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

SAFETY

PRECAUTIONS DURING OPERATION

ENSURE GOOD VISIBILTY

This machine is equipped with mirrors to improve the visibility, but even with mirrors, there are places, which cannot
be seen from the operator's seat, so always be careful when operating.
When operating or traveling in places with poor visibility, if it is impossible to confirm the condition of the job side or
obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator may
suffer serious personal injury. When operating or traveling in places with poor visibility, always observe the following
items strictly.

If the visibility cannot be sufficiently assured, position a flagman if necessary.  The operator should pay careful
attention to the signs and follow the instructions of the flagman.
The signals should be given only by one flagman.
When working in dark places, turn on the working lamps and front lamps of the machine, and if necessary, set
up additional lighting in the area.
Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms.
Check the mirrors on the machine before starting operations every day.  Clean off any dirt and adjust the view
to ensure good visibility.
In areas where it is impossible to confirm the area behind the machine and observation cameras have been set
up, clean off any dirt from the lens and make sure that the camera gives a clear view of the rear.

CONFIRMATION OF MARK

On soft road shoulders or ground, set up signs to inform of the condition. If the operator does not know the condition
of the jobsite, the machine may tip over or fall, resulting in injury to the operator. Make sure that all operation
personnel understand the meanings of all the signs.

PRECAUTION FOR WARNING TAG

If there is a "DO NOT OPERATE" warning tag on gear shift lever
(1), it means that someone is carrying out inspection and
maintenance of the machine. If you ignore the warning tag and
operate the machine, the service personnel may be caught in
rotating parts or crushed by moving parts, and may suffer serious
personal injury. Always obey the warning tag, and do not start the
engine or touch the levers.

2 - 18

SAFETY

PRECAUTIONS DURING OPERATION

CHECK BEFORE STARTING ENGINE,ADJUST

Before starting the engine, carry out the following checks to confirm that there is no problem with operating the
machine. If the checks are not carried out properly, there is danger that it may cause serious personal injury or
damage to the machine during operation.

Remove all dirt from the window glass to prevent any reduction in the visibility during operation.
Carry out the "WALK-AROUND CHECK (PAGE 3-74)".
Remove all dirt from the lens surface of the front lamps, working lamps, and combination lamps.
Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake pedal,
and check that the pedals work properly.
Adjust the operator's seat so that it is easy to see to the front, and check that there is no damage or wear to the
seatbelt or seatbelt mounts.
Check that the instruments and gauges are working properly, that the gear shift lever is at the Neutral position,
and that the dump control lever is at the HOLD position.
Before starting the engine, check that the lock knob of the dump control lever is at the LOCK position.
Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat
Check that there are no persons or obstacles above, below, or in the area around the machine.
Check that the parking brake switch is in the PARKING position.

PRECAUTIONS WHEN STARTING

When starting the engine, always sit in the operator's seat. If you do not sit in the operator's seat, it will be
impossible to stop operations if a problem occurs. There is danger that this may lead to serious personal injury.
Before starting the engine, sound the horn to give a warning. If there is anyone in the area around the machine,
there is danger of serious injury when the machine moves.
Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious
bodily injury or fire.

2 - 19

SAFETY

PRECAUTIONS DURING OPERATION

STARTING WITH BOOSTER CABLES

If the method of connecting the booster cables is mistaken, the
battery may explode and cause serious personal injury, so always
do as follows.

Always wear safety goggles and rubber gloves when starting
the engine with booster cable.
When connecting a normal machine to a problem machine with
booster cables, always use a normal machine with the same
battery voltage as the problem machine.
When starting with a booster cable, carry out the starting
operation with two workers (one worker sitting in the operator's
seat and the other working with the battery).
When starting from another machine, do not allow the two
machines to touch.
When connecting the booster cables, turn the starting switch
OFF position for both the normal machine and problem
machine. There is a hazard that the machine will move when the
power is connected.
Be sure to connect the positive (+) cable first when installing the
booster cables. Disconnect the negative (-) cable (ground side)
first when removing them.
When removing the booster cables, be careful not to let the
booster cable clips touch each other or to let the clips touch the
machine.
For details of the starting procedure when using booster cables,
see "STARTING ENGINE WITH BOOSTER CABLE (PAGE
3-148)" in the OPERATION section.

