Komatsu D375A-5 Manual

SEAM048900
Operation & Maintenance
Operation & MaintenanceOperation & Maintenance
Operation & Maintenance
Manual
ManualManual
Manual
D375A
-5
RADIO CONTROL SPECIAL
SMALL ELECTRIC POWER
SPECIFICATION
This manual describes only Radio control. Please refer to this
manual and D375A-5 Operation and Maintenance Manual for
bulldozer.
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International 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 improvements at any time withour incurring any obligation to install such changes on
products sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It
is recommended that customers contact their distributor for information on the latest revision.
Copyright 2002 Komatsu
DataKom Publishing Division
July 2002
BASE MANUAL

1-1
FOREWORD
11

1. FOREWORD FOREWORD
1-2
1. FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precau-
tions in this manual must be followed at all times when performing operation and maintenance. Most accidents are
caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents
can be prevented by knowing beforehand conditions that may cause hazard when performing operation and main-
tenance.
This manual contains important precautions to be followed when carrying out work using a bulldozer equipped with
this radio control system.
Always read this manual together with the Operation and Maintenance Manual for the bulldozer equipped with
radio control.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or mainte-
nance.
●Always be sure to read and understand this manual thoroughly before performing operation and
maintenance.
●Read the safety messages given in this manual and the safety labels affixed to the machine thor-
oughly and be sure that you understand them fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below, and
have all personnel read it periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual
immediately from Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety devices and speciffications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult Komatsu or your Komatsu distributor before operat-
ing the machine.

FOREWORD 2. SAFETY INFORMATION
1-3
2. SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa-
tions.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous injury. This signal word is to be limited to most extreme situations.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-
erate injury. It may also be used to alert against unsafe practices.
Example of safety message using signal word
WARNING
To avoid hitting unlocked operation levers, lower equipment to ground and move SAFETY LOCK LEVER
(located near seat) to LOCK position before starting up from operator's seat.
Sudden and unwanted machine movement can cause serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This gives information that is useful to know.
DANGER
WARNING
CAUTION
NOTICE
REMARK

2. SAFETY INFORMATION FOREWORD
1-4
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety
pictograms use pictures in order to let the operator or mainte-
nance worker understand the level and type of hazardous con-
dition at all times. Safety pictograms show the type of
hazardous condition at the top or left side, and the method of
avoiding the hazardous condition at the bottom or right side. In
addition, the type of hazardous condition is displayed inside a
triangle and the method of avoiding the hazardous condition is
shown inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions. If any procedures or actions not specifically recommended or allowed in this manual are used, it is your
responsibility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: →(1))
Part No.
Part No.

FOREWORD 3. INTRODUCTION
1-5
3. INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
●Dozing
●Smoothing
●Ripping
For further details, see "WORK POSSIBLE USING BULLDOZER " and "RIPPER OPERATION"

4. PRODUCT INFORMATION FOREWORD
1-6
4. PRODUCT INFORMATION
4.1 LOCATION OF NAMEPLATE FOR TRANSMITTER (TX. UNIT)
This is on the right side of the front face of the transmitter.
4.2 LOCATION OF NAMEPLATE FOR RECEIVER (RX. UNIT)
This is on the side face of the receiver.
4.3 LOCATION OF NAMEPLATE FOR CONTROLLER
This is on the front face* of the controller.
(* Remove the cover to see the nameplate.)

FOREWORD 4. PRODUCT INFORMATION
1-7
4.4 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Distributor name
Address
Service Personal
Phone/Fax

