. Remove the remaining valve sections, together with the load sense shuttle discs, installed between the nine valve
sections.
Service Information

Valve section, disassembling 912 Service Information 9/10/2022
Profile:
G780B Volvo
Valve section, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-097
Figure 1
Removing spring seats, spring and spool stop ring
1. Lightly clamp the valve section housing in a vise with soft jaws.
NOTE!
Excessive clamping force may distort the valve spool bore and compensator piston bore.
2. Remove the machine screws and the seal plate.
3. Remove the socket head screws and the spring cap.
4. Remove the spool end.

NOTE!
To prevent the valve spool from rotating, insert a thin rod or similar tool in the linkage pin hole.
Figure 2
Removing valve spool from valve section housing
5. Remove the spring seats, spring and spool stop ring.
6. Pull the valve spool out of the valve section housing.
7. Remove the O-ring from the spring retaining screw.
8. Remove and discard the wiper seals and O-rings.
Figure 3
Removing spool wiper seals and O- rings

A careful and thorough inspection of all parts is extremely important. If there is any evidence of damage or wear, replace all
Retain O-rings and wiper seals only for inspection and troubleshooting purposes. Replace all O-rings and wiper seals when
overhauling the main hydraulic control valve.
Valve section housing
Inspect the spool bore and compensator piston bore or load check valve for excessive wear, scratches and grooves that will
cause excessive leakage.
All ports within the O-ring mating area of the valve sections rely on the machined surface for sealing. Inspect the machined
surfaces for scratches, grooves or other damage that may cause leakage between ports.
Inspect the housing casting for cracks especially at the tank passage section. This would be the result of excessive back pressure.
Service Information

Valve section, assembling 912 Service Information 9/10/2022
Profile:
G780B Volvo
Valve section, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-098
1. Lightly clamp the valve section housing in a vise with soft jaws.
Figure 1
Installing valve spool in valve section housing
2. Lubricate new valve spool O-rings and install them in the valve section housing counterbores. Lubricate and install new
wiper seals against the O-rings in the valve section housing counterbores.
3. Lubricate and install the valve spool in the valve section housing.
Figure 2
Torque-tightening spool end assembly
4. Lubricate and install a new O-ring on the spool end. Assemble the spring seats, spring and spool stop ring on the spool
end.
5. Install the spool end assembly on the end of the valve spool. Torque-tighten the spool end assembly to 9 1,3 N•m (1
0,1 kg•m)(7 1.0 lbf•ft).
NOTE!
To prevent the valve spool from rotating, insert a thin rod or similar tool in the linkage pin hole.
6. Install the spring cap. Make sure the mating face notches are clean.
7. Secure the spring cap with the socket head screws. Torque-tighten the screws to 9 1,3 N•m (1 0,1 kg•m) (7 1.0 lbf•ft).
8. Secure the seal plate with the machine screws. Torque-tighten the screws to 5 1,3 N•m (0,5 0,1kg•m) (4 1.0 lbf•ft).
Figure 3
Inlet end cap and three tie rods
Service Information

assembling
Profile:
G780B Volvo
Main control valve, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-089
1. Install a new special nut and compression washer on each tie rod. Ensure two or three threads show at the end of each
rod.
NOTE!
The outside edge of the compression washer must contact the valve section housing and the center must contact the nut.
2. Insert the tie rods into the inlet end cap.
3. Place the inlet end cap on its end, resting on the three tie rod ends.
4. Lubricate the mating surface with system oil. Lubricate and install a new O-ring in the groove.
Figure 1
Installing compensator piston or load check valve into valve section housing
5. Install the valve section that is identified as being adjacent to the inlet end cap.
NOTE!
Install the valve sections in their original order as identified before disassembly.
Figure 2
Installing load sense shuttle disc
6. Insert the compensator piston or the load check valve into the bore of the valve section, nose end first.
7. Insert the bias spring into the hollow end of the compensator piston.
8. Install the load sense shuttle disc into the recess of the load sense passage.
9. Lubricate and install a new O-ring in the O-ring groove.
10. Repeat the installation steps until all the valve sections, including the outlet end cap, are installed.
11. Install the compression washers with the outside edge contacting the valve section housing. Install new special nuts and
torque-tighten to finger tightness.
12. Place the valve assembly on a precision flat surface.

NOTE!
Torque-tightening the tie bolt nuts on a non-flat surface may cause spool or shuttle disc binding.
Figure 3
Torque-tightening tie rods nuts
13. To align all valve sections and endcaps, press down on the end caps before tightening the tie bolt nuts to the final
torque value.
14. Torque-tighten the lower tie rod nuts to 9 3,4 N•m (1 0,3 kg•m)(7 2.5 lbf•ft). This is a preliminary torque-tightening
procedure.
15. Torque-tighten the upper tie rod nuts to 9 3,4 N•m (1 0,3 kg•m)(7 2.5 lbf•ft). This is a preliminary torque-tightening
procedure.
16. Torque-tighten the lower tie rod nuts to 19 N•m (2 kg•m)(14 lbf•ft). This is the final torque value.
17. Torque-tighten the upper tie rod nuts to 45 N•m (5 kg•m)(33 lbf•ft). This is the final torque value.
18. Check for proper spool movement.

Service Information

installing
Profile:
G780B Volvo
Main control valve, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-092
1. Attach a safe lifting device to the valve assembly. Carefully install the control valve assembly onto the support.
2. Secure the valve assembly with the three bolts, nuts, flat washers and lock washers.
Torque-tighten the nuts to 31 N•m (3 kg•m)(23 lbf•ft).
3. Connect the control rods to the valve spools. Install the shoulder socket head bolts and new locknuts.
NOTE!
Make sure the linkages do not bind. After connecting each rod, move the control lever to confirm that the assembly
moves freely and that the lever returns to the center (neutral) position.
4. Connect all hoses as identified during disassembly.
5. Turn the isolation switch to the ON position. Start the engine when it is safe to do so and operate the hydraulic control
levers. If the hydraulic controls react slowly or not at all, bleed air out of the main hydraulic system.
Service Information

Main Control Valve Bleeding 912 Service Information 9/10/2022
Procedure
Profile:
G780B Volvo
Main Control Valve Bleeding Procedure


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-099
Figure 1
Purging air out of hydraulic cylinders
1. Place the grader in the Service positions. Remove the rear cover plate under the radiator grille to uncover the load
sense line quick-disconnect fitting. Start the engine when it is safe to do so and bring it up to operating temperature.
Centralize all hydraulic control levers (neutral position).
2. Fully extend and retract all piston rods several times to purge air out of the hydraulic cylinders. Shut down the engine.
3. Connect a long hose to the load sense line quick-disconnect fitting. Place the other end of the hose in a clean container
– capacity 7,5 L (2 US gal)– partially filled with fresh hydraulic oil. Immerse the hose in the oil.
4. Operate each hydraulic control lever –starting from the right-hand side to the left-hand side. Hold each lever in the
forward direction and backward direction for 5 seconds. The hydraulic cylinders will not move as the load sense line
cannot build up pressure.
5. When the service technician is operating the hydraulic control levers, have an assistant observe the hydraulic oil and air
bubbles flowing out of the hose immersed in the container. Continue operating the hydraulic control levers until air
bubbles cease coming out of the hose.
6. After the air has been bled out of the main control valve, bleed the steering circuit in a similar manner. Turn the steering
wheel in one direction for 5 seconds, then in the other direction for 5 seconds. If air bubbles continue to emerge from
the hose, repeat the entire bleeding procedure.
7. At the end of the bleeding procedure, shut down the engine. Remove the hose at the load sense line quick-disconnect
fitting.
8. Refill the hydraulic tank to the proper level with fresh oil. Refer to Recommended lubricants.
The main hydraulic control valve overhaul is now complete.

Test the grader to ensure that there are no problems with the control valve functions. Check all connections for leaks.
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Torque value for washer retaining bolts is 18 N•m (1,8 kgf•m)(13 lbf•ft).
Ensure pipe plugs are flush with top of spool.
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The hydraulic swivel joint valve is used on all Volvo motor graders. It is located in the center of the circle and underneath the
drawbar frame.
A drive arm fastened to the circumference of the circle turns the hydraulic swivel joint spool. The hydraulic swivel joint allows 360
degrees of circle rotation without twisting the hoses to the moldboard slide shift cylinder and moldboard tilt cylinders.
Figure 1
Swivel joint top view and section
Port Identification:
A. Slide Shift Extend

B. Slide Shift Retract
C. Blade Tilt Extend
D. Blade Tilt Retract
Figure 2
Hydraulic swivel joint
1. Bolt
2. Lock washer
3. Flat washer
4. Spacer
5. Cover
6. Bolt
7. Lock washer
8. Washer
9. Body
10. Bolt
11. Back-up ring
12. Seal
13. O-ring
14. Spool
15. Pipe plug
16. Drive arm
Service Information

Hydraulic swivel joint, 912 Service Information 9/10/2022
removing
Profile:
G780B Volvo
Hydraulic swivel joint, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-100
NOTE!
Place the grader in the Service positionsbefore starting this overhaul procedure.
1. This procedure describes how to overhaul the hydraulic swivel joint used with power moldboard tilt.
2. Remove the four nuts and lock washers securing the cover plate to the drawbar. Remove the three bolts (1), lock
washers (2) and flat washers securing the cover plate to the hydraulic swivel joint. Remove the cover plate.
Figure 1
3. Remove the three bolts (4), lock washers (2), spacers (3) and cover (13).
Figure 2
4. Identify the hydraulic hoses to prevent confusion during assembly.
Figure 3
5. Support the drive arm (6) with a block of wood. Disconnect the hoses from the body (9) and clean up any oil leakage.
Immediately plug the open ports and fittings to prevent contamination.
Figure 4
6. Rotate the body (9) 90 degrees and slide the body from the drive arm (6).
Figure 5
Service Information

disassembling
Profile:
G780B Volvo
Hydraulic swivel joint, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-102
1. Place the bottom of the spool (7) in a vise with soft jaws. Clean the top surface of the body (9).
Figure 1
2. Remove the two bolts (12) and lock washers (11). Remove the washer (10).
Figure 2
3. Carefully remove the body (9) by lifting it straight up.
Figure 3
4. Remove the pipe plugs (5) from the spool (7) only if they are leaking.
Figure 4
5. Remove and discard the O-rings (8), back-up rings and seals from the spool (7).
Figure 5
6. Thoroughly clean the spool (7) and body (9). Inspect the spool and body for serviceability. Place to one side for cleaning
and inspection.
NOTE!
The body and spool are a matched set and cannot be separately interchanged with another body or spool.
Figure 6

Retain O-rings, back-up rings and seals only for inspection and troubleshooting purposes. Replace all O-rings, back-up rings and
seals when overhauling the hydraulic swivel joint.
Inspect each part for scoring, wear or pitting. Remember that the body and spool are a matched set. If one of the parts is
damaged, replace both of them.
After inspection, dip all parts in system oil and set them to one side.
Service Information

assembling
Profile:
G780B Volvo
Hydraulic swivel joint, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-103
1. Place the base of the spool (7) in a vise with soft jaws. Place a clean plastic bag over the spool to prevent the O-rings
(8), back-up rings and seals from being cut when they are installed. Secure the bag in place with adhesive tape.
Figure 1
2. Generously lubricate and install new O-rings (8), back-up rings and seals over the bag on the spool (7). When all O-
rings, back-up rings and seals are in place, remove the plastic bag and ensure the O-rings, back-up rings and seals are
seated properly.
NOTE!
Install the seals in the top and bottom grooves.
Figure 2
3. Apply a light coating of thread sealant P/N 19167 to each pipe plug (5). Install the pipe plugs into the spool (7). Fully
tighten the pipe plugs. Wipe off any excess thread sealant. Remove and reinstall the plugs only if they are leaking.
Figure 3
4. Apply a coat of grease to the base of the spool (7), O-rings (8), back-up rings and seals.
Figure 4
5. Carefully install the body (9) over the spool (7) ensuring the O-rings (8), back-up rings and seals are not damaged.
Figure 5
6. Coat the underside of the washer (10) with grease. Secure the washer to the spool (7) with bolts (12) and lock washers
(11). Install the cover protecting the spool washer (10). Seal the cover by applying a bead of gasket eliminator (P/N
32338) around the joint.
Figure 6
Service Information

installing
Profile:
G780B Volvo
Hydraulic swivel joint, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-101
1. Slide the body (9) onto the drive arm (6). Reposition the body.
Figure 1
2. Connect each hose to its correct location.

Figure 2
3. Install the three spacers (3) and secure with the bolts (4) and lock washers (2).
Figure 3
4. Position the cover plate. Secure it to the drawbar with the four nuts and lock washers. Install the three bolts (1), lock
washers (2) and flat washers securing the hydraulic swivel joint to the cover plate.
Figure 4
5. Make a visual check around the grader. Signal the intention to start the engine. Start the engine when it is safe to do so.
Raise the moldboard off the ground. Operate the slide shift cylinder and moldboard tilt cylinders to purge any air in the
system. Test the hydraulic swivel joint by moving these cylinder pistons to the end of their strokes in both directions. Do
not hold the control levers with the cylinders at the end of their stroke for more than ten seconds. Shut down the
engine. Check all connections for leaks.
Figure 5
6. Refill the hydraulic tank to the proper level with clean oil. Refer to Recommended lubricants.
The hydraulic swivel joint overhaul is now complete.

Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Port Identification:
The circle turn valve is located on top of the drawbar. It is connected between the main hydraulic control valve and circle turn
circuits.
Ensure pipe plugs are flush with top of spool.
A....................................................... to R.H. Valve port
B....................................................... to L.H. Valve port
1....................................................... to R.H. Cylinder rear port
2....................................................... to L.H. Cylinder rear port
3...................................................... to R.H. Cylinder front port
4...................................................... to L.H. Cylinder front port
Figure 1
Section through circle turn valve spool
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The circle turn valve is installed on top of the drawbar and is a major component of all Volvo circle turn systems.
The function of the circle turn valve is to distribute oil to the correct end of each circle turn cylinder in the proper sequence,
depending upon the direction of circle rotation.
Volvo motor graders use two hydraulic cylinders to turn the circle. For satisfactory operation and long life, the circle must be
properly adjusted and kept that way. As part of the overhaul procedure, it may be necessary to re-time the circle turn valve.
Position A B Other
1 4 2 1-3
2 1 and 4 2 and 3 -
3 1 3 2-4
4 1 and 2 3 and 4 -
5 2 4 1-3
6 2 and 3 1 and 4 -
7 3 1 2-4
8 3 and 4 1 and 2 -
9 Circle turn cylinder
10 Bi-directional
Service Information

Components 912 Service Information 9/10/2022
Profile:
G780B Volvo
Components

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Circle turn valve
1. Valve casting
2. Spool
3. Hexagon screw
4. Washer
5. End cap
6. Relief valve
7. Gasket
8. Spacer
9. Oil seal
10. Seal retaining plate
12. Dust seal
13. Guard tube
14. Drive shaft
15. Snap ring
16. Thrust washer
17. Bearing
18. Pinion shaft
19. Valve pinion
20. Lock nut
21. Grease fitting
22. Nut
23. Washer
Service Information

Circle Turn Valve Overhaul 912 Service Information 9/10/2022
Procedure
Profile:
G780B Volvo
Circle Turn Valve Overhaul Procedure


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-104
1. Fully retract the left-hand cylinder so that a straight line intersects all three pivot points. Ensure the right-hand cylinder
and crank is towards the drawbar. Position the cylinder so that the anchor stud, crank stud and crank center line form
an approximate 90º angle. This set-up is crucial to the outcome of the overhaul procedure.
2. Adjust the front guide plate until there is a 1,0 – 2,0 mm (0.040 in. – 0.080 in.) backlash between the drive pinions and
circle teeth. The turn valve pinion should have approximately the same backlash.
Service Information

Circle turn valve, removing 912 Service Information 9/10/2022
Profile:
G780B Volvo
Circle turn valve, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-105
NOTE!
Place the grader in the Service positions before starting this overhaul procedure.
1. Identify the hydraulic hoses to prevent confusion during assembly. Disconnect the hoses from the circle turn valve
fittings. Immediately plug the open ports and fittings to prevent contamination.
Figure 1
2. Remove the nuts (22) and washers (23) securing the circle turn valve to the drawbar.
Figure 2
3. Remove the circle turn valve from the drawbar.
Figure 3
4. Count and record the number of gaskets since they also serve as shims. Remove and discard the gaskets. Withdraw the
driveshaft (14) and guard tube.
Figure 4
Service Information

Circle turn valve, 912 Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Circle turn valve, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-106
NOTE!
Before performing this procedure, ensure that the area is clean. Use shop towels to prevent dirt and particles from
contaminating the valve.
1. Remove the hexagon screws (3) and washers (4) retaining the end cap (5). Remove the end cap and gasket (7). Discard
the gasket. Ensure that the relief valve (6) in the center of the end cap opens freely. Refer to Figs. 1 and 2.
Figure 1
Removing hexagon screws and washers
Figure 2
Removing end cap and gasket
2. Remove the spool (2) by pushing it out of the top of the valve casting (1). Refer to Fig. 3
Figure 3
Removing spool
3. Remove the spacer (8) and oil seal (9). Discard the oil seal. Refer to Fig. 4.
Figure 4
Removing spacer and oil seal
4. Using an appropriate Allen wrench, remove the four socket head screws (11) from the seal retaining plate (10) at the
bottom of the valve. Remove the seal retaining plate. Refer to Fig. 5.
Figure 5
Removing seal retaining plate
5. Remove the bottom spacer and oil seal. Discard the oil seal. Refer to Fig. 6.
Figure 6
Removing bottom spacer and oil seal
6. With a pair of needle nose pliers, carefully remove the dust seal (12) from the seal retaining plate. Discard the dust seal.
Refer to Fig. 7.
Figure 7
Removing dust seal
7. Inspect the inner sleeve of the valve casting for any damage. If there are slight scratches, use crocus cloth to recondition
the surface of the sleeve. If the damage is more extreme, replace the circle turn valve assembly.
NOTE!
Service Information

Circle turn valve, assembling 912 Service Information 9/10/2022
Profile:
G780B Volvo
Circle turn valve, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 912-107
NOTE!
Use the appropriate circle turn valve repair kit before assembling the valve. The kit includes two oil seals, one dust seal and one
gasket. Replace the spacers if there are signs of wear and scoring.
1. Lubricate and install the new oil seals. Ensure that the lips of the oil seals point inward. Refer to Fig. 1.
Figure 1
Oil seal lip pointing inward
2. Replace the dust seal within the seal retaining plate and ensure that the lip of the dust seal points outward.
3. Lightly lubricate the spool and sleeve bore with clean hydraulic oil. Reinsert the spool into the valve casting. Refer to
Fig. 2.
NOTE!
Use a slight twisting action to carefully install the spool into the valve casting.
Figure 2
Lubricating spool
4. Replace the spacers.
5. Replace the seal retaining plate and retain with four socket head screws using an appropriate Allen wrench and tighten.
Refer to Fig. 3.
Figure 3
Seal retaining plate and dust seal
6. Install the new gasket. Install the end cap and torque hexagon screws and washers to specification.
7. Using a screwdriver, carefully turn the spool to ensure that it does not bind. Refer to Fig. 4. If the spool binds, remove
then reinstall the spool.
Figure 4
Check for binding in spool
NOTE!
The circle turn valve will be correctly timed later.
Service Information

Circle turn valve, installing 912 Service Information 9/10/2022
Profile:
G780B Volvo
Circle turn valve, installing


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Op nbr 912-108
1. Install the guard tube. Lower the driveshaft (14) into the drawbar frame and connect the notched end into the pinion
shaft. Place the same number of new gaskets on the draw-bar as were removed during disassembly. The gaskets also
act as shims to prevent the spool from bottoming out on the driveshaft .
Figure 1
2. Install the circle turn valve.

