Komatsu Motor Grader GD530A-2B GD650A-2B GD670A-2B service & repair manual

Description Komatsu Motor Grader GD530A-2B GD650A-2B GD670A-2B service & repair manual

Komatsu Motor Grader GD530A-2B, GD650A-2B, GD670A-2B pdf workshop service repair manual + operation & maintenance manual

MANUAL CONTENT:
GENERAL
GENERAL ASSEMBLY DRAWING
FUEL, COOLANT, AND LUBRICANTS
ACCORDING TO AMBIENT TEMPERATURE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
ENGINE OIL SPECIFICATIONS
NORMAL OPERATION
ARCTIC OPERATION
TRANSMISSION, TORQUE CONVERTER AND OIL COOLER, TANDEM DRIVE
CASES,FRONT-WHEEL-DRIVE GEAR CASE, IF EQUIPPED, AND HYDRAULIC SYSTEM OIL SPECIFICATIONS
REAR-DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL SPECIFICATIONS
DIESEL FUEL SPECIFICATIONS
COOLANT SPECIFICATIONS
GENERAL
WATER
ANTIFREEZE
SUPPLEMENTAL COOLANT ADDITIVES
MAINTENANCE OF SUPPLEMENTAL COOLANT ADDITIVES
COOLANT TESTING FOR CONDITIONER CONCENTRATION
REPLENISHING COOLANT CONDITIONER
SUPPLEMENTAL COOLANT ADDITIVE MAINTENANCE GUIDE
COOLING SYSTEM TEST KIT
CIRCLE DRIVE GEAR CASE OIL SPECIFICATIONS (HDTF)

