Galeo HD785-7 DUMP TRUCK. Operation and Maintenance Manual (2006)

FOREWORD

BEFORE READING THIS MANUAL

This manual gives details of the operation and methods of inspection and maintenance for this machine that must
be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety
rules for the operation and maintenance of machines.

Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.

Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If you carry out any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you
or others engage in the prohibited uses or actions described in this manual. If the machine is operated mistakenly
when carrying out inspection and maintenance, there is danger that it may lead to serious injury or death.

If you sell the machine, be sure to give this manual to the new owner together with the machine.

Always keep this Operation and Maintenance Manual in the
location shown on the right so that all relevant personnel can read
it at any time.

Storage location for the operation and maintenance manual:On
inside of left door

If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. To ensure that
the correct manual is sent, check the serial number of the machine and inform your Komatsu distributor.

This manual uses the international units (SI) for units of measurement. For reference, units that have been used in
the past are given in ( ).

The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your machine or with questions regarding information contained in this manual.

The numbers in circles in the illustrations correspond to the numbers in ( ) in the text.
(For example:

→

(1))

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, it may lack certain safety devices and
specifications 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 operating the machine.

1 - 2

FOREWORD

SAFETY INFORMATION

To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.

To identify important safety messages in the manual and on the machine labels, the following signal words are used.

The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.

This signal word indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.

This signal word indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.

This signal word indicates a potentially hazardous situation exists which, if not avoided,
may result in minor or moderate injury.

The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.

This precaution is given where the machine may be damaged or the service life reduced if
the precaution is not followed.

This word is used for information that is useful to know.

