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 01 - Machine

 03 - Safety

 18 - Operating Safety

01 - 8

9813/4800-3

01 - 8

18 - Operating Safety
Introduction

Training

Make sure that you have had adequate training and

that you are confident in your ability to operate the

machine safely before you use it. Practice using the

machine and its attachments until you are completely

familiar  with  the  controls  and  what  they  do.  With

a  careful,  well  trained  and  experienced  operator,

your machine is a safe and efficient machine. With

an  inexperienced  or  careless  operator,  it  can  be

dangerous. Do not put your life, or the lives of others,

at risk by using the machine irresponsibly. Before you

start to work, tell your colleagues what you will be

doing and where you will be working. On a busy site,

use a signalman.
Before doing any job not covered in this manual, find

out the correct procedure. Your local JCB distributor

will be glad to advise you.

Fuel

Fuel is flammable, keep naked flames away from the

fuel  system.  Stop  the  engine  immediately  if  a  fuel

leak is suspected. Do not smoke while refuelling or

working on the fuel system. Do not refuel with the

engine  running.  Completely  wipe  off  any  spilt  fuel

which could cause a fire. There could be a fire and

injury if you do not follow these precautions.

Machine Condition

A defective machine can injure you or others. Do not

operate a machine which is defective or has missing

parts. Make sure the maintenance procedures in this

manual are completed before using the machine.

Machine Limits

Operating the machine beyond its design limits can

damage  the  machine,  it  can  also  be  dangerous.

Do  not  operate  the  machine  outside  its  limits.  Do

not  try  to  upgrade  the  machine  performance  with

unapproved modifications or additional equipment.

Engine/Steering Failure

If the engine or steering fails, stop the machine as

quickly as possible. Do not operate the machine until

the fault has been corrected.

Exhaust Gases

Machine exhaust gases can harm and possibly kill

you or bystanders if they are inhaled. Do not operate

the machine in closed spaces without making sure

there  is  good  ventilation.  If  possible,  install  an

exhaust extractor. If you begin to feel drowsy, stop

the machine at once and get into fresh air.

Worksites

Worksites  can  be  hazardous.  Examine  the  site

before working on it. You could be killed or injured

if  the  ground  gives  way  under  your  machine  or  if

piled material collapses onto it. Check for potholes

and hidden debris, logs, ironwork etc. Any of these

could  cause  you  to  lose  control  of  your  machine.

Check for utilities such as electric cables (overhead

and  underground),  gas  and  water  pipes  etc.  Mark

the positions of the underground cables and pipes.

Make sure that you have enough clearance beneath

overhead cables and structures.

Communications

Bad  communications  can  cause  accidents.  Keep

people  around  you  informed  of  what  you  will  be

doing.  If  you  will  be  working  with  other  people,

make sure any hand signals that may be used are

understood by everybody. Worksites can be noisy, do

not rely on spoken commands.

Parking

An incorrectly parked machine can move without an

operator.  Follow  the  instructions  in  the  Operator's

Manual to park the machine correctly.

Banks and Trenches

Banked material and trenches can collapse. Do not

work or drive too close to banks and trenches where

there is danger of collapse.

Safety Barriers

Unguarded  machines  in  public  places  can  be

dangerous. In public places, or where your visibility

is reduced, place barriers around the work area to

keep people away.

Sparks

Explosions and fire can be caused by sparks from

the exhaust or the electrical system. Do not use the

machine in closed areas where there is flammable

material, vapour or dust.

Hazardous Atmospheres

This  machine  is  designed  for  use  in  normal  out

door  atmospheric  conditions.  It  must  not  be  used

in  an  enclosed  area  without  adequate  ventilation.

Do  not  use  the  machine  in  a  potentially  explosive

atmosphere, i.e. combustible vapours, gas or dust,

without first consulting your JCB dealer.

Regulations

Obey all laws, worksite and local regulations which

affect you and your machine.

Содержание 455ZX

Страница 1: ...You must understand and follow the instructions in the Operator s Manual If you do not understand anything ask your employer or JCB dealer to explain it Do not operate the machine without an Operator s Manual or if there is anything on the machine you do not understand Treat the Operator s Manual as part of the machine Keep it clean and in good condition Replace the Operator s Manual immediately i...

