jcb 455ZX, Service Manual

Page 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...

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

Page 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 ...

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

Page 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...

Page 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 ...

Page 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 ...

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

Page 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 ...

Page 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...

Page 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...

Page 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 ...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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 ...

Page 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...

Page 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 ...

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

Page 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 ...

Page 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...

Page 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 ...

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

Page 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 ...

Page 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 ...

Page 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 ...

Page 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 ...

Page 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 ...

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

Page 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...

Page 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...

Page 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 ...

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

Page 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 ...

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

Page 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...

Page 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 ...

Page 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 ...

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

Page 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 ...

Page 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...

Page 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...

Page 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 ...

Page 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 ...

Page 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...

Page 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 ...

Page 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 ...

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