Komatsu GD530A, GD530AW, GD650A, GD650AW, GD670A & GD670AW Series Motor Grader 1998–2005 Shop Manual (P/N CEBMG65194, CEBM003901)

Use the applicable volume and component serial breaks to match the repair procedure to the grader’s configuration. Earlier component sections and later chassis revisions have different applicability limits.

Engine coverage: These are chassis shop manuals with machine-level engine checks and interface information. Full internal engine overhaul requires separate engine publications. The 2001 volume references CEBM000601; the 2002 volume assigns that publication to the 114E-2 series and SEBM010011 to the 102E-2 series.

Earlier engine identification distinguishes GD530 KDC610T/S6D102-1/S6D102E-1 builds from GD650/GD670 KDC614T/S6D114-1/S6D114E-1 builds.

PDF Search, Bookmarks and Diagram Detail

Search and navigation: The 1996 PDF has partial OCR text search; several service pages and its wiring foldouts lack searchable text. The 2001 and 2002 text chapters are searchable, although some illustration labels are not. All three PDFs have extensive bookmarks, but some links in the 2001 volume lead to the wrong sections. Small wiring and connector labels require zooming.

The ZIP contains three printable English PDFs totaling 2,903 pages. All original covers and diagram foldouts are included in those counts, along with 15 blank/form pages in the 1996 volume, 16 revision/form/blank/memorandum pages in the 2001 volume, and 34 form/blank/memorandum pages in the 2002 volume.

Powershift, AWD and Grader-System Service

The following selected workshop topics show the main repair areas. Other sections address hood and cowling removal and fuel/hydraulic-tank removal.

• Powertrain repair: Funk 2263E130B coverage, torque-converter and clutch-pack work, transmission control-valve service, transfer-case repair, tandem cases and final-drive overhaul.

• Hydraulic service: Rexroth AWD pump repair, Eaton steering/brake pump service, Husco 5000C manifolds, the main pump, four-way swivel block, HIC valve and cylinders.

• AWD diagnosis: Functional and electrical tests, hydraulic and mechanical pump centering, controller pinouts, speed-sensor checks and sensor-gap adjustment.

• Steering and grader equipment: Char-Lynn Orbitrol service, articulation-joint repair, circle-reverse motors and slip clutch, four-shoe circle adjustment, front-wheel alignment and turning-radius checks.

• Brake systems: Perrot and MICO parking brakes, brake-valve service, accumulator checks, hydraulic pressure testing, bleeding and final operational checks.

• Schematics and service references: Electrical and hydraulic diagrams, test-port locations, troubleshooting charts, torque tables, lubricant data, inspection limits and special-tool drawings.

These manuals are written for service personnel working on motor graders; the hydraulic pressure-test procedures specifically require two trained and experienced technicians.

Transmission, Tandems and Final Drives

Step-by-step procedures cover transmission removal and installation, front-cover and main-case teardown, torque-converter service, and the 1/5, 2/6 and 3/4 clutch packs. Cleaning, inspection, reassembly and post-overhaul startup checks accompany the component work.

The converter procedures distinguish earlier and later serial ranges. They also warn that forcing a converter into place before its splines and gear teeth align can damage the assembly.

Final-drive setup: JD TeamMate II coverage distinguishes planetary and nonplanetary reduction, NoSPIN and lock/unlock differentials. It extends to quill and pinion setup, bearing preload, backlash, gear-contact patterns, brake-disc inspection and road testing.

Single- and double-strand tandem chains have separate inspection data. AWD gearbox and front-axle procedures address their own seals, bearings and alignment requirements.

Hydraulic Circuits and AWD Fault Diagnosis

The circuit explanations trace blade lift and float, blade shift, circle reverse, moldboard tilt, articulation, circle side shift, leaning-wheel and scarifier functions. Associated testing covers pump pressures, accumulator precharge and ball-and-socket shimming.

Controller pinouts and wire-to-wire test tables let a technician compare electrical commands with pump response when tracing a loss of front-wheel assistance. Both later volumes include an AWD electrical test form and electronic-control-module terminal identification.

The 2002 volume adds E66442V controller diagnostics, distinguishing legacy 1259559H3/H4 behavior from the additional input-test sequence for the H4 controller.

The AWD sensor section warns against continuity-testing its solid-state speed sensors: reverse polarity can damage their circuitry.

Circle Drive, Brakes and Cab Equipment

Circle-service material covers gear-case repair, slip-clutch overhaul and retrofit, circle-tooth rebuilding, and vertical and pinion adjustments. The later motor procedures distinguish Char-Lynn and Parker assemblies by machine serial number.

Brake coverage separates the relevant caliper and valve designs rather than treating them as interchangeable. The rear-axle cooling and lock/unlock differential pump also has dedicated service material.

The 2002 volume includes tilt-steering-console repair and air-conditioning work, covering the compressor clutch, receiver/dryer, condenser, heater unit and R-134a charging procedures.

Schematics, Tooling and Workshop Checks

Visual references include Rexroth AWD pump rotary-group and EP2 control views, standard-versus-AWD hydraulic overviews, and planetary/nonplanetary final-drive sections. The 2002 volume provides original and revised electrical sheets, the 800 Transmission with AWD Diagram, and two-sheet hydraulic circuit diagrams.

Its revision notes identify transmission/differential warning-circuit changes, the Komatsu U-gate shifter and parking-brake revision, the hour-meter change and the brake-light relay addition.

Special tools: Drawings cover transmission channel supports, clutch-pack removal and spring-compression tools, circle-motor bearing/seal tools, tandem lifting and rolling-torque fixtures, and an AWD gearbox seal tool. Final-drive setup includes differential backlash tool DR08-111. Pre-delivery inspection and test procedures are also included.

Motor-grader repair involves stored accumulator pressure, suspended moldboard and drawbar components, and heavy transmission, tandem, axle and final-drive assemblies. The manuals specify pressure-release, blocking, lifting and post-repair checks for the affected work.

Examples of AWD Test Data and Chain-Wear Limits

The 2002 AWD sensor test specifies an 8.5–9.5 VDC supply between wires 4 AWD and 5 AWD. Its right-front sensor adjustment specifies a 0.045 in. (1.143 mm) gap between the gear tooth and pickup, with further adjustment addressed if front-wheel creep remains.

For the planetary single-strand tandem chain, the ten-link inspection reference is 20.00 in. new, with a 20.30 in. wear limit. Separate values are provided for the nonplanetary double-strand chain.