PM 05-12-01

No.
Introduction of
New machine

Dat 12 December 05
e

WA500-6
Wheel Loader

Machine Model
No.

Content

Category

1 New Machine

2 Model change

3 Minor change
Page

1.

Introduction Plan (this page)

2.

Details

2-1

Preparation Schedule for Machine introduction

2-2

Background of Development

2-3

Strategy of Development

2-4

Sales Features

6 - 23

2-5

Major Specification and Competitors

24 - 25

2-6

Outlook Design

26 - 28

Attachment & Option Table WA500-6

Major Component, Expendable Part

29 - 30

2-7
2-8
Interchangeability

1. Introduction Plan

1
2
3-4
5

31 - 32
Planned Distribution Date

Planned Mass Production

Week 12 / 2005

Planned first Unit Shipment

Week 15 / 2005

WA500-6 Market Introduction

2-1 Preparation Schedule for Machine Introduction

1. Publications WA 500-6
Item

completion

start distribution

Fundamentals

Operation manual WA500-6

Parts book

Week 4
Week 4

Week 8
Week 8

Sales related

Product brochure

Week 12

Week 16

Promotion related

Advertising, poster

2nd quarter 2006

2nd quarter 2006

Service related

Shop manual Structure and Function

Shop manual Testing and Adjusting
Shop manual Disassembly and
Assembly

Week 5
Week 5
Week 14

Week 8
Week 8
Week 17

2. Training
Train the Trainer

Sales

Service

2nd quarter 2006

2nd quarter 2006

3. Spare parts supply

Recommended parts list
Week 4

order parts
Week 6

parts distribution
Week 8
WA500-6 Market Introduction

2-2 Background of development

To meet the requirements of TIER 3 starting from 1st of January 2006

Exhaust Regulations
The WA500 classes machines are subject to restrictions
of exhaust gases by EPA Tier3 and EU Stage3 from
January of 2006, and by Japan Stage3 from October of
2006. Tier III or Stage3 demands 60% further reduction
from the Tier II level.

Tier2

Tier3

HC

g/kw h

1.0

0.4

Nox

g/kw h

6.0

3.6

PM

g/kw h

0.2

0.17

As one of a few equipment manufacturers that develop engines in house for

its own use, Komatsu has :
Self-developed Tier III technology;
Over 70 years experience in the production of engines
The ability to keep the engine control optimally matching to
the machine job requirements in a comprehensive manner.
With emphasis on these, Komatsu makes an extensive campaign to promote
the new engine named ecot3 (ecology & economy technology 3).

Noise Regulation
We are required to take measures to reduce the emissions of our machines.
EU (European union) will enforce the stricter Stage2 regulations from January of 2006.
Stage2 demands 3dB further reduction from Stage1 level.

WA500-6 Market Introduction

2-2 Background of development

To meet the requirements of TIER 3 starting from 1st of January 2006
to get ahead of the main competitors.
The Volvo L220E has been introduced in 2001 as first
model of E-Series. To meet the TIERIII regulation, the
machine gets an updated engine.This wheel loader
has very efficient drive line. The weakness of this
machine can be seen in lower durability in comparison
to WA500-3 & CAT980GII regarding frame design and
component life time. This limits the utilisation profile of
this machine to lighter application like loose material
handling.

Volvo L220E

The CAT980H replaces the CAT980G-II to fulfil

TIERIII regulations. The new H-Series features a new
engine and a load-sensing hydraulic system however
for steering only. The fuel efficiency is fair but climbing
ability and speed are significantly worse than Volvo
L220E.