Figure 2
3. Retain the circle turn valve assembly with the washers and nuts.
Figure 3
4. Remove the plugs from all hoses and fittings. Connect each hose to its correct location.
Figure 4
Service Information

Circle Timing 912 Service Information 9/10/2022
Profile:
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Circle Timing

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Op nbr 912-109
1. Whenever the circle turn valve has been removed, make a circle timing check. Two of the three steps in the circle timing
procedure have been performed by ensuring correct drive pinion clearance and positioning the circle turn cylinders and
cranks. The third step in the sequence is adjusting the circle turn valve spool (5). To start, disconnect the hose at the
forward left port on the circle turn valve. Immediately cap the hose end to prevent contamination. Remove the fitting.
WARNING
Figure 1
2. Look inside the open port. A hole on the spool (5) should be visible and it must be in the center of the port. If so, the
spool is in the proper position. Connect the hose.
Figure 2
3. If the hole in the spool is not visible or it is not in the center of the port, the spool (5) needs adjustment.
Figure 3
4. To adjust the spool (5), first loosen the locknut (12) retaining the valve pinion (14).
Figure 4
5. Turn the pinion shaft (16) until the hole on the spool (5) is visible and is in the center of the port. Move the spool back
and forth until the edges are visible. Now centralize the spool.
Figure 5
6. Tighten the locknut (12). Check the position of the spool (5) and make sure that it has not moved when tightening the
locknut. Install the fitting and connect the hose.
Figure 6
7. Make a visual check around the grader. Signal the intention to start the engine. Start the engine when it is safe to do so
and push the circle turn control lever forward. The circle should turn smoothly in a counter clockwise direction. If the
circle turns in a clockwise direction as viewed from the operator's seat when the lever is pushed forward, the spool (5) is
180 degrees out of position. Shut down the engine. Repeat steps 4 through 6, but this time, turn the pinion shaft (16)
180 degrees. Repeat step 7.
8. Refill the hydraulic tank to the proper level with clean lubricant. Refer to Recommended lubricants.
Circle turn valve overhaul and circle timing is now complete.

Test the grader to ensure there are no problems with the circle turn valve functions. Check all connections for leaks.
Service Information

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Specifications

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Torque value for bolts 102 13 N•m

(10,4 13,5 kgf•m)(75 10 lbf•ft)
Torque value for orifice 7,3 – 9,6 N•m
(0,7 – 1 kgf•m)(65 – 85 lbf•in)
Torque value for relief valve 34 – 54 N•m (3,5 – 5,5 kgf•m)
(25 – 40 lbf•ft)
Relief valve setting 8273 kPa (83 bar)(1200 psi)
Figure 1
P – Pressure port
CF – Controlled flow port
EF – Excess flow port
LS – Load sense port
T – Tank
Service Information

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Description

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The priority valve is located inside the frame, just ahead of the hydraulic tank on the left-hand side of the machine. It is
connected between the main hydraulic control valve, steering and main hydraulic pump pressure circuits. It's purpose is to
provide priority flow to the steering circuit ensuring consistent steering response regardless of engine rpm or main hydraulic
requirements.
All excess flow is available for use in the main hydraulic control valve through port “EF”. A relief valve built into the priority flow
valve limits steering circuit pressure independently of the main hydraulic relief valve. Oil exiting from the steering valve returns to
the left side of the main hydraulic control valve and enters the return to tank passage.
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Specifications

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Electric float valve
Relief pressure 20,7 MPa (207 bar)

(3000 psi)
Coil resistance 28.8 ohms @ 20ºC (68ºF)
Torque values
Torque value for cartridges 44,7 N•m (4,5 kgf•m)(33 lbf•ft)
Torque for relief valve cartridge 21,7 N•m (2,2 kgf•m)(16 lbf• ft)
Coil retaining nut 3,4 N•m (0,34 kgf•m)(2.5 lbf•ft)
Service Information

Test procedures 912 Service Information 9/10/2022
Profile:
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Test procedures

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Oil bypassing in the counterbalance portion of the float valve or through the solenoid valves can cause hydraulic cylinder drift.
SeeTest procedures for checking the counterbalance portion of the valve. Remove the hose from the tank port of the valve to
check for oil bypassing through the solenoid valves. A problem with one or both of the solenoid valves will not allow the cylinder
to float. Test the coils for open or short circuits and that both coils are receiving power simultaneously using a voltmeter. When
reinstalling a cartridge into the body, dip it in clean system oil and screw in by hand until the top O-ring contacts the body.
Torque to specification.
NOTE!
R.H. and L.H. are for purpose of explanation only. R.H components are identical to L.H.
Figure 1
1. Valve body
2. Counterbalance valve cartridge
3. Solenoid valve coil
4. Solenoid valve cartridge
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Description

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The electric float valve is essentially the same as the counterbalance valve described on the previous page with the addition of
two solenoid valve cartridges. It is an option available in the hydraulic blade lift and attachment circuits. As a secondary function,
it allows the hydraulic cylinder to float up and down for snow plowing and ditch cleaning applications.
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Function

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Two normally closed solenoid operated valves are incorporated into the R.H. and L.H. cylinder passages along with the check
valve and relief valve cartridges. A switch on the pedestal energizes both solenoids at once. This joins the top and bottom of the
cylinder together along with a line to the hydraulic tank. The hydraulic tank line is necessary to compensate for the differential
area of the cylinder piston caused by the cylinder rod. When the cylinder moves up, oil from the top of the cylinder is displaced
to the bottom and excess oil is sent to tank. When the cylinder moves down, oil from the bottom of the cylinder is displaced to
the top and additional oil is drawn from the tank.
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Specifications

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Torque value for cartridges 44,7 N•m (4,5 kgf•m)(33 lbf•ft)

Cracking pressure 310 kPa (3 bar)(45 psi)
Pilot ratio 5:1
Relief pressure 20,7 MPa (207 bar)(3000 psi)
Service Information

Test procedures 912 Service Information 9/10/2022
Profile:
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Test procedures

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Hydraulic cylinder drift is the most obvious indication that a counterbalance valve is faulty and allowing oil to bypass. Remove
the valve and check with a hand pump at low pressure first to confirm that the check valves are seating properly. Circle turn relief
pressure setting is 18,6 MPa (186 bar)(2700 psi). The counterbalance valve for the articulation hydraulic cylinder is set to 24,8
mPa (248 bar) (3600 psi). All other relief valves have a pressure setting of 20,7 MPa (207 bar)(3000 psi). Because this is higher
than the main relief valve setting, it must also be checked with a hand pump. When installing a cartridge into the valve body, dip
it in clean system oil and screw in by hand until the top O-ring contacts the body.
Figure 1
1. Valve port
2. Cylinder port
3. Pilot piston port
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Description

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The counterbalance valve is used between the control valve sections and hydraulic cylinders for all hydraulic functions except the
moldboard slide. Primarily, it prevents hydraulic cylinder drift under load caused by internal leakage which is characteristic of
spool valves. Its secondary function is to provide anti-cavitation and pressure relief protection to the hydraulic cylinder.
Service Information

Profile:
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Function

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The main component of the counterbalance valve is the counterbalance cartridge. This is a combination cartridge incorporating
a relief and check valve. The counterbalance valve uses two cartridges. With the control valve in neutral, oil is locked in the
cylinder by the check valves.
Setting a Counterbalance Valve
The setting of a counterbalance valve is very difficult to determine when it is in the circuit. This is due to cross piloting load
induced pressure and cylinder ratio. The best way to check the setting is to remove the valve from the circuit. Before removing
any valve, ensure that machine loads are mechanically held in position and that the valve is not under pressure at the time of
removal.
Op nbr
1. Screw the valve into a simple, single cavity line mounted body. Port 1 should be connected to a pressure source gauge.
Ports 2 and 3 should be open.
2. Increase the pressure in port C1 until the valve begins to open (cracking pressure) and note the pressure indicated on
the gauge. Repeat several times to ensure consistency.
When a control valve section is activated, oil directed to V1 enters the valve port of the cartridge, opens the check valve, and
flows to the cylinder through C1. Oil exiting the opposite end of the cylinder enters through C2 at the cylinder port of the
cartridge, but is trapped by the relief valve. As pressure builds in the piston pilot area of the cartridge shown on the right, the
piston moves to compress the relief valve springs and open a passage that allows oil to flow to V2. The oil then flows to the
control valve section and back to tank.
Figure 1
Counterbalance valve cartridge function
1. Shims
2. Cartridge body
3. Pilot to open area
4. Piston
5. Cap
6. Springs
7. Pilot piston port
8. Cylinder port
9. Valve port
10. To valve
If the cylinder encounters a shock load, a pressure spike is generated. If the pressure spike exceeds the relief valve setting, the
relief valve opens. This allows oil to flow from the C1 to V1 ports of the valve. The relief valve also opens to protect the circuit
from thermal expansion of oil. The control valve section uses motor spools; therefore, the oil can return to tank. This reduces the
chance of damage to grader components caused by the shock load.
The pilot-to-open area is five times larger than the relief-to-open area. The pressure required to open the pilot piston against
spring force is approximately 4,1 MPa (41 bar)(600 psi), while the relief-to-open pressure is 20,7 MPa (207 bar)(3000 psi).
NOTE!
R.H. and L.H. are for explanation purposes only. R.H. and L.H components are identical.
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Specifications

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Location Precharge pressure Max. operating pressure

Circle shift cylinder 4826 kPa (48 bar)(700 psi) 20,7 MPa (207 bar)(3,000 psi)
Blade lift cylinders 4826 kPa (48 bar)(700 psi) 20,7 MPa (207 bar)(3,000 psi)
Blade lift – EEC 4826 kPa (48 bar)(700 psi) 20,7 MPa (207 bar)(3,000 psi)
Figure 1
Cross section of typical piston-type accumulator
1. Piston ring
2. Square ring seal
3. Multi-ridge seal
4. Square seal ring
5. Piston ring
6. O-ring
7. Gas valve O-ring
8. Gas valve cap
9. Protector
10. Gas valve
Service Information

Profile:
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Description

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Piston-type accumulators are used in the blade lift and circle shift hydraulic circuits.
The accumulators contain a precharged amount of nitrogen gas. The nitrogen absorbs shock loads in the hydraulic circuit. For
blade lift and circle shift hydraulic circuits, shock loads can be caused by higher than normal pressure developing in the piston
end of the cylinder. If this pressure is greater than the precharge pressure in the accumulator, hydraulic oil flows from the piston
end of the cylinder into the accumulator. The cylinder then retracts.
After the shock load, the pressure at the piston end of the cylinder reduces. When the precharge pressure in the accumulator
exceeds the pressure in the cylinder, hydraulic oil flows out of the accumulator and into the cylinder. The cylinder then extends
to its position before experiencing the shock load.
Service Information

Preventive maintenance 912 Service Information 9/10/2022
Profile:
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Preventive maintenance

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Check accumulators once a month for precharge pressure and signs of damage. Also, check the precharge pressure if an
accumulator relieves too easily or requires excessive force to relieve. If a continuous change in the precharge pressure is noticed,
replace the seals. A seal kit is available. Volvo recommends installing all the seals supplied in the kit at the same time.
Service Information

Accumulator precharge 912 Service Information 9/10/2022
pressure, checking
Profile:
G780B Volvo
Accumulator precharge pressure, checking


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Op nbr 912-110
Check the precharge pressure in the accumulators using a charging kit and gauge. Apply a light coating of thread sealing
compound onto the gauge connector threads. Install the gauge into the adapter.
Figure 1
Charging kit components and gauge
1. Swivel nut
2. Air chuck
3. Bar handle
4. Bleeder valve
5. Adapter
6. Gauge
7. Hose
8. Coupling
9. Swivel connector
NOTE!
Accumulators should be at operating temperature when checking the pre charge pressure and during the charging procedure.
NOTE!
1. Remove the hydraulic tank filler cap to release any pressure and replace the cap loosely.
WARNING
personal injuries.
NOTE!
Always wear face or eye protection when disconnecting hydraulic fittings. Do not operate hydraulic system when the
accumulator is disconnected.
2. Disconnect the hydraulic hose from the accumulator. Immediately plug the open port and fitting to prevent
contamination.
3. Before installing the charging kit, turn the bar handle counterclockwise and fully retract the air chuck stem. Install the
air chuck onto the accumulator gas valve and secure with the swivel nut. Close the bleeder valve.
4. Turn the bar handle clockwise until the air chuck stem depresses the core in the accumulator gas valve. Check the
precharge reading on the gauge. Refer to Specificationsforaccumulator precharge and maximum operating
pressures. Significant temperature differences can occur between the charging temperature and operating
temperature. Adjust the precharge pressure using the appropriate correction factor listed in the Accumulator precharge
adjustment chartaccumulator precharge adjustment chart.
For example, if the precharge temperature is 33ºC (90ºF) and the expected accumulator operating temperature is 4ºC
(40ºF), the accumulator precharge pressure should be increased by a factor of 1.10, i.e. 2758 kPa x 1.10 = 3034 kPa (400
psi x 1.10 = 440 psi).
If operating temperatures below -1ºC (30ºF) are anticipated, make the following correction. For every 12ºC (10ºF) drop
below -1ºC (30ºF), increase the precharge pressure by using the formula:
Precharge minus (precharge multiplied by 520/530)
For example, at 10ºF, increase the precharge pressure for a 400 psi accumulator as follows:
400 - (400 x 520/530) x 2 (i.e. 30ºless 2 x 10º)
= 400 - (392.5) x 2
= 15
Precharge pressure = 400 + 15
= 415 psi
5. Accumulator precharge pressure can rise if oil gathers on the gas side of the piston. Also, precharge pressure can fall if
gas leaks into the oil side of the piston or out pass the gas end seals.
6. If the precharge reading is below the specified pressure (corrected according to temperature differences), charge the
accumulator.
Service Information

Accumulator -Charging 912 Service Information 9/10/2022
Profile:
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Accumulator -Charging

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Op nbr 912-111
WARNING
Gas under high pressure!
1. Connect the hose coupling to a nitrogen bottle.

NOTE!
Do not loop or twist the hose as it will stiffen when gas pressure is released from the nitrogen bottle.
2. Connect the swivel connector to the adapter and hand tighten to prevent gas leaks. Slowly open the nitrogen bottle
valve. Close the valve occasionally to allow the gauge to stabilize and show an accurate reading. When the correct
precharge pressure is reached, close the nitrogen bottle valve.
Use the bleeder valve to exhaust gas that exceeds the correct precharge pressure.
WARNING
NOTE!
Do not reduce pressure by depressing the valve core. High pressure may rupture the valve seat. Slowly remove the gas valve
until gas begins to escape through the bleed hole in the valve threads. The hole is a safety feature. It warns of stored pressure
whenever the gas valve is being removed. Install a new o-ring each time the gas valve is removed.
3. Before removing the charging kit, turn the bar handle counter clockwise and fully retract the air chuck stem. Open the
bleeder valve to relieve any gas pressure remaining in the charging kit and hose.
4. Prevent the charging kit from turning and loosen the air chuck swivel nut. Remove the charging kit. Use soapy water or
fresh system oil to check the accumulator gas valve for leaks.
5. Install the accumulator gas valve cap and protector.

6. Remove the caps and connect the hydraulic hose onto the accumulator fitting.
and test the accumulator function.
8. If the blade lift cylinders are tested, lower the moldboard to the ground. Shut down the engine. Check the hydraulic
fluid level. If any oil leaks are visible, check and tighten all connections. If leakage persists, disassemble the accumulator
and replace any faulty parts.
WARNING
NOTE!
Slowly discharge all gas pressure BEFORE disassembling the accumulator. Failure to do so can cause rapid discharge of gas and /
or hydraulic fluid. Death, personal injury and property damage could occur. Always wear face and eye protection.
The accumulator precharge check and charging procedure is now complete.

