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Komatsu GD530A, GD650A, GD670A Series Motor Grader Manual – PDF DOWNLOAD
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Description
Komatsu GD530A, GD650A, GD670A Series Motor Grader Manual
FILE DETAILS:
Komatsu GD530A, GD650A, GD670A Series Motor Grader Manual
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBMG65194
Total Pages : 1053
TABLE OF CONTENTS:
Komatsu GD530A, GD650A, GD670A Series Motor Grader Manual
MAIN MENU........................................................................................................................... 0 CONTENTS FOR CEBMG65194............................................................................................................. 2 A-01.50K - ARTICULATION JOINT ASSEMBLY ............................................................................................ 3 TABLE OF CONTENTS............................................................................................................... 5 INTRODUCTION.................................................................................................................... 6 SERVICING....................................................................................................................... 7 REMOVAL..................................................................................................................... 7 DISASSEMBLY................................................................................................................. 12 CLEANING AND INSPECTION..................................................................................................... 14 REASSEMBLY.................................................................................................................. 16 INSTALLATION................................................................................................................ 19 A-10.40K - CHAR-LYNN ORBITROL UNIT ................................................................................................. 23 TABLE OF CONTENTS............................................................................................................... 23 INTRODUCTION.................................................................................................................... 26 SERVICING....................................................................................................................... 28 REMOVAL..................................................................................................................... 28 DISASSEMBLY................................................................................................................. 28 CLEANING INSPECTION......................................................................................................... 35 REASSEMBLY.................................................................................................................. 37 INSTALLATION................................................................................................................ 42 C-11.40K R1 - TRANSMISSION POWER SHIFT (FUNK 2263E130B)............................................................................. 43 TABLE OF CONTENTS............................................................................................................... 45 SPECIAL TOOLS................................................................................................................... 46 CHANNEL SUPPORT TOOL........................................................................................................ 46 CLUTCH PACK REMOVAL TOOL.................................................................................................... 47 CLUTCH SPRING COMPRESSION TOOL.............................................................................................. 48 INTRODUCTION.................................................................................................................... 49 OPERATION................................................................................................................... 49 RULES OF OPERATION.......................................................................................................... 49 SERVICE..................................................................................................................... 51 RECOMMENDED LUBRICANT AND FILTER CHANGE INTERVALS........................................................................... 52 GENERAL LOCATION OF COMPONENTS.............................................................................................. 53 VOLTAGE AND ELECTRICAL POWER REQUIREMENTS................................................................................... 54 CLUTCH SOLENOID VALVE REQUIREMENTS.......................................................................................... 54 PRESSURE AND FLOW CHECKS.................................................................................................... 55 SETTING THE CLUTCH PRESSURE................................................................................................. 56 TRANSMISSION SCHEMATICS..................................................................................................... 57 TROUBLESHOOTING................................................................................................................. 58 FLYWHEEL DIMENSIONAL CHECKS..................................................................................................... 64 CONVERTER ASSEMBLY INSTALLATION INTO TRANSMISSION IF SEPARATED FROM TRANSMISSION................................................ 67 SERVICING....................................................................................................................... 68 REMOVAL..................................................................................................................... 68 TRANSMISSION................................................................................................................ 78 Disassembly............................................................................................................. 78 Transmission/Torque Converter Disassembly........................................................................... 78 Front Cover Disassembly............................................................................................. 80 Main Case Disassembly............................................................................................... 82 Torque Converter Disassembly (S/N 200417 Thru 202050)............................................................... 86 Torque Converter Disassembly (S/N 202051 and UP).................................................................... 88 Clutch Pack 1 and 5 Disassembly (First Stage)....................................................................... 90 Clutch Pack 2 and 6 Disassembly (Second Stage)...................................................................... 93 Clutch Pack 3 and 4 Disassembly (Third Stage)....................................................................... 96 Control Valve Disassembly........................................................................................... 100 Cleaning and Inspection................................................................................................. 102 Reassembly.............................................................................................................. 104 Front Cover Reassembly.............................................................................................. 104 Torque Converter Reassembly (S/N 200417 Thru 202050)................................................................ 108 Torque Converter Reassembly (S/N 202051 and UP)..................................................................... 110 Clutch Pack 1 and 5 Reassembly (First Stage)........................................................................ 112 Clutch Pack 2 and 6 Reassembly (Second Stage)....................................................................... 117 Clutch Pack 3 and 4 Reassembly (Third Stage)........................................................................ 122 Control Valve Reassembly............................................................................................ 128 Main Case Reassembly................................................................................................ 130 Transmission/Torque Converter Reassembly............................................................................ 134 TRANSFER CASE............................................................................................................... 136 Disassembly............................................................................................................. 136 Cleaning and Inspection................................................................................................. 137 Reassembly.............................................................................................................. 138 INSTALLATION................................................................................................................ 141 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL................................................................................... 152 STARTUP PROCEDURE............................................................................................................... 153 E-01.15K - ALL WHEEL DRIVE PUMP (REXROTH) .......................................................................................... 155 TABLE OF CONTENTS............................................................................................................... 157 INTRODUCTION.................................................................................................................... 158 INTERPRETATION OF TYPE CODES.................................................................................................... 163 DIAGNOSTIC PORTS................................................................................................................ 164 TROUBLESHOOTING................................................................................................................. 166 SERVICING....................................................................................................................... 169 REMOVAL..................................................................................................................... 169 CHARGE PUMP (IN WARRANTY SERVICE)........................................................................................... 171 Disassembly............................................................................................................. 171 Reassembly.............................................................................................................. 172 SHAFT SEAL (IN WARRANTY SERVICE)............................................................................................ 173 Disassembly............................................................................................................. 