JCB 455ZX TIER II, 455ZX BSIII Operator Manual 9831-0150-5

Description

• Model List:
  • 455ZX TIER II, 455ZX BSIII

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