JCB 422ZX Operator Manual 9821-1850

Description

• Model List:
  • 422ZX

• 1. Safety Notices
• 2. Important Information …………………………………………………………………………1
• 3. The Operator Manual …………………………………………………………………….1
• 4. Safety Warnings ……………………………………………………………………………1
• 5. Introduction
• 6. About this Manual ………………………………………………………………………………3
• 7. Machine Model and Serial Number ………………………………………………….3
• 8. Using this Manual ………………………………………………………………………….3
• 9. Left Side, Right Side ………………………………………………………………………3
• 10. Cab-Canopy …………………………………………………………………………………3
• 11. Cross References ………………………………………………………………………….3
• 12. Machine Description …………………………………………………………………………..4
• 13. The JCB Wheeled Loader ………………………………………………………………4
• 14. Intended Use ………………………………………………………………………………..4
• 15. Component Location ……………………………………………………………………..4
• 16. Safety Check List ……………………………………………………………………………….6
• 17. Safety – Yours and Others ………………………………………………………………6
• 18. General Safety ……………………………………………………………………………..6
• 19. Operating Safety …………………………………………………………………………..8
• 20. Maintenance Safety …………………………………………………………………….. 11
• 21. Safety Labels …………………………………………………………………………………..16
• 22. Introduction …………………………………………………………………………………16
• 23. Safety Label Locations …………………………………………………………………17
• 24. Part Numbers and Descriptions …………………………………………………….18
• 25. Identifying Your Machine …………………………………………………………………..20
• 26. Machine Identification Plate ………………………………………………………….20
• 27. Component Identification Plates …………………………………………………….21
• 28. Operation
• 29. Introduction ……………………………………………………………………………………..23
• 30. Before Entering the Cab ……………………………………………………………………24
• 31. Entering and Leaving the Cab ……………………………………………………………25
• 32. Doors and Windows …………………………………………………………………………26
• 33. Opening and Closing the Door ………………………………………………………26
• 34. Opening and Closing the Window ………………………………………………….26
• 35. Emergency Exit …………………………………………………………………………..26
• 36. Seat ……………………………………………………………………………………………….27
• 37. Introduction …………………………………………………………………………………27
• 38. Suspension Seat (Type 1) …………………………………………………………….27
• 39. Inertia Reel Seat Belt …………………………………………………………………..28
• 40. Console Arm Rest ……………………………………………………………………….29
• 41. Visibility Aids ……………………………………………………………………………………30
• 42. Mirrors ……………………………………………………………………………………….30
• 43. Cab Layout ……………………………………………………………………………………..33
• 44. Component Key …………………………………………………………………………..33
• 45. Drive Controls, Switches and Instruments ……………………………………………35
• 46. Drive Controls ……………………………………………………………………………..35
• 47. Switches …………………………………………………………………………………….38
• 48. Instrument Panel …………………………………………………………………………42
• 49. Heater-Air Conditioning Controls ……………………………………………………47
• 50. Operating Levers ……………………………………………………………………………..48
• 51. Introduction …………………………………………………………………………………48
• 52. Control Layouts …………………………………………………………………………..48
• 53. Servo-Controls Lever …………………………………………………………………..49
• 54. Servo-Control Lever with Auxiliary Lever (Option) ……………………………50
• 55. Auxiliary Controls (Option) ……………………………………………………………51
• 56. Lower the Loader Arms in an Emergency ……………………………………….51
• 57. Safety Equipment …………………………………………………………………………….52
• 58. Neutral Lock ……………………………………………………………………………….52
• 59. Beacon (Option) ………………………………………………………………………….52
• 60. Fire Extinguisher (if fitted) …………………………………………………………….53
• 61. Before Starting the Engine …………………………………………………………………54
• 62. Starting The Engine ………………………………………………………………………….56
• 63. Preparing the Machine for Travel ……………………………………………………….57
• 64. Introduction …………………………………………………………………………………57
• 65. Preparing for Road travel ……………………………………………………………..57
• 66. Preparing for Site travel ………………………………………………………………..58
• 67. Getting the Machine Moving ………………………………………………………………59
• 68. Operating Practices ……………………………………………………………………..59
• 69. Operating Procedure ……………………………………………………………………60
• 70. Stopping and Parking the Machine ……………………………………………………..61