173 Reassembly.............................................................................................................. 174 MAIN PUMP DISASSEMBLY (OUT OF WARRANTY SERVICE)............................................................................. 175 CLEANING AND INSPECTION..................................................................................................... 183 MAIN PUMP REASSEMBLY (OUT OF WARRANTY SERVICE).............................................................................. 185 INSTALLATION................................................................................................................ 194 TESTS AND ADJUSTMENTS........................................................................................................... 196 E-03.90K R1 - CIRCLE REVERSE MOTOR (DANFOSS) ....................................................................................... 197 TABLE OF CONTENTS............................................................................................................... 197 LOCATION ON MACHINE............................................................................................................. 199 DESCRIPTION..................................................................................................................... 200 SERVICING....................................................................................................................... 204 REMOVAL..................................................................................................................... 204 DISASSEMBLY................................................................................................................. 204 CLEANING AND INSPECTION..................................................................................................... 210 REASSEMBLY.................................................................................................................. 212 INSTALLATION................................................................................................................ 219 E-03.95K - CIRCLE REVERSE MOTOR P/N 1435 598 H91 (CHAR-LYNN)........................................................................ 220 TABLE OF CONTENTS............................................................................................................... 222 SPECIAL TOOLS................................................................................................................... 223 INTRODUCTION.................................................................................................................... 227 SERVICING....................................................................................................................... 228 REMOVAL..................................................................................................................... 228 DISASSEMBLY................................................................................................................. 228 CLEANING AND INSPECTION..................................................................................................... 231 REASSEMBLY.................................................................................................................. 233 INSTALLATION................................................................................................................ 236 TESTS AND ADJUSTMENTS........................................................................................................... 237 E-04.60K - STEERING & BRAKE PUMP (EATON MODEL 70422 RDU) ........................................................................... 238 TABLE OF CONTENTS............................................................................................................... 240 LOCATION ON MACHINE............................................................................................................. 241 DESCRIPTION..................................................................................................................... 241 SPECIFICATIONS.................................................................................................................. 244 SERVICE DIAGNOSIS............................................................................................................... 245 SERVICE/SPECIAL TOOLS........................................................................................................... 247 PRESSURES....................................................................................................................... 247 SPECIAL TORQUES................................................................................................................. 247 TESTS AND ADJUSTMENTS........................................................................................................... 247 START-UP PROCEDURE.......................................................................................................... 247 SERVICING....................................................................................................................... 249 REMOVAL..................................................................................................................... 249 DISASSEMBLY................................................................................................................. 251 CLEANING AND INSPECTION..................................................................................................... 254 REASSEMBLY.................................................................................................................. 257 INSTALLATION................................................................................................................ 259 E-13.30K - HYDRAULIC MOTOR (VICKERS) (ALL WHEEL DRIVE) ............................................................................. 260 TABLE OF CONTENTS............................................................................................................... 262 LOCATION ON MACHINE............................................................................................................. 263 DESCRIPTION..................................................................................................................... 263 OPERATION....................................................................................................................... 264 SPECIFICATIONS.................................................................................................................. 265 SERVICE DIAGNOSIS............................................................................................................... 266 SERVICE/SPECIAL TOOLS........................................................................................................... 268 SERVICING....................................................................................................................... 270 REMOVAL..................................................................................................................... 270 DISASSEMBLY................................................................................................................. 270 CLEANING AND INSPECTION..................................................................................................... 273 REASSEMBLY.................................................................................................................. 275 INSTALLATION................................................................................................................ 279 TESTS AND ADJUSTMENTS........................................................................................................... 280 E-30.40K - HYDRAULIC OIL SWIVEL BLOCK (FOUR-WAY) ................................................................................... 281 TABLE OF CONTENTS............................................................................................................... 283 SPECIAL TOOLS................................................................................................................... 284 INTRODUCTION.................................................................................................................... 285 SERVICING....................................................................................................................... 286 REMOVAL..................................................................................................................... 286 DISASSEMBLY................................................................................................................. 287 CLEANING AND INSPECTION..................................................................................................... 288 REASSEMBLY.................................................................................................................. 289 INSTALLATION................................................................................................................ 290 TESTING AND ADJUSTMENTS......................................................................................................... 291 E-32.35K - CONTROL VALVE MANIFOLDS (HUSCO 5000C SERIES) ............................................................................ 292 TABLE OF CONTENTS............................................................................................................... 294 INTRODUCTION.................................................................................................................... 295 TROUBLESHOOTING................................................................................................................. 307 SERVICING....................................................................................................................... 310 REMOVAL..................................................................................................................... 310 DISASSEMBLY................................................................................................................. 313 Disassembly of Control Valve Bank....................................................................................... 313 Disassembly of Valve Section............................................................................................ 315 Valve Section Identification............................................................................................ 315 CLEANING AND INSPECTION..................................................................................................... 317 REASSEMBLY.................................................................................................................. 319 Reassembly of Valve Section............................................................................................. 319 Reassembly of Control Valve Bank........................................................................................ 321 INSTALLATION................................................................................................................ 323 E-32.45K - MAIN SYSTEM PUMP ........................................................................................................ 