1 - 5

FOREWORD

CONTENTS

FOREWORD

BEFORE READING THIS MANUAL

SAFETY INFORMATION

INTENDED USE

USE OF MACHINE

DIRECTIONS OF MACHINE

VISIBILITY FROM OPERATOR'S SEAT

LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE

EPA REGULATIONS, ENGINE NUMBER PLATE

SERVICE METER POSITION

1- 10

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

1- 10

SAFETY

SAFETY INFORMATION

SAFETY LABELS

POSITION FOR ATTACHING SAFETY LABELS

SAFETY LABELS

PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE

2- 10

PRECAUTIONS DURING OPERATION

2- 17

PRECAUTIONS FOR MAINTENANCE

2- 24

PRECAUTIONS WITH TIRES

2- 31

PRECAUTIONS FOR MACHINE

2- 32

OPERATION

GENERAL VIEW

GENERAL VIEW OF MACHINE

GENERAL VIEW OF CONTROLS AND GAUGES

EXPLANATION OF COMPONENTS

MACHINE MONITOR

OTHER FUNCTIONS OF MACHINE MONITOR

3- 27

SWITCHES

3- 32

CONTROL LEVERS AND PEDALS

3- 41

BODY PIVOT PIN

3- 46

LOCATION OF FIRE EXTINGUISHER

3- 46

DUST INDICATOR

3- 47

FUSES

3- 48

CAR RADIO

3- 51

CAR STEREO

3- 57

AIR CONDITIONER

3- 66

HANDLING MACHINES EQUIPPED WITH VHMS

3- 72

OPERATION

3- 74

CHECK BEFORE STARTING ENGINE

3- 74

STARTING ENGINE

3- 97

BREAKING-IN THE MACHINE

3- 99

OPERATIONS, CHECKS AFTER STARTING ENGINE

3- 99

STOPPING ENGINE

3-100

CHECKS AFTER STOPPING ENGINE

3-100

MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING

3-101

SHIFTING GEAR

3-106

TRAVELING DOWNHILL

3-108

1 - 11

FOREWORD

CONTENTS

STEERING THE MACHINE

3-122

LOADING OPERATIONS

3-122

DUMP OPERATIONS

3-123

PRECAUTIONS FOR OPERATION

3-125

PARKING MACHINE

3-126

CHECKS AFTER COMPLETION OF WORK

3-127

LOCKING

3-127

HANDLING TIRES

3-128

DETERMINING AND MAINTAINING TRAVEL ROAD

3-131

DETERMINING TRAVEL ROAD

3-131

MAINTAINING TRAVEL ROAD

3-131

TRANSPORTATION

3-132

PRECAUTIONS WHEN TRANSPORTING

3-132

STEPS FOR TRANSPORTATION

3-132

METHOD OF SECURING MACHINE

3-132

METHOD OF LIFTING MACHINE

3-133

COLD WEATHER OPERATION

3-136

PRECAUTIONS FOR LOW TEMPERATURE

3-136

PRECAUTIONS AFTER COMPLETION OF WORK

3-137

AFTER COLD WEATHER

3-138

LONG-TERM STORAGE

3-139

BEFORE STORAGE

3-139

DURING STORAGE

3-139

AFTER STORAGE

3-139

PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE

3-139

TROUBLESHOOTING

3-140

AFTER RUNNING OUT OF FUEL

3-140

IF TRANSMISSION HAS TROUBLE

3-141

METHOD OF LOWERING DUMP BODY IN EMERGENCY

3-141

METHOD OF TOWING MACHINE

3-142

IF BATTERY IS DISCHARGED

3-146

OTHER TROUBLE

3-150

MAINTENANCE

GUIDES TO MAINTENANCE

OUTLINE OF SERVICE

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC

OUTLINE OF ELECTRIC SYSTEM

WEAR PARTS

4- 10

WEAR PARTS LIST

4- 10

RECOMMENDED FUEL, COOLANT, AND LUBRICANT

4- 11

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

4- 12

RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL

4- 13

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

4- 14

TORQUE LIST

4- 14

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

4- 15

SAFETY CRITICAL PARTS

4- 16

MAINTENANCE SCHEDULE CHART

4- 23

MAINTENANCE SCHEDULE CHART

4- 23

SERVICE PROCEDURE

4- 25

1 - 12

FOREWORD

CONTENTS

INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)

4- 25

WHEN REQUIRED

4- 26

CHECK BEFORE STARTING

4- 52

EVERY 250 HOURS SERVICE

4- 53

EVERY 500 HOURS SERVICE

4- 66

EVERY 1000 HOURS SERVICE

4- 70

EVERY 2000 HOURS SERVICE

4- 84

EVERY 4000 HOURS SERVICE

4- 87

EVERY 8000 HOURS SERVICE

4- 91

EVERY 15000 HOURS SERVICE

4- 92

SPECIFICATIONS

ATTACHMENTS, OPTIONS

SELECTING DUMP BODY

HANDLING AIR SUSPENSION SEAT

SEAT ADJUSTMENT

REMOVAL AND INSTALLATION OF HEADREST

HANDLING AUTOMATIC SPIN REGULATOR (ASR)

EXPLANATION OF COMPONENTS

ACTUATION OF ASR SYSTEM

PRECAUTIONS WHEN USING

TROUBLESHOOTING

BLEEDING AIR FROM ASR CIRCUIT

HANDLING ABS

6- 10

EXPLANATION OF COMPONENTS

6- 10

ABS SYSTEM CHECK AFTER STARTING ENGINE

6- 12

OPERATION OF ABS

6- 12

PRECAUTIONS WHEN USING

6- 13

TROUBLESHOOTING

6- 14

HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)

6- 16

OUTLINE OF SYSTEM

6- 16

NORMAL OPERATION DISPLAY

6- 17

EXTERNAL DISPLAY LAMPS

6- 19

PERFORMING CALIBRATION

6- 20

DATA STORED IN PAYLOAD METER

6- 22

PROCEDURE WHEN DOWNLOADING

6- 22

MACHINE ID, OPEN ID

6- 26

PAYLOAD (CYCLE DATA ITEM)