• 71. Working with the Machine …………………………………………………………………62
• 72. Operating Practices and Site Safety ………………………………………………62
• 73. Safety Practices ………………………………………………………………………….62
• 74. Danger Zone ………………………………………………………………………………63
• 75. Log Moving-Handling ……………………………………………………………………63
• 76. Clothing and Safety Equipment ……………………………………………………..63
• 77. Working with a Shovel ………………………………………………………………….64
• 78. Working on Slopes ………………………………………………………………………66
• 79. Object Lifting ………………………………………………………………………………68
• 80. Operating Environment ……………………………………………………………………..70
• 81. Operating in Low Temperatures …………………………………………………….70
• 82. Operating in High Temperatures ……………………………………………………70
• 83. Operating in Dusty or Sandy Areas ………………………………………………..70
• 84. Operating in Coastal Regions ……………………………………………………….70
• 85. Operating on Wet or Soft Ground …………………………………………………..70
• 86. Refuelling the Machine ……………………………………………………………………..71
• 87. Low Fuel Levels ………………………………………………………………………….71
• 88. Filling the Tank ……………………………………………………………………………71
• 89. Moving a Disabled Machine ………………………………………………………………72
• 90. Introduction …………………………………………………………………………………72
• 91. Preparation for Towing …………………………………………………………………72
• 92. Transporting the Machine ………………………………………………………………….74
• 93. Articulation Lock ………………………………………………………………………….75
• 94. Lifting the Machine …………………………………………………………………………..76
• 95. Storage of the Machine …………………………………………………………………….77
• 96. Introduction …………………………………………………………………………………77
• 97. Storage Area ………………………………………………………………………………77
• 98. Prepare the Machine for Storage …………………………………………………..77
• 99. Put the Machine into Storage ………………………………………………………..77
• 100. During Storage ……………………………………………………………………………77
• 101. Take the Machine Out of Storage …………………………………………………..78
• 102. Routine Maintenance
• 103. Service Requirements ………………………………………………………………………79
• 104. Introduction …………………………………………………………………………………79
• 105. Owner-Operator Support ………………………………………………………………79
• 106. Service-Maintenance Agreements …………………………………………………79
• 107. Initial Service and Inspection …………………………………………………………79
• 108. Fit for Purpose Tests for Lifting Equipment ………………………………………80
• 109. Obtaining Replacement Parts ………………………………………………………..80
• 110. Health and Safety …………………………………………………………………………….81
• 111. Lubricants …………………………………………………………………………………..81
• 112. Battery ……………………………………………………………………………………….83
• 113. Service Schedules ……………………………………………………………………………85
• 114. Introduction …………………………………………………………………………………85
• 115. How to Use the Service Schedules ………………………………………………..85
• 116. Calendar Equivalents …………………………………………………………………..85
• 117. Pre-start Cold Checks, Service Points and Fluid Levels ……………………86
• 118. Functional Test and Final Inspection ………………………………………………89
• 119. Fluids, Lubricants and Capacities ……………………………………………………….91
• 120. Anti-Corrosion Additives ……………………………………………………………….92
• 121. Coolant Mixtures …………………………………………………………………………92
• 122. Fuels ………………………………………………………………………………………….93
• 123. Tools ………………………………………………………………………………………………95
• 124. Toolbox ………………………………………………………………………………………95
• 125. Carrying Tools onto the Machine ……………………………………………………95
• 126. Prepare the Machine for Maintenance ………………………………………………..96
• 127. Introduction …………………………………………………………………………………96
• 128. How to Make the Machine Safe (Loader Arm Lowered) ……………………97
• 129. How to Make the Machine Safe (Loader Arm Lifted) ………………………..97
• 130. Safety Mechanism ……………………………………………………………………….98
• 131. Cleaning the Machine ……………………………………………………………………….99
• 132. Introduction …………………………………………………………………………………99
• 133. Preparing the Machine for Cleaning ……………………………………………..100
• 134. Cleaning the Machine …………………………………………………………………100
• 135. Checking for Damage ……………………………………………………………………..101
• 136. Check the Machine Body and Structure ………………………………………..101
• 137. Check the Seat and Seat Belt ……………………………………………………..101