Страница 2: ...9813 4800 3 Notes Find manuals at https best manuals com ...

Страница 3: ... 4800 3 SERVICE MANUAL Volume 1 455ZX EN 9813 4800 SERVICE MANUAL Volume 2 455ZX EN 9813 4800 SERVICE MANUAL Volume 3 455ZX EN 9813 4800 SERVICE MANUAL Volume 4 455ZX EN 9813 4800 Find manuals at https best manuals com ...

Страница 4: ...Notes 9813 4800 3 Find manuals at https best manuals com ...

Страница 5: ...fety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 01 06 About this Manual 01 06 03 Model and Serial Number 01 17 01 06 06 Using the Manual 01 18 01 09 Description 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 23 01 33 Cleaning 01 33 00 General 01 27 Find manuals at https best man...

Страница 6: ...9813 4800 3 2017 10 26 Acronyms Glossary FOPS Falling Object Protective Structure PIL Parts Identification List ROPS Roll Over Protective Structure Find manuals at https best manuals com ...

Страница 7: ...ty Yours and Others 01 3 01 03 06 Safety Warnings 01 4 01 03 09 General Safety 01 5 01 03 12 Maintenance Safety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 Find manuals at https best manuals com ...

Страница 8: ...Notes 01 2 9813 4800 3 01 2 Find manuals at https best manuals com ...

Страница 9: ... hazards and how to avoid them If you do not fully understand the warning messages ask your employer or JCB dealer to explain them Safety is not just a matter of responding to the warnings All the time you are working on or with the machine you must be thinking of what hazards there might be and how to avoid them Do not work with the machine until you are sure that you can control it Do not start ...

Страница 10: ...tion which if not avoided could result in death or serious injury The signal word CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury The signal word Notice indicates a hazardous situation which if not avoided could result in machine damage The safety alert system shown also helps to identify important safety messages in this manual and on the mach...

Страница 11: ...aware of medicines which can cause drowsiness Feeling Unwell Do not attempt to operate the machine if you are feeling unwell By doing so you could be a danger to yourself and those you work with Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere Sparks in such an area could cause an explosion or fire resulting in death or serious injury Switc...

Страница 12: ...aulic Pressure Hydraulic fluid at system pressure can injure you Before connecting or removing any hydraulic hose residual hydraulic pressure trapped in the service hose line must be vented Make sure the hose service line has been vented before connecting or removing hoses Make sure the engine cannot be started while the hoses are open O rings Seals and Gaskets Badly installed damaged or rotted O ...

Страница 13: ...ecomposition e g charring is found refer to the next paragraph for safety instructions Do not touch component or surrounding area Used fluoroelastomeric components subjected to temperatures greater than 300 C 571 6 F e g engine fire must be treated using the following safety procedure Make sure that heavy duty gloves and special safety glasses are worn Thoroughly wash contaminated area with 10 cal...

Страница 14: ...ly kill you or bystanders if they are inhaled Do not operate the machine in closed spaces without making sure there is good ventilation If possible install an exhaust extractor If you begin to feel drowsy stop the machine at once and get into fresh air Worksites Worksites can be hazardous Examine the site before working on it You could be killed or injured if the ground gives way under your machin...

Страница 15: ...y Modification of the machine s configuration by the user e g the fitting of large and non approved attachments may result in a restriction of the machine visibility Hands and Feet Keep your hands and feet inside the machine When using the machine keep your hands and feet clear of moving parts Keep your hands and feet within the operator compartment while the vehicle is in motion Controls You or o...

Страница 16: ... leak is suspected contact the local gas company immediately and warn all personnel on the site Ban smoking make sure that all naked lights are extinguished and switch off any engines which may be running You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near buried gas pipes CAUTION Before you start using the mach...

Страница 17: ...and is there sufficient fuel to complete the job if applicable The Load How heavy is it Is it within the capabilities of the machine How bulky is it The greater the surface area the more affected it will be by wind speeds Is it an awkward shape How is the weight distributed Uneven loads are more difficult to handle Is there a possibility of the load shifting while being moved Loading Unloading Are...

Страница 18: ...necessary empty the shovel 2 Make sure that the machine is parked correctly in the straight ahead position on solid level ground 3 Apply the park brake 4 Lower the lift arm and put the attachment flat on the ground 5 Stop the engine 6 Remove the ignition key 7 Put chocks on both sides of all the wheels 8 Remove the battery isolation key Refer to PIL 33 03 9 Install the articulation lock Refer to P...

