Description

Komatsu D355A-3 1989 Repair Manual – Factory Specs on the Bench

You’re staring at a pile of parts from a Komatsu D355A-3 that someone else took apart, and you’re supposed to put it back together. I’ve been there. Without the factory specs, you’re guessing on clearances, torque values, and hydraulic pressures. That guesswork costs you time and sometimes a ruined component. The Komatsu D355A-3 1989 Repair Manual is the only way to get the exact OEM data from the factory. It’s 702 pages of Japanese engineering, printed in 1989 for serial numbers 9872 and up.

Engine Overhaul: What This Manual Covers

Section 10 through 13 covers the entire engine disassembly, testing, and reassembly. Section 12 (page 12-1) lists the normal values for engine testing and adjustment – compression pressures, injection timing, valve clearances. Without these numbers, you’re flying blind. The manual also includes the tool list for testing and adjustment – you’ll know exactly what gauge or fixture to use. Don’t expect a generic list; this is the exact Komatsu part numbers for the tools.

1989 Komatsu D355A-3 Repair Manual – Powertrain Diagnostics

The TORQFLOW transmission described in section 21 requires specific pressure checks and adjustments. Page 22-1 gives the control points for oil pressure measurement. The manual includes the hydraulic circuit diagrams – not generic sketches, but the actual factory diagrams. Section 23 walks you through disassembly of the torque converter, transmission, steering clutches, and final drives. Each step comes with required tool lists and torque values.

Where Do You Find Torque Specs and Clearances?

The answer is in the maintenance standards tables. Each major section (24, 34, 64, 74) has tables of normal values. For example, section 24 covers transmission torque converter clearances, clutch pack clearances, and valve body adjustments. You measure, compare to the table, and decide whether to replace or adjust. No guesswork.

Why Factory OEM Documentation Beats Aftermarket

Aftermarket manuals often cobble together data from multiple sources, with rounded figures and missing steps. This is an original Japanese factory publication from Komatsu. The Russian language edition, but the specs are the same. No translation errors on torque values. I’ve seen aftermarket manuals list the wrong bolt torque for a D355A-3 cylinder head – that’s a leak waiting to happen. This book is the real deal.

6 Major Systems Detailed in 702 Pages

The manual breaks down into: General (01), Engine (10), Powertrain (20), Undercarriage (30), Hydraulic System (60), and Work Equipment (70). Each system has its own testing, disassembly, and assembly procedures, plus maintenance standards. That’s six complete system-level guides in one book. If you work on other Komatsu equipment, check the Komatsu WA65-3 to WA95-3 2001 Repair Manual: 422 Pages of Factory Specs”>Komatsu WA65-3 to WA95-3 2001 Repair Manual: 422 Pages of Factory Specs for wheel loaders, or the Komatsu PW200-7K, PW220-7K 2003 Repair Manual – OEM Specs”>Komatsu PW200-7K, PW220-7K 2003 Repair Manual – OEM Specs for excavators. For graders, the Komatsu GD750A-1 Repair Manual – 1066 Page OEM Shop Manual”>Komatsu GD750A-1 Repair Manual – 1066 Page OEM Shop Manual is massive.

For a refresher on how a Manual Transmission”>Manual Transmission works, see the Wikipedia article. The hydraulic system in this dozer is complex; understanding Manual Transmission”>Manual Transmission fundamentals might help with the power flow, but the manual has all the diagrams you need.

Is this manual in English?

No, it is in Russian. The specifications are universal.

Does it cover the engine removal and installation?

Yes, section 13 covers disassembly and assembly of the engine. It includes the starting motor, fan belt, alternator, oil radiator, fuel injection pump, water pump, turbocharger, aftercooler, nozzle holder, cylinder head, radiator, fuel tank, PTO, torque converter oil cooler, and the complete engine. Each component has step-by-step instructions with required tool lists and torque values. The manual assumes you have standard shop tools and a torque wrench that reads in ft-lbs. Do not attempt without a proper engine hoist and support fixture.

Does it include wiring diagrams?

Yes, section 91 covers the electrical system. However, the manual is primarily mechanical; wiring diagrams are included but may not be as detailed as a dedicated electrical manual.

Is this manual suitable for a beginner?

If you have mechanical aptitude and can read a torque chart, yes. But this is a factory manual, not a training book. It expects you to know how to use a micrometer and understand hydraulic schematics. Start with the testing sections before tearing anything apart.

You need the numbers from the factory. Access the Factory Manual to get the complete 702-page OEM document and stop relying on bad information from forums.