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Komatsu D375A-5 Operation & Maintenance Manual

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BASE MANUAL
Operation & Maintenance
Operation & Maintenance
Operation & Maintenance
Operation & Maintenance
Manual
Manual
Manual
Manual
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.
July 2002
D375A
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.
SEAM048900
-5
Copyright 2002 Komatsu
DataKom Publishing Division

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  • Page 1 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.
  • Page 2 FOREWORD...
  • Page 3 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.

  • Page 4: Foreword

    FOREWORD 2. SAFETY INFORMATION 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.
  • Page 5 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.

  • Page 6: Introduction

    FOREWORD 3. INTRODUCTION 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"...

  • Page 7: Product Information

    FOREWORD 4. PRODUCT INFORMATION 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.

  • Page 8: Your Machine Serial Numbers And Distributor

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

  • Page 9: Table Of Contents

    FOREWORD 5. CONTENTS 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................
  • Page 10 FOREWORD 5. CONTENTS 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...........................
  • Page 11 FOREWORD 5. CONTENTS MEMO 1-10...
  • Page 12 SAFETY 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.

  • Page 13: General Precautions

    SAFETY 6. GENERAL PRECAUTIONS 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.
  • Page 14 SAFETY 6. GENERAL PRECAUTIONS 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.
  • Page 15 SAFETY 6. GENERAL PRECAUTIONS 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.
  • Page 16 SAFETY 6. GENERAL PRECAUTIONS 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.
  • Page 17 SAFETY 6. GENERAL PRECAUTIONS 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.
  • Page 18 SAFETY 6. GENERAL PRECAUTIONS 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.
  • Page 19 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.
  • Page 20 SAFETY 6. GENERAL PRECAUTIONS 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.
  • Page 21 SAFETY 6. GENERAL PRECAUTIONS DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious injury or property damage. On jobsites where the machine may go close to electric cables, always do as follows.
  • Page 22 Do not allow other persons to approach during the opera- tion. Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2-11...

  • Page 23: Precautions For Operation

    SAFETY 7. PRECAUTIONS FOR OPERATION 7. PRECAUTIONS FOR OPERATION BEFORE STARTING ENGINE If there is a warning tag hanging from the work equipment con- trol lever, do not start the engine or touch the levers . CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work.
  • Page 24 SAFETY 7. PRECAUTIONS FOR OPERATION ENSURING SAFETY AT THE JOBSITE The person operating the radio control cannot see the other side of the machine, so always check beforehand that there is no danger before starting operation. When operating by radio control, the operating position of the operator is different from when operating from the operator's seat.
  • Page 25 SAFETY 7. PRECAUTIONS FOR OPERATION MEMO 2-14...

  • Page 26: Operation

    OPERATION This operation section gives the basic precautions. For details of the operation precautions for the overall machine, follow the Operation and Maintenance Manual for the standard machine. WARNING Please read and make sure that you understand the SAFETY section before reading this section.

  • Page 27: General View

    OPERATION 8. GENERAL VIEW 8. GENERAL VIEW 8.1 GENERAL VIEW OF MACHINE...
  • Page 28 OPERATION 8. GENERAL VIEW...

  • Page 29: Explanation Of Components

    (box or unit). This product complies with PART 15 and PART 90 of the FCC regulations. If there is any question about whether your product complies with the applicable standards and regulations of your country, please consult your Komatsu distributor.

  • Page 30: Transmitter (Tx. Unit)

    OPERATION 9. EXPLANATION OF COMPONENTS 9.1 TRANSMITTER (TX. UNIT) WARNING Always check the operating pattern used on this machine before starting operations. This sends electric signals to the receiver unit (RX.UNIT) on the machine according to the movement of the switches and levers.
  • Page 31 OPERATION 9. EXPLANATION OF COMPONENTS 9.1.1 CONTROL LEVERS Proportional control is used for operation of the control levers, so it is possible to control the speed according to the amount the levers are operated. In addition, any combination of levers can be used at the same time. Right control lever (1) Direction of operation Front / rear direction...
  • Page 32 OPERATION 9. EXPLANATION OF COMPONENTS Right control lever (2) Direction of operation Front / rear direction Push Pull Right control lever (2) Deceleration Acceleration REMARK Use this lever to temporarily raise or lower the speed set by the e ngine s p eed contro l sw itch de scribed on "SWITCHES(3-10 page)".
  • Page 33 OPERATION 9. EXPLANATION OF COMPONENTS Pitch operation Push the blade/ripper selector switch towards the blade. hen left control lever (2) is operated, the blade is pitched. REMARK If the pitch and tilt operations (both in dual mode and sin- gle mode) are operated at the same time, priority is given to the pitch operation.
  • Page 34 OPERATION 9. EXPLANATION OF COMPONENTS 9.1.4 OPERATION METHOD FOR SSC MODE SELECTION USING RADIO CONTROL CAUTION Check that the radio control can be operated (yellow rotating lamp is flashing). Selecting dozing mode Each time the center control lever is pulled back fully, the mode is switched as follows.
  • Page 35 OPERATION 9. EXPLANATION OF COMPONENTS 9.1.5 SWITCHES WARNING When waiting to start work, set the switch to the PARKING position to apply the parking brake. Do not run the starting motor continuously for more than 20 seconds. Engine starting switch Keep this switch pushed down to start the engine.
  • Page 36 OPERATION 9. EXPLANATION OF COMPONENTS 9.1.6 OTHERS Cable connector This connector is used when using the cable (option) for operations. Power source lamp When the key switch is ON, the pilot lamp flashes. External power source input connector 3-11...