CHECK BEFORE STARTING OPERATION

Before starting the engine, carry out the "CHECK BEFORE STARTING (PAGE 3-76)" to confirm that there is no
problem with operating the machine. If this check is not carried out properly, there is danger that it may lead to
damage during operation or may lead to serious personal injury. When carrying out the checks, stop the machine
in a wide area where there are no obstacles, pay careful attention to the surrounding area, and operate slowly. Do
not allow any person to enter the area around the machine. If any problem is found, always repair the problem.

2 - 20

SAFETY

PRECAUTIONS DURING OPERATION

PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE

When operating the machine, always sit in the operator's seat.
If you do not sit in the operator's seat, it will be impossible to stop
operations if a problem occurs. There is danger that this may
lead to serious personal injury.
Do not allow any other person on the machine unless they are
sitting in the assistant's seat. If they are not sitting in the
assistant's seat, there is danger that they made for when the
machine is traveling and suffer serious personal injury.
Always wear the seatbelt. There is danger that you may be
thrown out of the operator's seat and suffer serious injury when
the brakes are applied suddenly.
If there is any person in the area around the machine when it is
traveling, there is danger that the person may be hit or caught up
by the machine and suffer serious personal injury. Before
starting to travel, always do as follows.

Before moving the machine off, check again that there is no
person or obstacle in the surrounding area.
Before starting to move the machine, sound the horn to warn
the people in the surrounding area.
When traveling in reverse, check first that the backup alarm
sounds properly.
If there is a blind spot behind the machine that cannot be
seen, position a signalman.

2 - 21

SAFETY

PRECAUTIONS DURING OPERATION

PRECAUTIONS WHEN TRAVELING

Never turn the starting switch key to the OFF position when the machine is traveling. If the engine stops when the
machine is traveling, the steering will become heavy. There is danger that this may cause mistaken operation of
the steering wheel and lead to serious personal injury. If the engine stops, depress the brake pedal immediately
and stop the machine.
To avoid accidents caused by coming in contact with people, structures, and other machines, always maintain
the proper distance when traveling.
Never transport anyone riding on the body or carry out any other operation besides the main use for the machine.
This is dangerous.
Do not load the dump body above the maximum payload. The brakes will lose their effect.
Lower the dump body, setting the dump lever at FLOAT position, then travel.
When traveling on rough ground, travel at low speed and avoid sudden changes in direction to prevent the
machine from turning over.
When passing over bridges or structures, check first that the structure is strong enough to support the weight of
the machine.
When operating in tunnels, inside buildings, or under bridges or electric wires, or other places where the height
is limited, operate slowly and be extremely careful not to let the machine or dump body contact anything.
Continuous long time traveling at high speed may cause tires to heat up, abnormally increasing the inflation
pressure inside the tires, and to blow up. The explosion of the tire is very destructive, and it can lead to serious
injury or death.
Contact with your Komatsu distributor before doing long continuous traveling.
Do not move the gear shift lever to the N position when the machine is traveling or when it is traveling down a
slope. Always place the transmission in gear before traveling.

If the transmission is in Neutral, the engine cannot provide any braking effect and the steering wheel will
become heavier. In addition, there will be lack of cooling oil for the retarder, so there is danger that it will
overheat or that the actuation of the brake will be poor.
There may also be damage to the transmission or other parts of the power train, and there is danger of
unexpected accidents.

PRECAUTIONS WHEN TRAVELING ON SLOPES

To prevent the machine from tipping over or slipping to the side, always do as follows.

When traveling downhill, use the retarder brake to reduce speed. Do not turn the steering wheel suddenly.
Travel on grass, fallen leaves, or wet steel plates with low speed. Even with slight slopes there is a hazard that
the machine may slip.
If the engine should stop on a slope, apply the brakes fully and apply the parking brake also to stop the machine.

PRECAUTIONS WHEN OPERATING DUMP BODY

Before starting the dumping operation, check to be sure there is no person or object behind the machine.
Stop the machine in the correct position, and check again that there is no person or object behind the machine.
Give the determined signal, then slowly operate the dump body.
If necessary, use blocks for the wheels or position a flagman.
Do not carry out dumping operations on slopes. The machine stability will become poor and there is the danger
that it could tip over.
Do not travel with the body raised.
Do not leave or return to the operator's seat during loading work.
When the dump body is raised, the center of gravity of the machine moves continuously. At this time, if the ground
is soft, the stability of the machine changes. Take care.
Take care particularly when dumping sticky material (wet clay, frozen material, etc.) on a soft ground. The stability
of the machine is reduced and there is danger that it may tip over.