CAT 980H
WA500-6 Market Introduction

2-3 Strategy of development

New dash WA500-6
W/L concept

To meet the
TIER III regulations

New modern and

attractive machine
design

To reduce the
fuel consumption

Load sensing
hydraulic system

To improve traction
& rim-pull

New transmission
with large torque
converter

To increase the
productivity

High speed on
slopes and
larger bucket

To lower the
maintenance cost

Optimum access
for fast repair &
maintenance

WA500-6

WA500-6 Market Introduction

2-4 Sales Features

Increased Operator Comfort
- Low operating noise
- Roomy operator cab
- Adaptive gas-pedal with variable shift timing
according to pedal angle and engine-rpm

New Hydraulic Concept

- High pressure variable piston
pumps (320bar)
- Load sensing hydraulics

New Engine
- New developed SAA6D 140E-5
engine for lowest emissions
- Increased power 263kW / 352HP
- Improved torque curve (max.
1.850Nm @ 1.250rpm)

Lower maintenance cost

Larger productivity
- Increased bucket capacity
- Higher top speed

Re-Designed Driveline

- Reversible fan (hinged) for quick and

easy cleaning
- Screwed engine bonnet top cover for
best accessibility to engine compartment

- Large capacity torque converter for better efficiency and lower

fuel consumption
- Rim-pull increased from 75% to 90% of operation weight
- Travel speed @ 10 slope 10km/h
- Torque converter lock-up (Option) also in 2nd gear for even
higher speed under all conditions.
WA500-6 Market Introduction

2-4 Sales Features

Increased engine performance and engine torque

New developed KOMATSU SAA6D140E-5 Engine

Due to employment of Exhaust Gas Recirculation

(EGR) system, both NOx and PM emissions are
considerably reduced.

WA500-6

WA500-3

Rated engine
power (Net)

263KW /
352 HP @
1.900rpm

235kW /
315 HP @
2.100rpm

Max. engine
torque

1850Nm @
1.250rpm

1400Nm @
1.400rpm

Fuel consumption
@ rated speed

215g p.
kW/h

230g p.
kW/h

Common rail
injection system

Yes
(1800bar)

Yes
(1200bar)

Air to Air
Aftercooler

Yes

No

Exhaust Gas Recirculation (EGR)

Yes

No

The engine complies to the EPA Tier 3 regulations.

WA500-6 Market Introduction

2-4 Sales Features

Low fuel consumption and low noise

Variable Piston Pumps and Load Sensing Hydraulics

Current: fixed capacity pump system

New: variable capacity piston pump system

Pump is delivering maximum flow all the time,

Pump is delivering exactly the required flow

the obsolete flow is redirected to tank

No loss of flow

Loss of flow

Pump

Pump

Valve

Loss

Valve
Quick
movement

Quick
movement

Feedback

WA500-3
Pump

WA500-6
Pump

Valve

Valve
Slow
movement

Slow
movement

Loss

Feedback
WA500-6 Market Introduction

2-4 Sales Features

Low fuel consumption

Innovative Normal and Power- Mode

New electric engine control to limit high
revolution to achieve low fuel consumption.
Engine Torque

N mode

New piston pump system limiting maximum

boom speed according to large bucket load
(forces of boom and bucket movement will not
change at any speed)
P mode

Normal

: For high fuel efficency

Power

: For high productivity

Engine RPM

Boom rise speed

P mode

Power Switch

N mode

Bucket half

Bucket full

Bucket load
WA500-6 Market Introduction

2-4 Sales Features

Low fuel consumption and great productivity

Increased Rimpull and Travelling Performance

Rim- pull / Weight Ratio

Increased Digging Power

(high initial rimpull!!!)

0.75

10 degree
8km/h -> 10km/h
WA500-3

0.5

Flat
34km/h -> 36km/h

WA500-6

10 degree slope

0.25

Flat
0
0

10

20

30

40

Speed (km/h)

Good acceleration and high speed on flat-ground and slopes

- Increased rim-pull at every speed will give good acceleration
- Load & carry and slope traveling are facilitated
- Easy material-penetration (digging) due to unequaled rim-pull at low speeds
WA500-6 Market Introduction

2-4 Sales Features

Low fuel consumption and great productivity

Torque Converter Lock-up (Option) for even larger Productivity

New sequential Lock-Up system for lowest fuel consumption in Load & Carry
WA480-5

