SEBMG6150109

2011 7All Rights ReservedPrinted in Japan 08-11(01)

00-1o

GD663A-2 1001andup

For GD663A-2, see pages prepared for GD623A-1 except two descriptions below.1) Front axle (page 41-9) 1. Steering cylinder has both types of single cylinder and dual cylinder.2) For rear mount ripper, see page 74-9.

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GD663A-2

1. Bracket2. Rod3. Shank4. Ripper cylinder

Outline Ripper lifting height and digging depth can be

controlled with ripper cylinder (4). Since the point tips cut into the ground under the load of the ripper's heavy weight, the ripper easily performs heavy-duty digging work that cannot be done by the scarifier.

74-9o

GD610, 620GD660, 670

Unit: mm

No. Check Item Criteria Remedy

5 Clearance between pin and bushing

Standard Size Tolerance

Standard Clearance

Clearance Limit

Replace

50Shaft Hole

0.105 to 0.192 0.5-0.025 -0.050

+0.142 +0.080

6 Clearance between pin and bushing 60 -0.030 -0.076+0.054

0 0.03 to 0.13 0.5

7 Clearance between trunnion and bushing 60 -0.100 -0.174+0.174 +0.100 0.200 to 0.348 0.5

8 Point wearStandard Size Repair Limit

290 150

GD610, 620GD660, 670

90-18

90 OTHERS

Air conditioner ................................................................... 90-2

GD610, 620GD660, 670

90-28

AIR CONDITIONER(if equipped)AIR CONDITIONER PIPINGH Type (Refrigerant: for R134a)

SYSTEM DIAGRAM 1. Air conditioner unit2. Dry receiver3. Compressor4. Condenser5. Hot water heater6. Evaporator7. Blower unit

A. Vent

GD610, 620GD660, 670

90-38

AIR CONDITIONER CONDENSER

1. Refrigerant outlet port2. Refrigerant inlet port3. Relief valve4. Clutch

SPECIFICATIONSType: Piston pump typeRefrigerant used: R134a

AIR CONDITIONER COMPRESSOR

1. Refrigerant gas inlet port2. Fan

3. Connector4. Refrigerant gas outlet port

GD610, 620GD660, 670

90-48

DRY RECEIVER

1. Cap2. Body3. Drier

GD610, 620GD660, 670

ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER

90-58

COVERCONTENTS10 ENGINE12 TESTING AND ADJUSTINGTABLE OF JUDGEMENT STANDARD VALUETESTING AND ADJUSTING TOOL LISTADJUSTING VALVE CLEARANCEMEASURING COMPRESSION PRESSURETESTING AND ADJUSTING FUEL INJECTION TIMINGBLEEDING AIR FROM FUEL SYSTEMENGINE SPEED CONTROLMEASURING EXHAUST GAS COLORTESTING AND ADJUSTING FAN BELT TENSIONMEASURING ENGINE OIL PRESSURE AND TEMPERATURE

13 DISASSEMBLY AND ASSEMBLYRADIATORREMOVALINSTALLATION

FUEL TANK(Incl.HYDRAULIC TANK)ASSEMBLYREMOVALINSTALLATION

20 POWER TRAIN21 STRUCTURE AND FUNCTIONGENERALPOWER TRAINHYDROSHIFT TRANSMISSION PIPINGHYDROSHIFT TRANSMISSION CONTROLPOWER TRAIN HYDRAULIC CIRCUIT SCHEMATICSPOWER TRAIN HYDRAULIC CIRCUIT DIAGRAMJOINTPTO(POWER TAKE OFF)HYDROSHIFT TRANSMISSION AND TRANSFERHYDROSHIFT TRANSMISSION PUMPTRANSMISSION CONTROL VALVEFINAL DRIVEDIFFERENTIAL LOCK PIPINGTANDEM DRIVE

22 TESTING AND ADJUSTINGTABLE OF JUDGEMENT STANDARD VALUETOOL LIST FOR TESTING AND ADJUSTINGINCHING PEDAL TRAVEL AND OPERATING FORCECHECKING OIL PRESSUREMACHINE TYPE AND INCHING PRESSURETRANSMISSION CONTROL LEVER TRAVEL AND OPERATING FORCECHECKING DIFFERENTIAL LOCKING DEVICE OIL PRESSURE