Service Information

Accumulator precharge 912 Service Information 9/10/2022
adjustment chart
Profile:
G780B Volvo
Accumulator precharge adjustment chart


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Charging temperature ºC (ºF)

Operating -1 4 10 15 21 26 33 38 43 49
temperature (30) (40) (50) (60) (70) (80) (90) (100) (110) (120)
ºC (ºF) -1 1.00 1.02 1.04 1.06 1.08 1.10 1.12 1.14 1.16 1.18
(30)
4 0.98 1.00 1.02 1.04 1.06 1.08 1.10 1.12 1.14 1.16
(40)
10 0.96 0.98 1.00 1.02 1.04 1.06 1.08 1 1.10 1.12 1.14
(50)
15 0.94 0.96 0.98 1.00 1.02 1.04 1.06 1.08 1.10 1.12
(60)
21 0.92 0.94 0.96 0.98 1.00 1.02 1.04 1.06 1.08 1.09
(70)
26 0.91 0.93 0.95 0.96 0.98 1.00 1.02 1.04 1.06 1.07
(80)
33 0.89 0.91 0.93 0.95 0.96 0.98 1.00 1.02 1.04 1.05
(90)
38 0.88 0.89 0.91 0.93 0.95 0.96 0.98 1.00 1.02 1.04
(100)
43 0.86 0.88 0.89 0.91 0.93 0.95 0.96 0.98 1.00 1.02
(110)
49 0.84 0.86 0.88 0.90 0.91 0.93 0.95 0.97 0.98 1.00
(120)
Service Information

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Specifications

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Figure 1
Typical 75 mm (3 in.) hydraulic cylinder

2. Piston
3. Cylinder barrel
4. Cylinder head
5. Wear ring
6. 90 Durometer O-ring
7. Back-up ring
8. Rod seal
9. Rod wiper
10. Piston rod
11. Cylinder nut
12. Flat washer
NOTE!
The above 3 in. hydraulic cylinder has a composite piston that is supplied with seals. The 3.5 in., 4 in., 4.5 in. and 5 in. cylinders
have conventional pistons and separate seals.
Service Information

Hydraulic Cylinder Overhaul 912 Service Information 9/10/2022
Procedure
Profile:
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Hydraulic Cylinder Overhaul Procedure


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Op nbr 912-112
89130 Cylinder wrench – 3, 3.5, 4, 4.5 in. diameter

89131 Cylinder wrench – 5 in. diameter
NOTE!
Figure 1
1. Relieve all hydraulic pressure. Take care with hydraulic circuits that contain lock valves. Disconnect the hydraulic hoses.
Immediately plug the open ports and fittings to prevent contamination. Remove the cylinder from the grader.
WARNING
Loosen carefully. There may be hot/high-pressure oil in the line.
Service Information

Hydraulic cylinder, 912 Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Hydraulic cylinder, disassembling


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Op nbr 912-113
1. Drain any oil remaining in the cylinder in an appropriate container.
Figure 1
2. Place the cylinder barrel (4) in a vise with soft jaws.

Figure 2
3. Use the appropriate size cylinder wrench to remove the cylinder nut (13) from the cylinder barrel (4).
Figure 3
4. Carefully remove the cylinder head (6) from the cylinder barrel (4).
Figure 4
5. Slowly remove the piston rod (12) and piston (3) from the cylinder barrel (4). Be prepared to catch any remaining oil in
an appropriate container. Handle the piston rod with care to prevent accidentally damaging the chrome plated surface.
Figure 5
6. Remove the cylinder barrel (4) from the vise. Secure the piston rod bearing end in a vise with soft jaws.
Figure 6
7. Remove the piston retaining bolt (1) and hardened flat washer (14).
Figure 7
8. Remove the piston (3) from the piston rod (12).

Figure 8
9. Remove and discard the piston seals (2) from the piston (3).
Figure 9
10. Remove the cylinder head (6) from the piston rod (12).
Figure 10
11. Remove and discard the 90 durometer O-ring (7) and back-up ring (8) from the cylinder head (6).
Figure 11
12. Remove and discard the wear ring (5), rod seal (9) and rod wiper (11) from the cylinder head (6).
Figure 12
13. Remove the cylinder nut (13) from the piston rod (12).
Figure 13
Cleaning and Inspection

A careful and thorough inspection of all parts is extremely important. If any evidence of damage or wear is visible, replace all
Retain O-rings, back-up rings and seals only for inspection and troubleshooting purposes. Replace all O-rings, back-up rings and
seals when overhauling hydraulic cylinders.
Use a hone to remove shallow scratches from the cylinder barrel bore. Use fine emery paper to remove scratches from the
piston.
After inspection, dip all parts in system oil and set them to one side.
Service Information

Hydraulic cylinder, 912 Service Information 9/10/2022
assembling
Profile:
G780B Volvo
Hydraulic cylinder, assembling


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Op nbr 912-114
1. Lubricate the piston rod (12) and carefully install the cylinder nut (13).
Figure 1
2. Lubricate and install a new 90 durometer O-ring (7) and back-up ring (8) in the cylinder head (6) outer groove.
NOTE!
Install only a 90 durometer O-ring. Do not install any other type of O-ring.
Figure 2
3. Lubricate and install a new wear ring (5)—removing surplus material—, rod seal (9), and rod wiper (11) in the cylinder
head (6). The rod seal lip points toward the small diameter end of the cylinder head. The rod wiper lip points toward the
outside of the cylinder nut.
NOTE!
Use the appropriate special tool to install the rod seal. See above.
Figure 3
4. Carefully install the cylinder head (6) on the piston rod (12). Note that the small diameter end of the cylinder head must
point toward the threaded end of the rod.
Figure 4
5. Lubricate and install new piston seals (2) on the piston (3). Note that the seal lips must point toward the ends of the
piston. Allow a short time for the seals to return to their original shape.
Figure 5
6. Carefully install the piston (3) on the piston rod (12).
Figure 6
7. Thoroughly clean the piston retaining bolt (1) and piston rod (12) with a solvent such as `Varsol'. Dry using moisture-
free compressed air. Ensure all threads are free of dirt, oil and grease.
NOTE!
Never substitute the piston retaining bolt with a bolt of a lower grade.
Figure 7
8. Install the piston retaining bolt (1) and the hardened flat washer (14). Tighten the bolt to the specified torque according
to the cylinder diameter size. See torque guide Specifications.
Figure 8
9. Lubricate the edge of the cylinder barrel (4). Carefully install the piston rod assembly.
Figure 9
10. Thoroughly clean the cylinder barrel (4) and cylinder nut (13) with a solvent such as `Varsol'. Dry using moisture-free
compressed air. Ensure all threads are free of dirt. Lubricate the threads with system oil.
Figure 10
11. Install the cylinder nut (13) and tighten to the specified torque according to the cylinder diameter size. See torque
guide Specifications.
Figure 11
The hydraulic cylinder overhaul is now complete.

Pressure check the cylinder at one end using a portable hydraulic power supply to 18 616 kPa (186 bar)(2700 psi). Hold at that
pressure to ensure that there are no leaks. Repeat pressure check at the other end. Install the cylinder. Road test the grader
before returning it to service.
Service Information

Special tools 912 Service Information 9/10/2022
Profile:
G780B Volvo
Special tools

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
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G780B Volvo
Figure 1
Installation tool
Cylinder size Installation tool P/N

75 mm (3 in.) 49765
100 mm (4 in.) 49766
100 mm (4 in.) (Heavy duty) 49822
Cylinder size Cylinder wrench P/N

75, 90, 100, 114 mm dia. cylinders (3 in., 3 1 /2 in., 4 in., 4 1 /2 in.) 89130
127 mm (5 in.) dia. cylinder 89131
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The solenoid valve is located on the left-hand side of the frame goose neck between the MBCS lock pin cylinder and the
transmission hydraulic circuit.
Torque Value for Cartridges 27 N•m (2,8 kgf•m)(20 lbf•ft)

Check Valve Cracking Pressure 27 kPa (0,3 bar)(4 psi)
Coil Resistance 39.3 ohms @ 20ºC (68ºF)
Service Information

Profile:
G780B Volvo
General

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The load sense shuttle valve is located at the front of the main frame on the right-hand side under the cab. It is connected
between the main hydraulic control valve and the pilot-to-close check valve load sense line circuits.
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Torque Value for Adapter 27 N•m (2,8 kgf•m)(20 lbf•ft)

Service Information

Profile:
G780B Volvo
Function

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The load sense shuttle valve(s) collect load sense signals from the main hydraulic control valve, the steering control unit, the
auxiliary hydraulic control valve and any additional valve(s). Although the pressure of these signals may be different, the valve(s)
transmit only the highest pressure signal to the pump. One shuttle valve is used on a machine with no auxiliary hydraulic control
valve. Two valves are used when the machine is equipped with an auxiliary hydraulic control valve.
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Torque Value N•m kgf•m lbf•ft

Cartridge 45 4,5 33 lbf•ft
Cracking pressure settings
Cracking pressure 21 MPa (207 bar)(3000 psi)

Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The crossover relief valve contains two relief valves in one body and protects both sides of the wing hydraulic circuit from high
pressure spikes created by shock loads. As the pressure reaches the preset level of the valve, the poppet pushes against the
spring and moves from its seat. This allows oil to by-pass to the opposite low pressure side. During normal operation, oil flows
straight through the valve and the poppets remain seated.
Typically, the crossover relief valve pressure setting is higher than the relief valve which protects the circuit. Therefore, the
crossover relief valve must be removed from its circuit for testing. Increasing or decreasing the spring pressure on the poppet
with the adjustment screw will alter the pressure setting.
Service Information

Profile:
G780B Volvo
Function

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The cross over relief valve in the wing circuit:
1. prevents shock forces being transferred to the wing.

2. smooths the wing movement during starts and stops.
Figure 1
Crossover relief valve ISO schematic
Figure 2
Crossover relief valve components
1. Body
2. Adjustment Screw
3. Locknut
4. Poppet
5. Relief valve cartridge
6. To valve
Service Information

Auxiliary load sense shuttle 912 Service Information 9/10/2022
valve
Profile:
G780B Volvo
Auxiliary load sense shuttle valve


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The auxiliary load sense shuttle valve is attached to the standard load sense shuttle valve, which is located at the front of the
main frame on the right-hand side under the cab.
Torque Value for Adapter 27 N•m (2,8 kgf•m)(20 lbf•ft)
Figure 1
ISO Schematic
Service Information

Counterbalance valve for 912 Service Information 9/10/2022
attachments
Profile:
G780B Volvo
Counterbalance valve for attachments


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Figure 2
Service Information

Counterbalance valve for 912 Service Information 9/10/2022
attachments
Profile:
G780B Volvo
Counterbalance valve for attachments


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Figure 2
ISO Schematic
Service Information

Single attachment valve 912 Service Information 9/10/2022
with relief (EEC)
Profile:
G780B Volvo
Single attachment valve with relief (EEC)


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Service Information

General Service Information 9/10/2022
Profile:
G780B Volvo
General

G780B Volvo
The 5 section auxiliary directional control valve is located at the front of the main frame on the right-hand side.
Service Information

General Service Information 9/10/2022
Profile:
G780B Volvo
General

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The 5 section auxiliary directional control valve is located at the front of the main frame on the right-hand side.
Service Information

Specifications Service Information 9/10/2022
Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Compensator spring:
Free length 21 mm (0.827 in.)
Outside diameter 7 0,1 mm (0.281 0.007 in.)
Length @ maximum load 11 mm (0.420 in.)
Length @ minimum load 18 mm (0.709 in.)
Center spool spring

Outside diameter 21 mm (0.827 in.)
1. Lower tie rod nuts 9 3 N•m (7 2.5 lbf•ft)

(pre-torque) 19 N•m (14 lbf•ft)
(final torque)
2. Upper tie rod nuts 9 3 N•m (7 2.5 lbf•ft)
(Pre torque) 45 N•m (33 lbf•ft)
(final torque)
3. O-ring plugs 65 7 N•m (48 5 lbf•ft)
4. Spring cap screws 9 1,3 N•m (7 1.0 lbf•ft)
5. Spool end assy 9 1,3 N•m (7 1.0 lbf•ft)
6. Seal plate screws 5 1,3 N•m (4 1.0 lbf•ft)
7. Connector fittings 65 7 N•m (6,6 0,7 kgf•m)
(48 5 lbf•ft)
Flow rates
Function Valve section L/min (gpm) Spool type

Extra circuit 1 64,4 (17) motor
Extra circuit 2 64,4 (17) motor
Snow wing front 3 37,8 (10) motor
Snow wing tilt 4 37,8 (10) motor
Snow wing rear 5 64,4 (17) motor
NOTE!
This valve requires the use of lock valves in the circuit.
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The 3 section auxiliary control valve is located underneath the cab floor on the right-hand side.
NOTE!
This valve requires that lock valves be used in the circuit with it.
Figure 1
Spring:
Outside diameter 7 0,1 mm (0.276 0.004 in.)
Spring:
Outside diameter 21 mm (0.827 in.)
1. Lower tie rod nuts

(pre-torque) 9 3 N•m (7 2.5 lbf•ft)
(final torque) 19 N•m (14 lbf•ft)
2. Upper tie rod nuts
(Pre torque) 9 3 N•m (7 2.5 lbf•ft)
(final torque) 45 N•m (33 lbf•ft)
3. O-ring plugs 65 7 N•m (48 5 lbf•ft)
4. Spring cap screws 9 1,3 N•m (7 1.0 lbf•ft)
5. Spool end assy 9 1,3 N•m (7 1.0 lbf•ft)
6. Seal plate screws 5 1,3 N•m (4 1.0 lbf•ft)
7. Connector fittings 65 7 N•m (6,6 0,7 kgf•m)
(48 5 lbf•ft)
Flow rates
Function Valve section L/min (gpm) Spool type

Snow wing front 1 37,9 (10) motor
Snow wing tilt 2 37,9 (10) motor
Snow wing rear 3 64,4 (17) motor
Service Information

Profile:
G780B Volvo
Specifications

G780B Volvo
Shaft rotation Counter-clockwise

Type of pump Pressure and flow compensating (load sensing) variable displacement
piston pump
Pump flow 284 Lpm (75 gpm) @2200 rpm
Pressure compensator setting 19 MPa (186 bar)(2700 psi)
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Shaft rotation Counter-clockwise

Type of pump Pressure and flow compensating (load sensing) variable displacement
piston pump
Pump flow 284 Lpm (75 gpm) @2200 rpm
Pressure compensator setting 19 MPa (186 bar)(2700 psi)
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Hydraulic pump
The main hydraulic pump is mounted on top of the hydraulic tank at the rear of the grader. Oil is drawn directly into the variable
displacement piston pump assisted by tank pressure (maximum pressure 0.3 bar, 5 psi) created by the check valve in the filler
cap of the hydraulic tank.
The steering system, cooling fan drive system, main control valve and any auxiliary hydraulic control valves are supplied by the
main hydraulic pump.
The pump has built in pressure and flow compensator control valves. The flow compensator control valve controls the standby
pressure which is also the pump bias pressure. The pressure compensator control valve limits maximum pump pressure. The
hydraulic system pressure is not regulated by the pump's pressure compensator. Instead, an external load sense relief valve is
used. The internal pressure compensator valve is set at a pressure higher than the external load sense line relief valve to prevent
it from opening. The external load sense pressure regulation is required to ensure that the system pressure and load sense
pressure are never equal. If these pressures would become equal, then the flow compensators in the hydraulic control valves
would shut and any movement of hydraulic functions would stop.
The pump maintains a standby pressure of 2413 kPa (24 bar)(350 psi) when the hydraulic controls and the steering valve are not
actuated (no demands on the pump). The cooling fan control valve always supplies oil to the cooling fan motor even if cooling
air is not required. In the “neutral” mode, the fan motor will turn at approximately 550 rpm. This demand on the pump raises the
standby pressure to a level of 3447 – 4137 kPa (34.5 – 41,4 bar)(500 – 600 psi). The actual standby pressure depends on the
temperature and viscosity of the hydraulic oil and the fan speed.
Figure 1
Main hydraulic pump, components
1. Driveshaft bearing retainer

2. Ring, shaft retainer
3. Bearing, front driveshaft
4. Seal retainer
5. Shaft seal
6. Driveshaft
7. Spline cover
8. Roll pin
9. Screw
10. Guide plate
11. Pump housing
12. Roll pin
13. Identification plate
14. Roll pin
15. Roll pin
16. Saddle bearing
17. Swashblock
18. Valve plate gasket
19. Valve plate
20. Hex head screw
21. Rear shaft cover
23. Cylinder barrel
24. Shoe retainer spring
25. Fulcrum ball
26. Shoe retainer
27. Piston/shoe assembly
28. Retainer ring
29. Cylinder bearing
30. Roll pin
Service Information

Principle of operation, main 913 Service Information 9/10/2022
hydraulic pump
Profile:
G780B Volvo
Principle of operation, main hydraulic pump


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Rotating the driveshaft turns the splined cylinder which contains the pumping pistons. When the cylinder is rotated, the pistons
move in and out of their bores as the shoes “ride” against the angled swashblock.
As the cylinder rotates, the individual piston bores are connected, alternately, to upper (port A) and lower (port B) crescent-
shaped ports in the valve plate. While connected to the upper side (suction) port A, each piston moves outward, drawing fluid
from port A into the piston bore until it's outermost stroke is reached. At that point, the piston bore passes from upper crescent
port to lower crescent port.
While rotating across the lower crescent, each piston moves across the angles swashblock face. Thus each piston is forced
inward. Each piston displaces fluid through the lower crescent to port B until it's inner most stroke is reached. At that point, the
piston bore passes from the lower to the upper crescent again and the operating cycle is repeated.
Figure 1
Position “B”. Piston pump shown delivering full volume from port B.
1. Lower crescent to pump port B

