JCB 457 Tier 4I Operator Manual 9821-2150

Description

• Model List:
  • 457 Tier 4I

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