Official Komatsu WA600-3 Service & Repair Manual - Comprehensive Maintenance Guide

Komatsu WA600-3 & WA600-3D Service & Repair Manual - 1994-2003

To maximize machine uptime and protect high-value capital assets, factory-precision maintenance is non-negotiable. This professional workshop manual provides the exact technical procedures required for everything from routine fluid analysis to complex drivetrain overhauls, ensuring every repair meets original equipment manufacturer standards.

Verbatim Model Coverage & Hardware Specifications

This manual provides deep-dive technical coverage for the following models and integrated power units:

• Komatsu WA600-3 (1994-2003)
• Komatsu WA600-3D (1994-2003) [TBG SPEC.]
• Engine Power Units: Fully covers the Komatsu SA6D170E-2 and SAA6D170E-3 high-output diesel engines.
• Drivetrain Components: Detailed service for 3-element, 1-stage Torque Converters (TCA43-7B / TCA45-2B) and Planetary gear, constant-mesh transmissions.

Service Advantages & Operational Precision

• Extended Component Longevity: Utilize factory-defined "Maintenance Standards" and wear limit tables to identify necessary part replacements before catastrophic failure occurs.
• Precision System Calibration: Follow exact factory set-points for hydraulic relief valves, steering orbitrol systems, and transmission modulation to maintain original performance.
• Rapid Diagnostic Accuracy: Minimize troubleshooting time with integrated logic flowcharts and diagnostic error code tables for both mechanical and electronic systems.
• Structural Integrity Assurance: Ensure assembly safety with comprehensive torque specification tables for all metric, tapered, and split-flange fasteners.

Industrial Documentation Scope

This digital service volume (Form No. SEBM013217) consists of over 1,100 pages of high-resolution technical data. The content is meticulously organized into five primary volumes: General Information, Structure and Function, Testing and Adjusting, Disassembly and Assembly, and Maintenance Standards.

Technical Data & Diagnostic Deep Dive

Engineering Identification & Factory Specifications

• Serial Number Locations: The Product Identification Plate is located on the front frame near the articulation joint; Engine Serial Numbers are stamped directly on the engine block.
• Technical Proof of Depth (Extracted Data Points):
  • Main Relief Valve Pressure: 20.6 MPa (210 kg/cm²)
  • Transmission Main Relief Pressure: 3.19 MPa (32.5 kg/cm²)
  • Standard Bolt Torque (M12 / 10.9): 98–123 Nm (10–12.5 kgm)
  • Low Idle Speed: 700–750 rpm (Model dependent)
  • Hydraulic Stall Speed: 2,080 ± 100 rpm

Diagnostic & Visual Support Features

• Comprehensive Schematic Library: Includes full-page Electrical Wiring Diagrams (Standard and Joystick/Auto-shift versions) and Hydraulic Circuit Schematics.
• Visual Repair Aids: Features high-resolution "Exploded Views" of the Planetary Final Drives, Transmission Clutch Packs, and the Torque Converter assembly.
• Electronic Diagnostics: Complete "Troubleshooting Charts" for the Engine System (S-Mode) and Engine Controller (EA-Mode) with over 45 specific error code definitions (e.g., Code 111-554).

Detailed Table of Contents

• 00 Index and Foreword: Safety protocols, hoisting instructions, and standard torque tables.
• 01 General: Machine dimensions, detailed weights (Engine: 2,900 kg), and fluid capacity charts.
• 10 Structure and Function: Mechanics of the PTO, Transmission Solenoids, and Articulated Steering logic.
• 20 Testing and Adjusting: Step-by-step procedures for Pm Clinic inspections, stall speed tests, and air bleeding.
• 30 Disassembly and Assembly: Rigging instructions for heavy components (Lift Arm: 3,262 kg) and installation guides.
• 40 Maintenance Standard: Critical wear limits for brake discs, bushings, and hydraulic cylinder tolerances.
• 90 Others: Supplemental circuit diagrams and attachment specifications.

Professional Value & Service Limits

This manual provides the critical "Service Limit Values" missing from standard operator guides. By utilizing the provided tolerance tables for hydraulic drift and brake disc wear, technicians can objectively determine component viability, ensuring the machine operates at peak industrial safety and capacity.