2. Upper crescent to pump port A
3. Driveshaft
4. Control pin
5. Saddle bearings
6. Swashblock
7. Fulcrum ball
8. Piston show retainer
9. Pumping pistons
10. Pump cylinder barrel
11. Swashblock angle for full port “B” delivery
12. Piston pump stroke
A study of the diagram will show that the degree of swashblock angle determines the length of piston stroke (difference
between outermost and innermost position) thereby determining the amount of delivery from the pump. In this case, the stroke
angle is one-half of the former stroke angle. Therefore, the piston stroke is one-half the former and pump delivery is one-half
the former delivery.
Figure 2
Piston pump “B/2”. Pump shown delivering one-half of maximum volume from port B.
1. Control pin
2. Swashblock angle for 1/2 delivery, port “B”
Neutral position results when the control centers the swashblock. The swashblock angle is now zero and swashblock face is now
parallel to cylinder face. Therefore, no inward or outward motion of the pump pistons exist as piston shoes rotate around the
swashblock face. The lack of inward and outward motion results in no fluid being displaced from the piston bores to the
crescents in the valve plate and consequently no delivery from the pumps.
Figure 3
Position N. Piston pump shown in neutral (no stroke, no delivery)
1. Control pin
2. Swashblock angle for zero delivery (neutral)
Service Information

Principle of operation, 913 Service Information 9/10/2022
pressure compensator
control
Profile:
G780B Volvo
Principle of operation, pressure compensator control


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
A. Starting
The bias control piston spring (1) positions the control device and connected pump swashblock (5) so the pump will deliver
maximum volume to raise pressure in the system.
B. Raising pump pressure (loading)
See Fig. 5
Pump delivery (and resultant pressure) is fed back to the control through port OP1. (In some cases, an orifice may be installed in
this port.) The four-way pilot control valve (7) is held in the “open” position by a pilot control valve spring (2). Flow (and resultant
pressure) is transmitted through the pilot control valve spool (7) to the area behind the bias control piston (1) and through
orifice port OP2. Therefore, pressure acting on either end of the pilot control valve is equal. The spool (7) is balanced and held in
the open position by the pilot control valve spring (2). Flow (and resultant pressure) is also transmitted through port OP3 and
OP4 to the adjustable pressure compensator control valve (8) and adjustable flow compensator control valve (10) which further
block flow in the control (and pressure transmittal).
NOTE!
The flow compensator valve plunger (4) is held in the closed position by a spring and system pressure.
Figure 1
Raising pump pressure
1. Bias control
2. Pilot control valve spring
3. Load sense control
4. Flow compensator plunger
5. Swashblock
6. Unloading control
7. Pilot control 4-way valve spool
8. Adjustable control relief valve
9. Relief valve plunger
10. Flow compensator control valve
11. Control pin
12. Flow control valve
C. Load sensing control

The load sensing control matches flow and pressure to load demand. As the load on the system increases, pump pressure will
also increase. But, the flow (volume) will remain constant. The flow compensator control valve (10) senses and maintains a
constant pressure differential across an orifice (flow control valve) in the delivery line. Pump flow becomes a function of the flow
control valve (12) opening area (orifice). For a given flow control valve setting, the pump will maintain a constant flow regardless
of changes in pump input speed and/or working pressure.
See Fig. 6
If differential pressure across the flow control valve (12) increases (due to increased pump input speed and/or lower working
[load] pressure), the pressure differential across the flow compensator plunger (4) also changes and the flow compensator valve
(12) opens to drain and pressure on the spring-end of the pilot control 4-way valve spool (7) is dropped. The pilot control 4-way
valve spool (7) shifts. The bias control is connected to drain and pump pressure is connected to the unloading control. Delivery is
reduced until differential pressure across the flow control valve (12) reaches the (closing) setting of the flow compensator control
valve (10).
See Fig. 5
If differential pressure across the flow control valve (12) decreases (due to decreased pump input speed and/or higher working
[load] pressure), the flow compensator control valve (10) will close to drain and the pilot control 4-way valve spool (7) will close
(by spring) to direct flow from unloading control to drain. Pump flow is transmitted to the bias control (1) to increase delivery
until the differential pressure across the flow control valve (12) reaches the setting of the flow compensator valve (10).
Figure 2
Load sensing (unloading)
D. Pressure compensating, pump unloading
Whether the differential pressure is increasing or decreasing, the pressure compensator control valve (8) takes priority. When
pressure on the cone-shaped compensator valve plunger (9) exceeds the pressure of the compensator control valve, the plunger
moves off it's seat and allows flow through the valve then through the drain line to pump case, and case drain to tank. Now,
pressure is no longer acting on the spring end of the pilot control valve spool (7). Due to the orifice in port OP2, there is still
pressure on the other end of the pilot control valve spool. This differential pressure forces the pilot control valve spool (7) to shift
and compress the pilot control valve spring (2). The pilot control valve spool (7) now allows pump delivery (and resultant
pressure) to flow to the unloading control piston (6). The pilot control valve spool (7) simultaneously drains the fluid from behind
the bias control piston (1).
The control piston now moves the control pin (11) and shifts the swashblock (5) to a position towards neutral where the pump
delivers just enough volume to maintain system pressure as regulated by the adjustable control relief valve (8).
As load pressure falls below pressure compensator valve (8) setting, the load sensing function automatically resumes.
Figure 3
Compensating pump delivery
Service Information

Hydraulic system, bleeding 913 Service Information 9/10/2022
air
Profile:
G780B Volvo
Hydraulic system, bleeding air


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 910-002
Hydraulic Pump Case Filling & Bleeding / Purging Procedure

Special Tools Required
Gauge (2 bar; 200 kPa; 30 PSI)

Air pressure regulator (outlet 0.69 bar; 69 kPa; 10 PSI maximum)
Tee fitting part number 12725662 (3/8" ORFS)
When removing the main hydraulic pump, inlet line or compensator valve, there is the possibility of air lock on the inlet side of
the pump. The following procedure should be used to bleed the main hydraulic pump.
1. Remove the pump case drain line at the pump and fill the case with clean hydraulic oil.
2. Use an air pressure regulator and gauge, set at (0.34 bar; 34 kPa; 5 PSI).
3. With the 3/8" ORFS tee connector, connect the regulated air into the hydraulic tank by way of the external load sense
line.
4. Start the engine and activate the wheel lean function several times. Avoid bottoming out the wheel lean cylinder.
5. Disconnect the air line and tee fitting
6. Replace the tank line of the load sense relief valve. The inlet side of the pump should be free of air locks.
NOTICE
Do not overpressure. Pump shaft seal may be damage.
If the air pressure is above 10 PSI (70 kPa;0.7 bar) the pump shaft seal may be damaged.
NOTE!
Do not attempt to pressurize the hydraulic tank through the oil filler cap.
Figure 1
1. To tank
2. From regulated air line (0.34 bar; 34.47 kPa; 5 psi)
3. External load sense relief valve
4. Fitting
Service Information

Main hydraulic pump 913 Service Information 9/10/2022
Profile:
G780B Volvo
Main hydraulic pump troubleshooting guide


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Malfunction Cause
Unresponsive or sluggish control
1. Low control input (pilot) pressure.
2. Swashblock saddle bearings worn or damaged.
Insufficient pump volume

1. Delivery limited by faulty control.
2. Obstructed suction circuit.
3. Insufficient engine speed.
4. Worn or grooved cylinder barrel and/or valve plate matching surfaces.
5. Worn piston/shoe assemblies or piston bores in cylinder.
6. Worn or damaged piston shoe or swashblock.
Irregular or unsteady operation

1. Faulty control.
2. Fluid level in reservoir is low.
3. Air entering hydraulic system.
4. Worn pump.
5. Faulty output circuit components (cylinders, valves, motors, etc.).
Loss of pressure
1. Worn pump.
2. Worn or grooved cylinder barrel and/or valve plate.
3. Worn piston/shoe assemblies or piston bores in cylinder.
4. Faulty output circuit components.
Excessive or high peak pressure Faulty output circuit components (pay particular attention to relief valves).
Excessive noise
1. Pump being incorrectly stopped or started under load.
2. Low fluid level in reservoir resulting in cavitation.
3. Air entering hydraulic system.
4. Fluid too cold or viscosity too high.
5. Suction line problem, i.e. obstructions in line, line too long, line diameter too
small, or too many bends/loops in line.
6. Broken or worn piston/shoe assembly.
Excessive heating
1. Operating pump above rated or peak pressure.
2. Low fluid level in reservoir.
3. Air entering hydraulic system
4. Worn piston pump.
5. Worn or grooved cylinder barrel and/or valve plate matching surfaces.
6. Faulty output circuit components (continuous blowing relief valves or “slip”
through valves, cylinder, etc.).
7. Insufficient cooling provision or clogged coolers.
Service Information

LS (load sense) pressure, 913 Service Information 9/10/2022
checking
Profile:
G780B Volvo
LS (load sense) pressure, checking


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 913-006
0 – 350 bar (0 – 5000 psi) pressure gauge
Testing and adjusting pressure settings
1. Install a gauge on the LS test ports (4) and operate the engine at an idle.
2. Lean the front wheels in either direction and hold the control lever in the fully leaned position. The pressure gauge
should read 2400 – 2550 psi (165 – 175 bar).
3. If the pressure reading is not within this range, loosen the jam nut on the external LS relief valve (5). Turn it in to
increase pressure and turn it out to reduce pressure.
4. Check the pressure again and tighten the jam nut.

Figure 1
1. Pump pressure test port

2. LS differential adjustment
3. Compensator adjustment
4. LS test port
5. External LS relief valve
Service Information

Compensator Valve Pressure 913 Service Information 9/10/2022
Setting - Checking
Profile:
G780B Volvo
Compensator Valve Pressure Setting - Checking


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 913-035
NOTE!
The LS setting must be set before setting the compensated pressure.
1. Install a gauge on pump pressure test port (1) on main hydraulic pump and operate the engine at an idle.
2. Lean the front wheels in either direction and hold the control lever in the fully leaned position. The pressure gauge
should read 2600 – 2750 psi (178 – 188 bar).
3. If it is not within this range, loosen the jam nut on the compensator valve (3). Turn it in to increase pressure and turn it
out to reduce pressure. When the pressure is set, tighten the jam nut.
Service Information

LS (load sense) Differential 913 Service Information 9/10/2022
Pressure - Checking
Profile:
G780B Volvo
LS (load sense) Differential Pressure - Checking


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 913-036
1. Install gauges at the pump pressure test port (1)(P1) and the LS test port (4)(P2). With the machine at operating
temperature, observe the two gauges and record the pressures.
2. Calculate the difference in pressure readings between the two gauges. This will be the LS pressure differential and
should be 22 – 26 bar (325 – 375 psi).
3. If the pressure differential is not 22 – 26 bar (325 – 375 psi), remove the plug from the end of the jam nut (2). Hold the
adjusting screw and loosen the jam nut on the LS valve. Turn it in to increase the pressure and turn it out to reduce
pressure. After the pressure is set, tighten the jam nut.
Hydraulic Pump - Compensator Valve Overhaul

At serial number 36591, a new compensator valve was introduced on all tandem drive models. The compensator valve is
designed with a filter edge spool. This filter edge spool design greatly reduces the possibility of contaminants plugging the
orifice in the pilot control spool. The AWD (All Wheel Drive) graders have the new compensator valve introduced at serial
number 36623.
Designation Replaced part No. New part No.

Main Hydraulic Pump 12723157 12737672
AWD - Main Hydraulic Pump 12723156 12737671
Compensator Overhaul Kit (includes seal 11704277 & (11704280) 12738956
kit)
A new compensator valve overhaul kit, part number 12738956, which includes the filter edge spool, is also available and will fit
pumps of both tandem drive and all wheel drive graders, serial number 35000 and up. The new compensator valve overhaul kit,
part number 12738956, replaces overhaul kit part number 11704277 and sealing kit part number 11704280. Applicable to
tandem drive motor grader models G710B, G720B, G730B, G740B and G780B from serial number 35000 to 36590; and AWD
motor grader models G726B and G746B from serial number 35004 to 36622.
Tools
Standard hand tools and shop equipment only
Op nbr
1. Place the grader in the Service Position. (Battery isolation switch OFF)
2. Allow sufficient time for the grader systems to cool down before starting any maintenance or repair procedure.
WARNING
3. In order to install the compensator valve overhaul kit, the compensator valve block must be removed from the body on
the main hydraulic pump.
4. On tandem drive models, access to the main hydraulic pump and compensator valve is gained by opening the rear fan
door and removing the pump cover.
The compensator valve is located on the lower right side of the main pump and can easily be removed from this
location.
Proceed to step 6 for instructions on removal of the valve block and installation of the new overhaul kit.
5. On AWD models, the compensator valve is located on the left side of the main pump. However, removing the valve
block from this location is restricted and will require disassembly and removal of the rear cooling module from the rear
frame of the grader.
Disassemble and remove the rear cooling module covers and any other components (such as the charge air cooler lines,
wiring harnesses etc.), between the cooling module and the engine compartment as required.
All lines should be tagged for identification and capped to prevent further leakage or contamination when conducting
repairs. Clean up all spilled fluids for recycling or disposal in an environmentally safe manner.
When all cooling module components and lines have been disconnected and the area is cleared, remove the mounting
bolts and carefully lift the cooling module off the grader frame to gain access to the AWD pump and compensator valve
WARNING
Proceed to step 6 for instructions on removal of the valve block and installation of the new overhaul kit.
6. When access to the compensator valve is obtained, remove the LS - load sense relief valve from the existing
compensator valve block by removing the 4 cap screws.
7. Set the LS relief valve and mounting screws aside as they will be reassembled to the new compensator valve block in
the kit.
8. Remove 2 x M12 cap screws, and 2 x M8 cap screws from the old compensator valve block.
9. Spring pressure will push the valve block away from the main body. Set the old compensator valve block assembly and
cap screws aside as they are replaced with the new kit.
10. Remove and discard the old gasket and o-ring seals.
11. If the plunger slides out of the cylinder when the valve block is removed it can be discarded along with the old
compensator valve as the new valve block includes a new plunger.
12. Thoroughly clean the valve body and apply a light coating of oil to the mating surfaces. Note: Do not allow pieces of
the old gasket, dirt, or other debris to fall into the openings in the valve assembly. Install 2 new o-ring seals.
13. Replace the existing spring into the body casting and install the new gasket supplied with the kit.
14. Install the new compensator valve block onto the body casting with 2 new M12 cap screws and torque to 68 lbf-ft, (92
N-m). Install 2 new M8 cap screws and torque to 30 lbf-ft, (40 N-m).
15. Clean the mating surfaces of the new valve block and LS relief valve. The new valve block includes 3 new o-ring seals for
the LS relief valve. Check to ensure the 3 o-ring seals are properly seated before mounting the LS relief valve.
16. Reinstall the LS relief valve onto the compensator valve block with the 4 cap screws and torque to 30 lbf-ft, (40 N-m).
17. Do not adjust the compensator or load sense valves as they are preset and do not need adjustment.
18. Reassemble all components and refill the pump case with oil. The case can be filled by disconnecting the main hydraulic
line. Reconnect all hose lines, and wiring harnesses as required and inspect for leaks.
NOTE!
Make sure the pump case has been refilled with clean hydraulic oil before the grader is started.
19. Test and confirm the compensator valve and load sense pressure settings.
20. Replace the pump cover when testing is completed, and place the grader back into service.
Specifications - ripper 2
Description-1246 3
Specifications - A-frame 4
Description-1206 5
Specifications - front mounted scarifier 6
Specifications - mid mount scarifier 7
Description-1050 8
Specifications - windrow eliminator 9
Specifications - utility dozer blade 11
Description-0948 12
Specifications - one way plow 13
Description-0908 14
Specifications - V-plow 15
Description-0828 16
Specifications - hydraulic snow wing 17
Description-0739 19
Specifications - push block 21
Description-0656 22
Service Information

Specifications - ripper 926 Service Information 9/10/2022
Profile:
G780B Volvo
Specifications - ripper

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Weight: 1 190 kg (2,625 lb)

Width of cut: 2 200 mm (86.5 in.)
Lift cylinder: Bore: 101 mm (4.00 in.)
Stroke: 438 mm (17.25 in.)
Integral counterbalance valve
Degree of tilt: 27 degrees
Ground clearance:
Tires Tooth – Work position Tooth – Carry position
13.00 X 24 377 mm (14.75 in.) 819 mm (32.25 in.)
14.00 X 24 377 mm (14.75 in.) 819 mm (32.25 in.)
17.50 X 25 390 mm (15.25 in.) 832 mm (32.75 in.)
16.00 X 24 425 mm (16.75 in.) 863 mm (34.0 in.)
20.50 X 25 445 mm (17.50 in.) 882 mm (34.75 in.)
Ripper Teeth: Accepts up to 5 ripper shanks
Tooth spacing: 584 mm (23 in.)
Maximum penetration: 457 mm (18 in.)
Scarifier teeth: Accepts up to 9 scarifier shanks
Maximum penetration: 279 mm (11 in.)
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The ripper is a rear-mounted attachment primarily useful for breaking up asphalt, loosening hard packed material or dislodging
large rocks, tree stumps and roots. It can be equipped with up to five ripper teeth and/or nine scarifier teeth depending on the
application.
Standard hydraulic components of the ripper assembly include a counterbalance valve configured for either EEC (European
Economic Community) or for non-EEC compliance. Refer to Counterbalance valve for attachments, for details regarding this
valve. The ripper also comes standard with two hydraulic cylinders located on either side of the grader frame. The purpose of
these cylinders is to raise or lower the ripper assembly. Hydraulic lines are also provided from a bulkhead located at the rear of
the grader to the counterbalance valve and then to the cylinders.
The ripper is hydraulically operated from inside the cab. Refer to the Operator's Manual for a more detailed description of
control lever location and function.
Serviceable items on the ripper assembly include pins and bushings located at all the joints. These items could show signs of
varying wear depending on the application. It is advised to inspect these pins and bushings regularly to avoid any pin failures.
The ripper teeth, scarifier teeth and shanks will display wear and can be removed and replaced as necessary. Mounting pins
located in the ripper box and upper portions of the ripper shanks may also display wear depending on operating conditions. The
counterbalance valve is a serviceable item. The hydraulic cylinder seals can be replaced should the cylinder show signs of leakage
internally or externally.
The ripper shanks can be manually raised and lowered for roading or transporting requirements. Scarifier teeth can also be
installed, removed or adjusted depending on site application and roading or transporting requirements. Refer to theOperator's
Manual for instructions on these adjustments.
Service Information