325 TABLE OF CONTENTS............................................................................................................... 325 INTRODUCTION.................................................................................................................... 327 TROUBLESHOOTING................................................................................................................. 332 SERVICING....................................................................................................................... 334 REMOVAL..................................................................................................................... 334 DISASSEMBLY................................................................................................................. 336 CLEANING AND INSPECTION..................................................................................................... 344 REASSEMBLY.................................................................................................................. 345 INSTALLATION................................................................................................................ 353 E-32.90K - ALL WHEEL DRIVE HYDRAULIC INTEGRATED CIRCUIT (HIC) VALVE ................................................................ 356 TABLE OF CONTENTS............................................................................................................... 358 INTRODUCTION.................................................................................................................... 359 TROUBLESHOOTING................................................................................................................. 365 SERVICING....................................................................................................................... 366 REMOVAL..................................................................................................................... 366 DISASSEMBLY................................................................................................................. 367 HIC Valve Disassembly................................................................................................... 367 Solenoid Cartridge Disassembly.......................................................................................... 369 CLEANING AND INSPECTION..................................................................................................... 370 REASSEMBLY.................................................................................................................. 372 Solenoid Cartridge Reassembly........................................................................................... 372 HIC Valve Reassembly.................................................................................................... 373 INSTALLATION................................................................................................................ 375 E-33.00K R1 - HYDRAULIC CYLINDERS .................................................................................................. 376 TABLE OF CONTENTS............................................................................................................... 378 INTRODUCTION.................................................................................................................... 380 SERVICE DIAGNOSIS............................................................................................................... 380 SPECIAL TORQUES................................................................................................................. 381 TESTS AND ADJUSTMENTS........................................................................................................... 382 FRONT WHEEL ALIGNMENT & TURNING RADIUS ADJUSTMENT........................................................................... 382 HYDRAULIC PRESSURE TESTING FOR CYLINDERS.................................................................................... 385 BALL AND SOCKET SHIMMING ADJUSTMENT......................................................................................... 386 SERVICING....................................................................................................................... 387 CLEANING AND INSPECTION..................................................................................................... 387 STEERING CYLINDERS.......................................................................................................... 388 Removal................................................................................................................. 388 Disassembly............................................................................................................. 389 Cleaning and Inspection................................................................................................. 389 Reassembly.............................................................................................................. 389 Installation............................................................................................................ 391 LEANING WHEEL CYLINDER...................................................................................................... 392 Removal................................................................................................................. 392 Disassembly............................................................................................................. 393 Cleaning and Inspection................................................................................................. 393 Reassembly.............................................................................................................. 393 Installation............................................................................................................ 395 MOLDBOARD TILT CYLINDERS.................................................................................................... 396 Removal................................................................................................................. 396 Disassembly............................................................................................................. 397 Cleaning and Inspection................................................................................................. 397 Reassembly.............................................................................................................. 397 Installation............................................................................................................ 399 MOLDBOARD SIDE SHIFT CYLINDER............................................................................................... 400 Removal................................................................................................................. 400 Disassembly............................................................................................................. 402 Cleaning and Inspection................................................................................................. 402 Reassembly.............................................................................................................. 402 Installation............................................................................................................ 404 DRAWBAR SIDE SHIFT CYLINDER (R.H. BLADE SUSPENSION ONLY).................................................................... 406 Removal................................................................................................................. 406 Disassembly............................................................................................................. 407 Cleaning and Inspection................................................................................................. 407 Reassembly.............................................................................................................. 407 Installation............................................................................................................ 409 DRAWBAR SIDE SHIFT CYLINDER (R.H. & L.H. BIAS BLADE SUSPENSION ONLY)........................................................ 410 Removal................................................................................................................. 410 Disassembly............................................................................................................. 411 Cleaning and Inspection................................................................................................. 411 Reassembly.............................................................................................................. 411 Installation............................................................................................................ 413 DRAWBAR LIFT CYLINDERS (R.H. BLADE SUSPENSION ONLY)......................................................................... 414 Removal................................................................................................................. 414 Disassembly............................................................................................................. 416 Cleaning and Inspection................................................................................................. 416 Reassembly.............................................................................................................. 416 Installation............................................................................................................ 418 DRAWBAR LIFT CYLINDERS (R.H. & L.H. BIAS BLADE SUSPENSION ONLY)............................................................. 420 Removal................................................................................................................. 420 Disassembly............................................................................................................. 422 Cleaning and Inspection................................................................................................. 422 Reassembly.............................................................................................................. 422 Installation............................................................................................................ 424 SCARIFIER CYLINDERS......................................................................................................... 426 Removal................................................................................................................. 426 Disassembly............................................................................................................. 428 Cleaning and Inspection................................................................................................. 428 Reassembly.............................................................................................................. 428 Installation............................................................................................................ 