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

• Three-publication chassis set: 2,903 PDF pages total: CEBMG65194 (1,053 pages, April 1996), CEBM003901 (920 pages, March 2001), and CEBM009900 (930 pages, December 2002). Together they cover standard and all-wheel-drive GD530A, GD650A, and GD670A configurations, including earlier -1/-2 builds, 2EY machines, and the later 2BY/2CY revisions.
• Powertrain and final-drive repair: Covers the Funk 2263E130B power-shift transmission, torque converter, clutch packs, control valve, transfer case, tandem cases, AWD gearbox, front axle, and JD TeamMate II final drives with planetary or nonplanetary reduction, NoSPIN, and lock/unlock differentials.
• Hydraulic and AWD diagnosis: Includes Rexroth AWD pump testing and rebuild work, hydraulic and mechanical centering, AWD controller and speed-sensor diagnosis, Eaton steering/brake pump service, Husco 5000C control manifolds, the main pump, four-way swivel block, HIC valve, accumulators, and hydraulic-cylinder repair.
• Steering, brakes, and grader functions: Details Char-Lynn Orbitrol service, circle-reverse motors and slip clutch, four-shoe circle adjustment, articulation-joint repair, moldboard and drawbar cylinder work, front-wheel alignment, MICO and Perrot parking brakes, brake valves, bleeding, and final operational checks.
• Schematics and troubleshooting: Provides original and revised electrical sheets, serial-break circuit notes, the 800 Transmission with AWD Diagram, hydraulic circuit sheets, test-port locations, pressure-test charts, controller terminal identification, and problem/cause troubleshooting tables.
• Factory specifications and tooling: Includes component torque tables, fluid and lubricant data, inspection limits, wear standards, hydraulic and electrical test values, adjustment data, and special-tool drawings for transmission, circle-motor, tandem, AWD gearbox, and final-drive work.

Publication and Serial Coverage

CEBMG65194 replaces CEBMG65193 and carries the earlier model/serial matrix. It covers standard and AW-series GD530A, GD650A, and GD670A -1 machines in the 200840–202000 range. The cover also identifies GD530A-1E S/N 201404, GD650A-2 S/N 202001, the listed -2A, -2B, and -2E combinations from S/N 202002 and up, and the listed -2C variants. Engine identification separates the GD530 family’s KDC610T/S6D102 builds from the GD650/GD670 KDC614T/S6D114 builds.

CEBM003901 is the 2EY chassis volume for GD530A(W)-2EY, GD650A(W)-2EY, and GD670A(W)-2EY, each from S/N 210098 and up.

CEBM009900 covers the later 2BY and 2CY chassis builds. Each listed serial is the starting number; coverage continues upward:

Workshop Repair and Diagnostic Depth

The transmission chapters document removal and installation, front-cover and main-case teardown, torque-converter service, 1/5, 2/6, and 3/4 clutch-pack work, control-valve service, transfer-case repair, cleaning and inspection, reassembly, and post-overhaul startup checks. Final-drive coverage separates planetary and nonplanetary reduction, NoSPIN and lock/unlock differential versions, with quill and pinion setup, bearing preload, backlash, gear-contact pattern checks, brake-disc inspection, bleeding, and road testing. Tandem cases with single- and double-strand chains, circle-reverse gear cases, slip-clutch overhaul, circle-tooth rebuilding, and four-shoe circle adjustment are also included.

Hydraulic information is organized around both standard and AWD machines. The manuals trace the main, steering/brake, and AWD circuits and identify operating paths for blade lift and float, blade shift, circle reverse, moldboard tilt, articulation, circle side shift, leaning wheel, and scarifier functions. Factory procedures cover pressure testing, accumulator precharge checks, steering and brake diagnosis, AWD functional and electrical testing, pump centering, sensor testing and gap adjustment, front-wheel alignment, turning-radius checks, and ball-and-socket shimming. The 2002 volume adds an AWD electrical test form, electronic-control-module terminal identification, and E66442V controller diagnostics.

Representative special-tool content includes transmission channel supports, clutch-pack removal and clutch-spring compression tools, circle-motor bearing and seal tools, tandem axle lifting and rolling-torque fixtures, an AWD gearbox seal tool, and final-drive differential backlash tool DR08-111. Pre-delivery inspection and test procedures are included, while the later volume also covers tilt-steering-console and air-conditioning-system repair.

Named visual references include Rexroth AWD pump rotary-group and EP2 control views, standard-versus-AWD hydraulic system overviews, planetary and nonplanetary final-drive section views, original and revised electrical diagram sheets, the 800 Transmission with AWD Diagram, and two-sheet hydraulic circuit diagrams. The revised 2002 material records the S/N 202844 transmission/differential warning-circuit changes, the S/N 210242 Komatsu U-gate shifter and parking-brake revision, the S/N 210655 hour-meter change, and the S/N 210877 brake-light relay addition.

These are chassis shop manuals. They include machine-level engine checks and chassis interfaces, but full internal engine overhaul is assigned to separate engine publications. CEBM003901 references engine manual CEBM000601; CEBM009900 references CEBM000601 for the 114E-2 series and SEBM010011 for the 102E-2 series.

Motor-grader repair involves stored accumulator pressure, suspended moldboard and drawbar components, and heavy transmission, tandem, axle, and final-drive assemblies. The manuals identify the required pressure-release, blocking, lifting, and post-repair checks before hydraulic lines, accumulators, brakes, or housings are opened.

Two cautions illustrate why the model-specific procedures matter. The transmission section warns that forcing the torque converter before the splines and gear teeth align can damage the assembly. The AWD diagnostic section warns that its solid-state speed sensors must not be continuity-tested like a simple switch because reverse polarity can damage the sensor.