23 DISASSEMBLY AND ASSEMBLYTRANSMISSION PUMPREMOVALINSTALLATION

ENGINE(Incl.TRANSMISSION)ASSEMBLYREMOVALINSTALLATION

PTODISASSEMBLYASSEMBLY

HYDROSHIFT TRANSMISSIONDISASSEMBLYASSEMBLY

TRANSFER ASSEMBLYDISASSEMBLYASSEMBLY

TANDEM AND FINAL DRIVEREMOVALINSTALLATION

TANDEM,FINAL DRIVE ASSEMBLYREMOVALINSTALLATION

FINAL DRIVEDISASSEMBLYASSEMBLY

TANDEM,FINAL DRIVE ASSEMBLYDISASSEMBLYASSEMBLY

SIDE CASE ASSEMBLYDISASSEMBLYASSEMBLY

BEVEL GEAR ASSEMBLYDISASSEMBLYASSEMBLY

PINION ASSEMBLYDISASSEMBLYASSEMBLY

24 MAINTENANCE STANDARDPTO,HYDROSHIFT TRANSMISSION AND TRANSFERHYDROSHIFT TRANSMISSION CONTROL VALVETRANSMISSION PUMPFINAL DRIVETANDEM DRIVE

40 STEERING SYSTEM41 STRUCTURE AND FUNCTIONSTEERING PIPINGSTEERING CIRCUIT DIAGRAMSTEERING CONTROL VALVEFRONT AXLESTEERING CYLINDERWHEEL

42 TESTING AND ADJUSTINGTABLE OF JUDGEMENT STANDARDTOOL LIST FOR TESTING AND ADJUSTINGCHECKING STEERING WHEELCHECKING TIRE RUNOUTCHECKING TIRE INFLATION PRESSURECHECKING TOE-IN

43 DISASSEMBLY AND ASSEMBLYFRONT AXLE ASSEMBLYREMOVALINSTALLATION

FRONT AXLE ASSEMBLYDISASSEMBLYASSEMBLY

STEEREMBLY VALVEDISASSEMBLYASSEMBLY

DOUBLE RELIEF VALVEDISASSEMBLYASSEMBLY

44 MAINTENANCE STANDARDFRONT AXLESTEERING CYLINDER

50 BRAKE SYSTEM51 STRUCTURE AND FUNCTIONBRAKE PIPINGBRAKE CIRCUIT DIAGRAMBOOST MASTERAIR BRAKE PIPINGAIR BRAKE CIRCUIT SCHEMATICSAIR BRAKE CIRCUIT DIAGRAMBRAKE VALVEAIR COMPRESSORAIR GOVERNORCHECK VALVEAIR TANKSAFETY VALVEAUTOMATIC DRAIN VALVE(IF EQUIPPED)AIR DRIER(IF EQUIPPED)WHEEL BRAKEPARKING BRAKE

52 TESTING AND ADJUSTINGTABLE OF JUDGEMENT STANDARD VALUETOOL LIST FOR TESTING AND ADJUSTINGCHECKING BRAKE PEDALAIR BLEEDING FROM BRAKE CIRCUITCHECKING PARKING BRAKE LEVERCHECKING WEAR OF BRAKE DISC

53 DISASSEMBLY AND ASSEMBLYBOOST MASTERDISASSEMBLY ASSEMBLY

WHEEL BRAKEREMOVALINSTALLATIONDISASSEMBLYASSEMBLY

WHEEL BRAKEREMOVALINSTALLATIONDISASSEMBLYASSEMBLY

54 MAINTENANCE STANDARDWHEEL BRAKEPARKING BRAKEBOOST MASTER

60 HYDRAULIC SYSTEM61 STRUCTURE AND FUNCTIONHYDRAULIC PIPINGHYDUAULIC CONTROLBLADE ACCUMULATOR SYSTEM(IF EQUIPPED)HYDRAULIC CIRCUIT DIAGRAMOIL COOLING FLOWHYDRAULIC PUMPCIRCLE ROTATION MOTORCONTROL VALVEFLOW DIVIDERPILOT CHECK VALVEFLOW CONTROL VALVEHYDRAULIC CYLINDER

62 TESTING AND ADJUSTINGTROUBLESHOOTING(CIRCLE ROTATION MOTOR)

63 DISASSEMBLY AND ASSEMBLYHYDRAULIC PUMP(Incl.STEERING PUMP)REMOVALINSTALLATION

BLADE LIFT CYLINDERREMOVALINSTALLATION

DRAWBAR SHIFT CYLINDERREMOVALINSTALLATION

BLADE SIDE SHAFT CYLINDERREMOVALINSTALLATION

ARTICULATE CYLINDERREMOVALINSTALLATION

SCARIFIER CYLINDERREMOVALINSTALLATION

POWER TILT CYLINDERREMOVALINSTALLATION

REAR MOUNT RIPPER CYLINDERREMOVALINSTALLATION

HYDRAULIC CYLINDERDISASSEMBLYASSEMBLY

CIRCLE ROTATION MOTORDISASSEMBLYASSEMBLY

64 MAINTENANCE STANDARDHYDRAULIC PUMPCONTROL VALVEHYDRAULIC CYLINDER

70 WORK EQUIPMENT71 STRUCTURE AND FUNCTIONDRAWBAR AND LIFTERBLADECIRCLE ROTATION GEARFRAMESCARIFIER(IF EQUIPPED)REAR MOUNTING RIPPER(IF EQUIPPED)