430 LOCK PIN CYLINDER (R.H. & L.H. BIAS BLADE SUSPENSION ONLY).................................................................. 431 Removal................................................................................................................. 431 Disassembly............................................................................................................. 432 Cleaning and Inspection................................................................................................. 432 Reassembly.............................................................................................................. 432 Installation............................................................................................................ 434 ARTICULATION CYLINDERS...................................................................................................... 435 Removal................................................................................................................. 435 Disassembly............................................................................................................. 436 Cleaning and Inspection................................................................................................. 436 Reassembly.............................................................................................................. 436 Installation............................................................................................................ 438 E-33.10K - ACCUMULATORS (P/N 1285 352 H91, 1279 537 H & 1233 789 H91) ............................................................. 439 TABLE OF CONTENTS............................................................................................................... 440 LOCATION ON MACHINE............................................................................................................. 441 BRAKE SYSTEM ACCUMULATORS................................................................................................... 441 DRAWBAR LIFT AND DRAWBAR SIDE SHIFT ACCUMULATORS............................................................................ 441 DESCRIPTION..................................................................................................................... 442 OPERATION....................................................................................................................... 443 BRAKE SYSTEM ACCUMULATORS................................................................................................... 443 DRAWBAR LIFT AND DRAWBAR SIDE SHIFT ACCUMULATORS............................................................................ 443 SPECIFICATIONS.................................................................................................................. 443 SERVICE/SPECIAL TOOLS........................................................................................................... 445 PRESSURES....................................................................................................................... 445 SPECIAL TORQUES................................................................................................................. 445 TESTS AND ADJUSTMENTS........................................................................................................... 445 PRE-CHARGING................................................................................................................ 445 SERVICING....................................................................................................................... 448 MAINTENANCE................................................................................................................. 448 PRE-CHARGE CHECKING PROCEDURE............................................................................................... 449 REMOVAL (BRAKE SYSTEM)...................................................................................................... 450 REMOVAL (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT)............................................................................... 451 DISASSEMBLY................................................................................................................. 452 CLEANING AND INSPECTION..................................................................................................... 453 REPAIR AND REPLACEMENT...................................................................................................... 454 REASSEMBLY.................................................................................................................. 455 INSTALLATION (BRAKE SYSTEM)................................................................................................. 456 INSTALLATION (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT).......................................................................... 456 E-33.80K - TROUBLESHOOTING AND ADJUSTMENT MANUAL ................................................................................... 457 TABLE OF CONTENTS............................................................................................................... 459 SPECIAL TOOLS................................................................................................................... 460 INTRODUCTION.................................................................................................................... 461 SETTING RELIEF VALVES........................................................................................................... 461 GENERAL DIAGNOSIS PROCEDURE..................................................................................................... 463 HEAT PROBLEMS............................................................................................................... 463 HYDRAULIC TEST PORT CONNECTIONS................................................................................................. 464 HYDRAULIC SYSTEM OVERVIEW....................................................................................................... 466 QUICK REFERENCE PRESSURE CHART.............................................................................................. 467 HYDRAULIC SCHEMATICS........................................................................................................ 468 STANDARD GRADER............................................................................................................. 470 STANDARD GRADER WITH ALL WHEEL DRIVE (AWD).................................................................................. 472 DETAILED HYDRAULIC SYSTEMS...................................................................................................... 475 MAIN HYDRAULIC CIRCUIT...................................................................................................... 475 Main System Pump Troubleshooting Chart.................................................................................. 485 R.H. & L.H. Control Valve Troubleshooting Chart......................................................................... 485 Main Hydraulic System Specification................................................................................. 488 Test Port Locations................................................................................................. 488 Test Procedure...................................................................................................... 489 Main System Control Valve Functions......................................................................................... 491 Scarifier Cylinders..................................................................................................... 491 R.H. & L.H. Blade Lift Cylinders........................................................................................ 493 Blade Shift Cylinder.................................................................................................... 496 Circle Reverse Motor.................................................................................................... 497 Moldboard Tilt Cylinders................................................................................................ 498 Articulation Cylinders.................................................................................................. 500 Circle Side Shift Cylinder.............................................................................................. 502 Leaning Wheel Cylinder.................................................................................................. 504 Float Valve for Optional Function....................................................................................... 505 STEERING AND BRAKE CIRCUIT (INCLUDES LOCK PIN).................................................................................. 506 Steering and Brake System Pressure Tests.................................................................................... 510 Steering and Brake System Specification................................................................................. 510 Test Port Locations..................................................................................................... 510 Test Procedure.......................................................................................................... 510 ALL WHEEL DRIVE CIRCUIT......................................................................................................... 511 Introduction................................................................................................................ 511 Hydraulic Operation......................................................................................................... 514 Electrical Operation........................................................................................................ 520 AWD Controller Programming.................................................................................................. 522 Final Drive Planetary/Non-Planetary Identification.......................................................................... 524 Part Number Tag......................................................................................................... 524 Physical Measurement of Tandem Case..................................................................................... 524 Testing and Troubleshooting................................................................................................. 526 AWD System Functional Test.............................................................................................. 528 AWD Hydraulic System Pressure Tests..................................................................................... 530 AWD Electrical System Tests............................................................................................. 533 Sensor Test and Adjustment.............................................................................................. 540 Problems.................................................................................................................... 