Komatsu Galeo HD255-5 User manual

HD255-5
WA
250
GROSS HORSEPOWER
241 kW 323 HP
NET HORSEPOWER
235 kW 316 HP
MAX. GROSS VEHICLE WEIGHT
47525 kg 104,770 lb
Photo may include optional equipment.
OFF-HIGHWAY TRUCK
HD
255

OPERATOR ENVIRONMENT
Powerful KOMATSU SAA6D125E-3 Engine
This engine delivers quicker acceleration and higher travel
speed with the highest output per weight. Advanced technol-
ogy, such as Common-Rail fuel Injection system, air-to-air
aftercooler, and an effi-
cient turbocharger
enables the engine to
meet the North American
EPA Tier 2 emission reg-
ulations. High torque at
low speed, impressive
acceleration, and low fuel
consumption ensures
maximum productivity.
6-Speed, Fully Automatic K-ATOMiCS
Transmission with Shift-Limiter Function
The K-ATOMiCS (Komatsu Advanced Transmission with Op-
timum Modulation Control System) automatically selects opti-
mum gear according to vehicle speed, engine speed and
shift position you’ve chosen. A shift-limiter function is
equipped as a standard. It enables to maintain 1st gear
when the vehicle desends a steep grade.
Oil-Cooled Multiple-Disc Retarder and Exhaust
Brake
The large capacity continu-
ously oil-cooled wet multiple
disc retarder and the exhaust
brake are equipped as stan-
dard and enable safe and
continuous faster downhill
drive.
High Strength Quarry
Body for Easy Loading Operation
The robust body is constructed of thick wear-resistant steel
having 500 Brinell hardness. The V-shape, flat-bottom design
also increases structural strength, and provides excellent
load stability.
Outstandingly Small Turning Radius
The A-frames employed to
the front wheels give a
large steering angle, and
realizes the outstandingly
small turning radius. It
enables to position the
truck at a desired place
easily and quickly.
Wide, Specious Cab with Excellent Visibility
The cab is integrated with ROPS and the structures conform
to ISO 3471 and SAE J1040 standards. The driver’s com-
partment makes it very easy and
comfortable for the operator to
use all the controls. The wide
windshield and large rearview
mirrors provide the superior visi-
bility and safety operation.
Suspension Seat
The suspension, fabric-covered seat which is adjustable to
the operator’s weight is provided as standard. The suspen-
sion seat dampens vibrations transmitted from the machine
and reduces operator fatigue as well as holding the operator
securely to assure confident operation.
Automatic Supplementary Steering and Secondary
Brakes
Automatic supplementary steering and secondary brakes are
employed as a standard.
If an abnormality occurs in the steering hydraulic circuits or
engine stops suddenly, this supplementary steering system
works automatically and enables to continue steering operation.
Steering: ISO 5010, SAE J1511, SAE J53
Brakes: ISO 3450, SAE J1473
Hydropneumatic Suspension for All Terrains
The hydropneumatic
suspension assures
comfortable ride even
over rough terrain and
ensures maximum pro-
ductivity and operator
confidence.
PRODUCTIVITY FEATURES
OFF-HIGHWAY TRUCK HD255-5
32
OFF-HIGHWAY TRUCK
HD255-5
A-frame
7.0m 23'0"
Photo may include optional equipment.
⁄Large-sized rear view mirror
¤Rubber mudguard
‹Rubber mudguard
(at right platform)
⁄
¤
‹
ROPS

Komatsu Components
Komatsu manufactures engine, torque converter, transmis-
sion, hydraulic units, and electrical devices on this dump truck.
Komatsu dump trucks are manufactured with an integrated
production system under a strict quality control system.
High Strength Body
The side plates of the body are reinforced with cross ribs to
increase the rigidity. The ribs of the bottom plate also increase
the rigidity greatly. Furthermore, the body is made of new steel
which we developed in cooperation with a Japanese steel
manufacturer having the best steel manufacturing technolo-
gies in the world. This ultra hard
wear-resisting steel has hard-
ness 25% higher than the con-
ventional steel and about 2.5
times higher than the common
lining steel.