WA500-6

2nd Gear

2nd Gear

3rd Gear
4th Gear

Slope
Angle

WA500-6 with
T/C Lock-up

WA500-6 with
Std. T/C

WA500-3 with
Std. T/C

Flat

40 km/h

36 km/h

35 km/h

5slope

20 km/h

16.5 km/h

13 km/h

10slope

11.8 km/h

9.8 km/h

7.8 km/h

Lock-up
engaged

Lock-up
engaged

3rd Gear

Lock-up
engaged

Driven distance in meter per minute

The new innovative sequential Torque Converter

Lock-up system for power-full acceleration and
highest speed in all conditions. In comparison to
the current dash-5 Lock-up system, the operation
of Lock-up in 2nd Gear is now possible ! For
superb up-hill speed and efficient load & carry
operation.

4th Gear

Lock-up
engaged

Example of shifting behaviour when 4 th Gear is pre-selected

WA500-6 Market Introduction

2-4 Sales Features

Low fuel consumption

Hourly Fuel Consumption (L/h)

50
40
30
20
10
0

38,4

36,1

E-mode

P-mode

43,6

WA500-3

WA500-6

Hourly Production
(m3/h)

697

707

640

E-mode

P-mode

WA500-3

WA500-6

Efficiency (m3/L)

Efficiency (m3/L)
25
20
15
10
5
0

19,4

18,7

E-mode

P-mode

Hourly Fuel Consumption (L/h)

60
40

49,5

51,5

47,5

47,5

E-mode

P-mode

E-mode

P-mode

56,9

20
0

WA500-6

Hourly Production (m3/h)

800
600
400
200
0

Load and carry 70m

Fuel consumption (L/h)

Fuel consumption (L/h)

V- shape Loading to 32ton Truck

WA500-3

WA500-6
With Lock-up

One of the key features of the WA500-6

machine is its extremely low fuel
consumption. With an average reduction of
approx. 15% and increase of productivity of
10%, the fuel efficiency is improved by 25%
in comparison to WA500-3.

14,7

WA500-3

WA500-6
WA500-6 Market Introduction

2-4 Sales Features

Great Productivity

Increased Bucket Capacity and Dumping Height

Standard BOOM

25ton

5.3m

The increased bucket capacity

enables the new WA500-6 to
reduce the loading cycles.
Example Komatsu HM250
current WA500-3 : 4 passes
new WA500-6 : 3 passes

32ton

HI-LIFT BOOM
5.3m

The increased dumping

height makes it possible to
load 32to Dump Trucks with
standard boom.

40ton

4.5m

The new WA500-6 High Lift

version is able to load even 40to
Dump Trucks which required e.g.
WA600-3 before.

WA500-6 Market Introduction

2-4 Sales Features

Easy operation and low fuel consumption

New Adaptive Gas Pedal with Variable Shifting Points

In L-mode, the shifting-pattern will be moved
to a lower speed-range. This keeps the
engine at lower engine rotation and results in
lower fuel consumption at traveling. Pressing
the gas pedal into a deeper angle, will either
hold gear or shift down up to maximum
possible speed (same as H mode)..
Mode selections are Manual, L, and H.

Gas pedal angle (%)

100
F

75

50

Mode
selector
switch

25
0
0

10

20
Speed (km/h)

30
WA500-6 Market Introduction

2-4 Sales Features

High safety standard and operation comfort

Enlarged Wheel Base and Tipping Load

+180 mm
WA500-6*

WA500-3*

Tipping Load straight

23.450 kg

22.200 kg

Tipping Load 40

22.200 kg

19.200 kg

Wheel Base

3.780 mm

3.600 mm

The extension of wheel-base by 180mm

improves the static tipping load and the
dynamic stability. That grants also for
excellent operator comfort and together
with E.C.S.S. (Option) the WA500-6 is
perfectly suited for load & carry
application.