2 - 22

SAFETY

PRECAUTIONS DURING OPERATION

PRECAUTIONS WHEN OPERATING

PRECAUTIONS FOR ACCUMULATED SNOW, AND ICE

When traveling on snow-covered or icy roads, there is danger that the machine may slip when traveling and tip over
or fall off the road. This may lead to serious personal injury and damage. Always do as follows.

Fit tire chains.
Do not apply the brake suddenly on slopes. Reduce the speed and use the braking force of the engine together
with the foot brake (depress the foot brake repeatedly; do not keep it depressed) to stop the machine.
Do not enter areas where the snow is deep. There is danger of driving off the road.

SHIPPING

When the machine is transported, there is danger of serious personal injury and damage during transportation.
Always do as follows.

The machine weight, transportation height, and overall length differ according to the attachments installed.
Confirm the specifications of the machine before transporting it.
Check beforehand that all bridges and other structures on the transportation route are strong enough to withstand
the combined weight of the transporter and the machine being transported.
When traveling on public roads, apply to the local authorities to obtain permission to transport the machine.

WHEN TOWING

For details of the procedure for towing, see the "METHOD OF TOWING MACHINE (PAGE 3-142)"

Always confirm that the wire rope or drawbar used for towing
has ample strength for the weight of the machine being towed.
Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope may
break during the towing operation.
Always wear leather gloves when handling wire rope.
Never tow a machine on a slope.
During the towing operation, never stand between the towing
machine and the machine being towed.

2 - 23

SAFETY

PRECAUTIONS FOR MAINTENANCE

UNAUTHORIZED MODIFICATION

If this machine is modified without permission from Komatsu, there is danger that problems may occur with safety
and that this may lead to serious personal injury. Modifications may have an adverse effect on items such as
machine strength and visibility. Before making any modifications, please consult your Komatsu distributor.
Komatsu cannot take any responsibility for accidents, failures, or damage caused by modifications not authorized
by Komatsu.

WARNING TAG

If others start the engine or operate the controls when it is being
serviced, there is danger that any person carrying out repairs may
suffer serious injury. ALWAYS attach the WARNING TAG to the
control lever to alert others the machine is in repair.

KEEP WORK PLACE FOR MAINTENANCE CLEAN AND TIDY

If the place of operation for carrying out inspection and maintenance is not kept tidy, there is danger of people
tripping up, slipping, or falling over and being injured. Always put away hammers and other tools that are lying
around in the work area, and wipe up all oil, grease, or other slippery substances. Always keep the workplace clean
and tidy to enable operations to be carried out in safety.

REPAIR WELDING

Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment.
There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel
to carry out welding.

USE CAUTION WHEN FUELING

Never fill the fuel tank while smoking or when near an open flame.
Never overfill the tank or spill fuel. If fuel is spilled, clean it up immediately.
Ground the fuel funnel or nozzle against the filler neck to prevent sparks and be sure to replace the fuel tank cap.

PERSONAL MAINTENANCE

Do not allow anyone other than the maintenance personnel near the machine. If necessary, position a guard to keep
people out.

2 - 24

SAFETY

PRECAUTIONS FOR MAINTENANCE

TWO WORKERS FOR INSPECTION AND MAINTENANCE WHEN ENGINE IS RUNNING

To prevent injury, do not carry out maintenance with the engine
running. If maintenance must be carried out with the engine
running, carry out the operation with at least two workers and do as
follows.

One worker must always sit in the operator's seat and be ready
to stop the engine at any time. All workers must maintain
contact with the other workers.

Lower the dump body, keep dump lever (1) in the HOLD position
and lock the lever with dump lever lock knob (2).

Set parking brake switch (3) to the PARKING position to apply
the brake, then put blocks under the tires to prevent the machine
from moving.

When carrying out operations near the fan, fan belt, or other rotating parts, there is a hazard of being caught in
the parts, so be careful not to come close.
Do not touch the steering wheel, gearshift lever, or dump lever. If the steering wheel, gearshift lever, or dump
lever must be operated, always give a signal to the other workers to warn them to move to a safe place.
Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.

2 - 27

SAFETY

PRECAUTIONS FOR MAINTENANCE

WORK UNDER THE MACHINE

When carrying out inspection with the dump body raised, always
set the dump control lever to the HOLD position, set the lock
knob to the LOCK position, then insert the body pivot pin. If the
body pivot pin is not inserted, the dump body may go down when
the dump control lever is operated, and catch or cause serious
injury or even death to the person carrying out the inspection.
Always carry out the operation to remove or insert the body pivot
pin with at least two workers. This operation is carried out with
the dump body raised, so if the dump body goes down during the
operation, it will lead to serious injury or even death.
Never use concrete blocks for supports. They can collapse
under even light loads.
Make sure the hoists or jacks you use are in good repair and strong enough to handle the weight of the
component. Never use jacks with cracked, bent or twisted parts. Never use frayed, twisted or pinched cables.
Never use bent or distorted hooks.