5. CONTENTS FOREWORD
1-8
5. CONTENTS
FOREWORD
1. FOREWORD .................................................................................................................................................... 1-2
2. SAFETY INFORMATION................................................................................................................................. 1-3
3. INTRODUCTION.............................................................................................................................................. 1-5
4. PRODUCT INFORMATION ............................................................................................................................. 1-6
4.1 LOCATION OF NAMEPLATE FOR TRANSMITTER (TX. UNIT) ........................................................ 1-6
4.2 LOCATION OF NAMEPLATE FOR RECEIVER (RX. UNIT) ............................................................... 1-6
4.3 LOCATION OF NAMEPLATE FOR CONTROLLER............................................................................ 1-6
4.4 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR .............................................................. 1-7
SAFETY
6. GENERAL PRECAUTIONS ............................................................................................................................ 2-2
7. PRECAUTIONS FOR OPERATION .............................................................................................................. 2-12
OPERATION
8. GENERAL VIEW ............................................................................................................................................. 3-2
8.1 GENERAL VIEW OF MACHINE .......................................................................................................... 3-2
9. EXPLANATION OF COMPONENTS............................................................................................................... 3-4
9.1 TRANSMITTER (TX. UNIT) ................................................................................................................. 3-5
9.2 RECEIVER UNIT (RX. UNIT) ............................................................................................................ 3-12
9.3 CONTROLLERS ................................................................................................................................ 3-13
9.4 CHARGER ......................................................................................................................................... 3-14
9.5 ROTATING LAMPS ........................................................................................................................... 3-15
10. HANDLING RADIO CONTROL ................................................................................................................... 3-16
10.1 FLOW CHART FOR STARTING, OPERATING USING RADIO CONTROl .................................... 3-17
10.2 FLOW CHART FOR STOPPING OPERATION USING RADIO CONTROL.................................... 3-18
10.3 DETAILS OF PROCEDURE FOR RADIO CONTROL OPERATION .............................................. 3-19
11. PRECAUTIONS WHEN OPERATING RADIO CONTROL ......................................................................... 3-25
12. Operation using radio control................................................................................................................... 3-26
12.1 Moving off ........................................................................................................................................ 3-26
12.2 Steering (changing direction of travel) ............................................................................................. 3-27
12.3 Work equipment (blade RAISE/LOWER/FLOAT, tilt left/right, ripper UP/DOWN, ripper tilt in/back)3-27
12.4 Acceleration/deceleration................................................................................................................. 3-27
12.5 Stopping (braking)............................................................................................................................ 3-28

FOREWORD 5. CONTENTS
1-9
13. PRECAUTIONS WHEN HANDLING RADIO CONTROL............................................................................ 3-29
13.1 TRANSMITTER ............................................................................................................................... 3-29
13.2 RECEIVER UNIT, CONTROLLER................................................................................................... 3-29
13.3 CHARGER FOR AC, DC ................................................................................................................. 3-29
13.4 PRECAUTIONS WHEN OPERATING FROM OPERATOR'S SEAT .............................................. 3-30
14. CHECKS AROUND MACHINE ................................................................................................................... 3-31
14.1 HYDRAULIC UNIT........................................................................................................................... 3-31
14.2 RECEIVER UNIT, CONTROLLER................................................................................................... 3-31
14.3 ANTENNA........................................................................................................................................ 3-31
14.4 ROTATING LAMPS ......................................................................................................................... 3-31
15. IF ANY FAILURE IS SUSPECTED ............................................................................................................. 3-32
15.1 Radio control operation.................................................................................................................... 3-32
15.2 On-board operation (only problems related to radio control) ........................................................... 3-32
15.3 REPORTING FAILURE ................................................................................................................... 3-32

5. CONTENTS FOREWORD
1-10
MEMO

2-1
SAFETY
2
●This safety section gives the basic precautions.
●For details of the safety precautions for the overall machine, follow the
Operation and Maintenance Manual for the standard machine.
WARNING
Please read and make sure that you fully understand precautions discribed in this manual and the
safety labels on the machine. When operating or servicing the machine, always follow these precaus-
tions strictly.

6. GENERAL PRECAUTIONS SAFETY
2-2
6. GENERAL PRECAUTIONS
SAFETY RULES
●Only trained and authorized personnel can operate and maintain the machine.
●Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
●If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine
may be severly impaired putting yourself and everyone else on your jobsite in danger.
●When working with another operator or with a person on worksite traffic duty, be sure that all personnel under-
stand all hand signals that are to be used.
IF ABNORMALITIES ARE FOUND
If you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the abnormality has been cor-
rected.
Do not wear loose clothing and accessories. There is a hazard that they may catch on
control levers or other protruding parts.
●Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other
protruding parts.
●If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine,
so tie your hair up and be careful not to let it get caught.
●Always wear a hard hat and safety shoes. If the nature of
the work requires it, wear safety glasses, mask, gloves, ear
plugs, and safety belt when operating or maintaining the
machine.
●Check that all protective equipment functions properly
before using it.
●When operating by radio control, the operator may change position while carrying out the radio control opera-
tion.
Check beforehand that there are no obstacles in the surrounding area. The area on the opposite side is a
blind spot, so be particularly careful to check that there are no persons or obstacles.

