HD255-5

HD255-5
Off-Highway Truck

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 PRODUCT BULLETIN
HD255-5
INTERNAL USE ONLY
Off-Highway Truck
CEN00017-00
Second Periodic Modification of the
HD255-5 Off-Highway Truck
Applicable Serial Numbers:
1601 and up

Photo may include optional equipment.

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 GALEO

Genuine Answers for Land & Environment Optimization

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TABLE OF CONTENTS [No.1]
OUTLINE OF MODIFICATION
• Aim of development
DETAILS OF IMPROVEMENTS
• High performance SAA6D125E-3 engine
• Features of SAA6D125E-3 engine
• High-pressure fuel injection
• Aluminum-core radiator
• Shift-limiter
• ARSC (auto retard speed control) (option)
• Retractable seat belt
• Improved visibility
• Flat face-to-face O-ring seal
• Double-lock sealed electric connector
• Transmission oil filter clogging caution lamp
• Engine overrun prevention caution and alarm
• Desiccant type air dryer (option)
• Improved safety
• Improved maintenance
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TABLE OF CONTENTS [No.2]

COMPARATIVE SPECIFICATIONS
INTERCHANGEABILITY
ATTACHMENTS AND OPTIONAL EQUIPMENT

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OUTLINE OF MODIFICATION [No.1]

AIM OF DEVELOPMENT
The modified HD255-5 incorporates the following features, retaining
the excellent performance of the current model.
• SAA6D125E-3 engine is Japan Tier 2 emission certified
• Aluminum-core radiator is utilized for environmental preservation
• ARSC (Auto Retard Speed Control) (option)
• Desiccant type air dryer (option)
• Improved ride comfort and maneuverability
• Improved reliability and durability
• Improved maintenance
• Improved safety

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OUTLINE OF MODIFICATION [No.2]

GALEO design
• New VI (Visual Identity) design is adopted.
• Cab interior color is changed (Brown-based color to Gray-based color).

Maintenance
• Engine oil replacement interval is
extended (from 250 h to 500 h).

Meeting regulation
• SAA6D125E-3 engine is
Japan Tier 2 emission
certified.

Comfort and easy operation

• Seat belt is changed to retractable type.
• Shift-limiter is added.
• Rubber mudguards are equipped on both sides of platform.
• ARSC (Auto Retard Speed Control) (option)

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OUTLINE OF MODIFICATION [No.3]
Safety
• Alternator belt cover and air conditioner compressor
pulley cover are installed.
• Exhaust manifold cover is installed.
• Fire prevention cover is installed.
• Left rear view mirror is enlarged.

Consideration to the
environment
• Aluminum-core radiator
is adopted.

Reliability and durability

• Flat face-to-face O-ring seal connectors are utilized for hydraulic hoses and fuel hoses
• Double-lock sealed electric connectors are utilized for engine control wiring harnesses
• Transmission filter clogging caution lamp is added.
• Desiccant type air dryer (option)

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DETAILS OF IMPROVEMENTS [No.1]

HIGH PERFORMANCE SAA6D125E-3 ENGINE

Engine output (net): 235kW (316 HP)

Comparison of engine specifications

Model HD255-5
Item New Current
Engine model — SAA6D125E-3 SA6D125E-2
Total displacement ltr (cu.in) 11.04 (674) 11.04 (674)
Rated output (Net) kW (HP)/rpm 235 (316)/2100 235 (316)/2100
N•m [kgf•m](ft.lb) 1375 [140](1,013) 1284 [131](948)
Max. torque
/rpm /1400 /1400
Torque rise % 27.4 20.2
Fuel consumption ratio
g/kW•h (lb/HP•h) 218 (0.357) 216 (0.355)
(at rated speed)

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DETAILS OF IMPROVEMENTS [No.2]

FEATURES OF SAA6D125E-3 ENGINE (1/7)

Electronically-controlled high-pressure fuel injection system
Reentrant type piston
High compression ratio
Extended replacement interval of engine oil and filter
Low noise and low vibration
Various added devices

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DETAILS OF IMPROVEMENTS [No.3]

FEATURES OF SAA6D125E-3 ENGINE (2/7)

Electronically-controlled fuel injection system (1/3)
Details of fuel injection system (fuel system) (1/2)

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DETAILS OF IMPROVEMENTS [No.4]

FEATURES OF SAA6D125E-3 ENGINE (3/7)

Electronically-controlled fuel injection system (2/3)
Details of fuel injection system (control system) (2/2)