6- 28

SERVICE FUNCTIONS

6- 28

OTHERS

6- 28

HANDLING DUMPING COUNTER

6- 29

INDEX

1 - 13

SAFETY

SAFETY INFORMATION

SAFETY LABELS

POSITION FOR ATTACHING SAFETY LABELS

SAFETY LABELS

PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE

2- 10

FOR SAFE OPERATION

2- 10

KNOW YOUR EQUIPMENT

2- 10

PREPARE FOR SAFE OPERATION

2- 10

CLOTHING AND PERSONAL PROTECTIVE ITEMS

2- 11

FIRE EXTINGUISHER AND FIRST AID KIT

2- 11

KEEP THE MACHINE CLEAN

2- 11

IF ABNORMALITIES ARE FOUND

2- 11

HANDRAILS AND STEPS

2- 12

MOUNTING AND DISMOUNTING

2- 12

INSIDE OPERATOR'S COMPARTMENT

2- 12

PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT

2- 13

PRECAUTIONS WHEN LEAVING THE MACHINE

2- 13

EMERGENCY ESCAPE FROM OPERATOR'S CAB

2- 13

FIRE PREVENTION

2- 14

ACTION IF FIRE OCCURS

2- 15

BATTERY HAZARD PREVENTION

2- 15

PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS

2- 16

PRECAUTIONS DURING OPERATION

2- 17

EXAMINATION AND CONFIRMATION OF WORKSITE

2- 17

WORKING ON LOOSE GROUND

2- 17

DO NOT GO NEAR HIGH-VOLTAGE CABLES

2- 17

ENSURE GOOD VISIBILTY

2- 18

CONFIRMATION OF MARK

2- 18

PRECAUTION FOR WARNING TAG

2- 18

CHECK BEFORE STARTING ENGINE, ADJUST

2- 19

PRECAUTIONS WHEN STARTING

2- 19

STARTING WITH BOOSTER CABLES

2- 20

CHECK BEFORE STARTING OPERATION

2- 20

PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE

2- 21

PRECAUTIONS WHEN TRAVELING

2- 22

PRECAUTIONS WHEN TRAVELING ON SLOPES

2- 22

PRECAUTIONS WHEN OPERATING DUMP BODY

2- 22

PRECAUTIONS WHEN OPERATING

2- 23

PRECAUTIONS FOR ACCUMULATED SNOW, AND ICE

2- 23

SHIPPING

2- 23

WHEN TOWING

2- 23

2 - 2

SAFETY

SAFETY INFORMATION

PRECAUTIONS FOR MAINTENANCE

2- 24

UNAUTHORIZED MODIFICATION

2- 24

WARNING TAG

2- 24

KEEP WORK PLACE FOR MAINTENANCE CLEAN AND TIDY

2- 24

REPAIR WELDING

2- 24

USE CAUTION WHEN FUELING

2- 24

PERSONAL MAINTENANCE

2- 24

PROPER TOOLS

2- 25

SELECTION WORK PLACE FOR MAINTENANCE

2- 25

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

2- 26

TWO WORKERS FOR INSPECTION AND MAINTENANCE WHEN ENGINE IS RUNNING

2- 27

WORK UNDER THE MACHINE

2- 28

PREVENTION BURNS FROM HOT WATER

2- 28

PREVENTION BURNS FROM HOT OIL

2- 28

COMPRESSED AIR

2- 28

HANDLING HIGH-PRESSURE HOSES, PIPING

2- 29

PRECAUTIONS WITH HIGH-PRESSURE OIL

2- 29

PRECAUTIONS FOR HIGH-PRESSURE

2- 29

PRECAUTIONS FOR HIGH VOLTAGE

2- 29

HANDLING SUSPENSION CYLINDER, ACCUMULATOR

2- 29

MAINTENANCE OF AIR CONDITIONER

2- 30

WASTE MATERIALS

2- 30

PRECAUTIONS WITH TIRES

2- 31

HANDLING TIRES

2- 31

PRECAUTIONS WHEN STORING TIRE

2- 31

PRECAUTION FOR MACHINE

2- 32

PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)

2- 32

2 - 3

SAFETY

PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE

Improper operation and maintenance can cause serious injury or death. Read the manual and safety labels before
operating or servicing the machine. Follow all warnings and instructions.

FOR SAFE OPERATION

For safe operation of this machine, you must be a qualified and authorized operator. To be qualified, you must
understand the written instructions supplied by the manufacturer, have training including actual operation of this
machine and know the safety rules and regulations for the job site.
On the job, an operator must not use drugs or alcohol which can impair his alertness or coordination. An operator
on prescription or over-the-counter drugs needs medical advice regarding whether or not he/she can safely operate
the machine.

KNOW YOUR EQUIPMENT

Know your machine. Know how to operate all equipment on your machine. Know the purpose of the controls,
gauges and indicators. Know the rated load capacity, speed range, braking and steering characteristics, turning
radius and operating clearances. Keep in mind that rain, snow, ice, loose gravel, soft ground, etc. change the
operating capabilities of your machine.
Study the Manual before starting the machine. If there is something in the Manual you do not understand, ask your
supervisor to explain it to you.

