Komatsu GD530A(W)-2 GD650A(W)-2 GD670A(W)-2 MOTOR GRADER Shop Manual PDF

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Komatsu GD530A(W)-2 GD650A(W)-2 GD670A(W)-2 MOTOR GRADER Shop Manual CEBM003902 – PDF DOWNLOAD

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Komatsu GD530A(W)-2 GD650A(W)-2 GD670A(W)-2 MOTOR GRADER Shop Manual CEBM003902 – PDF DOWNLOAD

Language : English
Pages : 928
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu GD530A(W)-2 GD650A(W)-2 GD670A(W)-2 MOTOR GRADER Shop Manual CEBM003902 – PDF DOWNLOAD

• SERIAL NUMBERS
  GD530A(W)-2EY 210098 and up
  GD650A(W)-2EY 210098 and UP
  GD670A(W)-2EY 210098 and up

MAIN MENU 0
COVER 1
CONTENTS 2
FORWARD 5
SAFETY 13
SAFETY NOTICE 15
IMPORTANT SAFETY NOTICE 15
GENERAL PRECAUTIONS 15
PREPARATIONS FOR WORK 15
PRECAUTIONS DURING WORK 15
GENERAL 15
HOW TO READ THE SHOP MANUAL 16
VOLUMES 16
DISTRIBUTION AND UPDATING 16
FILING METHOD 16
REVISED EDITION MARK 16
REVISIONS 16
SYMBOLS 16
HOISTING INSTRUCTIONS 17
HOISTING 17
WIRE ROPES 17
COATING MATERIALS 18
STANDARD TIGHTENING TORQUE 20
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 20
TIGHTENING TORQUE OF HOSE NUTS 21
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 21
TIGHTENING TORQUE FOR FLARED NUTS 21
ELECTRIC WIRE CODE 22
CLASSIFICATION BY THICKNESS 22
CLASSIFICATION BY COLOR AND CODE 22
CONVERSION TABLES 23
METHOD OF USING THE CONVERSION TABLE 23
01 GENERAL 29
GENERAL ASSEMBLY DRAWING 30
GD530 30
GD650/670 30
FUEL, COOLANT, AND LUBRICANTS 31
ACCORDING TO AMBIENT TEMPERATURE 31
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS 31
ENGINE OIL SPECIFICATIONS 33
NORMAL OPERATION 33
ARCTIC OPERATION 33
TRANSMISSION, TORQUE CONVERTER AND OIL COOLER, TANDEM DRIVE CASES, FRONT-WHEEL-DRIVE GEAR CASE, I 34
REAR-DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL SPECIFICATIONS 34
DIESEL FUEL SPECIFICATIONS 34
COOLANT SPECIFICATIONS 35
GENERAL 35
WATER 35
ANTIFREEZE 35
SUPPLEMENTAL COOLANT ADDITIVES 37
MAINTENANCE OF SUPPLEMENTAL COOLANT ADDITIVES 37
COOLANT TESTING FOR CONDITIONER CONCENTRATION 37
REPLENISHING COOLANT CONDITIONER 37
SUPPLEMENTAL COOLANT ADDITIVE MAINTENANCE GUIDE 38
COOLING SYSTEM TEST KIT 40
CIRCLE DRIVE GEAR CASE OIL SPECIFICATIONS (HDTF) 40
10 STRUCTURE AND FUNCTION 41
ORBITROL 45
TRANSMISSION POWER SHIFT 47
OPERATION 49
RECOMMENDED LUBRICANT AND FILTER CHANGE INTERVALS 51
GENERAL LOCATION OF COMPONENTS 53
ALL-WHEEL-DRIVE PUMP 54
ROTARY GROUP 56
EP2 HYDRAULIC CONTROL 58
INTERPRETATION OF TYPE CODES 60
CIRCLE REVERSE MOTOR 61