STRUCTURE AND FUNCTION
ORBITROL
TRANSMISSION POWER SHIFT
OPERATION
RECOMMENDED LUBRICANT AND FILTER CHANGE INTERVALS
GENERAL LOCATION OF COMPONENTS
ALL-WHEEL-DRIVE PUMP
ROTARY GROUP
EP2 HYDRAULIC CONTROL
INTERPRETATION OF TYPE CODES
CIRCLE REVERSE MOTOR
CIRCLE REVERSE GEAR CASE MOTOR
CIRCLE REVERSE MOTOR
STEERING AND BRAKE PUMP
STEERING AND BRAKE PUMP MOUNTING
SPECIFICATIONS
AWD HYDRAULIC MOTOR
OPERATION
HYDRAULIC OIL SWIVEL BLOCK
FOUR WAY
CONTROL VALVE MANIFOLDS
OPTIONAL CONTROL LEVER (SCARIFIER)
OPTIONAL CONTROL LEVERS (AUXILIARY)
CONTROL VALVES - LEFT BANK
CONTROL VALVES - R.H. BANK
VALVE SECTION
MAIN SYSTEM PUMP
AWD HIC VALVE
SOLENOID VALVE CARTRIDGE
ACCUMULATOR
SPECIFICATIONS
BRAKE SYSTEM ACCUMULATORS
DRAWBAR LIFT AND DRAWBAR SIDE SHIFT ACCUMULATORS
HYDRAULIC SYSTEM OVERVIEW
STANDARD GRADER
MAIN HYDRAULIC CIRCUIT
STEERING AND BRAKE HYDRAULIC CIRCUIT (INCLUDES LOCK PIN)
STANDARD GRADER WITH ALL WHEEL DRIVE (AWD)
MAIN HYDRAULIC CIRCUIT
ALL WHEEL DRIVE CIRCUIT
STEERING AND BRAKE HYDRAULIC CIRCUIT (INCLUDES LOCK PIN)
MAIN HYDRAULIC CIRCUIT
SPOOL VALVE POSITIONS
NEUTRAL (CENTER)
PULLED (PRESSURIZED "B" PORT)
PUSHED (PRESSURIZED "A" PORT)
MAIN SYSTEM CONTROL VALVES
SCARIFIER
RIGHT AND LEFT BLADE LIFT
FLOAT VALVE
BLADE SHIFT
CIRCLE REVERSE MOTOR
MOLDBOARD TILT
ARTICULATION
CIRCLE SIDE SHIFT
LEANING WHEEL
OPTIONAL FLOAT VALVE
STEERING AND BRAKE CIRCUIT
ALL-WHEEL-DRIVE CIRCUIT
NORMAL MODE
AGGRESSIVE MODE
HYDRAULIC OPERATION
ELECTRICAL OPERATION
AWD CONTROLLER PROGRAMMING
LOCK/UNLOCK DIFFERENTIAL PUMP
CIRCLE REVERSE SLIP CLUTCH
CIRCLE REVERSE GEAR CASE
WITHOUT SLIP CLUTCH
WITH SLIP CLUTCH
MOTOR INSTALLATION
TANDEM CASE
LOCATION
DESCRIPTION
NONPLANETARY FINAL DRIVE
PLANETARY FINAL DRIVE
FINAL DRIVE IDENTIFICATION
PART NUMBER TAG
TANDEM CASE MEASUREMENT
SPECIFICATIONS
AWD GEARBOX ASSEMBLY
AWD GEARBOX
FRONT AXLE ASSEMBLY
NON ALL-WHEEL-DRIVE FRONT AXLE
AWD FRONT AXLE
FINAL DRIVE ASSEMBLY
FINAL DRIVE WITHOUT PLANETARY REDUCTION
FINAL DRIVE WITH PLANETARY REDUCTION
NO-SPIN DIFFERENTIAL CASE ASSEMBLY
INPUT QUILL ASSEMBLY
BRAKES
NO-SPIN DIFFERENTIAL BEARING QUILLS
LOCK/UNLOCK DIFFERENTIAL BEARING QUILLS
LOCK/UNLOCK DIFFERENTIAL ASSEMBLY
LOCK/UNLOCK DIFFERENTIAL CASE OIL LINE
NO-SPIN DIFFERENTIAL ASSEMBLY
NOSPIN DIFFERENTIAL
PLANETARY ASSEMBLY AND RING GEAR
NONPLANETARY FINAL DRIVE CROSS SECTION
PLANETARY REDUCTION FINAL DRIVE CROSS SECTION
MICO PARKING BRAKE
OPERATION
PARKING BRAKE INSTALLATION
PARKING BRAKE CALIPER
MICO BRAKE VALVE
BRAKE PEDAL LINKAGE
HYDRAULIC BRAKE LINES - WITHOUT AWD
HYDRAULIC BRAKE LINES - WITH AWD
BRAKE VALVE
PRE-DELIVERY PROCEDURES
PRE-UNLOADING CHECKS
RECORD THE SERIAL NUMBERS
COMPONENT SERIAL NUMBER LOCATION
OPERATION AND MAINTENANCE MANUAL
REVIEW THE TEXT WITH OWNER/OPERATOR
INSPECT THE MACHINE AND ATTACHMENTS
INSPECT THE PRODUCT GRAPHICS (decals)

TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLES
TABLE OF JUDGEMENT STANDARD VALUE
FOR ENGINE ON TEST BENCH
FOR ENGINE ON CHASSIS
FOR CHASSIS
TESTING AND ADJUSTING TOOL LIST
TRANSMISSION POWER SHIFT
VOLTAGE AND ELECTRICAL POWER REQUIREMENTS
CLUTCH SOLENOID VALVE REQUIREMENTS
PRESSURE AND FLOW CHECKS
FLOW RATES
SETTING THE CLUTCH PRESSURE
TROUBLESHOOTING
FLYWHEEL DIMENSIONAL CHECKS
FLYWHEEL DIMENSIONS
CHECKING FOR THE CORRECT PILOT SLEEVE LENGTH
ALL-WHEEL-DRIVE PUMP
REXROTH
DIAGNOSTIC PORTS
TROUBLESHOOTING
CIRCLE REVERSE MOTOR
TESTS AND ADJUSTMENTS
STEERING AND BRAKE PUMP
SERVICE DIAGNOSIS
STEERING AND BRAKE PUMP TEST
SPECIFICATION
PROCEDURE
STARTUP PROCEDURE
AWD HYDRAULIC MOTOR
TROUBLESHOOTING
FOUR-WAY SWIVEL BLOCK
CONTROL VALVE MANIFOLDS
MAIN SYSTEM PUMP
HYDRAULIC CYLINDERS
FRONT WHEEL ALIGNMMENT AND TURNING RADIUS ADJUSTMENT
PRESSURE TESTING HYDRAULIC CYLINDERS
BALL AND SOCKET SHIMMING ADJUSTMENT
ACCUMULATORS
PRECHARGE
TESTS AND ADJUSTMENTS
PROCEDURE FOR ACCUMULATORS UP TO 3000 PSI
PROCEDURE FOR ACCUMULATORS UP TO 5000 PSI
HYDRAULIC CIRCUITS
RELIEVING ACCUMULATOR PRESSURE
SETTING RELIEF VALVES
GENERAL DIAGNOSIS PROCEDURE
HEAT PROBLEMS
SPECIAL TOOLS
TROUBLESHOOTING CHARTS
MAIN SYSTEM PUMP
RIGHT AND LEFT CONTROL VALVE
MOLDBOARD TILT CYLINDER
BLADE SHIFT CYLINDER
CIRCLE REVERSE MOTOR
HYDRAULIC PRESSURE TESTS
QUICK-REFERENCE PRESSURE CHART
MAIN HYDRAULIC SYSTEM SPECIFICATIONS
TEST PORT LOCATIONS
TEST PROCEDURE: Low-Pressure Standby
TEST PROCEDURE: High-Pressure Standby
STEERING AND BRAKE SYSTEM PRESSURE TEST
STEERING AND BRAKE SYSTEM SPECIFICATION
TEST PORT LOCATION
TEST PROCEDURE
AWD SYSTEM TEST
AWD SYSTEM FUNCTIONAL TEST
AWD HYDRAULIC SYSTEM PRESSURE TEST
AWD ELECTRICAL SYSTEM TESTS
PROBLEMS
Problem 1. Test lamp does not light
Problem 2. Test lamp blinks green when in reverse
Problem 3. Test lamp blinks red
Problem 4. No change between the normal mode and aggressive mode
Problem 5. System appears to lack power
Problem 6. Wheels turn when in neutral
Problem 7. Wheels don’t turn either direction
Problem 8. Wheels do not turn forward
Problem 9. Wheels do not turn in reverse
Problem 10. Wheels do not stop
ALL-WHEEL-DRIVE PUMP
ADJUSTMENT
RELIEF VALVES
HYDRAULIC CENTERING ADJUSTMENT PROCEDURE
MECHANICAL CENTERING ADJUSTMENT PROCEDURE
AWD HYDRAULIC SYSTEM FILTERING PROCEDURE
LOCK/UNLOCK DIFFERENTIAL RELIEF VALVE
REAR AXLE COOLING SYSTEM
CIRCLE REVERSE SLIP CLUTCH
CIRCLE ADJUSTMENT
SLIP CLUTCH ADJUSTMENT
ENGINE AND TRANSMISSION GEAR RANGE TEST
TANDEM CASE
SINGLE AND DOUBLE STRAND CHAINS
ROAD TEST
GEARBOX ASSEMBLY
ALL WHEEL DRIVE
FRONT WHEEL ALIGNMENT AND TURNING RADIUS ADJUSTMENT
PROCEDURE
FRONT AXLE ASSEMBLY
FINAL DRIVE ASSEMBLY
WITH NoSPIN AND LOCK/UNLOCK DIFFERENTIAL
TROUBLESHOOTING
NoSPIN TEST
BRAKE DISC INSPECTION
CIRCLE ADJUSTMENT
FOUR SHOES
VERTICAL ADJUSTMENT
PINION ADJUSTMENT
PARKING BRAKE CALIPER
TROUBLESHOOTING
PERROT PARKING BRAKE ADJUSTMENT
MICO PARKING BRAKE ADJUSTMENT
BRAKE VALVES
REXROTH BRAKE VALVE
FREE PEDAL CLEARANCE
BRAKE PEDAL STOP
FULL BRAKE VALVE STROKE
MICO BRAKE VALVE
BRAKE PEDAL BUMPER ADJUSTMENT
BRAKE PEDAL FREE HEIGHT
BRAKE PEDAL STOP
PRESSURE TEST
PREDELIVERY PROCEDURES
CHECKS AND ADJUSTMENTS
FAN BELT TENSION
AIR CLEANER SYSTEM
AIR INDUCTION PRESSURE CHECK
SERVICE INDICATOR SAFETY FILTER
RADIATOR HOSES
FUEL LINES AND FITTINGS
WATER TRAP
TRANSMISSION FLUID LEVEL
TRANSMISSION FILL PLUG
HYDRAULIC OIL TANK LEVEL
HYDRAULIC OIL AND FUEL TANK FILL POINT
TANDEM CASE OIL LEVEL
TANDEM CASE BREATHER/FILL POINT
CIRCLE REVERSE OIL LEVEL
CIRCLE REVERSE FILL POINT
REAR AXLE OIL LEVEL
REAR AXLE OIL FILL POINT
FUEL TANK DRAIN PLUG
GREASE ZERKS
MOLDBOARD SLIDE RAILS
CONTROL LEVER LINKAGES
CONTROL VALVE LINKAGES
OIL LEVEL - AWD FRONT WHEEL GEAR
ENGINE OIL LEVEL AND FILL POINT
BATTERY WATER LEVEL
ENGINE COOLANT
ENGINE SPEED TABLE
ENGINE SPEED CHECK PROCEDURE
THROTTLE ADJUSTMENT PROCEDURE
HYDRAULIC PRESSURE TESTS
QUICK-REFERENCE PRESSURE CHART
MAIN HYDRAULIC SYSTEM SPECIFICATION
TEST PORT LOCATIONS
TEST PROCEDURE: Low-Pressure Standby
TEST PROCEDURE: High-Pressure Standby
STEERING AND BRAKE SYSTEM PRESSURE TEST
STEERING AND BRAKE SYSTEM SPECIFICATION
TEST PORT LOCATION
TEST PROCEDURE
AWD HYDRAULIC SYSTEM PRESSURE TEST
AWD SYSTEM SPECIFICATION
TEST PORT LOCATIONS
CLUTCH PACK PRESSURE CHECK
TIRES AND RIMS
TIRE INFLATION
TIRE PRESSURES
RIM CENTERING
CONTROL VALVE OPERATION
CONTROL LEVERS - RIGHT BANK
CONTROL LEVERS - LEFT BANK
OPTIONAL EQUIPMENT
LIGHTING
WARNING LIGHTS
YARD TEST
BRAKE VALVES
REXROTH BRAKE VALVE
MICO BRAKE VALVE
PARKING BRAKE CALIPER
PERROT PARKING BRAKE ADJUSTMENT
MICO PARKING BRAKE ADJUSTMENT