PREVENTION BURNS FROM HOT WATER

Wait for the coolant temperature to go down before checking the
level of coolant in the radiator. If the radiator cap is opened
immediately after stopping the engine, boiling water or steam may
spurt out and cause burns.
To prevent burns, when inspecting or draining the coolant, always:

Check that the temperature has gone down to a point where the
radiator cap can be touched with your bare hand.
Loosen the cap slowly to release the pressure inside the
radiator, then take off the cap.

PREVENTION BURNS FROM HOT OIL

Immediately after the engine is stopped, the oil and other parts are
at high temperature. If you touch the hot oil or hot parts immediately
after the engine is stopped, you will suffer burns.

Check that the temperature has gone down to a point where the
cap can be touched with your bare hand, then loosen the cap
slowly and remove it.
When removing the oil drain plug, release the internal pressure,
then remove the plug.

COMPRESSED AIR

When compressed air is used for cleaning, dirt and dust will fly and may cause serious personal injury.
When using compressed air to clean the element or radiator, wear safety glasses, anti-dust mask, gloves, and
other protective equipment.

2 - 28

SAFETY

PRECAUTIONS FOR MAINTENANCE

HANDLING HIGH-PRESSURE HOSES, PIPING

Do not bend hoses or hit them with hard objects.
Do not use any cracked piping or hoses. There is danger that they may rupture.
Always repair loose fuel or oil hoses and consult with your Komatsu distributor if there are any damaged hoses
or piping.

PRECAUTIONS WITH HIGH-PRESSURE OIL

Diesel fuel or hydraulic fluid under pressure can penetrate the skin or eyes and cause serious injury, blindness or
death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks but do not use
your bare hand.

Do not forget that the work equipment circuits are always under
pressure.
Do not carry out any inspection or replacement operation before
the pressure has been completely removed.
Check for cracks in the piping and hoses and for swelling in the
hoses.
Always wear safety glasses and leather gloves.
If you are hit by a jet of high-pressure oil and suffer injury to your
skin or eyes, wash the place with clean water, and consult a
doctor immediately for medical attention.

PRECAUTIONS FOR HIGH-PRESSURE FUEL

When the engine is running, high-pressure is generated in the engine fuel piping. When carrying out inspection or
maintenance of the fuel piping system, stop the engine and wait for at least 30 seconds to allow the internal pressure
to go down before starting the operation.

PRECAUTIONS FOR HIGH VOLTAGE

When the engine is running or immediately after it has stopped,
high voltage is generated at the injector terminal and inside the
engine controller, so there is danger of electrocution. Never touch
the injector terminal or the inside of the engine controller.
If it is necessary to touch the injector terminal or the inside of the
engine controller, please contact your Komatsu distributor.

HANDLING SUSPENSION CYLINDER, ACCUMULATOR

The suspension cylinder and accumulator are charged with high-pressure nitrogen gas. If any mistake is made in
handling, there is danger that it may cause an explosion or serious personal injury.

Do not remove or disassemble unless necessary.
Do not bring it near flame or dispose of it in fire.
Do no make holes in it weld it, or use a cutting torch.
Do not bear any shock by hammering, rolling or similar activity.
Ask your Komatsu distributor when sealing gas into the cylinder or replacing gas from it.

2 - 29

SAFETY

PRECAUTIONS WITH TIRES

HANDLING TIRES

Explosive separation of a tire and/or rim parts can cause serious
injury or death.
To ensure safety, always do as follows.

When carrying out maintenance, disassembly, repair, or
assembly of the tire or rim, special tools and procedures must be
used. Always ask your Komatsu distributor to do the work.
Use only specified tires and inflate them to the specified
pressure.
Suitable inflation pressure : see HANDLING TIRES (PAGE
3-128).
When pumping up the tires, check that no other person is
standing near the tire, and install an air chuck with a clip that can
be secured to the air valve.
To prevent the tire inflation pressure from becoming too high,
measure the pressure from time to time with an air gauge while
pumping up the tire.
If the pressure goes down abnormally or the rim parts go not fit
the tire, there is a problem with the tires or rim parts. Always
contact your Komatsu distributor for repairs.
If the rim parts are not fitted properly when the tire is being
pumped up, there is danger that the rim parts may fly off, so set
up a protective fence around the tire, and do not stand directly
in front of the rim. Stand beside the tread when pumping up the
tire.
Do not adjust the tire inflation pressure immediately after traveling at high speed or carrying out operations under
heavy load.
Never carry out welding or light a fire near the tire.
Always release all pressure from a single tire, or from both tires of a dual assembly, prior to removing any rim
components.