• 138. Check the Tyres ………………………………………………………………………..101
• 139. Check the Electrical Circuits ………………………………………………………..101
• 140. Check the Hydraulic Hoses and Fittings ……………………………………….102
• 141. Check the ROPS-FOPS Structure ………………………………………………..102
• 142. Greasing ……………………………………………………………………………………….103
• 143. Introduction ……………………………………………………………………………….103
• 144. Preparing the Machine for Greasing …………………………………………….103
• 145. Loader Arm and Shovel ………………………………………………………………104
• 146. Centre Pivot, Rear Axle Pivots and Steer Rams …………………………….105
• 147. Driveshafts ……………………………………………………………………………….106
• 148. Access Panels ……………………………………………………………………………….107
• 149. Engine Covers …………………………………………………………………………..107
• 150. Rear Grille ………………………………………………………………………………..108
• 151. Heater Door ………………………………………………………………………………108
• 152. Heating and Air Conditioning ……………………………………………………………109
• 153. Cleaning the Air Intake Filter ……………………………………………………….109
• 154. Cleaning the Re-Circulation Filter ……………………………………………….. 110
• 155. Brakes …………………………………………………………………………………………. 111
• 156. Testing the Brakes …………………………………………………………………….. 111
• 157. Electrical System …………………………………………………………………………… 112
• 158. Battery …………………………………………………………………………………….. 112
• 159. Battery Isolation Switch ……………………………………………………………… 113
• 160. Jump Starting The Engine ………………………………………………………….. 114
• 161. Fuses and Relays ……………………………………………………………………… 115
• 162. Engine …………………………………………………………………………………………. 117
• 163. Oil and Filter …………………………………………………………………………….. 117
• 164. Cooling System ………………………………………………………………………… 119
• 165. Drive Belt ………………………………………………………………………………….121
• 166. Air Cleaner ……………………………………………………………………………….122
• 167. Fuel System …………………………………………………………………………………..123
• 168. Introduction ……………………………………………………………………………….123
• 169. Water Separator and Filters ………………………………………………………..124
• 170. Hydraulic System ……………………………………………………………………………129
• 171. Introduction ……………………………………………………………………………….129
• 172. Releasing the Hydraulic Pressure ………………………………………………..130
• 173. Checking the Oil Level ……………………………………………………………….131
• 174. Changing the Filter Element ………………………………………………………..132
• 175. Transmission …………………………………………………………………………………133
• 176. Gearbox ……………………………………………………………………………………133
• 177. Axles and Hubs …………………………………………………………………………135
• 178. Tyres and Wheels …………………………………………………………………………..137
• 179. Tyre Inflation ……………………………………………………………………………..137
• 180. Checking the Wheel Nut Torques …………………………………………………138
• 181. Windscreen Washers ……………………………………………………………………..139
• 182. Fire Extinguisher (if fitted) ………………………………………………………………..140
• 183. Checking the Fire Extinguisher ……………………………………………………140
• 184. Optional Attachments
• 185. Introduction ……………………………………………………………………………………141
• 186. Connecting-Disconnecting Hydraulic Hoses ……………………………………….142
• 187. Introduction ……………………………………………………………………………….142
• 188. Connecting the Hydraulic Hoses ………………………………………………….142
• 189. Disconnecting the Hydraulic Hoses ………………………………………………143
• 190. Quick Release Couplings ……………………………………………………………144
• 191. Work Platforms ………………………………………………………………………………146
• 192. Specifications
• 193. Turning Circle ………………………………………………………………………………..147
• 194. Dimensions ……………………………………………………………………………………148
• 195. Tyre Sizes and Pressures ………………………………………………………………..150
• 196. Introduction ……………………………………………………………………………….150
• 197. Specifications ……………………………………………………………………………150
• 198. Maximum Travel Speeds …………………………………………………………………151
• 199. Noise Data …………………………………………………………………………………….152
• 200. Introduction ……………………………………………………………………………….152
• 201. Vibration Data ………………………………………………………………………………..153
• 202. Introduction ……………………………………………………………………………….153
• 203. All Models …………………………………………………………………………………154
• 204. Warranty Information
• 205. Machine Service Record Sheet ………………………………………………………..155
• 206. Registration Information ………………………………………………………………….157