CIRCLE REVERSE GEAR CASE MOTOR 61
CIRCLE REVERSE MOTOR 63
STEERING AND BRAKE PUMP 65
STEERING AND BRAKE PUMP MOUNTING 65
STEERING AND BRAKE PUMP 66
SPECIFICATIONS 68
AWD HYDRAULIC MOTOR 69
OPERATION 71
SPECIFICATIONS 72
HYDRAULIC OIL SWIVEL BLOCK 73
FOUR WAY 73
CONTROL VALVE MANIFOLDS 74
OPTIONAL CONTROL LEVER (SCARIFIER) 76
OPTIONAL CONTROL LEVERS (AUXILIARY) 78
CONTROL VALVES – LEFT BANK 80
CONTROL VALVES – R H BANK 82
VALVE SECTION 84
MAIN SYSTEM PUMP 86
MAIN SYSTEM PUMP 88
AWD HIC VALVE 90
SOLENOID VALVE CARTRIDGE 92
ACCUMULATOR 93
SPECIFICATIONS 94
BRAKE SYSTEM ACCUMULATORS 95
DRAWBAR LIFT AND DRAWBAR SIDE SHIFT ACCUMULATORS 95
HYDRAULIC SYSTEM OVERVIEW 96
STANDARD GRADER 96
MAIN HYDRAULIC CIRCUIT 97
STEERING AND BRAKE HYDRAULIC CIRCUIT 97
(INCLUDES LOCK PIN) 97
STANDARD GRADER WITH ALL WHEEL DRIVE (AWD) 98
MAIN HYDRAULIC CIRCUIT 99
ALL WHEEL DRIVE CIRCUIT 99
STEERING AND BRAKE HYDRAULIC CIRCUIT 99
(INCLUDES LOCK PIN) 99
MAIN HYDRAULIC CIRCUIT 101
SPOOL VALVE POSITIONS 106
NEUTRAL (CENTER) 106
PULLED (PRESSURIZED “B” PORT) 107
PUSHED (PRESSURIZED “A” PORT) 108
MAIN SYSTEM CONTROL VALVES 110
SCARIFIER 110
RIGHT AND LEFT BLADE LIFT 112
FLOAT VALVE 114
BLADE SHIFT 114
CIRCLE REVERSE MOTOR 115
MOLDBOARD TILT 116
ARTICULATION 118
CIRCLE SIDE SHIFT 120
LEANING WHEEL 122
OPTIONAL FLOAT VALVE 123
STEERING AND BRAKE CIRCUIT 124
ALL-WHEEL-DRIVE CIRCUIT 127
NORMAL MODE 128
AGGRESSIVE MODE 130
HYDRAULIC OPERATION 131
ELECTRICAL OPERATION 134
AWD CONTROLLER PROGRAMMING 136
LOCK/UNLOCK DIFFERENTIAL PUMP 138
CIRCLE REVERSE SLIP CLUTCH 140
CIRCLE REVERSE GEAR CASE 142
WITHOUT SLIP CLUTCH 142
WITH SLIP CLUTCH 144
MOTOR INSTALLATION 146
TANDEM CASE 148
LOCATION 148
DESCRIPTION 148
NONPLANETARY FINAL DRIVE 148
PLANETARY FINAL DRIVE 150
FINAL DRIVE IDENTIFICATION 152
PART NUMBER TAG 152
TANDEM CASE MEASUREMENT 152
SPECIFICATIONS 154
AWD GEARBOX ASSEMBLY 155
AWD GEARBOX 156
FRONT AXLE ASSEMBLY 158
NON ALL-WHEEL-DRIVE FRONT AXLE 158
AWD FRONT AXLE 160
FINAL DRIVE ASSEMBLY 162
FINAL DRIVE WITHOUT PLANETARY REDUCTION 162
FINAL DRIVE WITH PLANETARY REDUCTION 164
NO-SPIN DIFFERENTIAL CASE ASSEMBLY 166
INPUT QUILL ASSEMBLY 170
BRAKES 172
NO-SPIN DIFFERENTIAL BEARING QUILLS 174
LOCK/UNLOCK DIFFERENTIAL BEARING QUILLS 176
LOCK/UNLOCK DIFFERENTIAL ASSEMBLY 178
LOCK/UNLOCK DIFFERENTIAL CASE OIL LINE 180
NO-SPIN DIFFERENTIAL ASSEMBLY 181
NOSPIN DIFFERENTIAL 183
PLANETARY ASSEMBLY AND RING GEAR 184
NONPLANETARY FINAL DRIVE CROSS SECTION 186
PLANETARY REDUCTION FINAL DRIVE CROSS SECTION 187
MICO PARKING BRAKE 188
OPERATION 188