542 Problem 1. Test lamp does not light (“AWD System Functional Test”Step 3.A).............................................. 542 Problem 2. Test lamp blinks green when in reverse (“AWD System Functional Test” Step 3.A)............................... 543 Problem 3. Test lamp blinks red (“AWD System Functional Test” Step 3.A)................................................. 544 Problem 4. No change between normal mode and aggressive mode (“AWD System Functional Test” Step 3.B).................... 544 Problem 5. System appears to lack power (“AWD System Functional Test” Step 3.B)......................................... 545 Problem 6. Wheels turn when in neutral (“AWD System Functional Test” Step 4.A).......................................... 545 Problem 7. Wheels don’t turn either direction (“AWD System Functional Test” Step 5.A, 6.A).............................. 546 Problem 8. Wheels do not turn forward (“AWD System Functional Test” Step 5.A)........................................... 547 Problem 9. Wheels do not turn in reverse (“AWD System Functional Test” Step 6.A)........................................ 548 Problem 10. Wheels do not stop (“AWD System Functional Test” Step 5.8, 5.C 5.D, 5.E, 5.F, 6.B, 6.C 6.D, 6.E, 6.F)....... 548 All Wheel Drive Pump Adjustment Procedure....................................................................................... 549 All Wheel Drive Pump Adjustment Procedure for Relief Valves................................................................. 550 Hydraulic Centering Adjustment Procedure.................................................................................... 555 Mechanical Centering Adjustment Procedure................................................................................... 556 Filtering Procedure for “AWD" Hydraulic System.................................................................................. 558 E-34.00K - REAR AXLE COOLING AND LOCK/UNLOCK DIFFERENTIAL PUMP...................................................................... 559 TABLE OF CONTENTS............................................................................................................... 561 INTRODUCTION.................................................................................................................... 562 SERVICING....................................................................................................................... 564 REMOVAL..................................................................................................................... 564 DISASSEMBLY................................................................................................................. 566 CLEANING AND INSPECTION..................................................................................................... 568 REASSEMBLY.................................................................................................................. 570 INSTALLATION................................................................................................................ 572 TESTS AND ADJUSTMENTS........................................................................................................... 573 LOCK/UNLOCK DIFFERENTIAL RELIEF VALVE ADJUSTMENT............................................................................ 573 REAR AXLE COOLING SYSTEM.................................................................................................... 573 F-01.20K R1 - CIRCLE REVERSE SLIP CLUTCH............................................................................................ 575 TABLE OF CONTENTS............................................................................................................... 577 INTRODUCTION.................................................................................................................... 578 SPECIAL TOOLS................................................................................................................... 580 SERVICING....................................................................................................................... 581 REMOVAL..................................................................................................................... 581 DISASSEMBLY................................................................................................................. 582 CLEANING AND INSPECTION..................................................................................................... 585 REASSEMBLY.................................................................................................................. 587 INSTALLATION................................................................................................................ 593 RETROFITTING A STANDARD CIRCLE GEAR CASE WITH A SLIP CLUTCH..................................................................... 595 FOR CIRCLE P/N 1430 851 H92................................................................................................. 595 CIRCLE IDENTIFICATION....................................................................................................... 595 RETROFITTING INSTRUCTIONS................................................................................................... 595 TESTS AND ADJUSTMENTS........................................................................................................... 598 CIRCLE ADJUSTMENT........................................................................................................... 598 SLIP CLUTCH ADJUSTMENT TEST................................................................................................. 600 Spring Scale Test....................................................................................................... 600 Engine and Transmission Gear Range Test................................................................................. 601 F-01.30K - CIRCLE REVERSE GEAR CASE ................................................................................................ 603 TABLE OF CONTENTS............................................................................................................... 605 INTRODUCTION.................................................................................................................... 606 SERVICING....................................................................................................................... 610 DISASSEMBLY................................................................................................................. 610 CLEANING AND INSPECTION..................................................................................................... 617 REASSEMBLY.................................................................................................................. 619 F-11.80K R1 - TANDEM CASE (SINGLE AND DOUBLE STRAND CHAINS) ........................................................................ 627 TABLE OF CONTENTS............................................................................................................... 629 LOCATION ON MACHINE............................................................................................................. 630 DESCRIPTION..................................................................................................................... 630 FINAL DRIVE PLANETARY/NON-PLANETARY IDENTIFICATION.............................................................................. 633 Part Number Tag............................................................................................................. 634 Physical Measurement of Tandem Case......................................................................................... 634 SPECIFICATIONS.................................................................................................................. 635 SERVICE DIAGNOSIS............................................................................................................... 636 SERVICE/SPECIAL TOOLS........................................................................................................... 637 WHEEL KNOCKER TOOL.......................................................................................................... 638 AXLE LIFTING TOOL........................................................................................................... 639 AXLE ROLLING TORQUE TOOL.................................................................................................... 640 SPREADER BAR AND CHAINS..................................................................................................... 641 TOLERANCES...................................................................................................................... 642 LUBRICANTS AND SEALANTS......................................................................................................... 642 SPECIAL TORQUES................................................................................................................. 642 TESTS AND ADJUSTMENTS........................................................................................................... 642 ROAD TESTING................................................................................................................ 642 SERVICING....................................................................................................................... 643 REMOVAL..................................................................................................................... 643 DISASSEMBLY................................................................................................................. 647 CLEANING AND INSPECTION..................................................................................................... 648 REASSEMBLY.................................................................................................................. 650 INSTALLATION................................................................................................................ 652 G-01.13K R3 - GEARBOX ASSEMBLY (ALL WHEEL DRIVE) ................................................................................... 655 TABLE OF CONTENTS............................................................................................................... 657 DESCRIPTION..................................................................................................................... 657 SERVICE/SPECIAL TOOLS........................................................................................................... 660 INSTALLATION OF TWO PIECE SEAL.............................................................................................. 660 TESTS AND ADJUSTMENTS........................................................................................................... 666 FRONT WHEEL ALIGNMENT & TURNING RADIUS ADJUSTMENT........................................................................... 666 SERVICING....................................................................................................................... 