PREPARE FOR SAFE OPERATION

Check the Safety Equipment
To protect you and others around you, your machine may be equipped with the following safety equipment. See
that each item is securely in place and in operating condition.

Rollover Protection
Falling Object Protection (Body pivot pin)
Lights
Horn
Backup alarm
Guards
Mirrors
Windshield Wipers & Washers

Never remove or disconnect any safety device.

Check the Machine
Before you begin your workday, you should inspect your machine and ensure that all systems in good operating
condition. Do not operate the machine until all deficiencies are corrected.

Check for broken, missing or damaged parts. Make necessary repairs.
Replace badly worn or damaged tires.
Replace any damaged pins, bushings, or other parts on the machine.
Check service, parking brake for proper operation.
Check cooling system.

Allow the radiator to cool before checking the level.

2 - 10

SAFETY

PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE

CLOTHING AND PERSONAL PROTECTIVE ITEMS

To avoid the risk of injury:

Do not wear jewelry or other accessories. They may catch on the dump control lever or other protruding parts and
cause you to fall.
Do not wear loose clothing. It may catch on the dump control
lever or gear shift lever and cause the machine to move
unexpectedly when it is being operated.
Always wear a hard hat and safety shoes. In addition,
depending on the nature of the work, wear safety glasses, mask,
ear mufflers, safety belt, or other protective equipment.
Do not let your hair extend outside your hard hat. It could get
caught in rotating parts.

FIRE EXTINGUISHER AND FIRST AID KIT

Make sure that a fire extinguisher is provided in case of fire.
Quick extinguishing of a fire can reduce the damage to the
machine and avoid risk of personal injury.
Check the fire extinguisher periodically and make sure that you
fully understand the method of use.
Make sure that a first aid kit is provided in case of injury. If
immediate action is taken in case of injury, the extent of the
injury can be reduced. Keep the first aid kit in the specified place,
check the contents periodically, and replace any items that have
been used or are missing.

KEEP THE MACHINE CLEAN

To avoid the risk of injury:

If there is mud or oil stuck to the machine, you may slip and fall when getting on or off the machine, wipe off any
mud or oil stuck to the machine, and always keep the machine clean.
If water gets into the electrical system, the electrical equipment
may malfunction or not work properly. If it malfunctions, there is
danger of the machine moving unexpectedly, leading to serious
personal injury or death. When cleaning the machine, do not to
wash the electrical system (sensors, connectors) with water or
steam.

IF ABNORMALITIES ARE FOUND

During operation, inspection or maintenance, if any abnormality is noticed (noise, vibration, smell, wrong display by
gauges, smoke, oil leakage, or abnormal displays on the gauges, warning devices or monitors), stop the machine
on flat ground and report the problem immediately to the jobsite supervisor. If the machine continues to be operated
without repairing the problem, it may lead to serious personal injury or death.

2 - 11

SAFETY

PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE

HANDRAILS AND STEPS

To avoid risk of injury when getting on or off the machine.

Always face the machine and maintain at least three-point
contact (both feet and one hand, or both hands and one foot)
with the handrail and steps to ensure that you support yourself.
Always check the handrails and steps for oil, grease, or mud.
Wipe them clean before using.
Repair any damage and tighten any loose bolts.
Never get on or off the machine while holding tools in your hand.
Never climb onto the engine hood, covers, or other places
where there are no anti-slip pads.
When entering the operator's compartment, never hold the
dump control lever. If the dump control lever is gripped, it may
move.

MOUNTING AND DISMOUNTING

Never jump onto the machine. There is danger that your feet will slip, and you will fall and be seriously injured.
Never jump off the machine. There is danger that you will break a bone or suffer other serious injury when landing.
Never get on or off a moving machine. You may be unable to support yourself with the handrail or steps, and fall
from the machine, suffering injury. Even if the machine starts off with no operator on it, do not jump on the machine
and try to stop it.