PRECAUTIONS WHEN STORING TIRE

Store the tires in a warehouse where unauthorized persons
cannot enter. Always erect a fence and put up "No Entry" signs
if the tires must be stored outside. Stand the tire on level ground,
and block it securely so that it cannot roll or fall over if any person
should touch it.
Do not lay the tire on its side. This will deform the tire and cause
it to deteriorate.
If the tire should fall over, do not attempt to stop it. Get out of the
way quickly.

2 - 31

SAFETY

PRECAUTIONS FOR MACHINE

PRECAUTIONS WHEN USING ROPS(Roll Over Protective Structure)

The operator's cab has a ROPS structure. In addition to supporting
of the load if the machine tips over, it also absorbs the impact
energy and protects the operator. If the function of ROPS is
reduced, it cannot protect the operator and he may be injured.
Always do the following.

Do not weld, drill holes, or make any other modification to the
operator's cab structure.
Repair or replace the operator's cab if it is deformed by falling
objects or when the machine tips over. For details of repair,
please consult your Komatsu distributor.

2 - 32

OPERATION

GENERAL VIEW

Enlargement of machine monitor

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Machine monitor mode selector switch 2
Machine monitor mode selector switch 1
Fog lamp switch (if equipped)
Yellow rotating lamp switch (if equipped)
Side lamp switch (if equipped)
Machine monitor bulb check switch
Night lighting dimmer switch
Hazard lamp switch

(9)

(10)
(11)
(12)
(13)
(14)
(15)

Emergency steering switch
Power mode selector switch
AISS LOW switch
Exhaust brake switch (if equipped)
Auto retarder (ARSC) switch (if equipped)
ASR switch (if equipped)
ABS switch (if equipped)

3 - 4

OPERATION

EXPLANATION OF COMPONENTS

The following is an explanation of devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operating
the equipment, and the meanings of the displays.

MACHINE MONITOR

A: Character display
B: Caution items
C: Emergency stop items

D: Meter display portion
E: Central warning lamp

NOTICE
When the engine starting switch is turned to the ON position before starting the engine, a system check is carried out for 3
seconds.

The central warning lamp lights up for 2 seconds, and then goes out.
The alarm buzzer sounds for 2 seconds, and then stops.
The monitor lamp lights up for 2 seconds and then goes out for 1 second.
The shift indicator displays 88 for 2 seconds and then goes out for 1 second.
After a 3-second system check, the meter starts to function.
The character display shows "KOMATSU" for 3 seconds.
If the lamps do not work, there is probably a failure or disconnection, so please contact your Komatsu distributor for
inspection.
When the starting switch is turned ON, if the shift lever is not at the neutral position, after completion of the system check, the
shift lever position pilot lamp and the central warning lamp will light up, and the alarm buzzer will continue to sound
intermittently. When this happens, if the shift lever is set at neutral, N is displayed, the central warning lamp goes out, and the
buzzer stops.

3 - 5

OPERATION

EXPLANATION OF COMPONENTS

Check central warning lamp, alarm buzzer, monitor lamps, and meters.

Before starting the engine, turn the starting switch to the ON
position, press machine monitor check bulb switch (1), and check
that there is no failure in the monitor lamps.

In addition to the gauges that function during the system check, the
meter display portion is also actuated. When this happens, the
character display shows the machine model and the software
version of the machine monitor.

The gauges that do not function have probably failed, so please
contact your Komatsu distributor for inspection.

3 - 6

OPERATION

EXPLANATION OF COMPONENTS

CHARACTER DISPLAY

The character display can display the following items.

(1)
(2)
(3)

Service meter
Odometer
Reverse travel odometer

(4)
(5)
(6)

Action code display
Filter, oil replacement time display
Payload display (if equipped)

Normally, the service meter/odometer is displayed on the character display.
If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out
inspection and maintenance, an action code is displayed to recommend suitable action.
When the time for replacing the filter or changing the oil is reached, after completion of the system check with the
starting switch at the ON position, the maintenance monitor caution lamps flash or light up, and at the same time,
the filter or oil to be replaced is displayed.
For details of the payload display, see "HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE) (PAGE 6-16)" in
ATTACHMENTS, OPTIONS.