669 REMOVAL..................................................................................................................... 669 DISASSEMBLY................................................................................................................. 673 CLEANING AND INSPECTION..................................................................................................... 683 REASSEMBLY.................................................................................................................. 685 INSTALLATION................................................................................................................ 696 G-01.15K - FRONT AXLE ASSEMBLY ..................................................................................................... 701 TABLE OF CONTENTS............................................................................................................... 703 DESCRIPTION..................................................................................................................... 704 FRONT AXLE TORQUE VALUES........................................................................................................ 708 TESTS AND ADJUSTMENTS........................................................................................................... 710 FRONT WHEEL ALIGNMENT & TURNING RADIUS ADJUSTMENT........................................................................... 710 SERVICING....................................................................................................................... 713 REMOVAL..................................................................................................................... 713 DISASSEMBLY................................................................................................................. 716 CLEANING AND INSPECTION..................................................................................................... 722 REASSEMBLY.................................................................................................................. 724 INSTALLATION................................................................................................................ 731 G-09.30K R1 - FINAL DRIVE ASSEMBLY (JOHN DEERE TeamMate II) WITH PLANETARY AND NON-PLANETARY REDUCTION (NoSPIN & LOCK/UNLOCK DIF.... 734 TABLE OF CONTENTS............................................................................................................... 736 LOCATION ON MACHINE............................................................................................................. 739 DESCRIPTION..................................................................................................................... 739 SERVICE DIAGNOSIS............................................................................................................... 757 NoSPIN...................................................................................................................... 758 BRAKE DISC INSPECTION....................................................................................................... 760 SERVICE/SPECIAL TOOLS........................................................................................................... 761 SPREADER BAR AND CHAINS..................................................................................................... 761 DIFFERENTIAL BACKLASH TOOL (DR08-111)....................................................................................... 762 LUBRICANTS AND SEALANTS......................................................................................................... 763 SPECIAL TORQUES................................................................................................................. 763 TESTS AND ADJUSTMENTS........................................................................................................... 763 PARKING BRAKE BLEEDING...................................................................................................... 763 PARKING BRAKE ADJUSTMENT.................................................................................................... 764 FINAL DRIVE BRAKE BLEEDING.................................................................................................. 765 ROAD TESTING................................................................................................................ 766 SERVICING....................................................................................................................... 767 REMOVAL..................................................................................................................... 767 DISASSEMBLY GENERAL......................................................................................................... 772 DISASSEMBLY OF PLANETARY CARRIER............................................................................................ 772 DISASSEMBLY OF NON-PLANETARY CARRIER........................................................................................ 778 DISASSEMBLY OF DIFFERENTIAL BRAKE PISTONS................................................................................... 782 DISASSEMBLY OF INPUT QUILL ASSEMBLY......................................................................................... 783 DISASSEMBLY OF DIFFERENTIAL CASE WITH NoSPlN DIFFERENTIAL................................................................... 785 Disassembly of NoSPlN Differential Quills............................................................................... 785 Disassembly of Ring Gear and NoSPlN Differential........................................................................ 785 Disassembly of Miscellaneous NoSPlN Differential Items.................................................................. 786 DISASSEMBLY OF DIFFERENTIAL CASE WITH LOCK/UNLOCK DIFFERENTIAL.............................................................. 787 Disassembly of Lock/Unlock Differential Quills.......................................................................... 787 Disassembly of Ring Gear and Lock/Unlock Differential................................................................... 788 Disassembly of Differential Pinions..................................................................................... 792 Disassembly of Miscellaneous Lock/Unlock Differential Items............................................................. 792 CLEANING AND INSPECTION..................................................................................................... 793 REASSEMBLY GENERAL.......................................................................................................... 797 REASSEMBLY OF DIFFERENTIAL CASE WITH NoSPIN DIFFERENTIAL.................................................................... 798 Reassembly of NoSPIN Differential Miscellaneous Items................................................................... 798 Reassembly of Ring Gear and NoSPlN Differential......................................................................... 798 Preload Adjustment of NoSPlN Differential Quills........................................................................ 799 REASSEMBLY OF DIFFERENTIAL CASE WITH LOCK/UNLOCK DIFFERENTIAL............................................................... 801 Reassembly of Lock/Unlock Differential Miscellaneous Items.............................................................. 801 Reassembly of Ring Gear and Lock/Unlock Differential.................................................................... 801 Preload Adjustment of Lock/Unlock Differential Quills................................................................... 806 PINION GEAR CONE POINT ADJUSTMENT........................................................................................... 809 PINION GEAR ENDPLAY ADJUSTMENT.............................................................................................. 812 PINION GEAR INPUT QUILL INSTALLATION AND BACKLASH ADJUSTMENT................................................................ 812 RING GEAR AND PINION ROLLING PATTERN CHECK.................................................................................. 813 FINAL ASSEMBLY OF DIFFERENTIAL CASE......................................................................................... 814 REASSEMBLY OF DIFFERENTIAL BRAKE PISTONS.................................................................................... 815 REASSEMBLY OF NON-PLANETARY CARRIER......................................................................................... 816 REASSEMBLY OF PLANETARY CARRIER............................................................................................. 824 INSTALLATION................................................................................................................ 830 H-03.00K R1 - CIRCLE ADJUSTMENT (FOUR SHOE) ........................................................................................ 836 TABLE OF CONTENTS............................................................................................................... 838 INTRODUCTION.................................................................................................................... 838 REBUILDING TEETH................................................................................................................ 839 VERTICAL ADJUSTMENT............................................................................................................. 840 PINION ADJUSTMENT............................................................................................................... 841 Y-02.00K - METRIC CONVERSIONS ......................................................................................................1044 TABLE OF CONTENTS...............................................................................................................1046 METRIC CONVERSIONS..............................................................................................................1047 AREA........................................................................................................................1047 DENSITY (Mass Density)......................................................................................................1047 FORCE.......................................................................................................................1047 FORCE PER LENGTH............................................................................................................1048 HEAT........................................................................................................................1048 LENGTH......................................................................................................................1048 MASS (WEIGHT)...............................................................................................................1049 POWER.......................................................................................................................1049 PRESSURE....................................................................................................................1049 TEMPERATURE.................................................................................................................1049 TEMPERATURE INTERVAL OR TOLERANCE...........................................................................................1049 VOLUME......................................................................................................................1051 TORQUE......................................................................................................................1051 VELOCITY....................................................................................................................1052 K-04.20K R1 - PARKING BRAKE CALIPER (PERROT P/N 40 023 002) ........................................................................ 