INSIDE OPERATOR'S COMPARTMENT

When entering the operator's compartment, always wipe off all mud and oil from the soles of your shoes. If you
try to operate the pedals with mud or oil on the soles of your shoes, your foot may slip and the machine may move
unexpectedly, causing serious personal injury to yourself or others.
Do not leave tools or a machine parts lying around inside the operator's compartment. If tools or parts get into the
equipment, it may obstruct operation and cause the machine to move unexpectedly, resulting in serious personal
injury.
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
Do not use a cell phone when driving or operating the machine. This may lead to mistakes in operation, which
could serious personal injury to yourself or others.
Do not bring any dangerous items, such as explosives or items that may ignite, into the operator's compartment.

2 - 12

SAFETY

PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE

PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT

When standing up from the operator's seat to adjust the operator's
seat, place gear shift lever (1) at Neutral, set parking brake switch
(2) to PARKING, set the dump control lever to HOLD, lock with lock
knob (3), then stop the engine. If the gear shift lever or dump
control lever is touched, there is a hazard that the machine may
suddenly move and cause serious personal injury or death.

PRECAUTIONS WHEN LEAVING THE MACHINE

If the correct procedures are not followed when stopping the machine, the machine may suddenly move off with no
operator on it. This may lead to serious personal injury. Always observe the following precautions strictly.

When leaving the operator's cab, place gear shift lever (1) at
Neutral, set parking brake switch (2) to PARKING, set the dump
control lever to HOLD, lock with lock knob (3), then stop the
engine.
Remove the key from the starting switch.
Lock all the doors of the operator's compartment.
Take the key with you and leave it in the specified place.

EMERGENCY ESCAPE FROM OPERATOR'S CAB

There are doors on the left and right sides of the operator's compartment. If the door on one side will not open,
escape through the door on the opposite side. If you do not escape quickly during an emergency, you may suffer
serious injury.

2 - 13

SAFETY

PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE

FIRE PREVENTION

Fire coming from fuel, oil, antifreeze, window washer fluid

Fuel, oil, antifreeze, and window washer fluid will ignite if
brought close to a flame, so there is danger of fire. Always obey
the following.

Do not smoke or use any flame near fuel, oil, antifreeze, or
window washer fluid.
Always stop the engine before adding fuel or oil.
When adding fuel, oil, antifreeze, or window washer fluid,
stay in the area and observe carefully that nothing is spilled.
After adding fuel or oil, tighten all the caps securely to prevent
the fuel or oil from flowing out.
Do not spill oil on hot surfaces or components of the electrical
system.
After adding fuel or oil, wipe up any spilled fuel or oil with a
cloth.
Put fuel-soaked or oily cloths and other flammable materials
in the specified container and keep the container in a place
where there is no danger of the contents igniting.
Use non-flammable flushing oil when washing parts. Do not
use fuel or gasoline or any other fluid that may ignite.
Do not weld or use a gas cutter on pipes or tubes containing
flammable fluids.
Store fuel and oil in a place where there is good ventilation.
Store fuel and oil in the specified place, do not store more
than the specified storage limit, and do not let any
unauthorized person enter the area.
When carrying out grinder operations or welding operations
on the machine, move any flammable substances to a place
where there is no danger of them igniting.

Fire coming from accumulated or spilled flammable substances

Remove dry leaves, wood chips, paper, or other flammable substances that may accumulate on the engine
compartment.

Fire coming from electric wiring

Clean all the electric wiring connectors and tighten the connections securely.
Check starting that there are no loose or damaged electric wires and tighten any loose connectors or wiring
clamps.
Repair or replace any damage wiring.

Fire coming from hydraulic line

Fix the cushions of the piping, guards, tubes, and hoses securely.

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.

2 - 14

SAFETY

PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE

ACTION IF FIRE OCCURS

Turn the starting switch OFF, stop the engine, and remove the key.
Leave the operator's compartment through the door in the direction of safety, and use the handrail and steps to
escape from the machine.
Do not jump off the machine. There is the danger of falling and suffering serious injury.

BATTERY HAZARD PREVENTION

Danger of battery exploding

When the battery is being charged, flammable hydrogen gas is
generated from the poles. If the gas ignites, it may explode and
cause serious injury or fire. Therefore:

Do not use or charge the battery if the battery electrolyte is
below the LOWER LEVEL mark. Always carry out periodic
inspection of the battery electrolyte level, and add distilled
water to the UPPER LEVEL mark.
Do not smoke or bring any flame close to the battery.
Remove the battery from the machine, take it to a
well-ventilated place, remove the battery caps, then carry out
the charging. After charging, tighten the battery caps
securely.

