Komatsu WA500-6R Wheel Loader Operation & Maintenance Manual (PEN00447-00) – PDF Download

Description

Komatsu WA500-6R Operation & Maintenance Manual – PEN00447-00

This is the complete Komatsu WA500-6R wheel loader Operation & Maintenance Manual, published under Form No. PEN00447-00 and applying to machines from serial number 60010 and up. It is the same document that ships with the machine, covering the full working life of the loader: daily checks, safe operating procedure, scheduled servicing, component removal and replacement, diagnosis of faults through the machine monitor, and the complete specification and capacity data for the Komatsu SAA6D140E-5 diesel engine and its drivetrain.

Everything in the manual is written around the WA500-6R as built, including the Electronic Controlled Suspension System (E.C.S.S.), the torque converter lock-up, automatic and manual shift transmission modes, the semi-auto digging function, the remote boom and bucket positioners, the load meter option, the joystick steering option and KOMTRAX-equipped machines. If your machine carries a different option package, the manual still tells you which sections apply because each option is introduced and explained separately.

File Details

• Manual type: Operation & Maintenance Manual
• Brand: Komatsu
• Model: WA500-6R Wheel Loader
• Serial numbers covered: 60010 and up
• Form / document number: PEN00447-00
• Publication date: 02-10 (February 2010)
• Language: English
• File format: PDF

Chapters Covered

• Before Reading This Manual – safety information, signal words, introduction, front/rear and left/right machine directions, visibility from the operator’s seat, position of the service meter, serial number and distributor table
• Safety – safety labels and their locations, general precautions common to operation and maintenance, fire prevention, precautions when getting on or off the machine, precautions for operation, precautions for maintenance, tyres
• Operation – general view of machine, general view of controls and gauges, explanation of components, machine monitor, switches, control levers and pedals, cap with lock, frame lock bar, towing pin, backup alarm, opening and closing cab doors and windows, handling cab wiper, dust indicator, fuse and slow blow fuse, power outlet, car radio, air conditioner, location of fire extinguisher
• Operation (continued) – check before starting engine, check before starting, starting engine, operations and checks after starting engine, moving the machine (directional, speed), stopping the machine, turning, emergency steering, operation of work equipment, semi auto digging operations, remote positioner, work possible using wheel loader, digging operations, loading operations, parking machine, checks after completion of operation, locking, handling the tyres, transportation, cold weather operation, long-term storage, troubleshooting
• Maintenance – guides to maintenance, outlines of service, wear parts list, recommended fuel, coolant and lubricant, use of fuel, coolant and lubricants according to ambient temperature, recommended brands and quality, standard tightening torques for bolts and nuts, torque list, periodic replacement of safety critical parts, safety critical parts list, maintenance schedule chart
• Service Procedure – air cleaner element check, clean or replace; water separator check and case cleaning; cooling system cleaning; transmission oil level; axle oil level; axle case breather; air conditioner condenser; window washing fluid; radiator fins and reverse fan cleaning; bucket teeth replacement; bucket tooth with segment edge; air conditioner refrigerant check; slow blow fuse replacement; bleeding air from hydraulic tank and fuel circuit; accumulator function check; tyre selection and inspection; every 100, 250, 500, 1000, 2000, 4000 and 8000 hour service procedures
• Specifications – operating weight, normal load, bucket capacity, engine horsepower, dimensions, dump angle, turning radius, permissible towing load, travel speeds
• Attachments, Options – handling load meter, handling joystick steering system, handling machines equipped with KOMTRAX
• Index

Read as a whole, the WA500-6R Operation and Maintenance Manual is a working reference rather than a brochure. The safety chapter is unusually thorough for a machine of this size, covering everything from fire prevention around the turbocharger and exhaust manifold to the correct way to approach high-voltage cables, how to handle blasted rock, and the limits of the ROPS/FOPS structure. The operation chapter then walks the operator through the machine monitor, every switch on the front and right panels, the transmission cut-off system, the shift hold function, the kickdown switch, the E.C.S.S. behaviour and the semi-auto digging cycle, so the loader is used within its intended envelope instead of against it.

The maintenance half is where the manual earns its place in the workshop. The service schedule chart maps out every interval from the initial 10-hour lubrication through to the 8000-hour replacement of engine high-pressure piping clamps and fuel spray prevention caps, and each entry points to a numbered procedure with its own torque values, refill capacities and safety warnings. The periodic replacement list for safety-critical parts is particularly important on this machine, since it covers the fuel hoses, steering hoses, brake hoses and accumulators that must be changed on a fixed schedule regardless of how the machine looks.

Machine and Engine Coverage

The manual is written specifically around the WA500-6R, a Komatsu wheel loader powered by the Komatsu SAA6D140E-5 diesel engine. Rated output is given as 256 kW (343 HP) at 1,800 rpm in economy mode and 263 kW (353 HP) at 1,900 rpm in power mode. Operating weight with a 80 kg operator is listed as 33,360 kg (73,550 lb), with a normal load of 9,250 kg (20,396 lb) and a bucket capacity of 5.6 m3 (7.3 cu.yd) when fitted with a bolt-on cutting edge.

Fluid capacities are listed in full: 45 litres of engine oil, 95 litres in the transmission case (76 litres on refill), 460 litres in the hydraulic system (337 litres on refill), 87 litres front axle, 81 litres rear axle, 120 litres cooling system and a 473 litre fuel tank. These figures are given both in litres and US gallons, and the manual also carries a coolant density table for ambient temperatures down to -50 C, so the machine can be set up correctly for cold-climate work.

What This Manual Enables You to Do

With the WA500-6R Operation & Maintenance Manual on hand, a workshop or owner-operator can carry out the full scheduled service routine without guesswork, from a simple 100-hour lubrication through to a 2000-hour hydraulic oil and filter change, axle oil change and PPC circuit strainer cleaning. The torque list gives target and service-limit values for metric bolts and hydraulic hose fittings, and the tightening torque tables for bucket teeth, segment edges and wheel hub bolts are reproduced in full.

It also supports diagnosis rather than just replacement. The troubleshooting chapter separates electrical system, chassis, transmission, axle, brake, steering, parking brake, hydraulic system and engine faults into a problem / main cause / remedy table, and the machine monitor chapter explains how action codes E01, E02 and E03 are displayed and how to reach the underlying failure code and identify which controller detected it. For a machine that relies on several electronic controllers, that information is the difference between a quick repair and a long downtime.

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This Komatsu WA500-6R Operation & Maintenance Manual is delivered as an instant PDF download – no shipping, no waiting, no physical book to keep track of. The file opens on any laptop, tablet or phone, and every page can be printed so the relevant section can go out to the machine with you. Whether you are servicing your own loader, running a fleet, or working as a field technician, having the correct procedures and specification values in front of you is what keeps the machine productive and the job safe. Download it now and put the full manual to work.