NOTICE
Information regarding the failure of the machine or maintenance is displayed on the character display when the starting switch
is at the ON position, check the display to confirm that there is no problem before starting to travel.

3 - 7

OPERATION

EXPLANATION OF COMPONENTS

SERVICE METER

This meter (1) shows the total time that the machine has been
operating.
While the engine is running, the service meter advances even if the
machine is not moving.
The meter advances by 1 for every hour of operation, regardless of
the engine speed.
Even if the starting switch is at the OFF position, the service meter
will display as long as the top part (

) of machine monitor mode

selector switch 1 is being pressed.

NOTICE
When the starting switch is at the OFF position, if the service meter is
displayed even although the top (

) of machine monitor mode selector

switch 1 is not being pressed, there is probably a failure in the machine, so
please contact your Komatsu distributor for inspection.

ODOMETER

This meter (2) indicates the total distance traveled in kilometers.
Even when the starting switch is at the OFF position, while the top
(

) of machine monitor mode selector switch 1 is being pressed,

it indicates the total distance traveled.

NOTICE
When the starting switch is at the OFF position, if the total distance is
displayed even although the top (

) of machine monitor mode selector

switch 1 is not being pressed, there is probably a failure in the machine, so
please contact your Komatsu distributor for inspection.

REVERSE TRAVEL ODOMETER

This meter (3) indicates the total distance traveled in reverse in
kilometers.
For details of the method of displaying the total distance traveled
in reverse, see "OTHER FUNCTIONS OF MACHINE MONITOR
(PAGE 3-27)".

3 - 8

OPERATION

EXPLANATION OF COMPONENTS

ACTION CODE DISPLAY

CAUTION

If action code E03 is displayed, stop the machine immediately. Then see "ACTION CODE (PAGE 3-155)" and contact your Komatsu
distributor for repairs.

If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out
inspection and maintenance, an action code is displayed on this panel (4) to recommend suitable action.
If more than one failure occurs at the same time, the most important action code is displayed. The order of
importance, starting from the highest, is E03, E02, and E01. If failures of equal importance occur at the same time,
the latest one is displayed.
When action codes E02 or E03 occur, the alarm buzzer sounds intermittently and the central warning lamp lights
up.

E03: When this code is displayed, stop the machine immediately,

check the failure code, and contact your Komatsu distributor
for repairs.

REMARK

The top line of the character display displays "E03" and the
bottom line displays "CHECK RIGHT NOW" and "CALL" in turn
for 3 seconds each.
The telephone number is displayed on the right of the "CALL"
display. If the telephone number has not been set, there is a
blank. For details of the method of setting the telephone
number, see "INPUT METHOD FOR TELEPHONE NUMBER
(PAGE 3-30)".

E02: If overrun related information is displayed, reduce the engine

speed and the speed of the machine while continuing
operations.
If the overheat related display is given, stop the machine and
run the engine under no load at a mid-range speed.
If an action code is still displayed after doing this, check the
failure code and contact your Komatsu distributor for repairs.

REMARK

The top line of the character display displays "E02" and the bottom
line displays the condition of the machine related to overrun or
overheat.

3 - 9

OPERATION

EXPLANATION OF COMPONENTS

OPERATION

EXPLANATION OF COMPONENTS

E01: If maintenance location is displayed and the maintenance

caution lamp lights up, carry out inspection and maintenance
of the displayed item after the completion of operations or
when the shift changes.
If "MAINTENANCE" is displayed together with E01, check
the failure code and contact your Komatsu distributor for
repairs.

REMARK

The top line of the character display displays "E01" and the bottom
line displays "MAINTENANCE" or displays the location needing
inspection, filling, or replacing.

FILTER, OIL REPLACEMENT TIME DISPLAY

After completion of the system check, this display (5) shows for 30
seconds the filters and oil which are near the replacement interval.
The maintenance caution lamp also flashes or lights up at the
same time.
After replacing the filter or changing the oil, reset the replacement
interval. For details, see "RESET METHOD FOR FILTER, OIL
REPLACEMENT TIME (PAGE 3-28)".