Danger from dilute sulphuric acid

The battery electrolyte includes dilute sulphuric acid. If dilute
sulphuric acid gets on your skin or in your eyes, you may suffer
serious injury. When handling the battery, always do as follows.

When handling the battery, always wear safety glasses and
rubber gloves.
If battery electrolyte gets into your eyes, immediately wash
your eyes with large amounts of fresh water for at least 15
minutes, and be sure to wash behind your eyelids. After that,
get medical attention immediately.
If battery electrolyte gets on your skin or clothes, wash it off
immediately with large amounts of water. When doing this,
do not use any alkaline fluid as a neutralizer. If you suffer any
chemical burn, get medical attention immediately.

Danger of sparks
If any sparks are caused, there is danger that the sparks may fly and cause serious damage. Always obey the
following precautions.

Do not allow any tool or other metal object to form a contact between both terminals of the battery.
Do not leave tools lying around.
When removing the battery terminals, remove the ground terminal (negative (-) terminal) first, then remove the
positive (+) terminal
When installing the battery terminals, follow the opposite procedure from above: connect the positive (+)
terminal first, then install the ground terminal.
Tighten the battery terminals securely.
Secure the battery firmly in the specified position.

2 - 15

SAFETY

PRECAUTIONS DURING OPERATION

EXAMINATION AND CONFIRMATION OF WORKSITE

Before starting operations, check first if there is any danger on the jobsite. If you do not understand the dangers of
the jobsite before starting operations, the machine may tip over, or the ground may collapse, or rocks may fall,
causing injury to the operator. Always:

Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do
not operate where there is a hazard of landslides or falling rocks.
Prevent any unauthorized person from entering the operating area.
Before operating in shallow water or on soft ground, check the depth of the water, speed of the current, and the
firmness and shape of the ground. Avoid any area where there is any obstruction to travel operations.
Maintain the travel path on the jobsite so that there is no obstruction to travel operations.

WORKING ON LOOSE GROUND

Do not operate close to cliffs, road shoulders, or deep ditches where the ground may be soft. There is danger that
the ground may collapse under the weight or vibration of the machine, causing the machine to tip over or fall, and
resulting in injury to the operator. In particular, be careful when carrying out operations after rain, after explosives
have been used, after earthquakes, or in other cases where the ground may easily collapse.
The ground on embankments or close to ditches may collapse under the weight or vibration of the machine,
causing the machine to tip over or fall, and resulting in injury to the operator. Take action to ensure that the ground
is safe before starting operations.

DO NOT GO NEAR HIGH-VOLTAGE CABLES

Electrocution can result from contacting or approaching underground or overhead power cables. Never approach
overhead power lines with any part of your machine. Use extreme caution.

Before starting work in the vicinity of electric cables, inform the local power company of the work to be performed,
and ask them to take the necessary steps to ensure safety.

Voltage of Cables

Safety Distance

100V - 200V

Over 2 m (7 ft)

6600V

Over 2 m (7 ft)

22000V

Over 3 m (10 ft)

66000V

Over 4 m (14 ft)

154000V

Over 5 m (17 ft)

187000V

Over 6 m (20 ft)

275000V

Over 7 m (23 ft)

500000V

Over 11 m (36 ft)

Know your margin of safety. If possible, have power to the lines
disconnected. If not possible, request a signal person for
guidance to maintain at least minimum distance required by law
from the overhead lines.
To prepare for any possible emergencies, wear rubber shoes
and gloves. Lay a rubber sheet on top of the seat, and be careful
not to touch the chassis with any exposed part of your body.
When carrying out operations near high voltage cables, do not
let anyone near the machine.
If the machine should come too close or touch the electric cable,
to prevent electric shock, the operator should not leave the
operator's compartment until it has been confirmed that the
electricity has been shut off.
Also, do not let anyone near the machine.

2 - 17

Galeo HD785-7 DUMP TRUCK. Operation and Maintenance Manual (2006) - page 1