PARKING BRAKE INSTALLATION 189
PARKING BRAKE CALIPER 191
MICO BRAKE VALVE 193
OPERATION 193
BRAKE PEDAL LINKAGE 193
HYDRAULIC BRAKE LINES – WITHOUT AWD 195
HYDRAULIC BRAKE LINES – WITH AWD 197
BRAKE VALVE 199
PRE-DELIVERY PROCEDURES 201
PRE-UNLOADING CHECKS 201
RECORD THE SERIAL NUMBERS 202
COMPONENT SERIAL NUMBER LOCATION 203
OPERATION AND MAINTENANCE MANUAL 205
REVIEW THE TEXT WITH OWNER/OPERATOR 205
INSPECT THE MACHINE AND ATTACHMENTS 205
INSPECT THE PRODUCT GRAPHICS (decals) 205
20 TESTING, ADJUSTING AND TROUBLESHOOTING 207
STANDARD VALUE TABLES 212
TABLE OF JUDGEMENT STANDARD VALUE 213
FOR ENGINE ON TEST BENCH 213
FOR ENGINE IN CHASSIS 215
IN CHASSIS 216
IN CHASSIS (CONTINUED) 217
IN CHASSIS (CONTINUED) 218
TESTING AND ADJUSTING TOOL LIST 221
TRANSMISSION POWER SHIFT 222
VOLTAGE AND ELECTRICAL POWER REQUIREMENTS 222
CLUTCH SOLENOID VALVE REQUIREMENTS 223
PRESSURE AND FLOW CHECKS 223
FLOW RATES 223
SETTING THE CLUTCH PRESSURE 224
TROUBLESHOOTING 224
FLYWHEEL DIMENSIONAL CHECKS 229
FLYWHEEL DIMENSIONS 230
CHECKING FOR THE CORRECT PILOT SLEEVE LENGTH 231
ALL-WHEEL-DRIVE PUMP 232
REXROTH 232
DIAGNOSTIC PORTS 232
TROUBLESHOOTING 235
CIRCLE REVERSE MOTOR 238
TESTS AND ADJUSTMENTS 238
STEERING AND BRAKE PUMP 239
SERVICE DIAGNOSIS 239
STEERING AND BRAKE PUMP TEST 240
SPECIFICATION 240
PROCEDURE 241
STARTUP PROCEDURE 242
AWD HYDRAULIC MOTOR 243
TROUBLESHOOTING 244
FOUR-WAY SWIVEL BLOCK 245
CONTROL VALVE MANIFOLDS 246
TROUBLESHOOTING 246
MAIN SYSTEM PUMP 248
TROUBLESHOOTING 248
HYDRAULIC CYLINDERS 250
TROUBLESHOOTING 250
FRONT WHEEL ALIGNMMENT AND TURNING RADIUS ADJUSTMENT 251
PROCEDURE 251
PRESSURE TESTING HYDRAULIC CYLINDERS 254
BALL AND SOCKET SHIMMING ADJUSTMENT 254
ACCUMULATORS 255
PRECHARGE 255
PRESSURES 255
TESTS AND ADJUSTMENTS 255
PROCEDURE FOR ACCUMULATORS UP TO 3000 PSI 256
PROCEDURE FOR ACCUMULATORS UP TO 5000 PSI 257
HYDRAULIC CIRCUITS 258
RELIEVING ACCUMULATOR PRESSURE 259
SETTING RELIEF VALVES 259
GENERAL DIAGNOSIS PROCEDURE 260
HEAT PROBLEMS 260
SPECIAL TOOLS 261
TROUBLESHOOTING CHARTS 262
MAIN SYSTEM PUMP 262
RIGHT AND LEFT CONTROL VALVE 262
MOLDBOARD TILT CYLINDER 264
BLADE SHIFT CYLINDER 264
CIRCLE REVERSE MOTOR 265
HYDRAULIC PRESSURE TESTS 266
QUICK-REFERENCE PRESSURE CHART 267
MAIN HYDRAULIC SYSTEM SPECIFICATIONS 268
TEST PORT LOCATIONS 268
TEST PROCEDURE: Low-Pressure Standby 269
TEST PROCEDURE: High-Pressure Standby 270
STEERING AND BRAKE SYSTEM PRESSURE TEST 271
STEERING AND BRAKE SYSTEM SPECIFICATION 271
TEST PORT LOCATION 271
TEST PROCEDURE 271
AWD SYSTEM TEST 272
