Dresser Komatsu 555 Rubber Tire Loader Shop Manual – SM555 PDF Download

Description

File Details

• Manual Type: Shop Manual
• Brand: Dresser / Komatsu
• Model: 555 Rubber Tire Loader
• Form Number: SM555
• Publication Date: November 1988
• Language: English
• File Format: PDF
• Page Count: 443 pages

This Dresser Komatsu 555 Rubber Tire Loader Shop Manual is the complete service publication for the 555 machine, issued under Form SM555. It opens with a full section index covering seventeen major systems, then works through safety, specifications, torque values, service tools and a system-by-system overhaul guide for the entire loader. The document is written for the serviceman responsible for the overhaul and repair of the machine, and it states that plainly on its introduction pages.

Chapters Covered

• Introduction – Safety Precautions (Personnel, Machine), Operation (Before Starting, Startup, General Operating Precautions, Driving the Machine, Operating the Attachments, Pulling/Towing, Shutdown), Maintenance (General Machine Precautions, General Work Precautions, Attachments, Brakes, Cab/ROPS, Cooling, Electrical, Engine, Fuel System, Hydraulics, Tires and Rims, Turbocharger), Serial Numbers, Inspection and Repair (Pins and Bushings, Clevises and Pins, Gaskets and Seals, Gears and Splines, Welds, Castings, Fuel Tanks and Hydraulic Reservoirs, Tubes and Hoses, Lubrication Fittings, Relief Valves, Lubrication), Recommended Bearing Procedures (New Bearings, Bearing Removal, Cleaning, Inspection, Bearing Installation, Heating Bearings for Installation, Adjustment, Lubrication), Surface Preparation and Use of Loctite, Service Diagnosis
• Specifications – Torque Values for Standard English Fasteners, Bolt Identification Chart, Type 1/5/8 Non-Phosphate Coated Hardware, Type 8 Phosphate Coated Hardware, Torque Values for Standard Metric Fasteners, Torque Values for Hose Clamps, Torque Values for Split Flange Connections, Torque Values for Hydraulic Tubes and Fittings, Service/Special Tools
• Air – system section
• Brakes – Parking Brake, Operational Check of Service Brakes, Service Diagnosis of Axle Brakes, Parking Brake Adjustment Procedure, Service Diagnosis of Parking Brake, Service Brake Accumulator (Checking the Nitrogen Charge, Charging with Nitrogen), Parking Brake Cylinder, Adjustment and Test Procedures for Pilot Brake Valve and Master Brake Valve
• Steering – Steering Column Diagnosis, Description of Operation, Lubrication, Steering Column removal and installation procedures, Recommended Torque Specifications
• Cooling – Hydraulic and Transmission/Torque Converter Coolers, Radiator, Lubricants and Sealants, Tolerances, Pressures, Material and Repairs
• Drive Train – Transmission, Torque Converter, Drive Shafts, Axles, Axle and/or Differential Removal, Front Differential Removal, Axle Housing Inspection, Axle Housing Disassembly
• Electrical – system section
• Frame – system section
• Hydraulics – system section
• Instruments – system section
• Power – system section
• Superstructure – system section
• Suspension – system section
• Wheels and Traction – system section
• Body-Bowl – system section
• Mounted Equipment – system section

As a whole, this 555 Rubber Tire Loader shop manual gives a technician the sequence, the numbers and the cautions needed to take the machine apart and put it back together correctly. It is not a generic guide – it carries the 555’s own torque tables for standard English and metric fasteners, its own accumulator charge pressures, clutch plate counts, bearing adjustment procedures, seal and O-ring fitting notes, Loctite application instructions and special tool drawings that the job actually requires.

Inside the Major Repair Sections

The Drive Train material is the deepest part of the book. The transmission is covered as a full power shift, soft shift countershaft unit with a 2.53 to 1 stall ratio torque converter, and the manual walks through removal from the machine, disassembly in a stand, clutch pack teardown and reassembly for the Forward/Reverse, 1st/3rd and 2nd/4th packs, output shaft end play setting, shimming the input shaft and re-timing the valve body stack. The Axle section covers both differential removal with an overhead hoist and with a transmission jack, planetary hub removal, ring gear and wheel hub extraction, brake housing removal and axle housing inspection for metal contamination.

The Brakes section explains the fully enclosed, hydraulically applied, pressure lubricated internal wet disc brake system, the two nitrogen accumulators, the pilot and master brake valves, the parking brake on the front axle differential and the correct procedure for checking and charging an accumulator with dry nitrogen. Torque values, pressures, lubricants and sealants are listed for each assembly.

Steering coverage deals with the tilt and telescoping column – diagnosis of lash, high effort, tilt lock failure and noise, plus step-by-step removal and installation of the shaft lock, turn signal switch, ignition lock, covers, wiper switch, housing and lower steering shaft. Cooling covers the aluminum air-to-oil coolers and the three-piece copper/brass radiator with tank bolt torque and test pressures.

Reference Data You Will Actually Use

The Specifications section is built for the shop floor: bolt head identification by radial dash markings, wet and dry thread torque correction factors, torque charts for Grade 5 and Grade 8 hardware from 1/4 inch up to 2 inch, metric class 10.9 values, hose clamp torques for radiator, air cleaner and hydraulic service, split flange bolt torques by flange size and JIC 37 degree flared fitting torques. The Service/Special Tools listing names the fabricated fixtures and purchased tools used through the book, including clutch pack stands, lifting brackets, bearing cup replacers, seal installers and pressure test gauges, with drawings for the locally fabricated items.

Who This Dresser Komatsu 555 Shop Manual Is For

Owners, fleet mechanics and independent shops working on a 555 Rubber Tire Loader will find the machine-level procedures, breakout figures and adjustment values needed to diagnose a slipping clutch, a low accumulator charge, a dragging wet brake, a leaking torque converter seal or a worn planetary. The Introduction section on safety, jacking, blocking, ROPS handling and relief valve pressure limits is worth reading before any teardown begins.

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With this Dresser Komatsu 555 Rubber Tire Loader Shop Manual on hand, you can carry out component overhauls, set the correct torques and clearances, verify pressures, bleed and adjust brake and steering circuits and follow factory disassembly and reassembly order instead of guessing. Correct procedures and the printed specifications are what keep a loader of this size running without repeat failures, and having Form SM555 on the bench puts that information within reach of every job. The manual is delivered as an instant PDF download after checkout – no shipping, no waiting, readable on a laptop, tablet or phone, and printable for the pages you want in the shop.