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SERVICE MANUAL
LOADER
455ZX
EN - 9813/4800 - ISSUE 3 - 11/2017
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2017 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. 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 if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12
-
Heating,
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
Ventilating
and
Air-

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Summary of Contents for jcb 455ZX

  • Page 1 Operator's Manual. 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. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
  • Page 2 Notes: 9813/4800-3 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 455ZX 455ZX EN 9813/4800 EN 9813/4800 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4 455ZX 455ZX EN 9813/4800 EN 9813/4800 9813/4800-3 Find manuals at https://best-manuals.com...
  • Page 4 Notes: 9813/4800-3 Find manuals at https://best-manuals.com...
  • Page 5: Table Of Contents

    01 - Machine Contents Page No. Acronyms Glossary ............................ 01-2 01-03 Safety 01-03-03 Safety - 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 ......................
  • Page 6: Acronyms Glossary

    Acronyms Glossary FOPS Falling Object Protective Structure Parts Identification List ROPS Roll-Over Protective Structure 9813/4800-3 2017-10-26 Find manuals at https://best-manuals.com...
  • Page 7 01 - Machine 03 - Safety 03 - Safety Contents Page No. 01-03-03 Safety - 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 ......................
  • Page 8 Notes: 01 - 2 9813/4800-3 01 - 2 Find manuals at https://best-manuals.com...
  • Page 9: Safety

    They inform you of potential 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.
  • Page 10: Safety Warnings

    01 - Machine 03 - Safety 06 - Safety Warnings 06 - Safety Warnings Introduction In this manual and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 11: General Safety

    Keep long hair restrained. Remove altered in any way which could affect or invalidate its rings, watches and personal jewellery. compliance. For advice consult your JCB dealer. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs.
  • Page 12: Maintenance Safety

    Repairs pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may If your machine does not function correctly in cause serious injury or death.
  • Page 13 Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®.
  • Page 14: Operating Safety

    Before doing any job not covered in this manual, find Parking out the correct procedure. Your local JCB distributor will be glad to advise you. An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Fuel Manual to park the machine correctly.
  • Page 15 01 - Machine 03 - Safety 18 - Operating Safety Electrical Power Cables Hands and Feet You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine. the machine or its attachments too close to electrical When using the machine, keep your hands and feet power cables.
  • Page 16: Worksite Safety

    01 - Machine 03 - Safety 21 - Worksite Safety 21 - Worksite Safety An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a Introduction collection of rules and procedures that coordinates the machines and people that work together in WARNING You or others can be killed or seriously the same area.
  • Page 17: Risk Assessment

    If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be a specific task, contact your JCB dealer who will be in or to enter the area while operations are in pleased to advise you.
  • Page 18: Maintenance Positions

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction Introduction ............ 01-12 Make the machine safe before you start a Health and Safety .......... 01-14 maintenance procedure. You can complete most of the maintenance procedures with the lift arm lowered.
  • Page 19 01 - Machine 03 - Safety 27 - Maintenance Positions Lift Arm Raised 13. Install the strap around the maintenance strut and the ram. Figure 3. 14. Start the engine. 15. Slowly lower the lift arm onto the maintenance struts. Stop the movement immediately when the maintenance struts support the weight of the lift arm.
  • Page 20 01 - Machine 03 - Safety 27 - Maintenance Positions Health and Safety 12. Put the maintenance strut in the tool box. 13. Remove the articulation lock. WARNING Maintenance must be done only by suitably qualified and competent persons. 14. Remove the chocks. Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground.
  • Page 21: About This Manual

    01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-03 Model and Serial Number ....................01-17 01-06-06 Using the Manual ......................01-18 01 - 15 9813/4800-3 01 - 15...
  • Page 22 Notes: 01 - 16 9813/4800-3 01 - 16...
  • Page 23: Model And Serial Number

    01 - Machine 06 - About this Manual 03 - Model and Serial Number 03 - Model and Serial Number Introduction This manual provides information for the following model(s) in the JCB machine range: Model From: 455ZX 2414602 2415103 01 - 17...
  • Page 24: Using The Manual

    06 - Using the Manual Introduction Information in this manual conforms to a standard List). These headings are assigned numerical JCB service manual format. The format uses section identification references. headings taken from a PIL (Parts Identification Table 1. Example...
  • Page 25: Description