AWD SYSTEM FUNCTIONAL TEST 274
AWD HYDRAULIC SYSTEM PRESSURE TEST 277
AWD ELECTRICAL SYSTEM TESTS 279
PROBLEMS 289
Problem 1 Test lamp does not light 289
Problem 2 Test lamp blinks green when in reverse 290
Problem 3 Test lamp blinks red 291
Problem 4 No change between the normal mode and aggressive mode 291
Problem 5 System appears to lack power 292
Problem 6 Wheels turn when in neutral 292
Problem 7 Wheels don’t turn either direction 293
Problem 8 Wheels do not turn forward 295
Problem 9 Wheels do not turn in reverse 296
Problem 10 Wheels do not stop 296
ALL-WHEEL-DRIVE PUMP 297
ADJUSTMENT 297
RELIEF VALVES 298
HYDRAULIC CENTERING ADJUSTMENT PROCEDURE 301
MECHANICAL CENTERING ADJUSTMENT PROCEDURE 304
AWD HYDRAULIC SYSTEM FILTERING PROCEDURE 305
LOCK/UNLOCK DIFFERENTIAL RELIEF VALVE 306
REAR AXLE COOLING SYSTEM 306
CIRCLE REVERSE SLIP CLUTCH 307
CIRCLE ADJUSTMENT 307
SLIP CLUTCH ADJUSTMENT 309
ENGINE AND TRANSMISSION GEAR RANGE TEST 310
TANDEM CASE 311
SINGLE AND DOUBLE STRAND CHAINS 311
ROAD TEST 312
GEARBOX ASSEMBLY 313
ALL WHEEL DRIVE 313
FRONT WHEEL ALIGNMENT AND TURNING RADIUS ADJUSTMENT 313
PROCEDURE 314
FRONT AXLE ASSEMBLY 317
PROCEDURE 318
FINAL DRIVE ASSEMBLY 321
WITH NoSPIN AND LOCK/UNLOCK DIFFERENTIAL 321
TROUBLESHOOTING 321
NoSPIN TEST 322
BRAKE DISC INSPECTION 323
CIRCLE ADJUSTMENT 324
FOUR SHOES 324
VERTICAL ADJUSTMENT 325
PINION ADJUSTMENT 326
PARKING BRAKE CALIPER 328
TROUBLESHOOTING 328
PERROT PARKING BRAKE ADJUSTMENT 329
MICO PARKING BRAKE ADJUSTMENT 330
BRAKE VALVES 331
REXROTH BRAKE VALVE 331
FREE PEDAL CLEARANCE 331
BRAKE PEDAL STOP 332
FULL BRAKE VALVE STROKE 333
MICO BRAKE VALVE 334
BRAKE PEDAL BUMPER ADJUSTMENT 334
BRAKE PEDAL FREE HEIGHT 334
BRAKE PEDAL STOP 335
PRESSURE TEST 336
PREDELIVERY PROCEDURES 337
CHECKS AND ADJUSTMENTS 337
FAN BELT TENSION 337
AIR CLEANER SYSTEM 337
AIR INDUCTION PRESSURE CHECK 338
SERVICE INDICATOR SAFETY FILTER 339
RADIATOR HOSES 340
FUEL LINES AND FITTINGS 341
WATER TRAP 341
TRANSMISSION FLUID LEVEL 341
TRANSMISSION FILL PLUG 342
HYDRAULIC OIL TANK LEVEL 342
HYDRAULIC OIL AND FUEL TANK FILL POINT 343
TANDEM CASE OIL LEVEL 343
TANDEM CASE BREATHER/FILL POINT 343
CIRCLE REVERSE OIL LEVEL 344
CIRCLE REVERSE FILL POINT 344
REAR AXLE OIL LEVEL 345
REAR AXLE OIL FILL POINT 345
FUEL TANK DRAIN PLUG 345
GREASE ZERKS 346
MOLDBOARD SLIDE RAILS 346
CONTROL LEVER LINKAGES 347
CONTROL VALVE LINKAGES 347
OIL LEVEL – AWD FRONT WHEEL GEAR 348
ENGINE OIL LEVEL AND FILL POINT 348
BATTERY WATER LEVEL 349
ENGINE COOLANT 349
ENGINE SPEED TABLE 350