Specifications - A-frame 926 Service Information 9/10/2022
Profile:
G780B Volvo
Specifications - A-frame

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Weight: 318 kg (700 lb)

Overall height: 1 086 mm (42 3/4in.)
Overall width: 902 mm (35 1/2 in.)
Lift cylinder: Bore: 102,6 mm (4.0 in.)
Stroke: 403.1 mm (15.9 in.)
1/2 in. SAE ports
Controlled by lever on pedestal
Mount: Noseplate with M24 class 10.9 bolts
Lower arm position to ground: 613,41 mm (24.15 in.) – 13.00 X 24 tires
639,83 mm (25.19 in.) – 14.00 X 24 tires
665,23 mm (26.19 in.) – 16.00 X 24 tires
Ground clearance: 642,37 mm (25.29 in.) – 13.00 X 24 tires
655,06 mm (25.79 in.) – 14.00 X 24 tires
707,14 mm (27.84 in.) – 16.00 X 24 tires
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The A-frame is the universal attaching mechanism designed for front mounted attachments. It is used for attaching the V-plow,
one way snow plow, and dozer blade.
The standard hydraulic components for the A-frame assembly include a counterbalance valve configured for either EEC or for
non-EEC compliance. Refer to Counterbalance valve for attachments for details regarding this valve. The A-frame also comes
standard with one hydraulic cylinder mounted between the frame itself and a lifting yolk. The purpose of this cylinder is to raise
or lower the attachment mounted to the A-frame. Hydraulic lines are provided from a bulkhead located on the side of the grader
nose to the counterbalance valve and then to the cylinder.
The A-frame is hydraulically operated from inside the cab. Refer to the Operator's Manual for a more detailed description of
There are very few serviceable components on the A-frame assembly. The hydraulic cylinder seals can be replaced should the
cylinder show signs of leakage internally or externally. The counterbalance valve is a serviceable item. Pins and bores throughout
the assembly could show signs of wear depending on the application. Inspect these joints regularly to avoid any pin failures.
Service Information

Specifications - front 926 Service Information 9/10/2022
mounted scarifier
Profile:
G780B Volvo
Specifications - front mounted scarifier


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Weight: 807 kg (1,780 lb)

Width of cut: 1 168 mm (46 in.)
Length: 1 295 mm (51 in.)
1/2 in. SAE ports
Number of teeth: 5 (capable of up to 11)
Tooth spacing: 114 mm (4 1/2 in.)
Ground clearance: Top adjustment notch: 501 mm (19 3/4 in.)
(14.00 X 24 tires) Bottom adjustment notch: 476 mm
(18 3/4 in.)
Added length to grader:

G710B: 1 207 mm (47 1/2 in.) (13.00 X 24 tires)
G720B to G730B: 1 207 mm (47 1/2 in.) (14.00X 24 tires)
G740B, G746B: 1 232 mm (48 1/2 in.) (14.00 X 24 tires)
G780B 1 181 mm (46 1/2 in.) (16.00 X 24 tires)
Service Information

Specifications - mid mount 926 Service Information 9/10/2022
scarifier
Profile:
G780B Volvo
Specifications - mid mount scarifier


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

Width of cut: 1 235 mm (48 5/8 in.)
Ground penetration: 260 mm (10 1/4 in.)
Stroke: 515,87 mm (20.31 in.)
1/2 in. SAE ports
Number of teeth: 5 (up to 11)
Tooth spacing: 120 mm (4 3/4 in.)
Mount: Frame between front axle and circle
Tilt adjustment: 3-position, manual
Ground clearance: 546 mm (21 1/2 in.) teeth removed
(14.00 X 24 tires) 286 mm (11 1/4 in.) teeth top position
260 mm (10 1/4 in.) teeth bottom position

G710B 1 207 mm (47 1/2in.) (13.00 X 24 tires)
G720B to G730B 1 207 mm (47 1/2in.) (14.00 X 24 tires)
G740B, G746B 1 232 mm (48 1/2 in.) (14.00 X 24 tires)
G780B 1 181 mm (46 1/2 in.) (16.00 X 24 tires)
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Scarifiers are available in two different configurations. The front-mount scarifier is mounted to the nose plate of the grader. The
mid-mount scarifier is mounted to frame brackets located between the circle/drawbar assembly and the front axle. The scarifier
is primarily useful when breaking up surfaces that are too hard to cut with the moldboard. Typical uses may include breaking up
compacted material, asphalt, rocky subgrade and ice to facilitate grading. It can be equipped with up to eleven teeth depending
on the application.
Standard hydraulic components of both front and mid-mount scarifier assemblies include a counterbalance valve configured for
either EEC or for non-EEC compliance. Refer to Counterbalance valve for attachments. The front and mid-mount scarifiers also
come standard with a hydraulic cylinder to lift or lower the scarifier assembly.
The front mount scarifier cylinder is mounted from an H-frame secured to the grader nose plate and to the parallel lifting group
frame. Hydraulic lines are provided from the bulkhead on the side of the grader nose to the cylinder.
The mid-mount scarifier cylinder is mounted to a lug welded on the grader frame and a cross shaft secured to the top of the
grader frame. Hydraulic lines are provided from a bulkhead on the side of the grader nose to the counterbalance valve and then
to the cylinder.
Both scarifier configurations are hydraulically operated from inside the cab. Refer toOperator's Manual for a more detailed
description of control lever location and function.
The scarifier has pins, bushings, and bolts located throughout most joints of both the front-mount and mid-mount units. Inspect
these joints regularly to avoid any pin failures. The hydraulic cylinder seals can be replaced should the cylinder show signs of
leakage internally or externally. The counterbalance valve is a serviceable item.
Scarifier teeth can be removed and replaced as required, depending on the degree of wear. The scarifier tooth shanks can be
installed, removed or adjusted depending on site application and roading or transporting requirements. Refer to Operator's
Manualfor instructions.
Service Information

Specifications - windrow 926 Service Information 9/10/2022
eliminator
Profile:
G780B Volvo
Specifications - windrow eliminator


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

Blade length: 3 962 mm (156 in.)
Blade height: 432 mm (17 in.) includes cutting edge
Width of cut: 3 200 mm (126 in.) at cut angle 35º
Discharge: Right or left
End shoes: Interchangeable left or right
Blade angle: Adjustable 0º to 45º, left or right
Wheels: 4.80 X 12 – Tube-type tires
Swivel caster mount
The windrow eliminator mounts to the rear of the grader and re-distributes the windrow from the grader moldboard eliminating
a second pass by the grader. This saves time and increases efficiency. The attachment is primarily used for one-pass road surface
or road shoulder maintenance.
Standard hydraulic components of the windrow eliminator assembly include a counterbalance valve configured for either EEC or
for non-EEC compliance. Refer toCounterbalance valve for attachments for more information. The windrow eliminator also
comes equipped with one hydraulic cylinder mounted between the main frame of the assembly and a lifting arm. The purpose of
this cylinder is to raise or lower the assembly from a work position to a roading or unused position. Hydraulic lines are also
provided from a bulkhead located at the rear of the grader to the counterbalance valve and to the cylinder.
The windrow eliminator is hydraulically operated from inside the cab. Refer to the Operator's Manual for a more detailed
description of control lever location and function.
The windrow eliminator has several serviceable components. These include wheel bearings, tires, hand crank bearings, hand
crank grease seals, pins, fasteners, pull tubes, connecting arms, cutting edges and the end bit. General wear can be sustained
throughout the assembly. It is advised to inspect all of the joints and connections for wear depending on the frequency of usage
and the severity of the application. The hydraulic cylinder seals can be replaced should the cylinder show signs of leakage
internally or externally. The counterbalance valve is a serviceable item.
The windrow eliminator assembly has several adjustments. Refer to the Operator's Manual for moldboard height, angle,
position and chain lift adjustments.
Service Information

Specifications - utility dozer 927 Service Information 9/10/2022
blade
Profile:
G780B Volvo
Specifications - utility dozer blade


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Two sizes available: 2 438 mm (8 ft)

2 743 mm (9 ft)
Weight: 1 188 kg (2,620 lb) – 8 ft
1 302 kg (2,870 lb) – 9 ft
Blade height: 914 mm (36 in.)
1/2 in. SAE ports
Control lever on pedestal
Attachment length: 1 321 mm (52 in.)

G710B 1 232 mm (48.5 in.) (13.00 X 24 tires)
G720B to G730B 1 232 mm (48.5 in.) (14.00 X 24 tires)
G740B to G746B 1 257 mm (49.5 in.) (14.00 X 24 tires)
G780B 1 206 mm (47.5 in.) (16.00 X 24 tires)
Operating range:
Tire size Raised clearance Depth of cut
13.00 X 24 533 mm (21 in.) 194 mm (7 5/8 in.)
14.00 X 24 533 mm (21 in.) 194 mm (7 5/8 in.)
17.50 X 25 546 mm (21 1/2 in.) 181 mm (7 1/8 in.)
16.00 X 24 578 mm (22 3/4 in.) 149 mm (5 7/8 in.)
20.50 X 25 600 mm (23 5/8 in.) 127 mm (5 in.)
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The dozer blade assembly is a front mounted attachment primarily used for light bulldozing jobs such as leveling gravel piles,
small stump removal, fallen rock clearance from road shoulders and other blading applications that may be difficult to access
with the grader moldboard.
Standard hydraulic components for the dozer blade assembly include a counterbalance valve configured for either EEC or for
non-EEC compliance. Refer toCounterbalance valve for attachments for details regarding this valve. The dozer blade hydraulic
cylinder is mounted from an H-frame secured to the grader nose plate and to the parallel lifting group frame. The purpose of
this cylinder is to raise or lower the dozer blade assembly. Hydraulic lines are provided from the bulkhead on the side of the
grader nose to the cylinder.
The dozer blade is hydraulically operated from inside the cab, refer to the Operator's Manual for a more detailed description of
There are very few serviceable components on the dozer blade assembly. The cutting edge on the blade can be replaced as
required and will wear based on working conditions. The hydraulic cylinder seals can be replaced should the cylinder show signs
of leakage internally or externally. The counterbalance valve is a serviceable item. Pins and bores throughout the assembly could
show signs of wear depending on the application. Inspect these joints regularly to avoid any pin failures.
Service Information

Specifications - one way 927 Service Information 9/10/2022
plow
Profile:
G780B Volvo
Specifications - one way plow


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Cutting width: 3 099 mm (122 in.)

Weight: 1 065 kg (2,350 lb)
Cutting angle: 35º
Length at cutting edge: 3 785 mm (149 in.)
Overall length: 4 392 mm (173 in.)
Height at discharge end: 1 670 mm (65 3/4 in.)
Height at nose: 895 mm (35 1/4 in.)
Tip adjustment: Three position manual
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The one-way snow plow is a front-mounted attachment used in applications where only right side snow discharge is required.
There are two main features attributed to this style of snow plow:
1. A spring loaded safety trip design allows the blade to lift if it strikes an obstacle.
2. A manual tip control can be adjusted to provide the most effective attack angle for maximum clearing and efficient
snow pick-up and discharge.
This style of snow plow is secured to the grader using the A-frame attachment. Refer to Description.
The one-way snow plow assembly has a skid shoe, a blade tilt and a lift chain adjustment procedure. Refer to the Operator's
Manual for more information on adjustments.
There are no standard hydraulic components that come with this attachment. The one-way snow plow is hydraulically raised and
lowered using the A-frame attachment controls. Refer to theOperator's Manualfor a more detailed description of A-frame
Serviceable items on the one way snow plow include cutting edges, outer skid shoes, lifting chain and the lifting spade. Pins and
bores throughout the assembly could also show signs of varying wear depending on the operating conditions. Inspect these
joints regularly to avoid any pin failures.
Service Information

Specifications - V-plow 927 Service Information 9/10/2022
Profile:
G780B Volvo
Specifications - V-plow

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
9 ft Plow (2,7 m)
Length: 2 700 mm (108 in.)
Weight (chain lift): 1 134 kg (2,500 lb)
Weight (down pressure): 1 102 kg (2,430 lb)
Height at nose: 1 016 mm (40 in.)
Height at tip: 1 828 mm (72 in.)
Width at tip: 3 600 mm (12 ft)
Length from nose plate: 2 578 mm (101 1/2 in.)
Skid shoes: Three adjustable skid shoes
10 ft Plow (3,0 m)
Length: 3 000 mm (120 in.)
Weight (chain lift): 1 202 kg (2,650 lb)
Weight (down pressure): 1 166 kg (2,570 lb)
Height at nose: 1 016 mm (40 in.)
Height at tip: 1 930 mm (76 in.)
Width at tip: 3 900 mm (13 ft)
Length from nose plate: 2 578 mm (101 1/2 in.)
Skid shoes: Three adjustable skid shoes
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The V-style snow plow is a front-mounted attachment designed for severe snow clearing applications such as opening uncleared
roads. The V-plow slices the material and displaces the snow in both directions for maximum single-pass snow clearance. This
style of snow removal attachment is secured to the grader with the use of an A-frame attachment. Refer to Description.
There are no standard hydraulic components that come with this attachment. The V-plow is hydraulically raised and lowered
using the A-frame attachment. Refer to the Operator's Manual for a more detailed description of A-frame control lever location
and function.
Serviceable items on the V-plow include cutting edges, a nose piece and the inner and outer skid shoes. Pins and bores
throughout the assembly could also show signs of varying wear depending on the operating conditions. Inspect these joints
regularly to avoid any pin failures.
The V-Style snow plow assembly has a skid shoe adjustment procedure. Refer to the Operator's Manualfor this procedure.
Service Information

Specifications - hydraulic 927 Service Information 9/10/2022
snow wing
Profile:
G780B Volvo
Specifications - hydraulic snow wing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Weight
High bench: 2 177 kg (4,800 lb)
Low bench: 1 814 kg (4,000 lb)
Moldboard dimensions:
Height at toe: 737 mm (29 in.)
Height at discharge end: 1 067 mm (42 in.)
Length of cutting edge: 3 810 mm (150 in.)
Cutting width maximum: 2 921 mm (115 in.)
Cutting width minimum: 2 235 mm (88 in.)
Mounted dimensions (G740B with 14.00 tires)

Overall height: 3 454 mm (136 in.)
Minimum width, carry position: 3 048 mm (120 in.)
Masts (no wing): 2 769 mm (109 in.)
Benching height – Low: 965 mm (38 in.)
Benching height – High : 1 564 mm (61 1/2 in.)
Stand-off arms
– Two 76 mm (3 in.) straddle-mounted
– Coil spring shock absorber
– 152 mm (6 in.) adjustments to vary width and tilt
Tilt angle
Arm adjustment:
Upper 1 981 mm to 2 743 mm (78 to 108 in.)
Lower 1 981 mm to 2 743 mm (78 to 108 in.)
Mast – High bench:

Maximum level benching height: 1 524 mm (60 in.)
Ground clearance (14.00 tires)

Front mast: 254 mm (10 in.)
Rear mast: 380 mm (15 in.)
Mast – Low bench:

Maximum level benching height: 965 mm (38 in.)
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The hydraulic snow wing is a mid to rear mounted attachment designed for high or low speed snow clearing applications. It is
used in combination with the grader moldboard or snow plow as the primary plowing tool. The wing is available in high and low
bench configurations.
As material is displaced from the snow plow or moldboard, the snow wing is designed to discard the material far back from the
road surface to eliminate snow buildup and facilitate continued snow displacement. The attachment allows non-restricted left or
right articulation of the grader.
Standard hydraulic components on the hydraulic wing vary depending on the configuration. High bench hydraulic wings come
standard with three counterbalance valves and one crossover relief valve. There is one counterbalance valve for the front mast
and two counterbalance valves and one crossover relief valve for the rear mast. Counterbalance valves may be configured for
either EEC or for non-EEC compliance. The high bench hydraulic wing also comes with 3 hydraulic cylinders as standard
equipment. One cylinder is located in the front mast. It's purpose is to lift or lower the front slider assembly of the wing blade in
a straight vertical motion. Another cylinder is located in the rear mast. It's purpose is to lift or lower the rear slider assembly in a
straight vertical motion. The third cylinder is mounted to the slider plate on the rear mast and to the single standoff arm of the
wing blade. This cylinder uses a combination of vertical and horizontal movement to rotate the rear portion of the blade around
the front swivel. This enables the blade to be raised for roading or transport and lowered for snow removal.
The low bench snow wing configuration comes standard with two counterbalance valves and one crossover relief valve. There is
one counterbalance valve for the front mast and one counterbalance valve and one crossover relief valve for the rear mast.
Counterbalance valves may also be configured for either EEC or for non-EEC compliance. The low bench hydraulic wing also
comes with 2 hydraulic cylinders as standard equipment. One cylinder is located in the front mast. It's purpose is to lift or lower
the front slider assembly of the wing blade in a straight vertical motion. The other cylinder is mounted to the rear mast and to
the single standoff arm of the wing blade. This cylinder uses a combination of vertical and horizontal movement to rotate the
rear portion of the blade around the front swivel. This enables the blade to be raised for roading or transport and lowered for
snow removal.
Both high and low bench configuration hydraulic snow wings are hydraulically operated from inside the cab. Refer to the
Operator's Manual for a more detailed description of control lever locations and functions.
Serviceable items on both configurations of the hydraulic snow wings are the same. General wear can be sustained throughout
this assembly. It is advised to inspect all of the joints and connections for wear depending on usage and application. Cutting
edges are a serviced item depending on usage and conditions. It is also advised to inspect the slider rails and plates on a regular
basis. These items may also demonstrate varying degrees of wear depending on frequency of use. The hydraulic cylinder seals
can be replaced should the cylinders show signs of leakage either internally or externally. The counterbalance valves and
crossover relief valves are serviceable items. Refer to Counterbalance valve for attachmentsandFunction.
Refer to the Operator's Manual for information on wing blade pitch adjustment and positioning the wing for roading.
Service Information

Specifications - push block 929 Service Information 9/10/2022
Profile:
G780B Volvo
Specifications - push block


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Height: 851 mm (33 1/2 in.)

