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Manual
GD530A(W)-2
GD650A(W)-2
GD670A(W)-2
MOTOR GRADER
SERIAL NUMBERS
This material is proprietary to Komatsu America Company and is not to be reproduced, used, or disclosed except in accor-
dance with written authorization from Komatsu America Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-
mended that customers contact their distributor for information on the latest revision.
GD530/650/670
June 2009
2
GD530A(W)-2EY
GD650A(W)-2EY
GD670A(W)-2EY
210098
210098
and UP
210098
Copyright 2009 Komatsu
DataKom Publishing Corporation
CEBM003902
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Table of Contents
Related Manuals for Komatsu GD530A-2
Summary of Contents for Komatsu GD530A-2
- Page 1 GD670A(W)-2EY 210098 This material is proprietary to Komatsu America Company and is not to be reproduced, used, or disclosed except in accor- dance with written authorization from Komatsu America Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.
- Page 2 FOREWORD CONTENTS CONTENTS GENERAL ............. 01-1 STRUCTURE AND FUNCTION .
- Page 3 Machine specific ..........1085 960 R2 Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America International Company Parts Inventory Processing System (PIPS) or the Extranet Lit- erature Ordering System.
- Page 4 REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM ö AND RETURN TO DataKom Publishing Corporation 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887 COMPANY NAME PURCHASE ORDER NO. ö...
- Page 5 FOREWORD The affected pages are indicated by using the following Mark Indication Action marks. It is requested that necessary actions be taken to New page to be added these pages according to the table below. Page to be replaced Replace Page to be deleted Discard Mark...
- Page 6 FOREWORD Mark Page Mark Page Mark Page Mark Page 10-77 10-110 10-143 20-9 10-78 10-111 10-144 20-10 10-79 10-112 10-145 20-11 10-80 10-113 10-146 20-12 10-81 10-114 10-147 20-13 10-82 10-115 10-148 20-14 10-83 10-116 10-149 20-15 10-84 10-117 10-150 20-16 10-85 10-118...
- Page 7 FOREWORD Mark Page Mark Page Mark Page Mark Page 20-42 20-75 20-108 20-141 20-43 20-76 20-109 20-142 20-44 20-77 20-110 20-143 20-45 20-78 20-111 20-144 20-46 20-79 20-112 20-145 20-47 20-80 20-113 20-146 20-48 20-81 20-114 20-147 20-49 20-82 20-115 20-148 20-50 20-83...
- Page 8 FOREWORD Mark Page Mark Page Mark Page Mark Page 30-1 30-34 30-67 30-100 30-2 30-35 30-68 30-101 30-3 30-36 30-69 30-102 30-4 30-37 30-70 30-103 30-5 30-38 30-71 30-104 30-6 30-39 30-72 30-105 30-7 30-40 30-73 30-106 30-8 30-41 30-74 30-107 30-9 30-42...
- Page 9 FOREWORD Mark Page Mark Page Mark Page Mark Page 30-133 30-166 30-199 30-232 30-134 30-167 30-200 30-233 30-135 30-168 30-201 30-234 30-136 30-169 30-202 30-235 30-137 30-170 30-203 30-236 30-138 30-171 30-204 30-237 30-139 30-172 30-205 30-238 30-140 30-173 30-206 30-239 30-141 30-174...
- Page 10 FOREWORD Mark Page Mark Page Mark Page Mark Page 30-265 30-298 30-331 30-364 30-266 30-299 30-332 30-365 30-267 30-300 30-333 30-366 30-268 30-301 30-334 30-367 30-269 30-302 30-335 30-368 30-270 30-303 30-336 30-369 30-271 30-304 30-337 30-370 30-272 30-305 30-338 30-371 30-273 30-306...
- Page 11 FOREWORD Mark Page Mark Page Mark Page Mark Page 30-397 30-430 30-463 30-496 30-398 30-431 30-464 30-497 30-399 30-432 30-465 30-498 30-400 30-433 30-466 30-499 30-401 30-434 30-467 30-500 30-402 30-435 30-468 30-501 30-403 30-436 30-469 30-502 30-404 30-437 30-470 30-503 30-405 30-438...
- Page 12 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-14 40-15 40-16 40-17 40-18 40-19 40-20 40-21 40-22 40-23 40-24 40-25 40-26 90-1 90-3 90-5 90-7 90-9 90-11 90-13 90-15 90-17 90-19 00-2-8 GD530/650/670...
- Page 13 FOREWORD SAFETY SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose.
- Page 14 FOREWORD SAFETY When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part.
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Page 15: General
FOREWORD GENERAL GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate under- standing of the product and by showing him the correct way to perform repairs and make judgements. Make sure you under- stand the contents of this manual and use it to full effect at every opportunity. - Page 16 FOREWORD HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES REVISIONS Shop manuals are issued as a guide to carrying out repairs. Revised pages are shown at the LIST OF REVISED PAGES They are divided as follows: between the title page and SAFETY page.
- Page 17 FOREWORD HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS HOISTING can result. Hooks have maximum strength at the middle portion. WARNING! Heavy parts (25 kg or more) must be lifted with a hoist etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indi- cated clearly with the symbol •...
- Page 18 FOREWORD COATING MATERIALS COATING MATERIALS # The recommended coating materials prescribed in the shop manuals are listed below. Category Code Part No. Quantity Container Main applications, features • Used to prevent rubber gaskets, rubber LT-1A 790-129-9030 150 g Tube cushions and cork plugs from coming out •...