ENGINE SPEED CHECK PROCEDURE 351
THROTTLE ADJUSTMENT PROCEDURE 352
HYDRAULIC PRESSURE TESTS 355
QUICK-REFERENCE PRESSURE CHART 356
MAIN HYDRAULIC SYSTEM SPECIFICATIONs 357
TEST PORT LOCATIONS 357
TEST PROCEDURE: Low-Pressure Standby 358
TEST PROCEDURE: High-Pressure Standby 359
STEERING AND BRAKE SYSTEM PRESSURE TEST 360
STEERING AND BRAKE SYSTEM SPECIFICATION 360
TEST PORT LOCATION 360
TEST PROCEDURE 360
AWD HYDRAULIC SYSTEM PRESSURE TEST 361
AWD SYSTEM SPECIFICATION 361
TEST PORT LOCATIONS 361
TEST PROCEDURE 362
CLUTCH PACK PRESSURE CHECK 363
TIRES AND RIMS 364
TIRE INFLATION 364
TIRE PRESSURES 364
RIM CENTERING 365
CONTROL VALVE OPERATION 366
CONTROL LEVERS – RIGHT BANK 367
CONTROL LEVERS – LEFT BANK 368
OPTIONAL EQUIPMENT 369
LIGHTING 369
WARNING LIGHTS 369
YARD TEST 369
BRAKE VALVES 370
REXROTH BRAKE VALVE 370
MICO BRAKE VALVE 373
PARKING BRAKE CALIPER 376
PERROT PARKING BRAKE ADJUSTMENT 376
MICO PARKING BRAKE ADJUSTMENT 377
30 DISASSEMBLY AND ASSEMBLY 379
ARTICULATION JOINT ASSEMBLY 386
SERVICING 387
DISASSEMBLY 392
CLEANING AND INSPECTION 394
ASSEMBLY 395
INSTALLATION 398
ORBITROL 402
REMOVAL 402
DISASSEMBLY 402
CLEANING AND INSPECTION 408
ASSEMBLY 409
INSTALLATION 415
TRANSMISSION POWER SHIFT 416
SPECIAL TOOLS 271
CHANNEL SUPPORT TOOL 416
CLUTCH PACK REMOVAL TOOL 417
CLUTCH SPRING COMPRESSION TOOL 418
REMOVAL 419
DISASSEMBLY 430
FRONT COVER DISASSEMBLY 432
MAIN CASE DISASSEMBLY 434
TORQUE CONVERTER DISASSEMBLY 436
CLUTCH PACK 1 AND 5 DISASSEMBLY (first stage) 438
CLUTCH PACK 2 AND 6 DISASSEMBLY (second stage) 440
CLUTCH PACK 3 AND 4 DISASSEMBLY (third stage) 442
CONTROL VALVE DISASSEMBLY 444
CLEANING AND INSPECTION 445
CLEANING 445
INSPECTION 446
REASSEMBLY 447
FRONT COVER REASSEMBLY 447
TORQUE CONVERTER ASSEMBLY 449
CLUTCH PACK 1 AND 5 REASSEMBLY (first stage) 451
Reassemble the first clutch pack as follows: 451
CLUTCH PACK 2 AND 6 REASSEMBLY (second stage) 455
CLUTCH PACK 3 AND 4 REASSEMBLY (third stage) 458
CONTROL VALVE REASSEMBLY 462
MAIN CASE REASSEMBLY 463
TRANSMISSION/TORQUE CONVERTER REASSEMBLY 466
INSTALLING THE CONVERTER INTO THE TRANSMISSION 467
TRANSFER CASE 468
DISASSEMBLY 468
ASSEMBLY 470
INSTALLATION 472
SERVICING THE MACHINE AFTER A TRANSMISSION OVERHAUL 259
STARTUP PROCEDURE 483
ALL WHEEL DRIVE (AWD) 483
ALL-WHEEL-DRIVE PUMP 484
REMOVAL 232
SHAFT SEAL (IN-WARRANTY SERVICE) 486
CHARGE PUMP (IN-WARRANTY SERVICE) 488
CONTROL PISTON COVER (IN-WARRANTY SERVICE) 490
LEFT COVER 490
RIGHT COVER 491
REPLACING THE VALVES (IN-WARRANTY SERVICE) 493
BOOST PRESSURE VALVE 493