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DETAILS OF IMPROVEMENTS [No.5]
FEATURES OF SAA6D125E-3 ENGINE (4/7)
Electronically-controlled fuel injection system (3/3)
Outline of structure and operation of system

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DETAILS OF IMPROVEMENTS [No.6]
FEATURES OF SAA6D125E-3 ENGINE (5/7)
HIGH-PRESSURE FUEL INJECTION (1/3)

Common rail injection system

(high-pressure fuel injection system controlled electronically).
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DETAILS OF IMPROVEMENTS [No.7]
FEATURES OF SAA6D125E-3 ENGINE (6/7)
HIGH-PRESSURE FUEL INJECTION (2/3)

REVERSE

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DETAILS OF IMPROVEMENTS [No.8]
FEATURES OF SAA6D125E-3 ENGINE (7/7)
HIGH-PRESSURE FUEL INJECTION (3/3)
Features of common rail injection system
(1) Complete combustion is attained by high-pressure injection.
(2) Exhaust gas color at start and during acceleration is improved.
(3) Engine sound is lowered.
Comparison of injection pressure

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DETAILS OF IMPROVEMENTS [No.9]

ALUMINUM-CORE RADIATOR
The radiator core is made of aluminum and no lead is used to preserve
global environment.

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DETAILS OF IMPROVEMENTS [No.10]

SHIFT-LIMITER

Gear position
New
Position of shift When shift-limiter When shift-limiter Current
lever switch is ON switch is OFF
R R R R

N N N N

D F2 – F6 F2 – F6 F2 – F6

5 F1 – F5 F1 – F5 F1 – F5

4 F1 – F4 F1 – F4 F1 – F4

3 F1 – F3 F1 – F3 F1 – F3
Shift-limiter switch L F1 F1 – F2 F1 – F2

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DETAILS OF IMPROVEMENTS [No.11]
ARSC (Auto Retard Speed Control) (OPTION)

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DETAILS OF IMPROVEMENTS [No.12]

RETRACTABLE SEAT BELT

The retractable seat belt is utilized for operator comfort.

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DETAILS OF IMPROVEMENTS [No.13]
IMPROVED VISIBILITY

Large-sized rear view mirror Large-sized rear view

(on left side) mirror (on right side)

Added rubber mudguards Added rubber mudguards

(at left platform) (at right platform)
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DETAILS OF IMPROVEMENTS [No.14]

FLAT FACE-TO-FACE O-RING SEAL

Model HD255-5
Item New Current
Flat face-to-face
Seal of hydraulic piping Tapered seal
O-ring seal

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DETAILS OF IMPROVEMENTS [No.15]

DOUBLE-LOCK SEALED ELECTRIC CONNECTOR

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DETAILS OF IMPROVEMENTS [No.16]

TRANSMISSION OIL FILTER CLOGGING CAUTION LAMP

Transmission oil filter

clogging caution lamp

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DETAILS OF IMPROVEMENTS [No.17]

ENGINE OVERRUN PREVENTION CAUTION AND ALARM

Centralized
caution lamp

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DETAILS OF IMPROVEMENTS [No.18]

DESICCANT TYPE AIR DRYER (OPTION)

Comparison of air dryers

Desiccant type air dryer
06_Comparison.xls

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DETAILS OF IMPROVEMENTS [No.19]
IMPROVED SAFETY (1/2) Air conditioner
compressor pulley cover
• Alternator cover
• Air conditioner compressor cover
• Exhaust manifold cover

Alternator belt cover

Exhaust manifold cover

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DETAILS OF IMPROVEMENTS [No.20]

IMPROVED SAFETY (2/2)

• Fire protective cover

Fire protective cover

is added.

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DETAILS OF IMPROVEMENTS [No.21]
IMPROVED MAINTENANCE
• Extended replacement interval of engine oil : 250h to 500h
Model HD255-5
Item New Current
Replacement interval of engine oil h 500 (1st interval: 250) 250
Refill capacity of engine oil ltr (cu.in) 38 (10.0) 27 (7.1)
Combination type Full-flow type
Type of filter —
(Full-flow + Bypass function) (Without bypass function)

• Directly mounted engine oil filter

Engine oil filter

Engine oil filter

New Current
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COMPARATIVE SPECIFICATIONS Comparative
specifications.xls

Manufacturer Model
KOMATSU KOMATSU
HD255-5 New HD255-5 Current
Item

Horsepower
Gross kW (HP) 241 (323) 241 (323)
Net kW (HP) 235 (316) 235 (316)
ISO 9249/SAE J1349

