Complete workshop repair service manual with electrical wiring diagrams for Komatsu Crawler Carrier CD60R-1. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Komatsu Crawler Carrier CD60R-1 service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

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EXCERPT:
CONTENTS
01 GENERAL . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE AND FUNCTION ..................... 10-1
20 TESTING AND ADJUSTING . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY .................. 30-1
90 OTHERS ............... 90-1
…
STRUCTURE AND FUNCTION - HYDRAULIC PUMP
Maintaining tilt
When tilt piston ( 1) moves under the actuating pressure and the pump discharges oil, arm (2), which is connected to tilt piston (1 ), moves together with the tilt piston and returns spool (7).
The oil passage of tilt piston ( 1) is closed by spool (7). Tilt piston (1) moves distance "s" and is held in position.
Tilt piston (1) moves within range "s" in proportion to stroke "x", which changes according to the pilot pressure.
The tilt position is determined by the balance of control spring (6) and the force generated according to the pilot pressure, so it becomes possible to carry out tilt control in proportion to the pilot pressure.
…

COVER.....1
FOREWORD.....2
  FOREWORD.....3
  SAFETY INFORMATION.....6
  INTRODUCTION.....8
    FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.....8
  NECESSARY INFORMATION.....9
    MACHINE SERIAL NO. PLATE AND POSITION.....9
    ENGINE SERIAL NO. PLATE AND POSITION.....9
    POSITION OF SERVICE METER.....10
    TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR.....10
CONTENTS.....11
SAFETY.....16
  SAFETY.....17
  SAFETY LABELS.....19
    POSITIONS OF SAFETY PICTOGRAMS.....20
    SAFETY LABELS.....21
  GENERAL PRECAUTIONS.....28
    SAFETY RULES.....28
    IF ABNORMALITIES ARE FOUND.....28
    CLOTHING AND PERSONAL PROTECTIVE ITEMS.....28
    FIRE EXTINGUISHER AND FIRST AID KIT.....28
    SAFETY FEATURES.....29
    KEEP MACHINE CLEAN.....29
    INSIDE OPERATOR'S COMPARTMENT.....29
    ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.....30
    HANDRAILS AND STEPS.....31
    MOUNTING AND DISMOUNTING.....32
    PREVENTION OF BURNS.....32
    FIRE PREVENTION.....33
    ACTION IF FIRE OCCURS.....34
    WINDOW WASHER LIQUID.....34
    CAB WINDOW GLASS.....34
    PROTECTION FROM FALLING OBJECTS, FLYING OBJECTS, AND INTRUDING OBJECTS.....34
    PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE).....34
    PRECAUTIONS FOR ATTACHMENTS.....35
    UNAUTHORIZED MODIFICATION.....35
    SAFETY AT WORKSITE.....35
    WORKING ON LOOSE GROUND.....35
    DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES.....36
    ENSURE GOOD VISIBILITY.....36
    VENTILATION FOR ENCLOSED AREAS.....37
    CHECKING SIGNALMAN'S SIGNALS AND SIGNS.....37
    EMERGENCY EXIT FROM OPERATOR’S CAB.....37
    BE CAREFUL ABOUT ASBESTOS DUST.....37
  PRECAUTIONS FOR OPERATION.....38
    BEFORE STARTING ENGINE.....38
      CHECKS BEFORE STARTING ENGINE.....38
      PRECAUTIONS WHEN STARTING.....39
      PRECAUTIONS IN COLD AREAS.....39
    AFTER STARTING ENGINE.....40
      CHECKS AFTER STARTING ENGINE.....40
      PRECAUTIONS WHEN CHANGING DIRECTION.....40
      PRECAUTIONS WHEN TRAVELING.....41
      TRAVELING ON SLOPES.....42
      PRECAUTIONS WHEN OPERATING DUMP BODY.....42
      OPERATIONS ON SLOPES.....43
      PROHIBITED OPERATIONS.....43
      OPERATE CAREFULLY ON SNOW.....43
      PARKING MACHINE.....44
    TRANSPORTATION.....45
      LOADING AND UNLOADING.....45
      SHIPPING.....45
    BATTERY.....46
      BATTERY HAZARD PREVENTION.....46
      STARTING WITH BOOSTER CABLE.....47
    TOWING.....48
      WHEN TOWING.....48
  PRECAUTIONS FOR MAINTENANCE.....49
    WARNING TAG.....49
    KEEP WORK PLACE CLEAN AND TIDY.....49
    APPOINT LEADER WHEN WORKING WITH OTHERS.....49
    STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.....50
    TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.....50
    PROPER TOOLS.....51
    ACCUMULATOR.....51
    PERSONNAL.....51
    PRECAUTIONS FOR WORK UNDER MACHINE.....51
    NOISE.....52
    PRECAUTIONS WHEN USING HAMMER.....52
    REPAIR WELDING.....52
    REMOVING BATTERY TERMINAL.....52
    PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION.....53
    DO NOT DISASSEMBLE RECOIL SPRING.....53
    PRECAUTION WITH HIGH-PRESSURE OIL.....54
    HANDLING HIGH-PRESSURE HOSES.....54
    WASTE MATERIAL.....54
    MAINTENANCE FOR CAR COOLER.....55
    COMPRESSED AIR.....55