  • Page 37: Receiver Unit (Rx. Unit)

    OPERATION 9. EXPLANATION OF COMPONENTS 9.2 RECEIVER UNIT (RX. UNIT) This checks the ID code of the electric signals (radio waves) sent from the TX. UNIT (transmitter) and carries out electric control and hydraulic control of the machine. It consists of the following components. 3-12...

  • Page 38: Controllers

    OPERATION 9. EXPLANATION OF COMPONENTS 9.3 CONTROLLERS This machine is equipped with three controllers. The three controllers are all the same in terms of hardware and software, but they act to control the transmission, steering, and work equipment according to the wiring harness used to connect them. 3-13...

  • Page 39: Charger

    OPERATION 9. EXPLANATION OF COMPONENTS 9.4 CHARGER The charger is used to charge the battery for the power supply. When charging with AC 100V Charger Battery When charging with DC 24V (cigarette lighter on bulldozer dashboard) Charger Battery The charger is equipped with an overcharge prevention function that automatically switches off the charger when the charging is completed.

  • Page 40: Rotating Lamps

    OPERATION 9. EXPLANATION OF COMPONENTS 9.5 ROTATING LAMPS The operating condition of the machine is displayed by rotating lamps on top of ROPS. (Standard installation: x 2; option: x 2) 9.5.1 STANDARD INSTALLATION Radio control operation display lamp(Yellow) When it is possible to operate the machine by radio control, the yellow operation display lamp lights up. When there is reception error, emergency stop, or tilting of the transmitter, the lamp goes out, so check each oper- ating condition.

  • Page 41: Handling Radio Control

    OPERATION 10. HANDLING RADIO CONTROL 10. HANDLING RADIO CONTROL To ensure that the radio control operations can be carried out safely, they must be carried out in the following order. If this order is not followed, the radio control cannot be operated, so be sure that you fully understand the correct order before operating.

  • Page 42: Flow Chart For Starting, Operating Using Radio Control

    OPERATION 10. HANDLING RADIO CONTROL 10.1 FLOW CHART FOR STARTING, OPERATING USING RADIO CONTROL Set selector switch to RADIO CONTROL. Set fuel control dial on machine to MIN position. Turn key on machine to ON position. Buzzer on machine sounds for approx. 3 seconds Lights and all rotating lamps light up for approx.

  • Page 43: Flow Chart For Stopping Operation Using Radio Control

    OPERATION 10. HANDLING RADIO CONTROL 10.2 FLOW CHART FOR STOPPING OPERATION USING RADIO CONTROL Transmitter has been tilted After approx. 3 seconds after Press emergency stop button continuously for more than turning power key switch on on transmitter. 2 seconds. transmitter OFF.