Sealed DT Connectors
Main harnesses and con-
troller connectors are
equipped with sealed DT
connectors providing high
reliability, water resistance
and dust resistance.
High-Rigidity Frames
Cast-steel components are used in the main frame for high-
stress areas where loads and shocks are most concentrated.
It provides a superior reliability and durability.
Flat Face-to-Face O-Ring Seals
Flat face-to-face O-ring seals
are used to securely seal
hydraulic hose and fuel line
hose connections and to pre-
vent oil or fuel leakage.
EXCELLENT RELIABILITY AND DURABILITY
54
OFF-HIGHWAY TRUCK
HD255-5
25 mm 0.98"
14 mm 0.55"
16 mm 0.63"
O-ring
Nipple
Hose
Cast steel
EASY MAINTENANCE
Extended Oil Change Intervals
In order to minimize operating costs, oil change intervals
have been extended.
Engine oil change intervals: 250 hours //500 hours
Wet Multiple-Disc Brakes
The wet multiple-disc brakes on rear wheels make mainte-
nance and adjustment unnecessary.
Flange Type Rim
The flange type rims provide easy removal/installation of the
tires.
Centralized Arrangement
of Filters and Greasing
Points
The engine oil filter and fuel fil-
ter are centralized on the left
side of the machine so that
they can be serviced easily.
The greasing points are also
centralized at two locations.
These filter and greasing main-
tenances can be done from the
ground level.
OFF-HIGHWAY TRUCK HD255-5
VALUE-ENHANCING OPTIONS
ARSC (Auto Retard Speed Control)
ARSC, which enables to maintain the constant downhill trav-
el speed, is available as an option. It allows the operator to
simply set downhill travel speed. Even after setting the trav-
el speed, the operator can still adjust it finely at increments
of 1 km/h 0.4MPH per click (±5 km/h 3.1 MPH within max.
travel speed) to match the optimum speed for the slope.
Also, since temperature of retarder cooling oil is always mon-
itored, the speed is automatically lowered.
Settable range: 7 km/h 4.3 MPH to 45 km/h 28.0 MPH
Desiccant Type Air Dryer
Desiccant type air dryer is available as
an option. It enables to get rid of the
moisture and oil content in the com-
pressed air that are provided from the
air compressor. Therefore, reliability
and durability of the air circuit is
improved spectacularly.
Front Brake Ratio Valve
The front brake ratio valve lowers the air pressure at the be-
ginning of braking operations to limit the efficiency of the
front brake to reduce heating and wear of the brake pad. If
the brake pedal is pressed more than half, however, the air
presser isn’t lowered, but the front brake works as designed.
Automatic Greasing System
This releases operators and mechanics from burdensome
greasing work on the undercarriage. Maintenance time is
shortened, and productivity is enhanced.
Go down sloop at
constant speed
UP
SET
DOWN
CANCEL
Display of set travel speed
ARSC set lever

SPECIFICATIONS
OFF-HIGHWAY TRUCK HD255-5
76
OFF-HIGHWAY TRUCK
HD255-5
AXLES
Rear Axle type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-floating
Final drive type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planetary gear
Ratios:
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.900
Planetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.941
TRANSMISSION
Torque converter . . . . . . . . . . . . . . . . . 3-elements, 1-stage, 2-phase
Transmission. . . . . . . . . . . . . . . . . . . . Full-automatic, planetary type
Speed range . . . . . . . . . . . . . . . . . . 6 speeds forward and 1 reverse
Lockup clutch. . . . . . . . . . . . . . . . . . . . . . . . . Wet, single-disc clutch
Forward . . . . . . . . . . . . . . . . . . . . Torque converter drive in 1st gear,
direct drive in 1st lockup and all higher gears
Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque converter drive
Shift control. . . . . . . . . . . . . . . Electronic shift control with automatic
clutch modulation in all gears
Maximum travel speed . . . . . . . . . . . . . . . . . . 47.0 km/h 29.2 mph
WEIGHT (APPROXIMATE)
Empty weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 22450 kg 49,490 lb
Max. gross vehicle weight:
Standard tire . . . . . . . . . . . . . . . . . . . . . . . . 47525 kg 104,770 lb
Optional tire . . . . . . . . . . . . . . . . . . . . . . . . . 48035 kg 105,900 lb
Not to exceed max. gross vehicle weight, including options, fuel
and payload.