72 TESTING AND ADJUSTINGTABLE OF JUDGEMENT STANDARDTOOL LIST FOR TESTING AND ADJUSTINGCHECKING CONTROL LEVERCHECKING HYDRAULIC OIL TEMPERATURECHECKING HYDRAULIC OIL PRESSUREHYDRAULIC DRIFTCHARGING BLADE ACCUMULATOR WITH GASADJUSTMENT OF CIRCLE GUIDE

73 DISASSEMBLY AND ASSEMBLYBLADE ASSEMBLYREMOVALINSTALLATION

CIRCLE ROTATION GEARREMOVALINSTALLATIONDISASSEMBLYASSEMBLY

REAR MOUNT RIPPER ASSEMBLYREMOVALINSTALLATION

CIRCLE ROTATION GEAR ASSEMBLYREMOVALINSTALLATIONDISASSEMBLYASSEMBLY

74 MAINTENANCE STANDARDDRAWBAR AND LIFTERBLADECIRCLE ROTATION GEARSCARIFIER(IF EQUIPPED)REAR MOUNT RIPPER(IF EQUIPPED)

80 ELECTRIC AND ELECTRONIC SYSTEM81 STRUCTURE AND FUNCTIONELECTRICAL CIRCUIT DIAGRAMCIRCUIT DIAGRAM OF CABELECTRONIC VEHICLE MONITORING SYSTEM(EVMS)ADJUSTING SPEEDOMETER MODULE(IF EQUIPPED)

82 TESTING AND ADJUSTINGTABLE OF ELECTRICAL JUDGEMENT STANDARD VALUECIRCUIT DIAGRAMCONNECTOR POSITION FOR TROUBLESHOOTINGPOSITION OF CONNECTOR(D TYPE)POSITION OF CONNECTOR(P,Q TYPE)CONNECTOR TERMINAL NUMBERSPROCEDURE FOR TROUBLESHOOTINGCHECKS BEFORE TROUBLESHOOTINGMETHOD OF USING TROUBLESHOOTING CHARTTROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM(M1 TO M-18)(D TYPE)M-1 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT APPEAR.a) NONE OF MONITOR PANEL WORKSb) PART OF MONITOR PANEL DOES NOT WORK

M-2 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL DISPLAY DOES NOT GO OUTM-3 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CHECK BEFORE STARTING ITEMS FLASH OR PREHEATING ITEM LIGHTS UP.a) COOLANT LEVELb) ENGINE OIL LEVELc) PREHEATER

M-4 WHEN STARTING SWITCH IS TURNED ON,(ENGINE STARTED),CHECK BEFORE STARTING ITEMS FLASH.a) ALTERNATOR SYSTEMb) ENGINE OIL PRESSURE CIRCUIT

M-5 WHEN STARTING SWITCH IS TURNED ON,(DO NOT START ENGINE),CAUTION ITEMS FLASHM-6 WHEN STARTING SWITCH IS ON(ENGINE STARTED),CAUTION ITEMS FLASHa) ENGINE OIL PRESSUREb) COOLANT LEVELc) COOLANT TEMPERATUREd) BATTERY CHARGEe) FINAL OIL TEMPERATUREf) AIR PRESSUREg) PARKING BRAKE

M-7 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANKM-8 NO DISPLAY IS GIVEN FOR FUEL LEVELM-9 ENGINE COOLANT TEMPERATURE IS HIGH,BUT LOWEST LEVEL DISPLAYEDM-10 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAYM-11 TURN SIGNAL LAMPS,HIGH BEAM LIGHT UP ABNORMALLY,OR DO NOT LIGHT UPa) PILOT DISPLAY OF TURN SIGNAL LAMP(RIGHT)LIGHTS UPb) PILOT DISPLAY OF TURN SIGNAL LAMP(LEFT)LIGHTS UPc) PILOT DISPLAY OF TURN SIGNAL LAMP(RIGHT)DOES NOT LIGHT UPd) PILOT DISPLAY OF TURN SIGNAL LAMP(LEFT)DOES NOT LIGHT UPe) HIGHT BEAM PILOT LAMP DOES NOT LIGHT UPf) HIGH BEAM PILOT LAMP DOES NOT GO OUT