    01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-21 01-09-15 Service Point Locations ....................01-23 01 - 19 9813/4800-3 01 - 19...
  • Page 26 Notes: 01 - 20 9813/4800-3 01 - 20...
  • Page 27: Main Component Locations

    01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Introduction Figure 5. A Shovel B Loader arms C ROPS (Roll-Over Protective Structure)/FOPS D Hydraulic fluid fill point (Falling Object Protective Structure) cab 01 - 21 9813/4800-3 01 - 21...
  • Page 28 01 - Machine 09 - Description 12 - Main Component Locations 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...
  • Page 29: Service Point Locations

    01 - Machine 09 - Description 15 - Service Point Locations 15 - Service Point Locations Introduction Figure 6. 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 01 - 23 9813/4800-3...
  • Page 30 01 - Machine 09 - Description 15 - Service Point Locations Figure 7. A Fresh air filter Figure 8. A Engine oil drain Figure 9. 01 - 24 9813/4800-3 01 - 24...
  • Page 31 01 - Machine 09 - Description 15 - Service Point Locations A Battery Figure 10. A Battery isolation switch B Radiator Figure 11. A Oil level gauge Figure 12. A Fuel filler cap 01 - 25 9813/4800-3 01 - 25...
  • Page 32 01 - Machine 33 - Cleaning 33 - Cleaning Contents Page No. 01-33-00 General ........................... 01-27 01 - 26 9813/4800-3 01 - 26...
  • Page 33 01 - Machine 33 - Cleaning 00 - General 00 - General Introduction WARNING When using cleaning agents, solvents Introduction ............ 01-27 or other chemicals, you must adhere to Preparation ............ 01-28 the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when...
  • Page 34 01 - Machine 33 - Cleaning 00 - General Preparation Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine 1. Make the machine safe. Stop the machine and is to be washed using a high pressure system.
  • Page 35 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 9813/4800-3 2017-01-09...
  • Page 36 Notes: 9813/4800-3 2017-01-09...
  • Page 37 03 - Attachments, Couplings and Load Handling 00 - Attachments 00 - Attachments Contents Page No. 03-00-00 General ..........................03-3 03 - 1 9813/4800-3 03 - 1...
  • Page 38 Notes: 03 - 2 9813/4800-3 03 - 2...
  • Page 39 A wide range of optional attachments are available Health and Safety ........... 03-4 to increase the versatility of your machine. Only JCB approved attachments are recommended for use with your machine. Consult your JCB Distributor for the full list of approved attachments available.
  • Page 40 00 - Attachments 00 - General Health and Safety Attachments Use only the JCB approved attachments that are specified for your machine. Operating with non- specified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others.
  • Page 41 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 09 - Lift Arm Quickhitch Contents Page No. 03-09-00 General ..........................03-7 03-09-06 Hydraulic Quickhitch ......................03-8 03 - 5 9813/4800-3 03 - 5...
  • Page 42 Notes: 03 - 6 9813/4800-3 03 - 6...
  • Page 43 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 00 - General 00 - General Introduction Quickhitches are used on machines to allow the rapid change of 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.
  • Page 44 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch 06 - Hydraulic Quickhitch Introduction WARNING If two people are doing this job make Introduction ............03-8 sure that the person working the controls is a Disconnect and Connect .........
  • Page 45 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch Disconnect and Connect Figure 13. Disconnect 1. Park the machine on hard, level ground, then lower the attachment. Refer to (PIL 01-03). 2. Apply the park brake and put the transmission into Neutral.
  • Page 46 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch Figure 15. 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.
  • Page 47 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch Lubricate There are two greasing points for the lubrication of the quickhitch. Refer to Figure 17. Figure 17. 03 - 11 9813/4800-3 03 - 11...
  • Page 48 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch Remove and Install Figure 19. Hydraulic 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.
  • Page 49 03 - Attachments, Couplings and Load Handling 09 - Lift Arm Quickhitch 06 - Hydraulic Quickhitch 1. Use a press to install the new bush and then replace the seal. Figure 21. H Shims 2. Install the spacer shims as necessary. 03 - 13 9813/4800-3 03 - 13...
  • Page 50 03 - Attachments, Couplings and Load Handling 30 - Shovel 30 - Shovel Contents Page No. 03-30-00 General ........................... 03-15 03 - 14 9813/4800-3 03 - 14...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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