KT600300

12/00

HD1500-5
GALEO Off-Highway Dump Trucks

Introduction and
General Service
Machine Overview

Section 1.1
NEXT EXIT
HD1500-5 Features

• Performance
• Engine & transmission
• 4-wheel oil cooled
brakes
• All-hydraulic system
• Power train
management control
(PMC)
Major Components
Machine Specification
Specifications
25’0” 7.625 m 9’8” 2.955 m
37’6”
11.44 m
RAISED

45° 19’2”
5.85 m
16’3” EMPTY
4.965 m
17’3”
5.25 m

5’5”
1.65 m

11’6” 3.495 m 17’9” 5.4 m

37’8” 11.48 m
Specifications
21’9” 6.62 m 20’0” 6.09 m
20’0” 6.09 m

18’9”
5.705 m

11’11”
3.635 m

13’6” 2’11” .88 m

4.125 m
6’9”
16’5” 5.01 m 2.055 m
19’5” 5.915 m 13’2” 4.02 m
19’8” 5.985 m
Specifications
Specifications
Performance

• 1486 hp for speed

and gradeability
• Komatsu 7-speed
electronic controlled
transmission
• Heavy-duty final
drive designed for
long life
4-wheel Oil-cooled Brakes

Long downhill
Retarding
Capability
All-hydraulic System

• No air in the truck

• Fewer components

AIR effected by moisture

• Faster response with
all-hydraulic brakes
Total Electronic Health Monitor

• Power train management

control™ linked with all
major truck systems
• Diagnostics to prevent
damage
• Management of truck
performance data
HD1500-5 Drivetrain
Cummins QSK 45 Engine
• V-12, 4 cycle
turbocharged &
aftercooled
• 45 L displacement
• 1486 hp (1108 kW)
@ 1900 rpm
• CENTRY™ electronic
control
Cummins CENSE™
Engine mounted electronic module that performs
constant analysis of
vital operations:
• Alerts truck operator
if a potential problem
is developing
• Charts trends of vital
engine parameters
over time
• Measures lubrication,
cooling, fuel & air,
crankcase pressure,
and individual
cylinder performance
7-speed Automatic Transmission
Electronic Transmission Control

Hydraulic Output
Pump Shaft
Drive

Oil
Reservoir

Torque Converter
Electronic Lock-up Clutch
During transmission shifting, lock-up clutch oil pressure
is lowered to a level so that clutch is balanced with
output speed of torque converter.

1. Torque spikes and shift

shock are reduced for
increased transmission life
2. Transmission efficiency is
improved

Non electronic lock-up systems have more shift shock.

Electronic Transmission Control
The electronics control clutch oil pressure so that.
The load is shared by the splitter clutch and the main.
Clutch during a shift.

Benefits are:
1. Longer clutch life
2. Improved transmission
efficiency
Remote Mounted Transmission
The transmission,
Torque converter,
And the hydraulic
Pumps are one
Module mounted
In between engine
And final drive
For excellent
Serviceability.
Cast Final Drive Housing
Heavy-duty Differential
Heavy-duty
Differential
Planetary Gear Final Reduction
Hub Bearings
The wheel hub bearings are “staked”
to prevent the race from moving.
Tires & Rims • Phase II New
Generation Rims
• Rear rim mounting
• Front rim mounting
• 33x51 tire rating
33x51 Tire Rating
Bias Ply Tire Radial Tire

78,500 lb Single Tire 85,500 lb

35 608 kg Rating (100%) 38 783 kg

90,275 lb Single Tire ---

40 949 kg Rating (115%)

--- Single Tire 91,485 lb

Rating (107%) 41 498 kg

541,650 lb Max. Load for 548,910 lb

245 692 kg Truck (6 Tires) 248 986 kg
Body
 Struck Capacity
71 Yd3 (54 M3)
Heaped Capacity
102 Yd3 (78 M3)
Bottom plate 175,000 psi (1207 mPa) tensile strength steel,
0.75” (19 mm), two piece construction

175,000 psi (1207 mPa) tensile strength steel,

Sides and
front 0.47” (12 mm), front wall, 0.35 (9 mm) side wall.
Rugged bolster and sill construction.
Body plate
Body is rubber mounted on frame.
Exhaust heated body is standard.
Horizontal Bolsters