- Page 19 FOREWORD COATING MATERIALS Category Code Part No. Quantity Container Main applications, features • Features: Resistance to water, oil • Used as sealant for flange surface, thread. • Also possible to use as sealant for flanges LG-4 790-129-9020 200 g Tube with large clearance.
- Page 20 FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND ASSEMBLY. Thread diameter of bolt Width across flats 13.2 ±1.4 1.35 ±0.15 31.4 ±2.9...
- Page 21 FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE OF HOSE NUTS Use these torques for hose nuts. Thread diameter Width across flat Tightening torque Nominal No. 24.5 ± 4.9 2.5 ± 0.5 49 ± 19.6 5 ± 2 78.5 ± 19.6 8 ± 2 137.3 ±...
- Page 22 FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe. CLASSIFICATION BY THICKNESS Copper wire Nominal num-...
- Page 23 FOREWORD CONVERSION TABLES CONVERSION TABLES METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE •...
- Page 24 FOREWORD CONVERSION TABLES Millimeters to Inches 1 mm = 0.03937 in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260...
- Page 25 FOREWORD CONVERSION TABLES Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661 7.925...
- Page 26 FOREWORD CONVERSION TABLES kgm to ft. lb. 1 kgm = 7.233 ft. lb. 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2...
- Page 27 FOREWORD CONVERSION TABLES kg/cm to lb/in 1 kg/cm = 14.2233lb/in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
- Page 28 FOREWORD CONVERSION TABLES Temperature Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
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Page 29: Table Of Contents
GENERAL GENERAL ASSEMBLY DRAWING ......... . 01-2 GD530 . -
Page 30: General Assembly Drawing
GENERAL GENERAL ASSEMBLY DRAWING GENERAL ASSEMBLY DRAWING GD530 GD650/670 01-2 GD530/650/670... -
Page 31: Fuel, Coolant, And Lubricants
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS It is not Komatsu’s policy to approve fuel, coolant and lubricants or to guarantee performance in service. The supplier is responsible for the quality of the fuel, coolant, and lubricants. When in doubt, consult your Komatsu distributor. The specified fuel, coolant, and lubricant recommended for this machine are as shown in the following table. - Page 32 346 liter Fuel tank fuel 91.5 gal 91.5 gal ASTM D975 No. 1 Komatsu Super Grease or NLGI No. 2 Multipurpose lithium grease All lube fittings Grease Fill as instructed with 3 percent molybdenum disulfide Cooling system Coolant See coolant specifications on page 01-7 32.6 liter...
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Page 33: Engine Oil Specifications
GENERAL FUEL, COOLANT, AND LUBRICANTS ENGINE OIL SPECIFICATIONS NORMAL OPERATION Oil performance recommendations are as follows: The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are critical factors in main- taining engine performance and durability. SAE 15W-40 multiviscosity oil meeting the API performance classification of CF-4 or CF-4/SG is recommended. -
Page 34: Transmission, Torque Converter And Oil Cooler, Tandem Drive
CASES, FRONT-WHEEL-DRIVE GEAR CASE, IF EQUIPPED, AND HYDRAU- LIC SYSTEM OIL SPECIFICATIONS Komatsu Heavy Duty Transmission Fluid, Dexron III/C4, engine oil with an API classification of CD/CC, CD or MIL-L- 2104D or E and meeting C-4 and TO-2, TO-4 and containing 0.10 percent zinc minimum is recommended. -
Page 35: Coolant Specifications
GENERAL FUEL, COOLANT, AND LUBRICANTS COOLANT SPECIFICATIONS GENERAL Selection and maintenance of the engine coolant is important to long engine life. The following information provides recom- mendations for selecting the engine coolant and maintaining the coolant inhibitors. Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additives. Supple- mental coolant additive recommendations are included in the section entitled "Inhibitors/Conditioners."... - Page 36 GENERAL FUEL, COOLANT, AND LUBRICANTS Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to maintain corro- sion protection. Antifreeze formulated with methoxy propanol or propylene glycol is not recommended for this system. Do not mix types of antifreeze solutions.
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Page 37: Supplemental Coolant Additives
GENERAL FUEL, COOLANT, AND LUBRICANTS SUPPLEMENTAL COOLANT ADDITIVES All cooling system inhibitors, including those in antifreeze solutions, become depleted through normal operation. If the inhibitors in antifreeze are allowed to become depleted, the antifreeze becomes corrosive and attacks and coats the metal- lic surfaces of the cooling system which reduces heat transfer. -
Page 38: Supplemental Coolant Additive Maintenance Guide
GENERAL FUEL, COOLANT, AND LUBRICANTS SUPPLEMENTAL COOLANT ADDITIVE MAINTENANCE GUIDE Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion. Antifreeze alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion protection must be supplied through periodic additions of supplemental coolant additives to the coolant. - Page 39 GENERAL FUEL, COOLANT, AND LUBRICANTS DCA4 PreCharge and Service Filters System Capacity PreCharge Filter Service Filter (See NOTE 1) (See NOTE 3) Liters Gallons 19-29 WF-2072 WF-2070 30-41 8-10 WF-2073 WF-2071 42-60 11-15 WF-2074 WF-2071 61-79 16-20 WF-2075 WF-2071 80-117 21-30 WF-2076 WF-2072...
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Page 40: Cooling System Test Kit
® The Fleet Guard Coolant Test Kit is used to check the concentration of coolant additives in the cooling system, and may be purchased from your Komatsu America International Company distributor. Part Number: CC-2626 Test strip bottles Solution #1 bottle... - Page 41 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...