* Japan sourced

WA500-6 Market Introduction

2-4 Sales Features

Operation comfort

New High Comfortable Operators Cab

WA500-6 Operator cab

WA500-6

WA500-3

Noise internal

74 dB(A)

77 dB(A)

Noise external

107 dB(A)

111 dB(A)

Sectional area

2.15m

1.66m

The new designed operators cab features

large glass areas for best visibility and
safety. An integrated ROPS Structure
ensures low machine height. A large door
opening angle in combination with rear
hinged door makes it as easy as possible
to enter the cab.

WA500-6 Market Introduction

2-4 Sales Features

Operation comfort

New High Comfortable Operators Cab

A new sliding type console and a large
armrest in combination with EPC-control
ensures a maximum of operation comfort.

WA500-6

Slide

Slide
WA500-3
WA500-6 Market Introduction

2-4 Sales Features

Operation comfort

New High Comfortable Operators Cab

A new logical and easily understandable
monitor display is showing all operation
parameters in superb quality. The roomy
cab features as standard a combined
cooling and heating box and a storage
compartment for documents.

Cool and heating box

Document storage compartment

WA500-6 Market Introduction

2-4 Sales Features

Easy operation

Bucket and Boom Kick-out Adjustable from the Operator Seat

(Option)
The new EPC short lever control features
also a variable boom and bucket kick-out
system. Thus, it enables the operator to
optimize the settings according to the
current application without having to perform
mechanical adjustments.

Upper position
Adjustable

Lower position
Adjustable

+5

Adjustable bucket positioner

-5

Remote positioner
switch in the console
WA500-6 Market Introduction

2-4 Sales Features

Low repair and maintenance cost

New Screwed Engine Bonnet for Quick Access

To reduce the repair and maintenance time,

a new concept of engine bonnet has been
realized. All covers are bolted-on type to
ensure quick access to all engine
components and large stability of the engine
bonnet itself.

By disassembly of the muffler, pre-cleaner

and top cover it is possible to get access to
the upper parts of the engine for
maintenance.This reduces the service cost
drastically for eventually adjustments or
engine inspection works.
WA500-6 Market Introduction

2-4 Sales Features

Low repair and maintenance cost

Optimum Access and Harmonized Position of Filters

Easy and quick access of the T/M oil

filters due to external mounting. On
WA500-3 it was necessary to
remove the body guard before
getting access to the filters.

All engine fluid filters are located at the r.h. side of

the engine. This simplifies the exchange of the
filter elements. A new pre-fuel filter element with
water separator extends the service interval of the
main fuel filter element up to 1.000hrs.
WA500-6 Market Introduction

2-4 Sales Features

Easy cleaning for lower maintenance cost

Reversible and Hinged Radiator Fan for Easy Cleaning

For quick cleaning, the radiator fan can change

the turning direction whilst the engine is running.
By pushing a button the blowing direction of the
radiator fan can be reversed whilst the engine is
running in order to perform a short-term cleaning
of the radiator. For intensive cleaning a hinged
radiator grid and fan motor ensures optimum
access within a few minutes. An auto-reverse fan
is foreseen as option.

Reversible
fan switch

WA500-6 Market Introduction

2-4 Sales Features

Lower repair and maintenance cost

Advanced Self Diagnosis Function

Real-Time-Monitoring of machine conditions
- no further measurement equipment needed
(hydr. oil pressure, engine rpm etc.)
- quick and easy check of machine condition

EMMS (Equipment Management

Monitoring System)
At a glance instrument monitor provides
operator with all necessary information
Maintenance control and troubleshooting
information are displayed on the character
display:

- helps maintaining max. machine performance

Maintenance indicator
- ensures longer machine life due to proper service
- each maintenance item is displayed individually
- avoids unnecessary maintenance

Display of Action and Failure Codes

Electric System Failure History
Mechanical System Failure History
Data transfer via KOMTRAX possible

WA500-6 Market Introduction

2-5 Major Specification and Competitors (Preliminary)