Newer body designs incorporate horizontal bolsters in the side sheet design to
improve body durability and manufacturability.
The horizontal bolster design requires fewer side sheet bolsters which reduces.
The number of parts to be fitted between mating surfaces. The long bolsters.
Allow continuous welds with fewer end tie-ins. The body durability is improved
through manufacturing simplicity of fewer mating parts and continuous welds.
Loading Height

16’3” (4.965 m)
Operator Cabin
Operator Cabin
Instrument Panel
Frame
Braking System

Systems meet SAE J1473 Dec. ‘84 and ISO 3450-

1985
up to 550,000 lb (249 480 kg) operating weight
Service brakes ------------- Komatsu oil-cooled, all-hydraulic actuated,
front/rear disc brakes, front and rear.
Braking surface ----------- 24,668 in2 (159 144 cm2)
Emergency brakes -------- Automatically applied prior to hydraulic
pressure dropping below level required to
meet secondary stopping requirements.
Retarding --------------------- Hand operated lever provides modulated
engagement of both front and rear brakes.
Parking brakes ------------- Spring-applied, oil-released, dry caliper disc
mounted on input shaft to differential.
All-hydraulic

• Reduced maintenance
because air system
is eliminated

AIR
• Electric start
• Faster response with all-
hydraulic brakes
• Auto lubrication system
is hydraulic powered
Brake Cooling
Cooling Flow
(400 gpm)
Brakes

Filters

Heat Exchanger

Reservoir

Pump

Brakes
Electronic Control

• Service brakes are activated by hydraulic

valve (foot pedal)
• Retarder system is activated by electronic
control (control on steer column)
• The retarder control module sends electric
signal to hydraulic brake control
Brake Design
• Simplicity & low
rebuild cost
• Hydraulic applied
• Oil-cooling flow
back pressure
releases brake
• Retarding horsepower:
continuous = 2150 hp
intermittent = 5080 hp
Emergency System
• 3 systems:
– Front brake and accumulator
– Rear brake and accumulator
– Spring-applied park brake (24” disc, 3 calipers)
• Manual emergency brake switch
– Will apply front & rear service brakes
and parking brake
• Automatic emergency brake
– When either accumulator drops to 1750 psi,
the operator is warned by warning light & buzzer
– At 1650 psi, the accumulators
apply service brakes
Suspension
Front Suspension

• Variable rate
hydro-pneumatic
with integral
rebound control
• Maximum front
stroke 14.76” (375
mm)
Rear Suspension

• Maximum rear
stroke 5.51”
(140 mm)
• Maximum rear
oscillation +/-9.2°
Hydraulic System
Hydraulic System
Steering Accumulator-assisted twin cylinders
provide constant rate steering
Oil reservoir 152 U.S. gal (576 L)
Filtration In-line replaceable elements
Suction Single, full flow, 100 mesh
Hoist and steering Dual, in-line, high pressure
Transmission Dual high pressure
Brake component cab Above deck, easy access
Hoist Two 3-stage cylinders with new
concept design and sealing system
Steering Circuit
• Pressure compensated piston pumps charge
steering accumulators

• Low pressure steering valve in cab with a

flow-amplifier mounted low on the frame rail

• Air-to-oil heat exchanger for steering oil

Hoist & Brake Cooling

• 4 gear pumps for

cooling flow of
400 gpm
• 2 brake control valves
limit flow through
cooler when brakes
are not applied (to
save horsepower and
fuel)
Hoist
Filtration
• One high pressure
filter between
steering pump and
accumulator
• Low pressure filters
between brakes
and heat exchanger
(1 front, 2 rear)

• 1 high pressure filter after steering pump

• 1 low pressure filter after front brakes
• 2 low pressure filters after rear brakes
• 2 low pressure filters after
transmission pump
Hydraulic Tank
• Split tank, with common
fluid for steering, hoist
and cooling.
• Divider plate with strainer
(at bottom of tank) which
allows flow between the
steer section and hoist
brake cooling section
Emergency Steering

• Emergency steering
warning is activated
at 1850 psi.
• Accumulators provide
hydraulic power to meet
SAE J1511
recommendations.
Emergency Steering

Bleed-down manifold
has ports for towing
The truck (good
Truck - bad truck
Connection or APU)
Steering Diameter Maneuverability

80’ (24.4 m)
Turning Circle

HD15
00-5
Electronics
Powertrain Management
Control
Visual Display in Cab

LCD Allows Operator

or Serviceman to:
• Check machine
condition
• Select operation
mode

The LCD is not to be used by the

operator during truck operation.