REMARK

The top line of the character display shows the name and ID number of the item needing replacement. The line
at the bottom shows the remaining time until replacement and the total number of times the item has been
replaced.
After giving the display for 30 seconds, the display does not appear again until the starting switch is turned again
to the ON position.
If the action code is being displayed, the message in the diagram above is not displayed on the character display.
If there two or more items to be displayed, they are displayed every three seconds.
If there are more than 10 items to be displayed, all the items are displayed once each.
The display is given when the time reaches 30 hours before the filter and oil replacement interval.
When the replacement interval approaches, the maintenance caution lamp flashes, and if the replacement
interval has passed, the lamp lights up.

3 - 10

OPERATION

EXPLANATION OF COMPONENTS

Items for display of filter, oil replacement time

Item

Replacement

interval

Character display

ID number

Fuel prefilter

500

FUEL P FILT

Engine oil

500

ENG OIL

Engine oil filter

500

ENG FILT

Transmission oil filter

500

TM FILT

Fuel main filter

1000

FUEL FILT

Corrosion resistor

1000

CORR RES

Torque converter, transmission and
brake cooling oil

1000

TC/TM/BKOIL

Brake oil filter

1000

BK OIL FILT

Brake cooling oil filter

1000

BK C FILT

Steering, hoist oil filter

2000

HYD FILT

Differential case oil

2000

DIFF OIL

Final drive oil

2000

FNL OIL

Steering, hoist oil

4000

HYD OIL

REMARK

See the section below for details of procedure for replacing the filter and oil.

Fuel prefilter
"REPLACE FUEL PREFILTER CARTRIDGE (PAGE 4-67)"
Engine oil
"CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-66)"
Engine oil filter
"CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-66)"
Transmission oil filter
"REPLACE TRANSMISSION OIL FILTER ELEMENT (PAGE 4-69)"
Fuel main filter
"REPLACE FUEL MAIN FILTER CARTRIDGE (PAGE 4-71)"
Corrosion resistor
"REPLACE CORROSION RESISTOR CARTRIDGE (PAGE 4-70)"
Transmission and brake cooling
"CHANGE OIL IN TRANSMISSION, BRAKE COOLING OIL TANK, WASH STRAINER (PAGE 4-74)"
Brake oil filter
"REPLACE BRAKE OIL FILTER ELEMENT (PAGE 4-78)"
Brake cooling oil filter
"REPLACE TRANSMISSION, BRAKE COOLING OIL FILTER ELEMENT (PAGE 4-77)"
Steering, hoist oil filter
"REPLACE STEERING, HOIST OIL TANK FILTER ELEMENT (PAGE 4-84)"
Differential case oil
"CHANGE OIL IN DIFFERENTIAL CASE (PAGE 4-85)"
Final drive oil
"CHANGE OIL IN FINAL DRIVE CASE (PAGE 4-84)"
Steering, hosit oil
"CHANGE OIL IN STEERING, HOIST OIL TANK (PAGE 4-87)"

3 - 11

OPERATION

EXPLANATION OF COMPONENTS

CAUTION ITEMS

CAUTION

If the monitor lights up during travel, inspect the location of the problem quickly and take the necessary action.

(1)
(2)
(3)

Seat belt caution lamp
Parking brake pilot lamp
Dump body pilot lamp

(4)
(5)
(6)

Emergency steering pilot lamp
Fuel level caution lamp
Maintenance caution lamp

SEAT BELT CAUTION LAMP

This monitor (1) lights up if the seat belt is not fastened.
There is danger when traveling, so always fasten your seat belt.

3 - 12

OPERATION

EXPLANATION OF COMPONENTS

PARKING BRAKE PILOT LAMP

This monitor (2) lights up when the parking brake is applied.

DUMP BODY PILOT LAMP

This monitor (3) lights up when the dump body is raised or the
dump body lever is at any position other than "FLOAT".

EMERGENCY STEERING PILOT LAMP

This monitor (4) lights up when the emergency steering is
actuated. If any abnormality occurs in the steering hydraulic circuit
when the machine is traveling, the automatic emergency steering
is actuated and the monitor lights up.

FUEL LEVEL CAUTION LAMP

This monitor (5) lights up when the level of the fuel remaining in the
fuel tank goes below 225 liters (59.45 US gal).
If it lights up, check the fuel level and add fuel.

3 - 13

OPERATION

EXPLANATION OF COMPONENTS

MAINTENANCE CAUTION LAMP

This monitor (6) lights up if any of the the following are applicable.
When it lights up, action code "E01" and the location needing
maintenance are displayed on the character display at the same
time, so carry out inspection, filling, or replacement.