RELIEF VALVE 493
PRESSURE CUT-OFF VALVE 494
CONTROL DEVICE (IN-WARRANTY SERVICE) 495
REGULATOR VALVE (IN-WARRANTY SERVICE) 496
REBUILDING THE PUMP (OUT-OF-WARRANTY SERVICE) 497
TORQUE VALUES 522
Tightening torques for shaft bolts (Metric ISO Standard Thread) 522
Tightening torques for locking screws VSTI (Metric ISO fine thread) 523
Tightening torque for seal lock nuts VSTI (Metric ISO standard thread) 523
Tightening torques for cross-slotted lens head screws DIN 7985 (Metric ISO standard thread) 524
INSTALLATION 525
CIRCLE REVERSE MOTOR (DANFOSS) 527
REMOVAL 527
DISASSEMBLY 527
CLEANING AND INSPECTION 533
ASSEMBLY 534
INSTALLATION 544
CIRCLE REVERSE MOTOR (CHAR-LYNN) 545
SPECIAL TOOLS 313
SEAL INSTALLATION TOOL 546
ASSEMBLY BULLET TOOL 547
SEAL BULLET TOOL 548
REMOVAL 549
DISASSEMBLY 549
CLEANING AND INSPECTION 551
ASSEMBLY 311
INSTALLATION 555
STEERING AND BRAKE PUMP 556
REMOVAL 556
DISASSEMBLY 557
CLEANING AND INSPECTION 560
ASSEMBLY 562
INSTALLATION 564
HYDRAULIC MOTOR 565
SPECIAL SERVICE TOOLS 565
SHAFT BEARING REMOVAL/INSTALLATION TOOL 565
HOUSING BEARING RACE REMOVAL TOOL 566
BEARING RACE INSTALLATION TOOL 330
SHAFT SEAL DRIVER TOOL 567
REMOVAL 568
DISASSEMBLY 569
CLEANING AND INSPECTION 573
ASSEMBLY 576
INSTALLATION 579
HYDRAULIC OIL SWIVEL BLOCK – 4 WAY 580
SPECIAL TOOLS 334
SWIVEL BLOCK SEAL TOOL 580
REMOVAL 581
DISASSEMBLY 582
CLEANING AND INSPECTION 583
ASSEMBLY 583
INSTALLATION 585
CONTROL VALVE MANIFOLDS 586
REMOVAL 586
DISASSEMBLY 589
CONTROL VALVE BANK 589
VALVE SECTION 591
VALVE SECTION IDENTIFICATION 592
CLEANING AND INSPECTION 593
ASSEMBLY 594
VALVE SECTION 594
CONTROL VALVE BANK 337
INSTALLATION 338
MAIN SYSTEM PUMP 355
REMOVAL 355
DISASSEMBLY 357
CLEANING AND INSPECTION 609
REASSEMBLY 610
INSTALLATION 617
HYDRAULIC INTEGRATED CIRCUIT VALVE 619
REMOVAL 619
DISASSEMBLY 620
HIC VALVE 620
SOLENOID CARTRIDGE DISASSEMBLY 347
CLEANING AND INSPECTION 622
ASSEMBLY 623
SOLENOID CARTRIDGE REASSEMBLY 623
HIC VALVE 624
INSTALLATION 349
HYDRAULIC CYLINDERS 627
CLEANING AND INSPECTION 627
STEERING CYLINDERS 628
REMOVAL 628
DISASSEMBLY 629
CLEANING AND INSPECTION 629
ASSEMBLY 630
INSTALLATION 631
LEANING WHEEL CYLINDER 632
REMOVAL 632
DISASSEMBLY 633
CLEANING AND INSPECTION 633
ASSEMBLY 634
INSTALLATION 634
MOLDBOARD TILT CYLINDERS 636
REMOVAL 636
DISASSEMBLY 637
CLEANING AND INSPECTION 637
ASSEMBLY 638
INSTALLATION 639
MOLDBOARD SIDE SHIFT CYLINDER 640
REMOVAL 640
DISASSEMBLY 642
CLEANING AND INSPECTION 642
ASSEMBLY 642
INSTALLATION 643
DRAWBAR SIDE SHIFT CYLINDER (R H BLADE SUSPENSION ONLY) 645