Komatsu
WA500-6

CAT
980H

Volvo
L220E

kW / HP

263 / 352

237 / 323

258 / 351

Std. bucket capacity @ 1.8to/m

5.3m

5.0m

5.0m

Operating weight

kg

32.500

31.100

31.200

mm

7.650

8.000

7.800

kN /kg

25.000

23.600

23.000

Static tipping load at 0

kg

23.450

22.200

23.500

Static tipping load 40

kg

20.400

19.950

20.600*

Hinge pin height

mm

4625

4.505

4.680

Dumping height at 45

mm

3.295

3.165

3.280

Dumping reach

mm

1.500

1.647

1.270

Total height

mm

3.785

3.765

3.730

Wheel base

mm

3.780

3.700

3.700

Engine torque

Nm

1.850

1.615

1.760

Engine displacement

ltr.

15.2

15.2

12.0

Horsepower net

Turning radius outside bucket

Breakout Force

*At 37 turning angle

WA500-6 Market Introduction

2-5 Major Specification Dimension

A. Overall length (Tip of bucket / BOC) 9670mm

B. Overall height

3760mm

C. Height top edge of bucket

6430mm

D. Overall width

3190mm

E. Min. ground clearance

F. Bucket width (Cutting edge width)

450mm

G. Clearance

H. Reach

I. Dump angle

Tip of bucket

3395mm

BOC

3295mm

Tip of bucket

1400mm

BOC

1500mm
45

3400mm
WA500-6 Market Introduction

2-6 Outlook Design

WA500-6 Market Introduction

2-6 Outlook Design

WA500-6 Market Introduction

2-6 Outlook Design

WA500-6 Market Introduction

1. Essential unit

Medium category

Axle
Transmission
Operation Lever

Operator Seat

Boom
Hydraulic oil
Steering
E.C.S.S.
Name Plate

Preparation priority

Large
category

Detail category

2-7 Attachment & Option Table WA500-6

Detail category

STD
Variable
OPT

Sales
unit
Code

Standard Front & Rear

Variable

X01,X02

Limited Slip Differential Front & Rear

Transmission standard T/C
Transmission with T/C Lock-up
2 PPC Lever hydraulic control

Variable
Variable
Variable
Variable

X05,X06
P50
P51
Pattern B

A
A
A
A

X
X
X
X

2 EPC Lever hydraulic control

PPC Multifunction Lever
Air suspension seat without heating (ISRI)
Air suspension seat with heating (ISRI)

Variable
Variable
Variable
Variable

Pattern C
Pattern E
K08
K09

A
C
A
A

X
X
X
X

Special seat for JS-Steering (Grammer)

STD Lift Arm
High Lift Arm
Standard

Variable
Variable
Variable
Variable

K07
B20
B24

C
A
C
A

X
X
X
O

Bio degradable oil

Standard steering
Joystick steering
With E.C.S.S. Travel damper system

Variable
Variable
Variable
Variable

B85
S01
S02
A80

A
A
C
A

O
X
X
X

Without E.C.S.S.
German
English
French
Italian

Variable
Variable
Variable
Variable
Variable

T11
T12
T13
T14

A
A
A
A
A

X
O
O
O
O

Variable

T15

Spanish

Development Classification and lead time

A : Available from mass production start
B : Available after 3 months from mass production start
C : Available after 6 months from mass production start
D : To be developed after firm order

Commonality
to WA500-3

Commonality
(Interchageability)
O Common
X Uncommon

WA500-6 Market Introduction

1. Essential unit

2. Optional unit

Medium category

Name Plate

Bucket & Attachment

Tire and rim

Special attachments

Preparation priority

Large
category

Detail category

2-7 Attachment & Option Table WA500-6

Detail category

STD
Variable
OPT

Sales
unit
Code

Norwegian

Variable

T16

Swedish
Finnish
Danish
Portuguese

Variable
Variable
Variable
Variable

T17
T18
T19
T20

A
A
A
A

O
O
O
O

Greek
Dutch
Bucket 5.2 w/o teeth Rock bucket
Bucket 5.3m w/o teeth Universal

Variable
Variable
Variable
Variable

T21
T22

A
A
B
A

O
O
X
X

Bucket 5.6m w BOC Universal

Bucket 5.7m w/o teeth Loose Material
Bucket 5.9m w. BOC Loose Material
29.5 R25 Michelin
D20, 21, 22, 23, 30, 31, 32, 33