Страница 19: ...the articulation lock Refer to PIL 06 27 10 Remove the maintenance struts from the tool box 11 Install the maintenance strut in correct position around the ram 12 Make sure that the maintenance strut is seated correctly on the ram 13 Install the strap around the maintenance strut and the ram 14 Start the engine 15 Slowly lower the lift arm onto the maintenance struts Stop the movement immediately ...

Страница 20: ...any maintenance make sure the machine is safe it must be correctly parked on solid level ground To prevent anyone starting the engine remove the ignition key Disconnect the battery when you are not using electrical power If you do not take these precautions you could be killed or injured WARNING Make the machine safe before getting beneath it Make sure that any attachments on the machine are corre...

Страница 21: ...01 Machine 06 About this Manual 01 15 9813 4800 3 01 15 06 About this Manual Contents Page No 01 06 03 Model and Serial Number 01 17 01 06 06 Using the Manual 01 18 ...

Страница 22: ...Notes 01 16 9813 4800 3 01 16 ...

Страница 23: ...this Manual 03 Model and Serial Number 01 17 9813 4800 3 01 17 03 Model and Serial Number Introduction This manual provides information for the following model s in the JCB machine range Model From To 2414602 455ZX 2415103 ...

Страница 24: ... Diagnostics Information in this manual can help you diagnose machine faults Before attempting to diagnose possible faults check the following Ensure that the operator understands the machine controls functions and use Refer to the applicable Operator Manual Check that the maintenance record complies with the applicable schedule for the operating environment Refer to PIL 78 24 Check that the fluid...

Страница 25: ...01 Machine 09 Description 01 19 9813 4800 3 01 19 09 Description Contents Page No 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 23 ...

Страница 26: ...Notes 01 20 9813 4800 3 01 20 ...

Страница 27: ...cations 01 21 9813 4800 3 01 21 12 Main Component Locations Introduction Figure 5 A B C Q K J L H C F D P E M N G A Shovel B Loader arms C ROPS Roll Over Protective Structure FOPS Falling Object Protective Structure cab D Hydraulic fluid fill point ...

Страница 28: ...1 22 E Engine cover F Hydraulic fuel tank tight glass G Articulation lock H Transmission dipstick and fill point J Engine oil dipstick and fill point K Diesel fill point L Tool box M Battery N Battery isolator switch P Coolant fill point below the panel Q Coolant level gauge ...

Страница 29: ...ions 01 23 9813 4800 3 01 23 15 Service Point Locations Introduction Figure 6 G A C B E D F A Coolant filler cap B Coolant expansion tank C Engine air filter D Engine oil dipstick E Engine oil filter F Engine oil filler cap G Hydraulic oil filler cap ...

Страница 30: ...01 Machine 09 Description 15 Service Point Locations 01 24 9813 4800 3 01 24 Figure 7 A A Fresh air filter Figure 8 A A Engine oil drain Figure 9 A ...

Страница 31: ... Machine 09 Description 15 Service Point Locations 01 25 9813 4800 3 01 25 A Battery Figure 10 D B C E F A A Battery isolation switch B Radiator Figure 11 A A Oil level gauge Figure 12 A A Fuel filler cap ...

Страница 32: ...01 Machine 33 Cleaning 01 26 9813 4800 3 01 26 33 Cleaning Contents Page No 01 33 00 General 01 27 ...

Страница 33: ...render the machine inoperable Remove dirt using a brush or damp cloth Clean the product with water and or steam Do not let mud debris etc to collect on the product Before you do any service procedures that require components to be removed The cleaning must be done either in the area of components to be removed or in the case of major work or work on the fuel system the whole engine and the surroun...

Страница 34: ...t aim the water jet directly at bearings oil seals or the engine air induction system Use a low pressure water jet and brush to remove dried mud or dirt Use a pressure washer to remove soft dirt and oil The product must always be greased if appropriate after pressure washing or steam cleaning Preparation 1 Make the machine safe Stop the machine and let it cool for at least one hour Do not try to c...