REMOVAL 645
DISASSEMBLY 646
CLEANING AND INSPECTION 646
ASSEMBLY 647
INSTALLATION 648
DRAWBAR SIDE SHIFT CYLINDER (R H & L H BIAS BLADE SUSPENSION) 649
REMOVAL 649
DISASSEMBLY 649
CLEANING AND INSPECTION 650
ASSEMBLY 650
INSTALLATION 651
DRAWBAR LIFT CYLINDERS (R H BLADE SUSPENSION ONLY) 652
REMOVAL 652
DISASSEMBLY 653
CLEANING AND INSPECTION 654
ASSEMBLY 654
INSTALLATION 655
DRAWBAR LIFT CYLINDERS (R H & L H BIAS BLADE SUSPENSION ONLY) 657
REMOVAL 657
DISASSEMBLY 659
CLEANING AND INSPECTION 660
ASSEMBLY 660
INSTALLATION 661
SCARIFIER CYLINDERS 663
REMOVAL 663
DISASSEMBLY 664
CLEANING AND INSPECTION 665
ASSEMBLY 665
INSTALLATION 666
LOCK PIN CYLINDER (R H & L H BIAS BLADE SUSPENSION ONLY) 668
REMOVAL 668
DISASSEMBLY 669
CLEANING AND INSPECTION 669
ASSEMBLY 669
INSTALLATION 670
ARTICULATION CYLINDERS 671
REMOVAL 671
DISASSEMBLY 672
CLEANING AND INSPECTION 673
ASSEMBLY 673
INSTALLATION 674
ACCUMULATORS 675
MAINTENANCE 675
CHECKING THE PRECHARGE 675
Accumulators with Parker valve p/n 5323640000 676
Accumulators with Parker valve p/n 6124330000 677
REMOVAL (BRAKE SYSTEM) 677
REMOVAL (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT) 678
DISASSEMBLY 680
CLEANING AND INSPECTION 681
REPAIR AND REPLACEMENT 681
ASSEMBLY 681
INSTALLATION (BRAKE SYSTEM) 682
INSTALLATION (DRAWBAR LIFT AND DRAWBAR SIDE SHIFT) 682
LOCK/UNLOCK DIFFERENTIAL PUMP 683
REMOVAL 683
DISASSEMBLY 685
CLEANING AND INSPECTION 686
REPAIR AND REPLACEMENT 687
REASSEMBLY 687
INSTALLATION 687
CIRCLE REVERSE SLIP CLUTCH 689
SPECIAL TOOLS 689
CIRCLE SLIP CLUTCH GAUGE TOOL 689
REMOVAL 690
DISASSEMBLY 691
CLEANING AND INSPECTION 693
ASSEMBLY 695
INSTALLATION 702
RETROFITTING A STANDARD CIRCLE GEAR CASE WITH A SLIP CLUTCH 704
CIRCLE IDENTIFICATION 704
RETROFITTING INSTRUCTIONS 704
CIRCLE REVERSE GEAR CASE 706
DISASSEMBLY 706
CLEANING AND INSPECTION 713
ASSEMBLY 714
TANDEM CASE 218
SINGLE AND DOUBLE STRAND CHAINS 722
SERVICE/SPECIAL TOOLS 722
WHEEL KNOCKER TOOL 218
AXLE LIFTING TOOL 218
AXLE ROLLING TORQUE TOOL 218
SPREADER BAR AND CHAINS 724
REMOVAL 219
DISASSEMBLY 220
CLEANING AND INSPECTION 220
ASSEMBLY 732
INSTALLATION 221
GEARBOX ASSEMBLY – AWD 738
SERVICE/SPECIAL TOOLS 738
SEAL INSTALLATION TOOL 738
TWO-PIECE SEAL INSTALLATION 738
REMOVAL 743
DISASSEMBLY 748
CLEANING AND INSPECTION 757
ASSEMBLY 758
INSTALLATION 769
FRONT AXLE ASSEMBLY 774
REMOVAL 774
DISASSEMBLY 777
CLEANING AND INSPECTION 782
ASSEMBLY 783
INSTALLATION 793
FINAL DRIVE ASSEMBLY 796
NoSPIN AND LOCK/UNLOCK DIFFERENTIALS 796
SERVICE/SPECIAL TOOLS 796