  • Page 44: Details Of Procedure For Radio Control Operation

    OPERATION 10. HANDLING RADIO CONTROL 10.3 DETAILS OF PROCEDURE FOR RADIO CONTROL OPERA- TION 10.3.1 CHECKS BEFORE STARTING Before operating the radio control, carry out the checks before starting for the base machine. For details of the checks before starting for the base machine, see the separate Operation and Maintenance Man- ual for the standard machine.
  • Page 45 OPERATION 10. HANDLING RADIO CONTROL WARNING If the following procedures are not followed, the machine may suddenly start on slopes. NOTICE In cold weather, preheating must be carried out before the engine is started. This operation cannot be car- ried out by radio control, so carry out the preheating manually. Set the radio control/on-board selector switch to the RADIO CONTROL position.
  • Page 46 OPERATION 10. HANDLING RADIO CONTROL Set the parking lever to the FREE position (raised). NOTICE When the above procedure is followed, electricity is sup- plied to the radio controller, and when the radio control is operated, the parking brake is applied. Checks before starting for transmitter, receiver unit, and controller When operating the radio control, even if radio control operation is a started with all the switches ON, the receiver may take this as a reception error and it may not be possible to operate the radio control.
  • Page 47 OPERATION 10. HANDLING RADIO CONTROL Keep the engine starting switch on the transmitter Starting switch pressed for at least 2 seconds. The engine will start. NOTICE Do not run the starting motor continuously for more than 20 seconds. If the engine does not start, wait for at least 2 minutes, then try again.
  • Page 48 OPERATION 10. HANDLING RADIO CONTROL If the base machine or operator are in danger, do as follows. Emergency stop When this switch is pressed, the engine stops and all output matching the operation of the levers is also stopped. (The hydraulic pressure of the valve unit is blocked, and all operations, including the horn, become ineffective.) The parking brake is applied.
  • Page 49 OPERATION 10. HANDLING RADIO CONTROL 10.3.2 TILT ANGLE NOTICE During radio control operations, do not operate with the transmitter tilted more than necessary (more than 45°). Tilt detection A tilt detection switch is built into the transmitter. If the radio control transmitter is tilted more than 45° in any direc- tion, the tilt detection switch is actuated and judges that the transmitter is tilted.

  • Page 50: Precautions When Operating Radio Control

    OPERATION 11. PRECAUTIONS WHEN OPERATING RADIO CONTROL 11. PRECAUTIONS WHEN OPERATING RADIO CON- TROL The person operating the radio control cannot see the other side of the machine, so always check that opera- tion is safe. To carry out operations by remote control efficiently, check beforehand that you are standing in a position where it is easy to see the overall operation (in particular the tip of the work equipment).

  • Page 51: Operation Using Radio Control

    OPERATION 12. Operation using radio control 12. OPERATION USING RADIO CONTROL The following explains the operation of the machine using the radio control from the point where the machine starts to move to the point where it stops. 12.1 MOVING OFF WARNING When the starting the machine off, check that the surrounding area is safe, then give a signal before moving the machine.

  • Page 52: Steering (Changing Direction Of Travel)

    OPERATION 12. Operation using radio control 12.2 STEERING (CHANGING DIRECTION OF TRAVEL) WARNING Avoid making sudden changes in the direction of travel. In particular, it is dangerous when traveling at high speed, as it is difficult to control the machine. CAUTION When carrying out steering facing the machine, the direction of steering is the opposite, so check the direction carefully.

  • Page 53: Stopping (Braking)

    OPERATION 12. Operation using radio control 12.5 STOPPING (BRAKING) WARNING Avoid stopping suddenly. Allow ample room when stopping. Avoid parking the machine on slopes. If it is necessary to park the machine on a slope, apply the parking brake, put blocks under the tracks, and dig the work equipment into the ground to prevent the machine from moving.

  • Page 54: Precautions When Handling Radio Control

    OPERATION 13. PRECAUTIONS WHEN HANDLING RADIO CONTROL 13. PRECAUTIONS WHEN HANDLING RADIO CON- TROL 13.1 TRANSMITTER The structure is not fully waterproof, so do not put it in water or wash it in water. In addition, store it in a place where there is low humidity and little change in temperature.

  • Page 55: Precautions When Operating From Operator'sseat

    OPERATION 13. PRECAUTIONS WHEN HANDLING RADIO CONTROL 13.4 PRECAUTIONS WHEN OPERATING FROM OPERATOR'S SEAT This machine is a radio control specification machine, and some parts are different from the standard machine. Be careful of the following points when operating from the operator's seat. Do not place objects around the radio control/on-board selector switch.

  • Page 56: Checks Around Machine

    OPERATION 14. CHECKS AROUND MACHINE 14. CHECKS AROUND MACHINE To ensure the safety of the operator and to maintain the performance of the machine, carry out checks around the machine before starting the engine. Look around and under the machine and check for loose bolts or nuts, accu- mulated dust, and leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic systems together with the items for the base machine.

  • Page 57: If Any Failure Is Suspected

    OPERATION 15. IF ANY FAILURE IS SUSPECTED 15. IF ANY FAILURE IS SUSPECTED 15.1 RADIO CONTROL OPERATION Problem Probable cause Remedy Transmitter pilot lamp does not Dead battery Install charged battery flash Transmitter key switch is not Turn to position 1 turned Emergency stop switch has Pull switch to cancel...
  • Page 59 D375A-5 BULLDOZER (RADIO CONTROL SPECIAL SMALL ELECTRIC POWER SPECIFICATION) Form No. SEAM048900 ©2002 All Rights Reserved Printed in Japan 09-02...

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