Weight distribution:
Empty: Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48%
Rear axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52%
Loaded: Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32%
Rear axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68%
ENGINE
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu SAA6D125E-3
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-cooled, 4-cycle
Aspiration. . . . . . . . . . . . . . Turbo-charged and air-to-air after-cooled
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 mm 4.92"
Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 mm 5.91"
Piston displacement. . . . . . . . . . . . . . . . . . . . . . . . . 11.04 ltr 674 in3
Flywheel horsepower
ISO 9249 / SAE J1349. . . . . . . . . . . . . . . . Gross 241 kW 323 HP
Net 235 kW 316 HP
Rated rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 rpm
Maximum torque . . . . . 1375 N•m 140 kg•m1,013 lb•ft at 1,400 rpm
Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronically controlled
Lubrication system
Method. . . . . . . . . . . . . . . . . . . . . . . Gear pump, force-lubrication
Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-flow type
Air cleaner. . . . . . . . . . . . . . . . . . Dry type with double elements and
precleaner, plus dust indicator
SUSPENSION SYSTEM
Independent hydropneumatic suspension cylinder with fixed throttle to
dampen vibration.
MAIN FRAME
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Box-sectioned structure
STEERING SYSTEM
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully hydraulic power steering
with two double-acting cylinders
Supplementary steering . . . . . . . Automatic control with manual switch
(meets ISO 5010, SAE J1511 and SAE J53)
Minimum turning radius . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 m 23'0"
BRAKES
Brakes meet ISO J3450 and SAE J1473 standards.
Service brakes:
Front. . . . . . . . . . . . . . . . . . . . Air-over-hydraulic, caliper disc type
Rear . . . . . . . . . . . Air-over-hydraulic, oil-cooled multiple-disc type
Parking brake. . . . . . . . . . . . Spring applied, internal-expanding brake
Retarder. . . . . . . . . . . . . . . . . . . . . . . . . Air-over-hydraulic, oil-cooled,
multiple-disc rear brakes act as retarder.
Secondary brake . . . . A relay valve automatically actuates the service
brakes when air pressure drops below
the rated level. Manual operation is also possible.
BODY
Capacity:
Struck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2 m317.2 yd3
Heaped (2:1, SAE) . . . . . . . . . . . . . . . . . . . . . . . 17.7 m323.2 yd3
Payload . . . . . . . . . . . . . . . . . . . . . . . 25 metric tons 27.6 U.S. tons
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 kg/mm2227,500 psi
high tensile strength steel
Structure. . . . . . . . . . . . . . . . . . . . . . . V-shape body with flat-bottom
Material thickness:
Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm 0.98"
Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 mm 0.63"
Sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm 0.55"
Target area
(inside length x width) . . . . . . . 4570 mm x 2995 mm 15'0" x 9'10"
Dumping angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49°
Height at full dump . . . . . . . . . . . . . . . . . . . . . . . . . . 7075 mm 23'3"
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust heating
HYDRAULIC SYSTEM
Hoist cylinder. . . . . . . . . . . . . . . . . . . Single, 3-stage telescopic type
Relief pressure . . . . . . . . . . . . . . . . 20.6 MPa 210 kg/cm22,990 psi
Hoist time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 sec
CAB
Dimensions comply with ISO 3471 and SAE J1040-1988c ROPS
(Roll-Over Protective Structure) standards.