SPREADER BAR AND CHAINS 796
DIFFERENTIAL BACKLASH TOOL (DR08-111) 798
PARKING BRAKE BLEEDING 799
FINAL DRIVE BRAKE BLEEDING 799
ROAD TESTING 800
REMOVAL 800
GENERAL DISASSEMBLY 806
DISASSEMBLY OF THE PLANETARY CARRIER 806
DISASSEMBLY OF THE NONPLANETARY CARRIER 812
DISASSEMBLY OF THE DIFFERENTIAL BRAKE PISTONS 816
DISASSEMBLY OF THE INPUT QUILL ASSEMBLY 817
DISASSEMBLY OF THE DIFFERENTIAL CASE WITH NoSPIN DIFFERENTIAL 819
DISASSEMBLY OF DIFFERENTIAL CASE WITH LOCK/UNLOCK DIFFERENTIAL 821
CLEANING AND INSPECTION 828
NoSPIN DIFFERENTIAL INSPECTION 829
LOCK/UNLOCK DIFFERENTIAL INSPECTION 829
PARKING BRAKE MOUNTING BRACKET 830
DIFFERENTIAL ASSEMBLY 831
NoSPIN DIFFERENTIAL CASE ASSEMBLY 832
LOCK/UNLOCK DIFFERENTIAL CASE ASSEMBLY 836
PINION GEAR ADJUSTMENTS 845
PINION GEAR CONE POINT ADJUSTMENT 845
PINION GEAR ENDPLAY ADJUSTMENT 847
PINION GEAR BACKLASH ADJUSTMENT 848
FINAL ASSEMBLY 850
ASSEMBLY OF THE DIFFERENTIAL BRAKE PISTONS 852
NONPLANETARY CARRIER ASSEMBLY 854
PLANETARY CARRIER ASSEMBLY 862
INSTALLATION 868
CIRCLE TOOTH REBUILD 874
REBUILDING THE TEETH 874
MICO PARKING BRAKE CALIPER 875
REMOVAL 875
BRAKE LINING REPLACEMENT 878
DISASSEMBLY 878
CLEANING AND INSPECTION 880
ASSEMBLY 881
INSTALLATION 883
REXROTH BRAKE VALVE 885
REMOVAL 885
DISASSEMBLY 888
CLEANING AND INSPECTION 889
ASSEMBLY 890
INSTALLATION 891
40 MAINTENANCE STANDARD 893
FINAL DRIVE 894
NO SPIN DIFFERENTIAL CASE ASSEMBLY 895
NO SPIN DIFFERENTIAL ASSEMBLY 896
FINAL DRIVE AND TANDEMS 897
TANDEM DRIVE 898
BRAKE VALVE 899
STEERING CYLINDER 900
LEANING WHEEL CYLINDER 901
MOLDBOARD TILT CYLINDER 902
MOLDBOARD SIDE SHIFT 903
DRAWBAR SIDE SHIFT CYLINDER 904
DRAWBAR LIFT CYLINDER 905
SCARIFIER CYLINDER 906
ARTICULATION CYLINDER 907
RIPPER CYLINDER 908
LUG NUTS 909
FRONT AXLE 910
POWER TILT MOLDBOARD CARRIER 911
FRAME 912
DRAWBAR AND CIRCLE 913
DRAWBAR LIFT 914
ENGINE AND TRANSMISSION 915
DRIVE LINE 916
ALTERNATOR 917
90 DIAGRAMS AND SCHEMATICS 919
HYDRAULIC DIAGRAM (SHEET 1 OF 2) 920
HYDRAULIC DIAGRAM (SHEET 2 OF 2) 921
ELECTRICAL DEG-20109 Page 1 of 2 (Sheet 1 of 5) 922
DEG-20109 Page 1 OF 2 (Sheet 2 of 5) 923
DEG-20109 Page 1 of 2 (Sheet 3 of 5) 924
DEG-20109 Page 1 of 2 (Sheet 4 of 5) 925
DEG-20109 Page 1 of 2 (Sheet 5 of 5) 926
DEG-20109 Page 2 of 2 (Sheet 1 of 2) 927
DEG-20109 Page 2 of 2 (Sheet 2 of t) 928

DESCRIPTION:

Komatsu GD530A(W)-2 GD650A(W)-2 GD670A(W)-2 MOTOR GRADER Shop Manual CEBM003902 – PDF DOWNLOAD

• SERIAL NUMBERS
  GD530A(W)-2EY 210098 and up
  GD650A(W)-2EY 210098 and UP
  GD670A(W)-2EY 210098 and up

G.B  21/12/24