SAFETY 6. GENERAL PRECAUTIONS
2-3
FIRE EXTINGUISHER AND FIRST AID KIT
Always follow the precautions below to prepare for action if any injury or fire should occur.
●Be sure that fire extinguishers have been provided and
read the labels to ensure that you know how to use them in
emergencies.
●Carry out periodic inspection and maintenance to ensure
that the fire extinguisher can always be used.
●Provide a first aid kit at the storage point. Carry out peri-
odic checks and add to the contents if necessary.
SAFETY FEATURES
●Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if
they are damaged.
●Understand the method of use of safety features and use them properly.
●Never remove any safety features. Always keep them in good operating condition.
KEEP MACHINE CLEAN
●If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not
use water or steam to wash the electrical system (sensors, connectors).
●If inspection and maintenance is carried out when the
machine is still dirty with mud or oil, there is a hazard that
you will slip and fall, or that dirt or mud will get into your
eyes. Always keep the machine clean.
INSIDE OPERATOR'S COMPARTMENT
●When entering the operator's compartment, always remove all mud and oil from the soles of your shoes.
●If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious
accident.
●Do not leave parts or tools lying around the operator's compartment.
●Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
●Do not use cellular telephones inside the operator's compartment when driving or operating the machine.
●Never bring any dangerous objects such as flammable or explosive items into the operator's cab.

6. GENERAL PRECAUTIONS SAFETY
2-4
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT
●Before standing up from the operator's seat, lower the work
equipment completely to the ground, set safety lock lever
and parking lever securely to the LOCK position, then stop
the engine.
If you accidentally touch the levers when they are not
locked, there is a hazard that the machine may suddenly
move and cause serious injury or property damage.
●When leaving the machine, always lower the work equip-
ment completely to the ground, set safety lock lever and
Parking lever securely to the LOCK position, then stop the
engine. Use the key to lock all the equipment. Always
remove the key, take it with you, and keep it in the specified
place.

SAFETY 6. GENERAL PRECAUTIONS
2-5
HANDRAILS AND STEPS
To prevent personal injury caused by slipping or falling off the machine, always do as follows.
●Use the parts marked by arrow A in the diagrams when
getting on or off the machine.
Never use the parts marked by arrow B when getting on or
off the machine. Use them only when moving along the top
of the track or when checking or carrying out maintenance
inside the side cover, or when filling the tank with oil.
●Never jump on or off the machine. In particular, never get
on or off a moving machine. This may cause serious injury.
●To ensure safety, always face the machine and maintain
three-point contact (both feet and one hand, or both hands
and one foot) with the handrails and steps (including the
track shoe) to ensure that you support yourself.
●Do not grip the control levers and safety lock lever when
getting on or off the machine.
●Never climb on the engine hood or covers where there are
no non-slip pads.
●Before getting on or off the machine, check the handrails
and steps (including the track shoe). If there is any oil,
grease, or mud on the handrails or steps (including the
track shoe), wipe it off immediately. Always keep these
parts clean. Repair any damage and tighten any loose
bolts.
●Do not get on or off the machine while holding tools in your
hand.
MOUNTING AND DISMOUNTING
●Never jump on or off the machine. Never get on or off a moving machine.
●If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try
to stop it.
NO PEOPLE ON ATTACHMENTS
Never let anyone ride on the work equipment, or other attachments. There is a hazard of falling and suffering seri-
ous injury.

6. GENERAL PRECAUTIONS SAFETY
2-6
PREVENTION OF BURNS
Hot coolant
●To prevent burns from hot water or steam spurting out
when checking or draining the coolant, wait for the water to
cool to a temperature where it is possible to touch the radi-
ator cap by hand before starting the operation. Even when
the coolant has cooled down, loosen the cap slowly to
relieve the pressure inside the radiator before removing the
cap.
Hot oil
●To prevent burns from hot oil spurting out when checking or
draining the oil, wait for the oil to cool to at temperature
where it is possible to touch the cap or plug by hand before
starting the operation. Even when the oil has cooled down,
loosen the
●cap or plug slowly to relieve the internal pressure before
removing the cap or plug.
FIRE PREVENTION
Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particularly
flammable and can be hazardous. To prevent fire, always
observe the following:
●Do not smoke or use any flame near fuel or oil.
●Stop the engine before refueling.
●Do not leave the machine while adding fuel or oil.
●Tighten all fuel and oil caps securely.
●Do not spill fuel on overheated surfaces or on parts of the
electrical system.
●Use well-ventilated areas for adding or storing oil and fuel.