Width: 305 mm (12 in.)
Depth: 591 mm (23 1/4 in.)
Push area: 2 594 cm (402 in)
Wear plates: 3 – 38 mm (1 1/2 in.) thick
Tie down lugs: 2 – 89 mm (3 1/3 in.) diameter at sides near bottom
Lift eye: 1 – 38 mm (1 1/2 in.) diameter on top
Added length to grader

G710B 500 mm (20 in.) (13.00 X 24 tires)
G720B to G730B 500 mm (20 in.) (14.00 X 24 tires)
G740B, G746B 525 mm (21 in.) (14.00 X 24 tires)
G780B 475 mm (19 in.) (16.00 X 24 tires)
Service Information

Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The push block is a front mounted attachment that performs three basic functions:
1. A counter weight for the rear ripper installation.

2. A push point in environments where the grader may be called upon to be used as a push vehicle.
3. A tie down point for the front of the grader during transport.
Serviceable components of the push block are the three replaceable wear plates on the front of the unit.
Circle adjustment 2
Pinion wear 5
Description-0524 7
Circle operation 10
Troubleshooting guide 13
G710B to G746B circle and drawbar 14
Circle and drawbar; removing and disassembling-0403 15
Circle and drawbar; assembling and installing-0337 18
Mouldboard; shimming-0309 24
G780B circle and drawbar 26
Circle and drawbar; removing and disassembling 27
Circle and drawbar; assembling and installing 29
Mouldboard; shimming 33
Circle turn mechanism; disassembling 34
Circle turn mechanism; assembling 36
Drawbar ball stud; disassembling 39
Drawbar ball stud; assembling 40
Circle Setup and Timing 41
Specifications 43
Description 44
Blade lift cylinder; removing 48
Blade lift stirrup; removing 50
Blade lift arm; removing 51
Blade lift arm; installing 53
Blade lift stirrup; installing-5737 54
Blade lift stirrup; installing 55
Service Information

Circle adjustment 981 Service Information 9/10/2022
Profile:
G780B Volvo
Circle adjustment

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Adjust the front guide plate(s) to contact the inner face of the circle. Contact should be across the complete width of the guide
plate(s). With the front guide plate contacting the inner face of the circle:
Figure 1
Circle
1. Guide plates
2. Drive pinion
For models G710B to G746B:
Adjust the clearance of the rear guide plates to 1,0 mm to 2,0 mm (0.040 in. to 0.080 in.) evenly between the guide
plates and the circle.
For model G780B:
Adjust the clearance of the rear guide plates to 1,0 mm (0.04 in.) plus 1,0 mm (0.04 in.) minus 0,0 mm (0.00 in.) between
the guide plates and the circle. See picture: Circle Adjustment - Model G780B.
Figure 2
Circle Adjustment - Model G780B
1. Front of grader (viewed from bottom)

2. 0,0 mm (0.00 in.)
3. 1,0 mm (0.04 in.) plus 1,0 mm (0.04 in.) minus 0,0 mm (0.00 in.)
Check the backlash of both drive pinions. It should be 2,2 mm (0.090 in.) for each pinion.
Refer to the Section 9,Circle Setup and Timing for further information.
Maximum pinion wear 3 mm (0.125 in.)

Pinion backlash 2,0 mm (0.090 in.)
plus 0,5 mm (0.020 in.)
minus 0,25 mm (0.010 in.)
Rear guide plate clearance 1,0 mm (0.040 in.)
plus 1,0 mm (0.040 in.)
minus 0,0 mm (0.00 in.)
Figure 3
Top view
1. Master tooth “X” to “T” in line with crank arm

2. Approx. 90 degrees
3. Total backlash for each pinion is 2,2 mm
(0.09 in).
4. Left-hand cylinder
5. Right-hand cylinder
6. Front of grader (viewed from top)
Service Information

Pinion wear 981 Service Information 9/10/2022
Profile:
G780B Volvo
Pinion wear

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Pinions are only to be replaced if wear exceeds 3,0 mm (0.125 in.) limits as shown in the illustration. Deburr protruding edges
before measuring. Measure the depth using a dial caliper from the edge of the tooth surface that is not worn, to the area visibly
showing the most wear. If this measurement exceeds the limits, replace the pinions.
Figure 1
Pinion wear
1. Max. 3,0 mm (0.125 in.)

Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Adjustments mm in.
Front guide plate backlash between circle drive pinions and 2,0 +0,5 0.09 +0.02
circle teeth –0,25 –0.01
Circle turn valve pinion backlash 2,0 0.09
Clearance between guide plate and circle inside edge 1,0 +1,0 0.04 +0.04
–0,0 –0.00
Clearance between Duramide™ bearing plates and circle top 1,0 +1,0 0.04 +0.04
edge –0,0 –0.0

Drawbar split cap bolts 244 25 180
Slide shift cylinder guard bolts 339 35 250
Slide shift cylinder U-bolt nuts 13 1 10
Slide shift cylinder piston rod anchor nut 1003 102 740
Guide plate jam nut (horizontal) 248 25 183
Guide plate nut 1301 133 960
Guide plate jam nut (vertical) 755 77 557
Service Information

Description Service Information 9/10/2022
Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
Circle, drawbar and moldboard (G710B to G746B shown)
1. Moldboard
2. Slide shift cylinder
3. Slide tube with Duramide™ Bearing
4. Power tilt cylinder
5. Circle
6. Shift cylinder anchor
7. Stirrup
8. Blade lift cylinders
9. Lock bar
10. Blade lift arm
12. Guide plate with Duramide™ bearing
13. Clamp plate with Duramide™ bearing
14. Circle turn cylinders
15. Timing valve
16. Drawbar
17. Drawbar ball stud
18. Ball stud shims
19. Duramide™ slide bearing
20. Trunnion cap
21. Quadrant
Service Information

Circle operation Service Information 9/10/2022
Profile:
G780B Volvo
Circle operation

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
The cylinders are arranged 90ºout of phase to insure consistent power. During the cranking action, one cylinder is operating at
minimum torque while the other cylinder is operating at maximum torque.
The twin cylinder circle drive system provides equal power in either direction. Full load capability is instantly available when an
operator wants to turn the circle. Volvo's circle turn system is based on the following:
1. The two circle turn cylinder cranks are always 90ºout of phase to each other.
2. Due to the internal porting of the circle timing valve:
Port “AA” is always connected to cavity “A”

Port “BB” is always connected to cavity “B”
Figure 1
Diagram 1
The cylinders and timing valve are in the circle timing position. The L.H. cylinder is fully retracted and cannot provide any useful
force. The R.H. cylinder is half way through its stroke, and at the maximum torque angle. It is capable of turning the circle under
load by itself. The timing valve spool is positioned so that 100% of the oil flow entering at “AA” is directed by cavity “A” to the
rod end of the R.H. cylinder. The R.H. cylinder retracts, driving the circle clockwise which also turns the timing valve spool and
L.H. cylinder towards diagram 2.
Figure 2
Diagram 2
The rotated spool permits oil to flow to the base end of the L.H. cylinder which extends and assists the left hand cylinder to turn
the circle. Oil exiting the cylinder enters cavity “B” of the timing valve and exits through Port “BB”.
Figure 3
Diagram 3
The cylinders are positioned 90ºfrom diagram 1. The L.H. cylinder is now turning the circle by itself as the R.H. cylinder is straight
and momentarily at rest. The timing valve spool has blocked the ports leading to the R.H. cylinder.
Figure 4
Diagram 4
The cylinders and timing valve are positioned 180ºfrom diagram 1. Oil still enters at Port “AA” and flows through the internal
porting of the valve to the base end of the R.H. cylinder which extends, driving the circle clockwise.
Figure 5
Diagram 5
The cylinders are now positioned exactly opposite of diagram 2. Oil now begins pressurizing the rod end of the L.H. cylinder as
well as the base end of the R.H. cylinder. Oil is now returning to the timing valve from the base end of the L.H. and the rod end
of the R.H. cylinders.
Figure 6
Diagram 6
The timing valve spool has blocked the ports to the R.H. cylinder. Oil now pressurizes only the rod end of the L.H. cylinder and
returns from the base end.
Service Information

Troubleshooting guide Service Information 9/10/2022
Profile:
G780B Volvo
Troubleshooting guide

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

Circle drifts under load. Circle cylinders are bypassing oil. Repair or replace cylinder.
Cushion valve or counterbalance valve is Repair or replace the valve.
bypassing.
Circle will not turn. Obstruction in the circle turn mechanism. Remove debris from the circle turn
mechanism.
Circle out of adjustment. Adjust the circle.
Circle turn valve pinion or driveshaft Adjust, repair or replace the circle turn
slipping, damaged or broken. valve pinion or driveshaft.
Damaged or broken circle drive Repair or replace circle drive
mechanism. components as required.
Circle timing is out of adjustment. Adjust the circle timing.
Hydraulic malfunction. Refer to details given in Hydraulics
section.
Circle turns in wrong direction. Circle turn valve spool is 180º out of Adjust the circle turn valve spool.
adjustment.
Circle turns in only one direction. Circle turn cushion valve or Refer to details given in hydraulics
counterbalance valve is out of section.
adjustment.
Moldboard is loose. Duramide™ slide bearings are worn. Replace the Duramide™ slide bearings.
Duramide™ bearing plates are worn Replace the Duramide™ bearing plates.
There should be 1,0 mm (0.04 in.) plus
1,0 mm (0.04 in.), minus 0,0 mm (0.00 in.)
clearance between the Duramide™
bearing plates and the circle top surface.
Service Information

G710B to G746B circle and Service Information 9/10/2022
drawbar
Profile:
G780B Volvo
G710B to G746B circle and drawbar


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Before starting the removal and disassembly procedure, use the circle side shift cylinder to move the circle and drawbar out to
one side of the frame. Tilt the moldboard forward and slide it sideways as far as possible. Lower the moldboard and level on
wooden blocks. Before removing the moldboard, remove the middle bolt for the end shoe on the left-hand side.
Service Information

Circle and drawbar, Service Information 9/10/2022
removing and disassembling
Profile:
G780B Volvo
Circle and drawbar, removing and disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-071
NOTE!
1. Remove the quadrant Duramide™ bearing plates.
2. Remove the retainer bolt and slide cylinder rod end pin.
On machines S/N 35000 to 35060, excluding 35050 and 35051, remove the nut, bolt and lock washer that retain the
slide shift cylinder piston rod (or rod extension) to the moldboard lugs.
3. Retract the piston rod. Place a block of wood between the end of the piston rod and the moldboard lugs. Put a chain
around the moldboard to secure the block of wood. Tilt the moldboard all the way back, then operate the slide shift
cylinder to push the moldboard all the way out of the left-hand quadrant.
NOTE!
Make sure that the piston rod does not bend or become damaged during this procedure.
Fully retract the piston rod. Use a safe lifting device on the upper rail to support the middle of the moldboard and
remove it from the right-hand quadrant.
Figure 1
Removing moldboard using slide shift cylinder
4. Manoeuvre the circle in the near vertical position. (This helps when removing the slide shift cylinder.)
Remove the clamping plate or U-bolt, and slide shift cylinder guard.
5. Identify the slide shift cylinder hoses to avoid confusion during assembly. Disconnect the hoses from the slide shift
cylinder. Remove the fitting at the fixed (barrel) end of the cylinder. Plug the open ports and fittings to prevent
contamination. Remove the slide shift cylinder.
WARNING
Risk of flying pieces of steel.
6. Use a safe lifting device to support the quadrant. Remove the bolts and lock plate, then use a hammer and soft metal
drift to remove the lower pin on the tilt cylinder. Secure the baled tilt cylinder out of the way.
7. Remove the retainer block. Remove the slide tube with endcap and Duramide™ slide bearing. Remove the quadrant.
Figure 2
1. Retainer block
2. Slide tube with endcap and Duramide™ slide bearing
8. For machines with S/N 35000 to 35060, excluding 35050 and 35051, remove the retainer, shim pack, slide tube, and
Duramide™ slide bearing. Remove the quadrant.
WARNING
Figure 3
Removing quadrant slide tube and DuramideTM slide bearing
9. Identify the blade tilt cylinder hoses to avoid confusion during assembly. Disconnect the hoses from the blade tilt
cylinder. Plug the open ports and fittings to prevent contamination. Remove the bolts and lock plate, then use a
hammer and soft metal drift to remove the upper pin. Remove the blade tilt cylinder. Remove and discard all snap rings
when replacing spherical bearings.
10. Identify the hoses between the hydraulic swivel joint and the circle. Disconnect the hoses and plug the open ports and
fittings to prevent contamination. Remove the drive arm. Maneuver the circle to the horizontal position.
11. Support the front of the circle on a safe stand. Support the guide plates. Remove the clamp plates and shim packs.
Remove the guide plates. Start the engine when it is safe to do so. Carefully drive the grader forward to disengage the
circle teeth from the circle drive pinions. Shut down the engine. Place the transmission in neutral and apply the parking
brake.
WARNING
12. Attach chains to a safe lifting device. Securely attach the chains at three equally spaced points around the circle. Raise
and move the circle away from the grader. Center and level the drawbar. Safely secure the drawbar with chains. Start
the engine when it is safe to do so. Carefully drive the grader and steer away from the circle. (Leaning the wheels helps
in this procedure.)
When the grader is clear of the circle, shut down the engine. Place the transmission in neutral and apply the parking
brake.
Removal and disassembly of the circle, drawbar and moldboard for Models G710B to G746B is now complete.
Service Information

assembling and installing
Profile:
G780B Volvo
Circle and drawbar, assembling and installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-072
WARNING
1. Attach chains to a safe lifting device. Securely attach the chains at three equally spaced points around the circle.
Reposition the circle under the drawbar. Support the front of the circle on a safe stand. Start the engine when it is safe
to do so. Maneuver the drawbar so that the circle is centered underneath. Carefully lower the drawbar onto the circle.
2. Carefully drive the grader backward, meshing the circle teeth and circle drive pinions. Use an assistant to make sure that
the circle teeth and circle drive pinions line up properly.
NOTE!
Clearance between the circle and drawbar is adjusted using shim packs. Calculate the shim pack thickness before
installing the clamp and guide plates.
Figure 1
Meshing circle teeth and drive pinions
3. Measure the thickness of the inside edge of the circle.
4. Measure the thickness of the Duramide™ bearing material on the clamp plate. Add the circle inside edge thickness
dimension to this measurement.
Figure 2
Measuring thickness of clamp plate DuramideTM bearing
5. Now, add the clearance specification of 1 mm (0.04 in.) plus 1,0 mm (0.04 in.) or minus 0,0 mm (0.00 in.) to the total
thickness dimension calculated in step 4.
6. Measure the thickness of the guide plate and subtract this figure from the total thickness calculated in step 5. The final
figure is the equivalent shim pack thickness.
7. Assemble a shim pack equal in thickness to the final figure calculated in step 6. Repeat the procedure for each clamp
and guide plate assembly.
8. Install the shim pack between the guide plate and clamp plate. Carefully install the plate and shim pack assembly.
9. Loosen all jam nuts securing the guide plate setscrews. Loosen the front guide plate setscrews by approximately 6 mm
(1/4 in.) to allow the circle to move freely. Use a safe method to move the circle teeth away from the drive pinions.
10. Measure the distance from the inside edge of the circle to the side of the drawbar. Repeat this procedure on the
opposite side of the grader until the distance is approximately the same on both sides. Tighten the front setscrews on
the rear guide plates.
Figure 3
Adjusting circle
11. Measure the backlash between each drive pinion and the circle teeth. If the backlash for each drive pinion is not the
same, tighten the front setscrews of the rear guide plates to move the circle until the backlash measurement is equal for
both drive pinions. This procedure is less critical in the early stages of adjusting the circle and the drive pinions. It is
critical, however, to the smooth operation of the circle and must be done during the final adjustments in step 12.
12. The front guide plate should always be in contact with the circle at both ends of the guide plate. Re-check the backlash
between the drive pinions and the circle teeth. If the backlash is not equal on both sides, repeat step 11. If the backlash
is equal, tighten the setscrews of the front guide plate to pull the circle closer to the drive pinions. The clearance is 2,0
mm (0.09 in.) plus 0,5 mm (0.02 in.) or minus 0,25 mm (0.01 in.) backlash to the face of each pinion. Note that it may be
necessary to further loosen the rear guide plate setscrews to allow the circle to move freely. When the correct backlash
is obtained at both drive pinions, fully tighten the jam nuts securing the front guide plate setscrews.
13. The timing valve pinion should have approximately the same backlash as the circle teeth to the drive pinions.
14. Measure the clearance between the rear guide plates and the circle inside edge. Adjust each rear guide plate to have a
clearance of 1,0 mm (0.04 in.) plus 1,0 mm (0.04 in.) or minus 0,0 mm (0.00 in.).
15. When the circle adjustment is complete, torque-tighten all clamp and guide plate jam nuts to 1302 N•m (133 kgf•m)
(960 lbf•ft) and check all clearances and backlash.
NOTE!
Use a 30 cm (12 in.) long feeler gauge to check clearances on the circle. As a final check, make sure that the clearance
between the circle face and drawbar is correct at both ends. Install shims where required. Refer to Product Support
Bulletin 443.
Figure 4
Checking clearance between guide plate and circle
16. Support and position the quadrant. Install the slide tube equipped with the Duramide™ slide bearing and end cap.
Secure the retainer block into the quadrant.
Figure 5
Installing quadrant slide tube and DuramideTM slide bearing
Figure 6
Installing quadrant slide tube and DuramideTM slide bearing
For machines S/N 35000 to 35060, excluding 35050 and 35051, carefully install the slide tube and Duramide™ slide bearing.
Install and secure the retainer and shim pack.
17. Install the blade tilt cylinder. DO NOT connect the hoses.
18. Carefully install the slide shift cylinder. Install the fitting at the fixed (barrel) end of the cylinder. Install the clamping
plate or U-bolt. Fully tighten the clamping plate bolts.
Torque-tighten the U-bolt nuts to 13 N•m (1 kgf•m)(10 lbf•ft).
19. Install the drive arm. Connect the hoses between the hydraulic swivel joint assembly and the circle. Install the slide shift
cylinder guard.
Connect all hoses and check for correct routing and freedom of movement.
WARNING
20. Use a safe lifting device to raise the moldboard. Align the upper and lower slide rails with the right-hand quadrant and
slide tube. Start the engine when it is safe to do so. Fully extend the slide shift cylinder piston rod. Use a chain to
connect the piston rod to the moldboard. While keeping the moldboard parallel to the circle, retract the slide shift
cylinder piston rod. Guide the moldboard into place. Make sure the lower slide rail aligns with the left-hand slide tube.
Check that the upper moldboard rail aligns with the upper portion of the quadrant. When the moldboard is safely in
place, remove the chain. Extend the piston cylinder rod to reconnect it to the moldboard lugs. Insert the pin and
retainer bolt.
Torque tighten the bolt to 106 20 N•m (11 2 kgf•m)(78 14.5 lbf•ft).
Figure 7
Installing moldboard using slide shift cylinder
21. On machines S/N 35000 to 35060, excluding 35050 and 35051, secure with the nut, bolt and lock washer.
Torque-tighten the nut to 1003 N•m (102 kgf•m)(740 lbf•ft).
22. Install the middle bolt for the end shoe on the left-hand side.
Figure 8
Duramide™ bearing plates on upper quadrant
1. Retaining bolt
2. Washer
3. Rear Duramide™ bearing plate
4. Shim
5. Front Duramide™ bearing plate
6. Clamp bar
23. Start the engine when it is safe to do so. Tilt the moldboard all the way back and lower the circle assembly down onto
wooden blocks with very little down pressure. Shut down the engine. Align the rear Duramide™ bearing plate with the
drilled holes in the top portion of the quadrant and install the retaining bolts to hold the bearing plate in place.
Repeat this procedure for all upper bearing plates. (G710B – 3 places; G720B to G746B – 2 places.)
24. Start the engine when it is safe to do so. Raise the circle assembly off the wooden blocks and tilt the moldboard
completely forward. Shut down the engine.
Install the lower Duramide™ bearing plates, steel shims (if necessary) and the clamp bar. Secure retaining bolts through
the quadrant to the clamp bar. Repeat this procedure for all bearing plates on the upper quadrant.
Service Information