3
Hauling capacity m 17.7 (23.2) 17.7 (23.2)
heaped (2:1, SAE) (cu.yd)

Operating weight
Empty kg (lb) 22450 ( 49,490) 21900 ( 48,280)
Loaded kg (lb) 47525 (104,770) 46975 (103,560)

km/h
Max. travel speed 47.0 (29.2) 47.0 (29.2)
(MPH)

Komatsu Komatsu
Engine model
SAA6D125E-3 SA6D125E-2

Tire size 16.00-25-28PR(E3) 16.00-25-28PR(E3)

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INTERCHANGEABILITY [No.1] Interchangeability.
xls

Interchangeability
Name Remarks
with current model
Engine assembly Not interchangeable Japan Tier 2 emission regulations.

• Exhaust brake Not interchangeable Changed from gate valve type to butterfly type.

• Alternator Not interchangeable *1 With pulley cover

Signal circuit connector is changed (connector is changed to
• Starting motor Not interchangeable
double-lock sealed type).
• Turbocharger Not interchangeable

• Water pump Not interchangeable

Output shaft damper Interchangeable

Radiator Not interchangeable

Retarder oil cooler Not interchangeable

Fuel tank Interchangeable

Torque converter Interchangeable Color is changed.

Transmission Not interchangeable Oil pan is changed (Number of strainer: 1 to 2)

Transmission control valve Interchangeable

Front drive shaft Interchangeable

*1: Not interchangeable from Current to New, but interchangeable vice versa.
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INTERCHANGEABILITY [No.2] Interchangeability.
xls

Interchangeability
Name Remarks
with current model
Rear drive shaft Interchangeable

Differential Interchangeable Color is changed.

Final drive Interchangeable Color is changed.

Front brake Interchangeable Color is changed.

Rear brake Interchangeable Color is changed.

Parking brake Interchangeable

Rim Interchangeable

Tire Interchangeable

Main frame Not interchangeable Engine mount and hydraulic tank installation seat are changed.

Front suspension Interchangeable Color is changed.

Rear suspension Interchangeable Color is changed.

Cab Not interchangeable Floor configuration is changed.

Operator's seat Not interchangeable Manufacturer is changed.

Transmission lubrication oil pump Interchangeable

Retarder cooling pump Interchangeable

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INTERCHANGEABILITY [No.3] Interchangeability.
xls

Interchangeability
Name Remarks
with current model
Steering and hoist pump Interchangeable

Steering valve Interchangeable

Demand valve Interchangeable Color is changed.

Hoist valve Interchangeable Color is changed.

Hoist cylinder Interchangeable

Steering cylinder Interchangeable Color is changed.

Hydraulic tank Not interchangeable Frame mount bracket is changed.

Protector, design of body side panel, and rock ejector bracket
Dump body Not interchangeable
are changed.
Air cleaner Interchangeable

Engine oil filter Not interchangeable

Fuel filter Not interchangeable

Transmission line filter Interchangeable

Hydraulic oil filter Interchangeable

Retarder cooling oil filter Interchangeable

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ATTACHMENTS AND OPTIONAL
EQUIPMENT [No.1]
Attachment.xls

Interchangeability
Name Classification Remarks
with current model
Body and exterior parts
Without body heating (with muffler) Not interchangeable A Mufflers are the same.
Engine side cover Not interchangeable B
Platform guard Not interchangeable A Assemblies are the same.
Body spill guard (150/250mm) Not interchangeable A Able to mount with assembly
Body liner Interchangeable A
Brake and safety parts
Working lamp (on side of body) Interchangeable A
Fog lamp Interchangeable A
Hazard lamp Interchangeable A
Yellow beacon lamp Interchangeable A
Front brake ratio valve Interchangeable A
Dump caution buzzer Interchangeable A
Fire extinguisher Interchangeable A
Oil pressure pickup plug (PM Clinic) Not interchangeable A Engine is changed.
Vandalism protection Not interchangeable C
Auto retard speed control (ARSC) — A New option set for modification
A : Can be shipped when machine order is acknowledged by Komatsu
B : Can be shipped 3 months after machine order is acknowledged by Komatsu
C : Can be shipped 6 months after machine order is acknowledged by Komatsu

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ATTACHMENTS AND OPTIONAL
EQUIPMENT [No.2]
Attachment.xls

A : Can be shipped when machine order is acknowledged by Komatsu

B : Can be shipped 3 months after machine order is acknowledged by Komatsu
C : Can be shipped 6 months after machine order is acknowledged by Komatsu

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