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....55
OPERATION.....56
  GENERAL VIEW.....57
    GENERAL VIEW OF MACHINE.....57
    GENERAL VIEW OF CONTROLS AND GAUGES.....58
  EXPLANATION OF COMPONENTS.....59
    MACHINE MONITOR.....59
    INCLINOMETER.....66
    SWITCHES.....67
    CONTROL LEVERS AND PEDALS.....71
    WINDSHIELD.....75
    LOWER WINDSHIELD.....78
    SLIDING WINDOW.....78
    DOOR LOCK.....78
    EMERGENCY ESCAPE HAMMER.....79
    CAP, COVER WITH LOCK.....80
    BODY SUPPORT ROD.....81
    FUSE.....82
    FUSIBLELINK.....83
    POWER SUPPLY TAKE-OFF PORT.....83
    TOOL BOX.....83
    OPERATION MANUAL STORAGE.....84
    GREASE GUN HOLDER.....84
    HANDLING ACCUMULATOR.....85
    CAR HEATER AND DEFROSTER CONTROLS.....87
  OPERATION.....89
    CHECK BEFORE STARTING ENGINE, ADJUST.....89
    STARTING ENGINE.....102
    OPERATIONS AND CHECKS AFTER STARTING ENGINE.....105
    STOPPING ENGINE.....108
    CHECK AFTER STOPPING ENGINE.....108
    MACHINE OPERATION.....109
    STEERING MACHINE.....113
    SWINGING.....115
    OPERATING DUMP BODY.....116
    PROHIBITIONS FOR OPERATION.....117
    PRECAUTIONS FOR OPERATION.....118
    PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS.....119
    PARKING MACHINE.....122
    CHECK AFTER FINISHING WORK.....124
    LOCKING.....124
    HANDLING RUBBER SHOES.....125
  TRANSPORTATION.....129
    LOADING, UNLOADING WORK.....129
    LIFTING MACHINE.....133
  COLD WEATHER OPERATION.....134
    PRECAUTIONS FOR LOW TEMPERATURE.....134
    AFTER COMPLETION OF WORK.....136
    AFTER COLD WEATHER.....136
  LONG-TERM STORAGE.....137
    BEFORE STORAGE.....137
    DURING STORAGE.....137
    AFTER STORAGE.....137
  TROUBLESHOOTING.....138
    AFTER RUNNING OUT OF FUEL.....138
    TOWING THE MACHINE.....138
    LIGHT-WEIGHT TOWING HOOK.....138
    IF BATTERY IS DISCHARGED.....139
    OTHER TROUBLE.....143
MAINTENANCE.....146
  GUIDE TO MAINTENANCE.....147
  OUTLINE OF SERVICE.....150
    HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....150
    RELATING TO ELECTRIC SYSTEM.....154
    HANDLING HYDRAULIC SYSTEM.....154
  WEAR PARTS.....155
    WEAR PARTS LIST.....155
  RECOMMENDED FUEL, COOLANT, AND LUBRICANT.....156
    RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.....158
  STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....159
    TORQUE LIST.....159
  PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....160
    SAFETY CRITICAL PARTS.....161
  MAINTENANCE SCHEDURE CHART.....162
    MAINTENANCE SCHEDURE CHART.....162
  SERVICE PROCEDURE.....164
    INITIAL 250 HOURS SERVICE.....164
    WHEN REQUIRED.....165
      CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.....165
      CLEAN INSIDE OF COOLING SYSTEM.....168
      CHECK RUBBER SHOES.....171
      CHECK AND ADJUST TRACK TENSION.....172
      REPLACE RUBBER SHOES.....173
      CHECK ELECTRICAL INTAKE AIR HEATER.....174
      CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.....174
    CHECK BEFORE STARTING.....175
    EVERY 100 HOURS SERVICE.....176
      DRAIN WATER, SEDIMENT FROM FUEL TANK.....176
      LUBRICATING.....177
    EVERY 250 HOURS SERVICE.....179
      CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.....179
      CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.....180
      CHECK LEVEL OF BATTERY ELECTROLYTE.....181
      REPLACE HYDRAULIC FILTER ELEMENT.....184
    EVERY 500 HOURS SERVICE.....185
      REPLACE FUEL FILTER CARTRIDGE.....185
      CHECK SWING PINION GREASE LEVEL, ADD GREASE.....186
      GREASE SWING CIRCLE (2 POINTS).....186
      CHANGE OIL IN FINAL DRIVE CASE.....187
      REPLACE HYDRAULIC LINE FILTER ELEMENT.....188
      CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS.....189
    EVERY 1000 HOURS SERVICE.....190
      CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.....190
      CHECK FAN BELT TANSION, ADJUST.....190
      CHECK ALL TIGHTENING PARTS OF TURBOCHARGER.....190
      CHECK PLAY OF TURBOCHARGER ROTOR.....190
    EVERY 2000 HOURS SERVICE.....191
      CHANGE OIL IN HYDRAULIC TANK AND CLEAN STRAINER.....191
      CLEAN, CHECK TURBOCHARGER.....193
      CHECK ALTERNATOR, STARTING MOTOR.....193
      CHECK ENGINE VALVE CLEARANCE, ADJUST.....193
      CHECK VIBRATION DAMPER.....193
    EVERY 4000 HOURS SERVICE.....194
      CHECK WATER PUMP.....194
SPECIFICATIONS.....196
  SPECIFICATIONS.....197
ATTACHMENTS, OPTIONS.....198
  CAR COOLER.....199
    CONTROL PANEL AND COMPONENTS.....199
    PRECAUTION WHEN USING.....200
    CAR COOLER MAINTENANCE.....200
INDEX.....204