Mouldboard, shimming Service Information 9/10/2022
Profile:
G780B Volvo
Mouldboard, shimming

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-073
Figure 1
1. Quadrant
2. Rear Duramide™ bearing plate
3. Front Duramide™ bearing plate
4. Duramide™ slide bearing
5. Shim
The moldboard can be shimmed to remove any excessive free play. This unwanted tilting movement is a result of wear to various
bearing surfaces and affects grade quality.
Shims are placed behind the front Duramide™ bearing plates to adjust the fit between the moldboard and the quadrant.
Shims are available for models G710B to G746B in 2 sizes. They can be used in any combination of 3 mm (0.12 in) and
1,5 mm (0.06 in).
1. Place the moldboard on blocks tilted all the way forward.
2. Add or remove either one or a combination of several shims behind the front Duramide™ bearing plate.
3. Shim this gap as tight as possible while still being able to move the shims in and out of position by hand.
4. Once the appropriate shims are installed and the bearing plates are reassembled, start the grader and slide the
moldboard completely from one side to the other. This will verify any binding between the upper moldboard rail and
the quadrants.
5. If the moldboard binds, stops horizontal movement or makes noise, it is because a slide area is shimmed too tight.
6. If binding occurs, tilt the moldboard completely forward. Shut down the engine. Remove the smallest of the steel shims
installed. (For example, if there are two 3 mm shims installed, one of them may be removed and a 1,5 mm shim
installed instead.)
Assembly and installation of the circle, drawbar and moldboard for models G710B to G746B is now complete.
Service Information

G780B circle and drawbar Service Information 9/10/2022
Profile:
G780B Volvo
G780B circle and drawbar


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
NOTE!
Place the grader in the Service Position before starting this overhaul procedure. Refer toService positions .
Before starting the removal and disassembly procedure, shift the circle and drawbar out to one side of the grader frame. Tilt the
moldboard forward and slide it out to the same side as far as possible. Lower and level the moldboard on wooden blocks.
Service Information

removing and disassembling
Profile:
G780B Volvo
Circle and drawbar, removing and disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-071
1. Remove both inner and outer slide bearing retainer plates on both upper and lower quadrants.
Figure 1
1. Slide bearing retainer plates

2. Cylinder rod mount
3. Slide shift cylinder rod
2. Remove the nut and bolt retaining the slide shift cylinder piston rod to the cylinder mount.
3. Retract the cylinder rod. Place a block of wood between the end of the piston rod and the cylinder mount. Use a safe
lifting device to support the end of the moldboard. Operate the slide shift cylinder to push the moldboard out of the
slides.
NOTE!
Make sure that the slide shift cylinder piston rod does not bend or become damaged during this procedure. Fully
retract the piston rod.
4. Remove any slide bearings from the quadrants that may not have come with the moldboard.
5. Put the circle in the near vertical position. This helps when removing the slide shift cylinder. Remove the U-bolt.
6. Identify the slide shift cylinder hoses to avoid confusion during assembly. Disconnect the hoses from the slide shift
cylinder. Remove the fitting at the fixed (barrel) end of the cylinder. Plug the open ports and fittings to prevent
contamination. Remove the slide shift cylinder.
WARNING
NOTE!
Quadrant assembly will tilt when lower pins are removed.
7. Fully retract both blade tilt cylinders. Use a safe lifting device to support the quadrant assembly. Disconnect the hoses
from the blade tilt cylinders. Plug the open ports and fittings to prevent contamination. Remove the bolts and lock
plate, then use a hammer and soft metal drift to remove the lower pins. When the lower pins are removed, use the
same procedure to remove the upper pins. Remove the blade tilt cylinders. Remove and discard all snap rings when
replacing spherical bearings.
8. Support the quadrant assembly. Remove the bolts and lock plates and remove the pivot pins. Remove the quadrant
assembly. Inspect the slide bearings for serviceability. Replace excessively worn or defective parts.
9. Identify the hoses between the hydraulic swivel joint and the circle. Disconnect the hoses and plug the open ports and
fittings to prevent contamination. Remove the drive arm. Maneuver the circle to the horizontal position.
10. Support the front of the circle on a safe stand. Support the guide plates. Remove the clamp plates and shim packs.
Remove the guide plates. Start the engine when it is safe to do so. Carefully drive the grader forward to disengage the
circle teeth from the circle drive pinions. Shut down the engine. Place the transmission in neutral and apply the parking
brake.
WARNING
11. Attach chains to a safe lifting device. Securely attach the chains at three equally spaced points around the circle. Raise
and move the circle away from the grader. Center and level the drawbar. Safely secure the drawbar with chains. Start
the engine when it is safe to do so. Carefully drive the grader and steer away from the circle. Leaning the wheels helps
in this procedure. When the grader is clear of the circle, place the transmission in neutral and apply the parking brake.
Shut down the engine.
Removal and disassembly of the circle, drawbar and moldboard for Model G780B is now complete.
Service Information

assembling and installing
Profile:
G780B Volvo
Circle and drawbar, assembling and installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-072
WARNING
1. Attach chains to a safe lifting device. Securely attach the chains at three equally spaced points around the circle.
Reposition the circle under the drawbar. Support the front of the circle on a safe stand. Start the engine when it is safe
to do so. Position the drawbar so that the circle is centered underneath. Carefully lower the drawbar onto the circle.
2. Carefully drive the grader backward, meshing the circle teeth and circle drive pinions. Use an assistant to make sure that
the circle teeth and circle drive pinions line up properly.
3. Measure the thickness of the inside edge of the circle.
4. Measure the thickness of the Duramide™ bearing on the clamp plate. Add the circle inside edge thickness dimension to
this measurement.
5. Now, add the clearance specification of 1,0 mm (0.04 in.) plus 1,0 mm (0.04 in.) or minus 0,0 mm (0.00 in.) to the total
thickness dimension calculated in step 4.
6. Measure the thickness of the guide plate and subtract this figure from the total thickness calculated in step 5. The final
figure is the equivalent shim pack thickness.
7. Assemble a shim pack equal in thickness to the final figure calculated in step 6. Repeat the procedure for each clamp
and guide plate assembly.
8. Install the shim pack between the guide plate and clamp plate. Carefully install the plate and shim pack assembly.
9. Loosen all jam nuts securing the guide plate setscrews. Loosen the front guide plate setscrews by approximately 6 mm
(1/4 in.) to allow the circle to move freely. Use a safe method to move the circle teeth away from the drive pinions.
10. Measure the distance from the inside edge of the circle to the side of the drawbar. Repeat this procedure on the
opposite side of the grader until the distance is approximately the same on both sides. Tighten the front setscrews on
the rear guide plates.
11. Measure the backlash between each drive pinion and the circle teeth. If the backlash for each drive pinion is not the
same, tighten the front setcsrews of the rear guide plates to move the circle until the backlash measurement is equal for
both drive pinions. This procedure is less critical in the early stages of adjusting the circle and the drive pinions. It is
critical, however, to the smooth operation of the circle and must be done during the final adjustments in step 12.
12. The front guide plate should always be in contact with the circle at both ends of the guide plate. Re-check the backlash
between the drive pinions and the circle teeth. If the backlash is not equal on both sides, repeat step 11. If the backlash
is equal, tighten the setscrews of the front guide plate to pull the circle closer to the drive pinions. Tighten until there is
2,0 mm (0.09 in.) plus 0,5 mm (0.02 in.) or minus 0,25 mm (0.01 in.) backlash to the face of each pinion. Note that it may
be necessary to further loosen the rear guide plate setscrews to allow the circle to move freely. When the correct
backlash is obtained at both drive pinions, fully tighten the jam nuts securing the front guide plate setscrews.
13. The timing valve pinion should have approximately the same backlash as the circle teeth to the drive pinions.
14. Measure the clearance between the rear guide plates and the circle inside edge. Adjust the four remaining rear plates to
have a clearance as indicated below.
Figure 1
Measure clearance between guide plates and circle. Viewed from bottom of circle; arrow indicates front of grader.
A. 0,0 mm (0.00 in.)
B. 1,0 mm (0.04 in.) plus 1,0 mm (0.04 in.) minus 0,0 mm (0.00 in.)
15. When the circle adjustment is complete, torque-tighten all clamp and guide plate jam nuts to 1302 N•m (133 kgf•m)
(960 lbf•ft).
Use a 30 cm (12 in.) long feeler gauge to check clearances on the circle. As a final check, make sure that the clearance
between the circle inside edge to the drawbar is correct on both sides and that the backlash has not changed.
16. Support and position the quadrant assembly. Carefully install the pivot pins.
17. Install the blade tilt cylinders. DO NOT connect the hoses.
18. Carefully install the slide shift cylinder. Install the fitting at the fixed (barrel) end of the cylinder. Install the U-bolt.
Torque-tighten the U-bolt nuts to 13 N•m (1 kgf•m)(10 lbf•ft).
19. Install the drive arm. Connect the hoses between the hydraulic swivel joint assembly and the circle. Connect all hoses
and check for correct routing and freedom of movement.
20. Before installing the moldboard, install the slide bearings in the left and right-hand lower tilt quadrants. Install the inner
and outer retaining plates on each side to hold the bearings in place.
WARNING
Figure 2
– G780B moldboard slide bearing installation
1. Retaining plate
2. Shim
3. Slide bearing
4. Moldboard slide shift cylinder
21. Use a safe lifting device to raise the moldboard. Make sure it is level. Align the upper and lower slide rails of the
moldboard with the right-hand quadrant. Start the engine when it is safe to do so. Fully extend the slide shift cylinder
piston rod (or rod extension option). Use a chain to connect the piston rod to the moldboard. While keeping the
moldboard parallel to the circle, retract the slide shift cylinder piston rod and guide the moldboard into place.
As the moldboard is sliding through the right quadrant, make sure the upper and lower slide rails align with the left
quadrant. Be careful that no binding occurs as the moldboard slides through the lower part of the left-hand quadrant.
22. Once the moldboard is in place, install the upper slide bearings.
NOTE!
Use a deadblow hammer or rubber mallet when installing the bearings.
Install the inner and outer retaining plates to hold the slide bearing in place.
23. Remove the chain from the moldboard. Connect the slide shift cylinder rod to the cylinder mount.
24. Tilt the moldboard forward and rest the cutting edge on wooden blocks.
On models serial number 35000 to 35060, excluding 35050 and 35051, torque-tighten the slide shift cylinder piston rod
nut to 1003 N•m (102 kgf•m)(740 lbf•ft).
On models serial number 35061 and up, including 35050 and 35051, insert the pin and retainer bolt. Torque tighten the
retainer bolt to 106 20 N•m (11 2 kgf•m)(78 14.5 lbf•ft).
Assembly and installation of the circle, drawbar and moldboard for Model G780B is now complete.
Service Information

Mouldboard, shimming Service Information 9/10/2022
Profile:
G780B Volvo
Mouldboard, shimming

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-073
Shims can be installed to reduce the distance between the bearing and the moldboard rail. For G780B models, they are only
available in one size.
If the bearing is worn to the extent that adding shims does not maintain a tight tolerance, replace the bearings.
1. Shims are installed between the slide bearing and the slide bearing housing.
2. Shim this area as tight as possible while still being able to move shims in and out of position by hand.
3. Once the appropriate shims are installed and the bearing plates are reassembled, start the grader and slide the
moldboard completely from one side to the other. This will verify any binding between the upper and lower moldboard
rail and the quadrants.
4. If the moldboard binds, stops horizontal movement or makes noise, it is because a slide area is shimmed too tight.
5. If binding occurs, raise the circle assembly off the ground and shut down the engine. Remove steel shims as required.
Service Information

Circle turn mechanism, Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Circle turn mechanism, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-074
1. Before disassembling the circle turn mechanism, maneuver the circle turn cylinders as follows: Retract the left-hand
circle turn cylinder so that a straight line intersects all three pivot points. Ensure the right-hand circle turn cylinder and
crank is towards the drawbar. Position the cylinder so that the anchor stud, crank stud and crank centerline form an
approximate 90ºangle. This setup is crucial to the outcome of the timing exercise.
Figure 1
Relative positions of left-hand and right-hand circle turn cylinders. Viewed from the top of the grader; arrow indicates
front of machine.
A. Approximately 90º
B. Left-hand cylinder
C. Right-hand cylinder
2. To start the disassembly procedure, remove and discard the external snap ring. Use an appropriate puller to remove the
cylinder rod end from the stud. Inspect the spherical bearing and stud for excessive wear or damage. Replace defective
bearings. If the fixed (barrel) end of the cylinder has excessive play, remove and inspect the spherical bearing and stud.
3. Remove the grease fitting and external snap ring from the circle crank. Discard the snap ring. Use an appropriate
hydraulic jack to remove the circle crank from the circle drive pinion.
Figure 2
Removing circle crank
4. Use an appropriate puller to remove the spherical bearing from the circle crank. Use an appropriate soft metal drift to
remove the spherical bearing from the circle drive pinion lower housing plate. Inspect the bearings for excessive wear
or damage. Replace defective bearings.
5. Remove the circle drive pinion and bottom spacer.
Figure 3
Removing circle drive pinion and bottom spacer
6. Remove the circle turn valve, driveshaft and guard tube. Inspect for signs of wear or damage.
7. Remove and discard the valve pinion locknut. Remove the valve pinion from the pinion shaft.
8. Remove the pinion shaft bearing. Remove and discard the snap rings. Remove the jam nut, pinion shaft and thrust
washer from the bearing. Inspect the pinion shaft and bearing for excessive wear or damage. Replace defective parts.
Service Information

Circle turn mechanism, Service Information 9/10/2022
assembling
Profile:
G780B Volvo
Circle turn mechanism, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-075
30453 Anti-seize compound
1. Install the pinion shaft into the bearing and thrust washer. Secure with new snap rings. Install the bearing jam nut.
2. Install the driveshaft into the drawbar and connect the notched ends of the two shafts. Install the guard tube. Carefully
turn the pinion shaft (from below) to engage the driveshaft with the spool. Install and retain the circle turn valve on the
drawbar.
3. Install the valve pinion on the pinion shaft. Retain the pinion with a new locknut.
4. Apply a thin coating of grease onto all surfaces of the circle crank spherical bearing. Install the bearing using a hammer
and soft metal tubular drift having the same diameter as the bearing inner race. Install the bearing into the circle drive
pinion lower housing plate using a hammer and soft metal tubular drift having same diameter as the bearing outer
race.
5. Apply a coating of anti-seize compound onto the circle crank splines.