DISASSEMBLY AND ASSEMBLY
ARTICULATION JOINT ASSEMBLY
SERVICING
CLEANING AND INSPECTION
ORBITROL
CLEANING AND INSPECTION
TRANSMISSION POWER SHIFT
SPECIAL TOOLS
CHANNEL SUPPORT TOOL
CLUTCH PACK REMOVAL TOOL
CLUTCH SPRING COMPRESSION TOOL
FRONT COVER DISASSEMBLY
MAIN CASE DISASSEMBLY
TORQUE CONVERTER DISASSEMBLY
CLUTCH PACK 1 AND 5 DISASSEMBLY (first stage)
CLUTCH PACK 2 AND 6 DISASSEMBLY (second stage)
CLUTCH PACK 3 AND 4 DISASSEMBLY (third stage)
CONTROL VALVE DISASSEMBLY
CLEANING AND INSPECTION
FRONT COVER REASSEMBLY
TORQUE CONVERTER ASSEMBLY
CLUTCH PACK 1 AND 5 REASSEMBLY (first stage)
CLUTCH PACK 2 AND 6 REASSEMBLY (second stage)
CLUTCH PACK 3 AND 4 REASSEMBLY (third stage)
CONTROL VALVE REASSEMBLY
MAIN CASE REASSEMBLY
TRANSFER CASE

DIAGRAMS AND SCHEMATICS

Engine 6D102E-1, 6D114E-1 series workshop service repair manual