844 TABLE OF CONTENTS............................................................................................................... 845 LOCATION ON MACHINE............................................................................................................. 846 DESCRIPTION..................................................................................................................... 846 OPERATION....................................................................................................................... 849 SERVICE DIAGNOSIS............................................................................................................... 851 LUBRICANTS AND SEALANTS......................................................................................................... 852 TESTS AND ADJUSTMENTS........................................................................................................... 852 PARKING/EMERGENCY BRAKE BLEEDING............................................................................................ 852 PARKING/EMERGENCY BRAKE ADJUSTMENT.......................................................................................... 853 SERVICING....................................................................................................................... 853 REMOVAL..................................................................................................................... 853 Method One.............................................................................................................. 854 Method Two.............................................................................................................. 854 Method Three............................................................................................................ 854 DISASSEMBLY................................................................................................................. 856 CLEANING AND INSPECTION..................................................................................................... 857 REASSEMBLY.................................................................................................................. 858 INSTALLATION................................................................................................................ 858 K-04.30K - PARKING BRAKE CALIPER (MICO) ............................................................................................ 860 TABLE OF CONTENTS............................................................................................................... 862 INTRODUCTION.................................................................................................................... 863 OPERATION....................................................................................................................... 867 TROUBLESHOOTING................................................................................................................. 869 SERVICING....................................................................................................................... 870 REMOVAL..................................................................................................................... 870 Method One.............................................................................................................. 870 Method Two.............................................................................................................. 871 Method Three............................................................................................................ 871 BRAKE LINING REPLACEMENT.................................................................................................... 872 DISASSEMBLY................................................................................................................. 872 CLEANING AND INSPECTION..................................................................................................... 875 REASSEMBLY.................................................................................................................. 877 INSTALLATION................................................................................................................ 879 TESTS AND ADJUSTMENTS........................................................................................................... 880 PARKING/EMERGENCY BRAKE BLEEDING............................................................................................ 880 PARKING/EMERGENCY BRAKE ADJUSTMENT.......................................................................................... 881 K-11.10K R2 - BRAKE VALVE (REXROTH) ................................................................................................ 882 TABLE OF CONTENTS............................................................................................................... 884 LOCATION ON MACHINE............................................................................................................. 885 DESCRIPTION..................................................................................................................... 885 OPERATION....................................................................................................................... 890 LUBRICANTS AND SEALANTS......................................................................................................... 890 SPECIAL TORQUES................................................................................................................. 891 TESTS AND ADJUSTMENTS........................................................................................................... 891 BRAKE PEDAL ADJUSTMENT...................................................................................................... 891 FINAL DRIVE BRAKE BLEEDING.................................................................................................. 893 SERVICING....................................................................................................................... 894 REMOVAL..................................................................................................................... 894 DISASSEMBLY................................................................................................................. 895 CLEANING AND INSPECTION..................................................................................................... 895 REASSEMBLY.................................................................................................................. 896 INSTALLATION................................................................................................................ 896 K-11.30K R1 - BRAKE VALVE (MICO).................................................................................................... 898 TABLE OF CONTENTS............................................................................................................... 900 DESCRIPTION..................................................................................................................... 901 OPERATION....................................................................................................................... 905 SERVICING....................................................................................................................... 905 REMOVAL..................................................................................................................... 905 DISASSEMBLY................................................................................................................. 907 CLEANING AND INSPECTION..................................................................................................... 908 REASSEMBLY.................................................................................................................. 910 INSTALLATION................................................................................................................ 911 TESTS AND ADJUSTMENTS........................................................................................................... 912 FINAL DRIVE BRAKE BLEEDING.................................................................................................. 912 BRAKE PEDAL ADJUSTMENT...................................................................................................... 912 L-01.45K - WIRING DIAGRAMS ......................................................................................................... 916 Foldout No. 1 Electrical Wiring Diagram 1 of 2.................................................................................. 918 Foldout No. 1 Electrical Wiring Diagram 2 of 2.................................................................................. 923 Foldout No. 2 Electrical Wiring Diagram 1 of 3.................................................................................. 928 Foldout No. 2 Electrical Wiring Diagram 2 of 3.................................................................................. 933 Foldout No. 2 Electrical Wiring Diagram 3 of 3.................................................................................. 938 Foldout No. 3 Electrical Wiring Diagram 1 of 3.................................................................................. 943 Foldout No. 3 Electrical Wiring Diagram 2 of 3.................................................................................. 948 Foldout No. 3 Electrical Wiring Diagram 3 of 3.................................................................................. 953 N-01.35K R1 - PRE-DELIVERY PROCEDURES............................................................................................... 958 TABLE OF CONTENTS............................................................................................................... 960 PRE-UNLOADING CHECKS............................................................................................................ 962 RECORD SERIAL NUMBERS........................................................................................................... 963 GENERAL INSTRUCTIONS............................................................................................................ 