TIRES
Standard tire. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.00-25-28PR(E3)
SERVICE REFILL CAPACITIES
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 ltr. 98.8 U.S. Gal
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ltr. 7.1 U.S. Gal
Torque converter, transmission and
retarder cooling. . . . . . . . . . . . . . . . . . . . . . . 70 ltr. 18.5 U.S. Gal
Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ltr. 4.8 U.S. Gal
Final drives (total) . . . . . . . . . . . . . . . . . . . . . . . . 14 ltr. 3.7 U.S. Gal
Hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . 80 ltr. 21.1 U.S. Gal
Suspension (total) . . . . . . . . . . . . . . . . . . . . . . . . 30 ltr. 7.9 U.S. Gal Standard equipment may vary for each country, and this specification sheet may contain attachments and optional equipment
that are not available in your area. Please consult your Komatsu distributor for detailed information.
STANDARD EQUIPMENT FOR BASE MACHINE
OPTIONAL EQUIPMENT
CAB:
●Air conditioner
●Cigarette lighter and ashtray
●Intermittent windshield wiper
●Passenger seat (Fabric)
●Radio, AM / AM&FM
●Seatbelt (Two point anchor /
78mm 3.1")
BODY:
●Without body heating
(with muffler)
●Body liner
GUARD AND COVERS:
●
Body spill guard (150 / 250 mm
5.9
" / 9.8" )
●Engine side cover
●
Platform guard (Right hand side)
●Radiator shutter (Canvas type)
●Vandalism protection
LIGHTING SYSTEM:
●Fog lamp
●Hazard lamp
●Side work lamps
●Yellow beacon
TIRES:
●16.00 R25 Radial tire
SAFETY:
●Dumping caution buzzer
●Fire extinguisher
●Front brake ratio valve
MAINTENANCE:
●Air dryer, desiccant type
●Auto greasing system
●Jack, 30ton 33 U.S. tons
●
Large capacity batteries (Wet type)
●PM-clinic
GAUGE
( MEASUREMENT EQUIPMENT):
●Revo-taco-graph
●Tacho-graph
OTHER:
● ARSC (Auto retard speed control)
●Cold area arrangement (-30˚C
thru 40˚C)
●Hot area arrangement (-20˚C
thru 50˚C)
●Poor fuel arrangement
● Sandy & dusty area arrangement
●Tire chains
ENGINE:
●Alternator 50A/24V
●Batteries 2 x 12V 150AH
●Komatsu SAA6D125E-3
●Starting motor, 7.5kW
●Engine auto preheater
CAB:
●Floor mat
●Foot rest
●Reclining suspension seat
●Retractable operator seat belt,
50mm 2" wide
●ROPS cab
●Sun-visor
●Tiltable and telescopic steering
wheel
●Tinted glass
●Windshield washer and wiper
GUARD AND COVERS:
●Engine under guard
●Exhaust thermal-guard
●Fire protective covers
●Mudguards
●Transmission under-guard
SAFETY:
●Automatic supplementary
steering
●Back up alarm
●Exhaust retarder
●Handrails for platform
●Horn, electric
●
Ladders, left and right hand side
●Rear view mirrors
●Secondary brake
●Under view mirror
LIGHTING SYSTEM:
●Back-up light
●Headlights
●Indicator, stop and tail lights
BODY:
●Body, 17.7m323.2 yd3 (Heaped
2:1 SAE), with exhaust heating
●Cab, guard, left side
TIRES:
●16.00-25-28PR
OTHER:
●Caliper disc brake (Front)
●Centralized greasing
● Fully automatic transmission with
all speeds electronic modulation
●Hydropneumatic suspension
(Front and Rear)
●Lock ejector
●Oil-cooled multiple disc brake
(Rear)
DIMENSIONS
2700 mm 8'10"
3200 mm 10'6" 495 mm
1'7"
280 mm
11" 7390 mm 24'3"
3600 mm 11'10" 2140 mm 7'0"
1650 mm
5'5"
7075 mm 23'3"
2940 mm
9'8"
525 mm
1'9"
2225 mm 7'4"
2995 mm 9'10"
3200 mm 10'6"
3590 mm 11'9"
3375 mm 11'1"
4570 mm
15'0"
6770 mm 22'3"
7000 mm
23'0"
49
61
515 mm
1'8"
1
6
.
0
0
-
2
5
-
2
8
P
R
1
6
.