Variable
Variable
Variable
Variable

A
A
A
A

X
X
X
X

29.5 R25 Bridgestone

D42, 53, 54, 52, 51 , 58, 57

Variable

29.5 R25 Goodyear

D70, 71, 73, 74

Variable

3. Spool Valve

Variable

L03

Additionally counterweight
Turbo II pre-cleaner
Roof rail
Add. Work lights

Variable
Variable
Variable
Variable

A15
A24
A50
A51

B
A
A
A

X
X
O
X

Development Classification and lead time

A : Available from mass production start
B : Available after 3 months from mass production start
C : Available after 6 months from mass production start
D : To be developed after firm order

Commonality
to WA500-3

O
Commonality
(Interchageability)
O Common
X Uncommon

WA500-6 Market Introduction

2-8 Major Component, Expendable Part Interchangeability

In contrast to WA 500-3H

Unit

No.
Part name
Interchangeability
Remarks
1 Engine
Current New engine SAA6D140-E5
New
2 Radiator
Current Larger radiator
New
3 Torque converter
New
Current New large capacity Torque converter
4 Transmission
New
Current New reinforced transmission
5 Transmission valve
New
Current New transmisson
6 Front axle
New
Current New front axle
7 Rear axle
New
Current New rear axle
8 Propeller shaft front
New
Current New propeller shaft
9 Propeller shaft middle
New
Current New propeller shaft
10 Proppeler shaft rear
New
Current New propeller shaft
11 Hydraulic pump
New
Current New variable piston type pump
12 Main control valve
New
Current New closed sensing main controll valve
13 Orbit roll valve
New
Current
14 Cut off valve
New
Current Abolished
15 PPC valve
New
Current
16 Brake valve
New
Current New brake system
17 Lift cylinder
New
Current Changed to smaller diameter
18 Bucket cylinder
New
Current Changed to smaller diameter
19 Steering cylinder
New
Current Changed to smaller diameter
20 Rim
New
Current Amount of fixing screws changed
21 Hydr.motor for cooling fan
New
Current
22 Monitor panel
New
Current New main monitor
Common

Uncommon

WA500-6 Market Introduction

2-8 Major Component, Expendable Part Interchangeability

In contrast to WA 500-3H

Unit

No.
Part name
23 ROPS Cab
24 Bucket A-Type
25 Bucket B-Type
26 Bucket C- Type
27 Air cleaner Outer element
28 Air cleaner Inner element
29 Engine oil filter
30 Fuel filter
31 Corrosion resistor
32 T/C Oil filter
33 Hydraulic oil filter
34 Air condition filter (outer)
35 Air condition filter (inner)
36 Tire
37 B.O.C.
38 One piece teeth
39 Service brake disc
40 Parking brake disc
41 Alternator belt
42 Aircon compressor belt
43 Hoses
44 Cabin classes all

Interchangeability
Remarks
Current New cab
New
Current New bucket with different connection
New
New
Current New bucket with different connection
New
Current New bucket with different connection
New
Current Larger type for new engine
New
Current Larger type for new engine
New
Current New engine oil filter
New
Current Fuel filter having improved fine filtration
New
Current
New
Current New filter element
New
Current Different filter design
New
Current New air condition system
New
Current New air condition system
New
Current
New
Current New type of bucket
New
Current
New
Current New axle with new brake system
New
Current New parking brake system
New
Current New engine
New
Current New engine
New
Current Different sizes
New
Current New operator cab
Common

Uncommon

WA500-6 Market Introduction