Drop in engine oil level (if equipped)
Clogged engine oil filter (if equipped)
Drop in oil level in steering, hoist oil tank (if equipped)
Clogged air cleaner
Clogged steering, hoist oil filter (if equipped)
Clogged transmission oil filter
Drop in engine cooling water level
Clogged brake cooling oil filter (if equipped)
Worn brake disc (if equipped)
Drop in battery electrolyte level (if equipped)
Drop in transmission oil level (if equipped)

REMARK

In addition to the above, if the filter or oil replacement time is displayed on the character display, the lamp will flash
or light up.

3 - 14

OPERATION

EXPLANATION OF COMPONENTS

EMERGENCY STOP ITEM

CAUTION

If the monitor lights up, stop operations immediately, then check the corresponding area and carry out the action.

If any problem is found in the emergency stop items, the alarm buzzer will sound intermittently, and the monitor for
the location of the problem and the central warning lamp will light up.

(1)
(2)
(3)
(4)
(5)
(6)
(7)

Engine water temperature caution lamp
Torque converter oil temperature caution lamp
Retarder oil temperature caution lamp
Battery charge circuit caution lamp
Steering oil temperature caution lamp
Engine oil pressure caution lamp
Brake oil pressure caution lamp
(accumulator oil pressure)

(8)
(9)

(10)
(11)
(12)

Tilt caution lamp
Machine monitor, option system caution lamp
Engine system caution lamp
Transmission system caution lamp
Retarder system caution lamp

3 - 15

OPERATION

EXPLANATION OF COMPONENTS

ENGINE WATER TEMPERATURE CAUTION LAMP

This monitor (1) warns the operator that the engine coolant
temperature has risen.
When it lights up, "E02 ENGINE OVERHEAT" is displayed on the
character display at the same time, and the engine output is
automatically limited.
Run the engine under no load at a mid-range speed until the lamp
goes out.

TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP

This monitor (2) warns the operator that the torque converter oil
temperature has risen.
When it lights up, "E02 TC OVERHEAT" is displayed on the
character display at the same time, so stop the machine in a safe
place, set the shift lever to the N position, and run the engine under
no load at a mid-range speed until the lamp goes out.

RETARDER OIL TEMPERATURE CAUTION LAMP

This monitor (3) warns the operator that the brake oil temperature
has risen.
When it lights up, "E02 BRAKE OVERHEAT" is displayed on the
character display at the same time , so stop the machine in a safe
place, set the shift lever to the N position, and run the engine under
no load at a mid-range speed until the lamp goes out.

BATTERY CHARGE CIRCUIT CAUTION LAMP

This monitor (4) lights up when the engine is running to warn the
operator of a problem in the charging system.
When it lights up, "E03 CHECK RIGHT NOW" is displayed on the
character display at the same time, so stop the machine
immediately at a safe place, then stop the engine and check the
charging circuit.

3 - 16

OPERATION

EXPLANATION OF COMPONENTS

STEERING OIL TEMPERATURE CAUTION LAMP

This monitor (5) lights up to warn the operator that the steering oil
temperature has risen.
When it lights up, "E02 STRG OVERHEAT" is displayed on the
character display at the same time, so stop the machine in a safe
place, set the shift lever to the N position, and run the engine under
no load at a mid-range speed until the lamp goes out.

ENGINE OIL PRESSURE CAUTION LAMP

This monitor (6) lights up to warn the operator that the engine
lubricating oil pressure has dropped.
When it lights up, "E03 CHECK RIGHT NOW" is displayed on the
character display, and the engine output is automatically limited.
Stop the machine immediately at a safe place, then stop the engine
and carry out inspection.

The lamp lights up if the engine lubricating oil pressure goes below
the specified value when the engine is running,
If the engine is not running, the lamp does not light up.

BRAKE OIL PRESSURE CAUTION LAMP

This monitor (7) lights up to warn the operator that the brake
accumulator oil pressure has dropped below the specified value.
The central warning lamp and alarm buzzer are not actuated when
the engine is stopped.
If the accumulator oil pressure is still lower than the specified value
60 seconds after the engine has been started, "E03 CHECK
RIGHT NOW" is displayed on the character display, so stop the
machine immediately at a safe place, then stop the engine and
carry out inspection.

TILT CAUTION LAMP

This monitor (8) lights up if the dump body has left its seat when the
rear frame of the machine has tilted beyond the safety range to the
left or right.
Lower the dump body and move the machine to a safe place where
the machine is stable.

3 - 17

Galeo HD785-7 DUMP TRUCK. Operation and Maintenance Manual (2006) - page 2