0
0
-
2
5
-
2
8
P
R

HESS611202 Materials and specifications are subject to change without notice.
is a trademark of Komatsu Ltd. Japan.
www.Komatsu.com Printed in Japan 200410 IP.As(15)
10 20 30 40 50 60 70 80 90 100
-5
-10
-15
-20
-25
-30
0
0102030
40 50 60
GROSS WEIGHT
EMPTY LOADED
TRAVEL SPEED
MPH
km/h
10 20 30 40 50 60 70 80 90 100 1100
10 20 30 40 50 60 70 80 90 1000
US ton
ton
F1
F2
F3 F4
TOTAL RESISTANCE (GRADE+ROLLING) (%)
F5 F6
10 20 30 40 50 60 70 80 90 100
-5
-10
-15
-20
-25
-30
0
0102030
40 50 60
GROSS WEIGHT
EMPTY LOADED
TRAVEL SPEED
MPH
km/h
10 20 30 40 50 60 70 80 90 100 1100
10 20 30 40 50 60 70 80 90 1000
US ton
ton
F1
F2
F3 F4
TOTAL RESISTANCE (GRADE+ROLLING) (%)
F5
F6
10 20 30 40 50 60 70 80 90 100
-5
-10
-15
-20
-25
-30
0
0102030
40 50 60
GROSS WEIGHT
EMPTY LOADED
TRAVEL SPEED
MPH
km/h
10 20 30 40 50 60 70 80 90 100 1100
10 20 30 40 50 60 70 80 90 1000
US ton
ton
F1
F2
F3 F4
TOTAL RESISTANCE (GRADE+ROLLING) (%)
F5 F6
TRAVEL PERFORMANCE
Grade distance: 600 m (1970 ft) Grade distance: 900 m (2950 ft) Grade distance: 1500 m (4920 ft)
10 20 30 40 50 60 70 80 90 100
-5
-10
-15
-20
-25
-30
0
0102030
40 50 60
GROSS WEIGHT
EMPTY LOADED
TRAVEL SPEED
MPH
km/h
10 20 30 40 50 60 70 80 90 100 1100
10 20 30 40 50 60 70 80 90 1000
US ton
ton
F1
F2
F3
TOTAL RESISTANCE (GRADE+ROLLING) (%)
F4 F5 F6
10 20 30 40 50 60 70 80 90 100
-5
-10
-15
-20
-25
-30
0
0102030
40 50 60
GROSS WEIGHT
EMPTY LOADED
TRAVEL SPEED
TOTAL RESISTANCE (GRADE+ROLLING) (%)
MPH
km/h
10 20 30 40 50 60 70 80 90 100 1100
10 20 30 40 50 60 70 80 90 1000
US ton
ton
F1
F2
F3
F4 F5 F6
Grade distance: Continuous Descent Grade distance: 450 m (1480 ft)
To determine travel performance: Read from
gross weight down to the percent of total
resistance. From this weight-resistance point,
read horizontally to the curve with the
highest obtainable speed range, then down
to maximum speed. Usable rimpull depends
upon traction available and weight on drive
wheels.
To determine brake performance: These
curves are provided to establish the
maximum speed and gearshift position
for safer descents on roads with a given
distance. Read from gross weight down
to the percent of total resistance. From
this weight resistance point, read
horizontally to the curve with the highest
obtainable speed range, then down to
maximum descent speed the brakes can
safely handle without exceeding cooling
capacity.
BRAKE PERFORMANCE
TOTAL RESISTANCE (GRADE+ROLLING)%
RIMPULL
MPH
km/h
0
0 10203040506070
40353025201510
TRAVEL SPEED
GROSS WEIGHT
US ton
ton
LOADEDEMPTY
US ton
kN
ton
0.5
0.6
0.7
0.8
0.9
1
2
3
4
5
6
7
8
9
10
20
30
40
50
70
60
50
40
30
20
10
80
90
100
400
300
200
500
10
20
30
40
50
60
70
80
90
100
200
300
400
500
45.0
40.0
35.0
30.0
25.0
20.0
15.0
13.0
14.0
12.0
11.0
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
20 30 40 50 60
6555453525