NOTE!
Installing the circle cranks into the drive pinions will always affect a correctly timed circle turn mechanism. An incorrectly
timed circle turn mechanism causes jumping and snapping at the end of the cylinder stroke. Follow this procedure to
correctly time the circle turn mechanism.
Figure 1
Positioning circle drive pinion master teeth (model G780B shown)
A. Left-hand cylinder
B. Right-hand cylinder
C. Tooth “X” in line with crank arm, left-hand side
D. Total backlash for each pinion is 2,0 mm (0.09 in.)
E. Tooth “X”, right-hand side
6. Circle drive pinion installation:
Circle drive pinions have a “master tooth” identified by an “X” or a “T”. The master tooth is used when aligning
the drive crank to the circle drive pinion.
Begin by placing the circle drive pinion and bottom spacer into the left-hand circle drive pinion housing.
Engage the master tooth with the circle as shown in the illustration (C).
Install the drive crank so the crank is in line with the circle drive pinion master tooth.
When the cylinder is installed onto the crank arm, all three pivot points should be in straight line.
Install the circle drive pinion and bottom spacer into the right-hand pinion housing so that the master tooth
points inward towards the circle turn valve (E).
When the cylinder is installed onto the crank arm, all three pivot points should form an approximate 90º angle.
Continue with the circle timing procedure.
Locate tooth “X” and insert crank into pinion as follows:
G710B to G746B – 1 internal spline tooth counter clockwise
G780B – 2 internal spline teeth counter clockwise
7. Engage the splines of the crank arm and circle drive pinion. Install the crank arm using a sledge hammer.
NOTE!
The upper spherical bearing must be guided into its bore. Make sure the lower spherical bearing is not displaced.
8. Check the installation for alignment. Install a new snap ring. Install the grease fitting.
9. Install the circle turn cylinders using a hammer and soft metal tubular drift with same diameter as the bearing inner
race. Install new snap rings.
10. Relieve all hydraulic pressure. To start, disconnect the hose at the forward left port on the circle turn valve. Immediately
cap the open port to prevent contamination. Remove the fitting.
WARNING
11. Look inside the open port. The shiny surface of the spool completely blocking the port should be visible. If so, the spool
is in the proper position. Install the fitting and connect the hose.
Figure 2
Correctly positioned spool in circle turn valve
12. If a dark portion is visible, the spool needs adjustment. To adjust the spool, first loosen the locknut retaining the valve
pinion. Turn the pinion shaft until the shiny surface of the spool is visible and completely blocks the port. Move the
spool back and forth until the edges are visible. Now centralize the spool. A hole on the spool must be visible in the
center of the port.
Check for wear between the timing valve drive shaft and timing valve spool. Excessive wear will affect timing
performance. Replace worn or damaged parts.
13. Tighten the valve pinion locknut. Check the position of the spool and make sure that it has not moved when tightening
the lock nut. Install the fitting and connect the hose.
and push the circle turn control lever forward. The circle should turn smoothly in a counter clockwise direction. If the
circle turns in a clockwise direction as viewed from the operator's seat when the lever is pushed forward, the spool is
180 degrees out of position. Shut down the engine. Repeat steps 12 and 13, but this time, turn the pinion shaft 180
degrees. Repeat step 14.
Service Information

Drawbar ball stud, Service Information 9/10/2022
disassembling
Profile:
G780B Volvo
Drawbar ball stud, disassembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-076
1. Before starting to disassemble the drawbar ball stud, center the moldboard and drawbar under the grader frame. Place
the grader in the Service Position. Refer to Service positions. Support the front of the drawbar with a safe stand.
2. Remove all bolts and lock washers securing the split ball cap to the ball seat, except the two top bolts. Remove all bolts
and lock washers securing the ball stud to the drawbar.
3. Start the engine when it is safe to do so. Drive the grader forward far enough to allow enough clearance to remove the
ball stud. Shut down the engine.
WARNING
Risk of personal injury. Very heavy object.
4. Remove the two remaining bolts and lock washers. Carefully remove the ball stud and shim pack.
5. Inspect the ball stud and ball seat for signs of wear or damage. Replace worn or damaged parts.
Service Information

Drawbar ball stud, Service Information 9/10/2022
assembling
Profile:
G780B Volvo
Drawbar ball stud, assembling


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-077
WARNING
Risk of personal injury. Very heavy object.
1. Install the ball stud on the drawbar and secure with the bolts and lock washers. Start the engine when it is safe to do so.
Drive the grader backward and mate the ball stud with the ball seat. Shut down the engine.
NOTE!
Do not install the shim pack.
2. Determine the required shim pack thickness by placing the split ball cap on the ball seat and retaining with three bolts
and lock washers.
3. Measure the gap between the ball seat and the split ball cap on four sides. Calculate the average measurement.
4. Assemble a shim pack equal in thickness to the measurement calculated in step 3. Remove the split ball cap.
5. Start the engine when it is safe to do so. Drive the grader forward far enough to insert the shim pack. Shut down the
engine. Lubricate the ball seat with general-purpose grease.
6. Start the engine when it is safe to do so. Drive the grader backward and mate the ball stud with the ball seat. Shut
down the engine. Align the shim pack and split ball cap. Install the bolts and lock washers.
7. Remove the stand and place the grader in the Service positions.
Service Information

Circle Setup and Timing Service Information 9/10/2022
Profile:
G780B Volvo
Circle Setup and Timing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-078
Figure 1
(G710B to G746B drawbar shown)
1. Circle timing valve

2. Timing shaft locknut
3. Timing valve pinion
4. L.H. Circle turn cylinder
5. Drawbar
6. R.H. Circle turn crank
7. Circle
A. Centering dimension
B. Tooth backlash
C. Guide plate to circle clearance
The Volvo grader uses two hydraulic cylinders in conjunction with a timing valve to turn the circle. The circle must be kept
properly adjusted through regular maintenance for smooth operation and long life. If the circle fails to turn smoothly, one of the
corrective measures is re-timing. Timing the circle is a 6 step procedure. Follow this procedure whenever the timing is checked or
whenever the circle is adjusted. For more detailed information, refer to Circle turn mechanism, assembling.
1. Preparing the circle for adjustment

Loosen all jam nuts securing the guide plate setscrews. Loosen the front guide plate setscrews approximately 6 mm (1/4
in.) to allow the circle to move freely. Use a safe method to move the circle teeth away from the drive pinions.
Measure the distance from the inside edge of the circle to the side of the drawbar on both sides of the grader (see
Figure, “A” dimension). Tighten the front setscrews on the rear guide plates to adjust the circle from side to side until
the distance is approximately equal on both sides.
2. Centering circle to pinions

Measure the backlash between each drive pinion and the circle teeth. If the backlash for each pinion is not the same,
tighten the front setscrews of the rear guide plates to adjust the circle until the backlash measurement is equal.
3. Setting pinion backlash

The front guide plate should always be in contact with the circle at both ends. Tighten the setscrews of the front guide
plate to pull the circle closer to the drive pinions. The backlash to the face of each pinion is set at 2,0 mm (0.090 in.)
plus 0,5 mm (0.020 in.) or minus 0,25 mm (0.010 in.). Note that you may have to further loosen the rear guide plate
setscrews to allow the circle to move freely. The timing valve pinion should have the same backlash as the circle teeth.
When you have obtained the correct backlash at both pinions, fully tighten the jam nuts securing the front guide plate
setscrews.
4. Setting guide plate clearance

Measure the clearance between the rear guide plates and the circle inside edge. Adjust each rear plate to have a
clearance of 1,0 mm (0.040 in.) plus 1,0 mm (0.040 in.) or minus 0,0 mm (0.0 in.).
Adjusting circle turn valve
5. Setting crank position

Fully retract the left-hand cylinder so that a straight line passes through all 3 pivot points. Ensure that the right-hand
cylinder and crank is towards the drawbar (5). Position the cylinder so that a straight line drawn between the center of
the cylinder anchor and the center of the crank shaft will form an approximate 90º angle with a line drawn through the
centers of both the crank shaft and pivot.
6. Set timing valve

After relieving all hydraulic pressures, locate and remove a hose and fitting from one of the ports on the timing valve
connected to the left-hand cylinder. The valve spool must completely block the port. If adjustment is required, loosen
the timing pinion shaft lock nut (2) and rotate the shaft until the spool is centered, completely blocking the port. A hole
on the spool must be visible in the center of the port.
Check for wear between the timing valve drive shaft and timing valve spool. If excessive, timing performance will suffer.
Secure the lock nut and ensure that the spool did not move. Replace all fittings and hoses.
The circle should turn in a counter clockwise direction when pushing the circle turn control lever forward. If the circle
turns in a clockwise direction, the spool is 180º out of position. Turn the valve spool 180º and repeat this step.
Service Information

Profile:
G780B Volvo
Specifications

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo

Blade lift arm retaining pin bolt 380 39 280
Blade lift arm retaining pin end cap bolts 380 39 280
Blade lift arm pivot pin bolts 380 39 280
Stirrup shank end cap bolts 380 39 280
Stirrup bushing housing bolts 108 11 80
Blade lift cylinder ball cap bolts 624 63 460
Service Information

Description Service Information 9/10/2022
Profile:
G780B Volvo
Description

G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Figure 1
1. Lock washer
2. Lock washer
3. Grease fitting
4. Nut
5. Bolt
6. Bolt
7. Bolt
8. Bolt
9. Plug
10. Washer
11. Thrust washer
12. Bushing
13. Housing - bushing
14. Arm - R.H.
15. Arm - L.H.
16. Pin - retaining
17. Stirrup
18. Bushing
19. Lockbar
20. Spacer
21. Bushing
22. Pivot pin
23. End cap
24. Bushing
25. Ball pin - lockbar
The Moveable Blade Control System (MBCS) provides extreme blade reach and mobility. The G780B features Heavy Moveable
Blade Control System (HMBCS). The MBCS's mobility is based around four pivot points with a lock cylinder to affix the system.
Visibility to the work area is unimpeded by “over the frame” components. Blade lift geometry features wide stance and parallel
lift cylinders to minimize blade end to end interaction. Additionally, the side shift cylinder is close to horizontal, minimizing side
swing when repositioning the circle.
Components
The arms are shaped to provide optimum visibility to the work area. The arms rotate on large diameter pins attached to the
frame and are supported by greaseable, solid bushings. A lock bar links the arms together and a lock cylinder prevents
movement of this assembly. By retracting the lock cylinder out of the lock bar and operating the blade lift cylinders to reposition
the arms, the lock bar can be swung back and forth under the frame to seven positions. The lock cylinder fixes the lock bar in
place when the arms have reached their desired angle. Dimples on the arms indicate when the lock cylinder is in line with a hole
in the lock bar. The circle side shift cylinder is mounted to the drawbar and the lock bar. The circle side shift provides lateral
movement of the circle and moldboard. Stirrups mount into the arms and are supported by greaseable solid bushings and thrust
washers. The blade lift cylinders are mounted into the stirrups with trunnion mounts which are supported by greaseable solid
bushings.
Adjustments
Bearing adjustment is rarely required as bushings with no preload adjustment are used at all bearing points. The large diameter
of the bearing pins lowers bearing surface pressure and thus increases their service life. Any visible movement of the
components indicates wear. Cylinder ball caps are a matched set and cannot be interchanged or reversed. Remove shims as
necessary to remove free play.
Lock cylinder hydraulic circuit
Oil is taken from a tee fitting on the outlet of the filter head (1) to operate the Moveable blade control system lock cylinder
circuit. A switch on the pedestal controls the flow of oil through the valve (2) to the lock cylinder (3). The valve incorporates a
check valve on the inlet which serves to lock the oil in the cylinder when the piston rod is extended forward (locked position). A
switch activated by the lock cylinder piston rod illuminates a status light in the pedestal display to indicate the lock bar is
disengaged.
The cylinder piston rod nose is tapered to mate with tapered holes in the lock bar. This eases engagement and ensures a tight fit.
The lock cylinder piston rod is made from hardened stainless steel to prevent corrosion during periods of long engagement with
the lock bar.
Figure 2

2. Solenoid valve
3. Lock cylinder
4. From transmission pump
Service Information

Blade lift cylinder, removing Service Information 9/10/2022
Profile:
G780B Volvo
Blade lift cylinder, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-081
NOTE!
WARNING
1. Attach a safe lifting device to the top of the blade lift cylinder. Make sure the lock bar lock pin is fully engaged.
2. Mark the two halves of the ball cap. This ensures correct orientation of the halves during assembly. Remove the ball cap
lower half, shims, bolts and washers.
Figure 1
Removing blade lift cylinder ball cap
3. Start the grader when it is safe to do so. Fully retract the cylinder rod. Shut down the engine. Temporarily reinstall the
ball cap lower half, shims, bolts and washers.
WARNING
NOTE!
Residual pressure may remain in hydraulic circuits containing lock valves. Refer toService positions for more information on
relieving trapped pressure in hydraulic lines.
4. Identify the hydraulic hoses to avoid confusion during assembly. Disconnect the blade lift cylinder hoses. Plug the open
ports and fittings to avoid contamination.
5. Remove the stirrup bushing housing bolts and lock washers.
6. Use jacking screws to remove the bushing housings. Inspect the bushings for serviceability. Replace defective bushings.
7. Remove the blade lift cylinder from the stirrup.

Service Information

Blade lift stirrup, removing Service Information 9/10/2022
Profile:
G780B Volvo
Blade lift stirrup, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-082
1. Attach a safe lifting device to the blade lift stirrup. Remove the bolts and lock washers retaining the end cap. Remove
the end cap and thrust washer.
2. Carefully slide the stirrup out of the blade lift arm. Remove the thrust washer.
3. Use a hammer and appropriate soft metal drift to remove the blade lift arm bushings.
Service Information

Blade lift arm, removing Service Information 9/10/2022
Profile:
G780B Volvo
Blade lift arm, removing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-083
1. Attach a safe lifting device to the blade lift arm. Remove the nuts, bolts and washers clamping the blade lift arm to the
pivot pin.
2. Carefully remove the pivot pin out of the blade lift arm.
3. Rotate the blade lift arm until the stirrup bore is uppermost.
Figure 1
Rotating the blade lift arm
4. Remove the bolts and lock washers retaining the end cap. Remove the end cap.
5. Remove the bolt, washer and spacer at the tab end of the blade lift arm retaining pin. Carefully remove the retaining pin
and thrust washers.
6. Carefully remove the blade lift arm.
7. Use a hammer and appropriate soft metal drift to remove the remaining blade lift arm bushings.
Service Information

Blade lift arm, installing Service Information 9/10/2022
Profile:
G780B Volvo
Blade lift arm, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-084
WARNING
1. Use a hydraulic press and appropriate driver to install new bushings in the blade lift arm counterbores. Use a hammer
and appropriate driver to install new bushings in the frame bracket bores. Apply grease to all bushings.
NOTE!
Align the grease holes in the bushings and blade lift arms before installing the bushings.
2. Attach a safe lifting device to the blade lift arm. Maneuver the arm into position at the frame brackets and align the
bores.
3. Install the blade lift arm retaining pin through the bushing bore of the front frame bracket. Install a thrust washer
between the bracket and arm as you install the pin.
4. Continue installing the retaining pin. Install a thrust washer between the arm and the rear frame bracket.
5. When the retaining pin is fully installed, secure it with the bolt, washer and spacer at the tab end.
Torque-tighten the bolt to 380 N•m (39 kgf•m)(280 lbf•ft).
6. Install the end cap and retain it with the bolts and lock washers.
7. Align the bores of the blade lift arm and lockbar. Grease the bores. Align the grooves in the pivot pin with the clamping
bolt holes in the arm.
8. Carefully install the pivot pin. Install the nuts, bolts and washers.
Service Information

Blade lift stirrup, installing Service Information 9/10/2022
Profile:
G780B Volvo
Blade lift stirrup, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-085
1. Attach a safe lifting device to the blade lift stirrup.
2. Install a thrust washer onto the stirrup shank. Carefully install the stirrup into the blade lift arm bore.
3. Install a thrust washer, end cap, bolts and lock washers.

Service Information

Blade lift stirrup, installing Service Information 9/10/2022
Profile:
G780B Volvo
Blade lift stirrup, installing


G710B Volvo
G720B Volvo
G726B Volvo
G730B Volvo
G740B Volvo
G746B Volvo
G780B Volvo
Op nbr 981-085
1. Attach a safe lifting device to the blade lift stirrup.
2. Install a thrust washer onto the stirrup shank. Carefully install the stirrup into the blade lift arm bore.
3. Install a thrust washer, end cap, bolts and lock washers.


Volvo G780B Motor Graders Repair Service Manual11 PDF

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0 - Foreword 2

Document Title: Function Group: Information Type: Date:

Read through and follow “Safety and Environment”.

Document Title: Function Group: Information Type: Date:

Valid for serial numbers

Document Title: Function Group: Information Type: Date:

Product identification plates

Valid for serial numbers

Document Title: Function Group: Information Type: Date:

Valid for serial numbers

Document Title: Function Group: Information Type: Date:

Transporting the machine

Valid for serial numbers

1. Articulation lock pin

Load and unload the grader on a level surface.

1. Rotating beacon light

1. Place the transmission in neutral and apply the parking brake.

3. Place grader in the Service position. Refer to Service positions

5. Relieve residual hydraulic pressure by operating all the control levers.

1. Battery isolation switch

Lifting arrangement and tie-down locations

1. 15° maximum lifting angle

Document Title: Function Group: Information Type: Date:

Valid for serial numbers

1. Inspect for leaks and other defects. Correct as necessary

Preparing for operation after long-term parking

Document Title: Function Group: Information Type: Date:

Grader setup instructions

Valid for serial numbers

Remove the protective coating using mineral spirits or degreasing solvents.

1. Air cleaner rain cap

General walk-around inspection

Perform the following general walk-around inspection.

Check the engine oil level

Check the engine oil level with the engine off.

Check the oil for contaminants or water.

1. Transmission oil level sight glass

Checking the hydraulic oil fluid level

Clean any dirt from around the filler cap.

Procedures before starting the machine

Starting the engine

4. Wait until the engine has stopped completely.

Starting a cold engine

A. Control lamp, preheating element

1. Left-hand blade lift lever

Installing rims and tires without a crane

Reassembly – Cab structure

Reassembly – Electrical, HVAC, seat

1. Left-hand cover moulding

1. Installation mounts for optional equalizer/converter or fire extinguisher

1. Right-hand door post

Reassembly – Blade lift cylinders

Other hydraulic connections

1. Circle turn counterbalance valve

Pictorial torque guide

Document Title: Function Group: Information Type: Date:

Operation numbers for additional work

Valid for serial numbers

Other work related to engine

Description of work that has been done

Other work related to electrical system

Description of work that has been done

Other work related to transmission, gearbox, travel motor, swing motor