SAFETY 6. GENERAL PRECAUTIONS
2-7
●Keep oil and fuel in the determined place and do not allow
unauthorized persons to enter.
●After adding fuel or oil, wipe up any spilled fuel or oil.
●When carrying out grinding or welding work on the chassis,
move any flammable materials to a safe place before start-
ing.
●When washing parts with oil, use a non-flammable oil. Die-
sel oil and gasoline may catch fire, so do not use them.
●Put greasy rags and other flammable materials into a safe
container to maintain safety at the work place.
●Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
Fire caused by accumulation of flammable material.
Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed
around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire.
●Always keep electric wiring connections clean and securely tightened.
●Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair
or replace any damaged wiring.
Fire coming from hydraulic line
Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the
hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.
Explosion caused by lighting equipment
●When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with anti-
explosion specifications. If such lighting equipment is not used, there is danger of explosion that may cause
serious injury.
●When taking the electrical power for the lighting from the machine itself, follow the instructions in this manual.
ACTION IF FIRE OCCURS
If a fire occurs, escape from the machine as follows.
●Turn the start switch OFF to stop the engine.
●Use the handrails and steps to get off the machine.
WINDOW WASHER LIQUID
Use an ethyl alcohol base washer liquid.
Methyl alcohol base washer liquid may irritate your eyes, so do not use it.

6. GENERAL PRECAUTIONS SAFETY
2-8
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)
Install ROPS when working in places where there is danger of
falling rocks, such as in mines and quarries, or in places where
there is danger of rolling over.
●If ROPS is installed, do not remove it when operating the
machine.
●ROPS is installed to protect the operator when machine
rolls over. When machine rolls over, ROPS supports its
weight and absorbs its impact energy.
●If ROPS is modified, its strength may lower. When modify-
ing it, consult your Komatsu distributor.
●If ROPS is deformed by falling objects or by rolling over, its
strength lowers and its design functions cannot be main-
tained. In this case, be sure to ask your Komatsu distribu-
tor about repair method.
Even when the ROPS is installed, if you do not fasten your
seat belt securely, it cannot protect you properly. Always
fasten your seat belt when operating the machine.
PRECAUTIONS FOR ATTACHMENTS
●When installing optional parts or attachments, there may be problems with safety or legal restrictions, There-
fore contact your Komatsu distributor for advice.
●Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.
●When installing and using optional attachments, read the instruction manual for the attachment, and the gen-
eral information related to attachments in this manual.
CAB WINDOW GLASSES
If the cab glass on the work equipment side is broken, there is a hazard that the work equipment may contact the
operator's body directly.
Stop operation immediately and replace the glass.
UNAUTHORIZED MODIFICATION
Any modification mode without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
●Komatsu will not be responsible for any injuries, accidents, or product failures resulting from modifications
made without authorization from Komatsu.

SAFETY 6. GENERAL PRECAUTIONS
2-9
SAFETY AT WORKSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
●When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass,
there is a hazard of fire, so be careful when operating.
●Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Do not carry out operations at places where there is a hazard of landslides or falling rocks.
●If water lines, gas lines, or high-voltage electrical lines may
be buried under the worksite, contact each utility and iden-
tify their locations. Be careful not to sever or damage any
of these lines.
●Take necessary measures to prevent any unauthorized
person from entering the operating area.
●In particular, if you need to operate on a road, protect
pedestrian and cars by designating a person for worksite
traffic duty or by installing fences around the worksite.
●When traveling or operating in shallow water or on soft
ground, check the shape and condition of the bedrock, and
the depth and speed of flow of the water before starting
operations.
WORKING ON LOOSE GROUND
●Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or
after earthquakes is weak in these areas.
●When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.