965 OPERATION AND MAINTENANCE MANUAL............................................................................................ 965 REVIEW TEXT WITH OWNER/OPERATOR............................................................................................. 965 INSPECT MACHINE AND ATTACHMENTS............................................................................................. 965 PRODUCT GRAPHICS (DECALS)................................................................................................... 965 LUBRICATION..................................................................................................................... 966 TORQUES......................................................................................................................... 969 TORQUE VALUES FOR STANDARD ENGLISH FASTENERS................................................................................ 969 BOLT IDENTIFICATION CHART............................................................................................... 969 TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE........................................................................... 969 TYPE 8 PHOSPHATE COATED HARDWARE........................................................................................ 970 TORQUE VALUES FOR STANDARD METRIC FASTENERS................................................................................. 971 TORQUE VALUES FOR HOSE CLAMPS............................................................................................... 972 TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS.................................................................................. 972 TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS.............................................................................. 973 SPECIFIC BOLT TORQUES....................................................................................................... 974 ENGINE CHECKS................................................................................................................... 985 ADJUST FAN BELT TENSION..................................................................................................... 986 CHECK AND TIGHTEN AIR CLEANER CONNECTIONS................................................................................... 986 PERFORM AIR INDUCTION PRESSURE CHECKS....................................................................................... 987 General................................................................................................................. 987 Test Procedure.......................................................................................................... 987 Service Indicator Safety Filter Check................................................................................... 988 Assembly Tips........................................................................................................... 989 CHECK AND TIGHTEN RADIATOR HOSES............................................................................................ 990 CHECK ALL FUEL LINES AND FITTINGS........................................................................................... 990 ENGINE SPEEDS............................................................................................................... 991 ENGINE SPEED TABLE.......................................................................................................... 991 ENGINE SPEED CHECK PROCEDURE................................................................................................ 992 THROTTLE ADJUSTMENT PROCEDURE............................................................................................... 993 PRESSURE TESTS.................................................................................................................. 995 HYDRAULIC PRESSURE CHECKS................................................................................................... 995 QUICK REFERENCE PRESSURE CHART.......................................................................................... 996 MAIN HYDRAULIC SYSTEM TESTING AND ADJUSTMENT PROCEDURE.................................................................. 997 Main Hydraulic System Specification................................................................................. 997 Test Port Locations................................................................................................. 997 Test Procedure...................................................................................................... 997 STEERING AND BRAKE SYSTEM PRESSURE TESTS................................................................................1000 Steering and Brake System Specification.............................................................................1000 Test Port Locations.................................................................................................1000 Test Procedure......................................................................................................1000 AWD HYDRAULIC SYSTEM PRESSURE TESTS.....................................................................................1001 All Wheel Drive System Specification................................................................................1001 Test Port Locations.................................................................................................1001 Test Procedure......................................................................................................1001 CLUTCH PACK PRESSURE CHECK..................................................................................................1003 CHECKS AND ADJUSTMENTS..........................................................................................................1004 TIRE INFLATION..............................................................................................................1009 CONTROL LEVER LINKAGE.......................................................................................................1010 RIM CENTERING...............................................................................................................1010 HYDRAULIC WET BRAKES........................................................................................................1011 PARKING/EMERGENCY BRAKE.....................................................................................................1017 TESTING.........................................................................................................................1019 CONTROL VALVE ASSEMBLY OPERATION............................................................................................1019 R.H. CONTROL LEVER BANK (STANDARD MACHINE)..............................................................................1020 Circle Shift........................................................................................................1020 Articulation........................................................................................................1020 Wheel Lean..........................................................................................................1020 R.H. Blade Lift.....................................................................................................1020 L.H. CONTROL LEVER BANK (STANDARD MACHINE)..............................................................................1020 L.H. Blade Lift.....................................................................................................1020 Auxiliary/Optional (Scarifier or Ripper)............................................................................1020 Blade Shift.........................................................................................................1020 Blade Tilt..........................................................................................................1020 Circle Rotation.....................................................................................................1020 OPTIONAL LIGHTING EQUIPMENT.............................................................................................1021 OPTIONAL WARNING EQUIPMENT..............................................................................................1021 YARD AND/OR ROAD TEST...................................................................................................1021 X-01.00K - SUSPENSION SEAT .........................................................................................................1022 TABLE OF CONTENTS...............................................................................................................1022 SERVICING.......................................................................................................................1024 GENERAL.........................................................................................................................1024 COMPLETE ASSEMBLY...............................................................................................................1025 LOWER SUSPENSION................................................................................................................1029 SEAT ADJUSTER...................................................................................................................1033 Y-01.00K - GENERAL TORQUE VALUES ...................................................................................................1035 TABLE OF CONTENTS...............................................................................................................1035 INTRODUCTION....................................................................................................................1037 TORQUE VALUES FOR STANDARD ENGLISH FASTENERS....................................................................................1038 BOLT IDENTIFICATION CHART...................................................................................................1038 TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE...............................................................................1038 TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE - CONTINUED...................................................................1039 TYPE 8 PHOSPHATE COATED HARDWARE............................................................................................1040 TORQUE VALUES FOR STANDARD METRIC FASTENERS.....................................................................................1041 TORQUE VALUES FOR HOSE CLAMPS...................................................................................................1042 TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS......................................................................................1042 TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS..................................................................................1043
KOMATSU GD530A, GD650A, GD670A SERIES MOTOR GRADER MANUAL – PDF DOWNLOAD:
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