Komatsu WA500-6 wheel loader - Operator review

Outside Grange Resources’ Port Latta iron ore pellet plant, situated approximately 70km west of Burnie, a gentle northerly breeze rolling in from the Bass Strait cooled the morning air as the new, bright yellow Komatsu WA500-6 rolled off the low loader and parked next to the machine that it was replacing.

The old WA500-6, covered in a thick layer of black iron ore dust from its near decade of handling iron ore every day, had more than proven its worth especially when it comes to durability and reliability.

Komatsu’s Tasmanian rep, Jason Cowling, says life in any iron ore operation is exceptionally hard on machinery and more so at Port Latta given its close proximity to the sea.

“That old WA500-6 has notched over 32,000 hours without any component replacement other than an alternator a month or so back,” Cowling explains.

“There are two WA500-6 machines here at Port Latta and they have really proved their durability and reliability working here in these conditions.

“It’s an extremely hostile environment on machinery, especially when you consider they are working right next to corrosive salt water mixed with windswept sea air and the material they move is extremely hot.”

Out with the old

On hand to view the arrival of the new Komatsu wheel loader were Grange Resources’ Day Works Supervisor, Tony Poke and Site Superintendent, Tim Duncombe.

“We were really keen to get our hands on this WA500-6, which we believe is one of the last Dash-6 machines available, not only because we’ve had such a good experience with them (Komatsu), but also to retain serviceability compatibility with our other loader,” Poke explains.

According to Cowling, Komatsu’s Dash-7 machines have been available in Australia for the past 12 months but the company is now taking orders for the new Dash-8 series, which is built on the reliability of the Dash-6 range.

Grange Resources’ iron ore processing operation is certainly unique. Concentrated iron ore slurry is pumped 83km from the mine at Savage River to the pellet plant at Port Latta via a 229mm internal diameter pipeline, and takes approximately 14 hours to travel. In mining terms, this project is considered a long life mine with the current predicted lifetime extending to 2034.

At the Port Latta plant, the cleaned concentrate is pressed into pellets using bentonite as a binding agent. The pellets are then fed into one of five vertical shaft pellet furnaces where they undergo heat induced processing for approximately 4.5 hours. The finished pellets are screened to grade excess coarse and fine material and then transported by conveyor to the stacker-reclaimer where the pellets are stockpiled to cool while awaiting shipping.

The new Komatsu WA500-6 is one of two that feeds slurry into the processing plant.

Komatsu WA500-6 smart systems

Standard features like the dual-mode Engine Power Select System (EPSS) on the new WA500-6 not only enhance the machine’s productivity but also add to the economy of the operation.

“This wheel loader features two selectable operating modes - ‘E’ (Economy) and ‘P’ (Power),” Cowling explains.

“The Economy mode is ideal for achieving maximum fuel economy for general loading and stockpiling, while the Power mode delivers maximum power output for hard digging and hill climbing operations.”

The automatic transmission in the WA500-6 comes complete with an operator controlled mode select system, which allows the operator to engage manual gear selection or two levels of automatic shifting – low and high.

“Auto ‘L’ is best suited for fuel saving operations with gear shift timed to change at lower engine speeds,” Cowling says.

“Therefore the engine is operating at a relatively low rpm range for fuel conservation while delivering adequate tractive force by depressing the accelerator pedal.”

He adds most customers specify the optional Lock-up torque convertor with their machine which has been designed to provide fuel savings and reduced cycle times in load-and-carry or hill-climb operations.

“Here at Port Latta, the WA500-6 loaders are travelling long distance shifting material from plant to stockpile and that’s where the Lock-up torque convertor really delivers significant economic advantages,” Cowling says.

The variable displacement piston pump (VDPP), combined with the closed-center load sensing system (CLSS) deliver the precise hydraulic flow that each job needs, hence preventing wasted hydraulic pressure.

“Minimising the waste lost in the hydraulic system notably contributes to better fuel economy,” Cowling adds.

The hydraulic hose connections are joined using flat face-to-face O-ring seals to securely seal and prevent oil leakage. In addition, buffer rings are installed to the head side of the all-hydraulic cylinders to lower the load on the rod seals for maximum reliability.

Reliable disc brake system

The WA500-6 features a full hydraulic wet multi-disc brake system that, according to Komatsu, means lower maintenance costs and better reliability.

“That’s because the wet disc brakes are fully sealed,” Cowling explains.

“It means contaminants are kept out, reducing wear and maintenance. The brakes on these machines require no adjustments for wear, meaning even lower maintenance.

“There is also a new parking brake that is also an adjustment-free, wet multi-disc for high reliability and long life.

“As an added safety measure and to further improve reliability, the braking system comprises two independent hydraulic circuits which provide hydraulic backup should one of the circuits fail,” Cowling says.

“The fully hydraulic brake system means there is no air system to bleed, or the condensation of water in the system that can lead to contamination, corrosion, or freezing.”

Manoeuvrability and paint quality

Komatsu says the WA500-6 boasts the widest tread in its class and the long wheelbase provides excellent machine stability. This gives a greater articulation angle that is extended to 40 degrees, meaning the operator can work efficiently in the tightest of job sites.

The excellent physical appearance of the 10-year-old WA500-6 once it is hosed down is testament to Komatsu’s superior paint quality.

“Spray some foaming machine wash over it and with a quick broom that old machine will come up looking pretty sharp,” Cowling says.

“Sure, there will be a few bumps and scratches but for the most part it will still look an extremely presentable machine.”

“Komatsu takes a lot of pride in the quality and finish of their machines,” Cowling explains.

“They use a Cathion electrode position paint which is applied as a primer paint. Then powder coating is applied as topcoat to the exterior sheet metal parts. This process results in a beautiful rust-free machine, even in the most severe environments, and you can see how the paint has stood the test of time here with these two machines side by side.”

Operator environment

The equipment management monitoring system (EMMS) is mounted in front of the operator for easy viewing, which allows viewing at a glance of all gauges and warning lights.

The operator can tilt and telescope the two-spoke steering wheel to obtain the most comfortable working position.

The cab is the largest in its class providing maximum space for the operator, and is mounted on Komatsu’s unique ROPS/FOPS viscous mounts. To assist with operator ergonomics, the engine, hydraulically driven fan and hydraulic pumps are all mounted on rubber cushions. The cab sealing has improved to provide a quiet, low-vibration, pressurised, dustproof and comfortable operating environment.

Wide, pillar-less flat glass provides excellent front visibility on the WA500-6. The wiper arm swipes a large area during rainy days to provide great visibility for the operator. The air-conditioner unit is now mounted up the front to allow increased seat adjustment for taller operators.

According to Grange Resources’ Tony Poke, all the latest features mean nothing if sufficient back up support is not available to keep the loader operational.

“We’re very fortunate that Komatsu provides great back-up support,” Poke says. “Komatsu’s ‘Komplimentary Maintenance’ package really goes a long way in cementing its commitment to excellent back-up service.”

Before I left Port Latta, Cowling extended an invitation to me.

“You’d better come back in 2027 to see how this latest WA500-6 lived up to the reputation of the old machine,” he says with a smile.

Find out more about Komatsu's offerings at komatsu.com.au