Страница 35: ...09 03 Attachments Couplings and Load Handling Contents Page No 03 00 Attachments 03 00 00 General 03 3 03 09 Lift Arm Quickhitch 03 09 00 General 03 7 03 09 06 Hydraulic Quickhitch 03 8 03 30 Shovel 03 30 00 General 03 15 ...

Страница 36: ...Notes 9813 4800 3 2017 01 09 ...

Страница 37: ...03 Attachments Couplings and Load Handling 00 Attachments 03 1 9813 4800 3 03 1 00 Attachments Contents Page No 03 00 00 General 03 3 ...

Страница 38: ...Notes 03 2 9813 4800 3 03 2 ...

Страница 39: ...dients on which it is safe to operate or the safe distance from power lines Practice using attachments off the job before working with them for the first time JCB attachments are designed and manufactured specifically to suit the machine s hydraulic system mounting arrangements and safe load requirements Attachments which are not designed for use with this machine may cause damage and create safet...

Страница 40: ...or s Manual do not install it use it or remove it until you have obtained read and understood the pertinent information Install attachments only on the machines for which they were designed WARNING Load and unload on firm level ground Always be alert for possible hazards Take special care when turning or reversing DANGER Before lowering the attachments to the ground make sure that the machine and ...

Страница 41: ...03 Attachments Couplings and Load Handling 09 Lift Arm Quickhitch 03 5 9813 4800 3 03 5 09 Lift Arm Quickhitch Contents Page No 03 09 00 General 03 7 03 09 06 Hydraulic Quickhitch 03 8 ...

Страница 42: ...Notes 03 6 9813 4800 3 03 6 ...

Страница 43: ...f buckets shovels and other attachments on the machine Quickhitches do not normally have a specific function themselves in that they do not carry out handling or digging operations but when installed on a machine they become a part of the overall machine system They are usually mounted on the machine by means of pins that would otherwise be the mountings for the shovel or attachment ...

Страница 44: ...ge the attachment If a second person is to be involved in this procedure make sure that they keep clear of the machine and attachment until signalled by you to proceed For more information on the servo control lever and the auxiliary controls A Quickhitch isolator valve is installed on all machines This valve can be used to hydraulically operate the locking pins to lock an attachment to the Quickh...

Страница 45: ...hen lower the attachment Refer to PIL 01 03 2 Apply the park brake and put the transmission into Neutral If necessary disconnect the hydraulic hoses 3 If installed push and hold the quickhitch isolator switch 4 Disengage the locking pins 4 1 Operate the auxiliary lever roller switch on the operating lever to disengage the locking pins 5 Release the quickhitch isolator switch 6 Disengage the attach...

Страница 46: ...Apply the park brake and put the transmission in neutral 5 Lift the loader arms and engage the pivot shaft into the hooks Stop the movement as soon as the pivot shaft is engaged 6 Engage the attachment 6 1 Operate the auxiliary lever roller switch on the operating lever to engage the locking pins 7 If installed push and hold the quickhitch isolator switch 8 Engage the locking pins 8 1 Operate the ...

Страница 47: ...nts Couplings and Load Handling 09 Lift Arm Quickhitch 06 Hydraulic Quickhitch 03 11 9813 4800 3 03 11 Lubricate There are two greasing points for the lubrication of the quickhitch Refer to Figure 17 Figure 17 2 1 ...

Страница 48: ...fer to PIL 01 03 2 Install the articulation strut Refer to PIL 06 27 3 Isolate the battery from the electrical circuit Refer to PIL 33 03 4 Use suitable lifting equipment to support the quickhitch 5 Disconnect the hydraulic hoses Figure 18 B B B Hydraulic hoses x2 6 Remove the bolts and the pivot pins from both sides of the quickhitch Figure 19 E D C C Bolts x2 D Pivot pins x2 E Quickhitch 7 Remov...

Страница 49: ...lings and Load Handling 09 Lift Arm Quickhitch 06 Hydraulic Quickhitch 03 13 9813 4800 3 03 13 1 Use a press to install the new bush and then replace the seal Figure 21 H H H Shims 2 Install the spacer shims as necessary ...

Страница 50: ...03 Attachments Couplings and Load Handling 30 Shovel 03 14 9813 4800 3 03 14 30 Shovel Contents Page No 03 30 00 General 03 15 ...

Страница 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com ...

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