M-12 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLYM-13 WHEN ENGINE IN STARTED,SERVICE METER DOES NOT MOVE,WHEN ENGINE IN STOPPED,SERVICE METER MOVESa) SERVICE METER DOES NOT MOVEb) SERVICE METER DOES NOT STOP MOVING

M-14 MONITOR PANEL LAMPS DO NOT LIGHT UPa) NO LAMPS ON PANEL LIGHT UPb) SOME LAMPS ON PANEL DO NOT LIGHT UP

M-15 CENTRAL WARNING LAMP DOES NOT GO OUTa) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLYb) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY

M-16 CENTRAL WARNING BUZZER DOES NOT STOPa) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLYb) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY

M-17 EMERGENCY ITEM OR NON-EMERGENCY ITEMS IS FLASHING,BUT WARNING LAMP DOES NOT FLASHM-18 EMERGENCY ITEM IS FLASHING,BUT ALARM BUZZER DOES NOT SOUND

TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM(M1 TO M-22)(P,Q TYPE)M-1 MONITOR PANEL PILOT LAMPS DO NOT LIGHT UP FOT 3 SECONDS WHEN STARTING SWITCH IS TURNED ONa) NO LAMPS ON MONITOR PANEL(MONITOR MODULE)LIGHT UPb) NO LAMPS ON MONITOR PANEL(SPEEDOMETER MODULE)LIGHT UPc) SOME LAMPS ON MONITOR PANEL DO NOT LIGHT UP

M-2 WHEN STARTING SWITCH IS TURNED ON,ALL MONITOR PANEL LAMPS LIGHT UP BUT DO NOT GO OUTM-3 WHEN STARTING SWITCH IS TURNED ON(WITH ENGINE STOPPED),CHECK ITEMS FLASHa) RADIATOR WATER LEVEL FLASHESb) ENGINE OIL LEVEL FLASHES

M-4 PREHEATING IS NOT BEING CARRIED OUT,BUT PREHEATING DISPLAY FLASHESM-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CHECK ITEMS FLASHa) ALTERNATOR SYSTEMb) ENGINE OIL PRESSURE SYSTEM

M-6 WHEN STARTING SWITCH IS TURNED ON WITH ENGINE STOPPED CAUTION ITEMS FLASHM-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CAUTION ITEMS FLASHa) ENGINE OIL PRESSURE FLASHESb) RADIATOR WATER LEVEL FLASHESc) ENGINE WATER TEMPERATURE FLASHESd) CHARGE FLASHESe) FINAL DRIVE OIL TEMPERATURE FLASHESf) AIR PRESSURE FLASHESg) PARKING BRAKE FLASHES

M-8 FOR ONE SECOND AFTER STARTING SWITCH IS TURNED ON(ENGINE STOPPED),ALARM BUZZER DOES NOT SOUND.CAUTION ITEM LAMPS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUNDM-9 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDSM-10 FOR TWO SECONDS AFTER STARTING SWITCH IS TURNED ON(ENGINE STOPPED),WARNING LAMP DOES NOT LIGHT UP.CAUTION ITEM LAMPS ARE FLASHING BUT WARNING LAMP DOES NOT LIGHT UP.M-11 THERE IS NO ABNORMALITY ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UPM-12 MONITOR PANEL LIGHTING DOES NOT LIGHT UPa) NO PANEL LIGHTING LIGHTS UPb) PART OF PANEL LIGHTING DOES NOT LIGHT UP

M-13 SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTED;OR SERVICE METER MOVES WHEN ENGINE IS STOPPED.(FOR MACHINES WITH SPEEDOMETER)a) SERVICE METER DOES NOT MOVE WHEN ENGINE IS STARTEDb) SERVICE METER MOVES WHEN ENGINE IS STOPPED

M-14 ENGINE WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATUREM-15 ENGINE WATER TEMPERATURE GAUGE SHOWS NO DISPLAYM-16 FUEL GAUGE ALWAYS SHOWS FULLM-17 NO DISPLAY IS GIVEN FOR FUEL LEVEL GAUGEM-18 HIGH BEAM DOES NOT LIGHT UPM-19 HIGH BEAM STAYS LIGHTED UPM-20 TURN SIGNAL INDICATOR DOES NOT LIGHT UPM-21 TURN SIGNAL INDICATOR STAYS LIGHTED UPM-22 SPEED DISPLAY STAYS AT "0" AND DOES NOT MOVE

90 OTHERSAIR CONDITIONER