Part of the JCB Repair Manuals.
Before the morning is out you'll have a filter wrench on the 457 and a drain pan under it. The first question is what goes back in: 25L engine oil with filter, 42L coolant, 41L transmission, 240L hydraulic, 300L fuel and 42.7L DEF (32L usable).
Coverage runs from the MTU 935.911 Tier 4 engine with EGR and SCR to the 4WG-210 or optional 5WG-210 gearbox and the MT-L3095II axles. It also covers the Rexroth tandem pump and the lift arm control valve block. A guessed torque or pressure strips studs or blows hoses. The book gives 620 N·m front and 600 Nm rear wheel nuts, plus the 280bar main relief setting.
Check which gearbox and which consumable specs your machine calls for, so the parts counter gets the order right first time.
What's Inside This JCB 457 Manual
| System | Pages | Key Topics |
|---|---|---|
| Machine | 7-34 | Safety, About This Manual, Description, Cleaning |
| Attachments, Couplings and Load Handling | 35-56 | Lift Arm Quickhitch, Shovel |
| Body and Framework | 57-146 | Chassis, Moveable Panel and Cover, Lift Arm, Transportation Lock, Pivot Pins, Articulated Joint, Identification Label, Tools, Maintenance Strut, Fire Extinguisher |
| Operator Station | 147-194 | Window, Seat Belt, Controls, Safety Label/Chart, Steering Wheel, Floor Mat, Air Vent, Mount |
| Heating, Ventilating and Air-Conditioning (HVAC) | 195-264 | HVAC Unit, Compressor, Receiver Drier, Condenser, Filter, Pipe |
| Engine | 265-374 | Cylinder Head, Oil Filter, Air Filter, Crankcase Ventilation Filter, Valve, Rocker and Fittings, Oil Sump, Timing Gear, Oil Pump, Mount |
| Fuel and Exhaust System | 375-460 | Tank, Filter, Water Separator, Injection, Fuel Pump, Exhaust, Exhaust Gas Recirculation (EGR), Selective Catalytic Reduction (SCR), Turbocharger, Fuel Pipe |
| Cooling System | 461-514 | Fan Motor, Expansion Tank, Pump, Thermostat, Hose |
| Brake System | 515-546 | Service Brake, Park Brake |
| Steering System | 547-590 | Pump, Steer Unit/Valve, Column |
| Driveline | 591-760 | Semi-Automatic Gearbox, Torque Converter, Axle, Drivehead, Differential, Hub, Wheel, Tyre, Propshaft, Driveshaft |
| Hydraulic System | 761-924 | Tank, Filter, Gear Pump, Variable Displacement Pump, Cylinder / Ram, Accumulator, Lift Arm Control Valve Block, Directional Control Valve, Hose, Connectors |
| Electrical System | 925-1220 | Battery, Battery Cable, Power Distribution, Harness, Instruments, Interior Switch, Console Switch, Interior Light, Bulb, Exterior Light |
| Fasteners and Fixings | 1221-1248 | Screws, Bolts, Bearings, Clips, Threaded Insert |
| Consumable Products | 1249-1304 | Oil, Grease, Fluids, Locking Fluids, Solvents and Primers, Adhesive, Sealant, Fuel |
| After Sales | 1305-1338 | Maintenance Schedules, Clothing and Personal Protective Equipment (PPE), Special Tools, Non JCB Tools, Units of Measurement |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Engine supplier | MTU | p. 270 |
| Engine assembly model series | 935.911 | p. 272 |
| Emissions standard | Tier 4 | p. 427 |
| Engine oil capacity including filter | 25L | p. 1254 |
| Coolant capacity - total system | 42L | p. 1254 |
| Fuel tank capacity | 300L | p. 1254 |
| DEF tank capacity and usable volume | 42.7L (32L) usable | p. 1254 |
| Hydraulic system capacity | 240L | p. 1254 |
| Lift arm control valve block main relief valve pressure | 280bar (4,058.0psi) | p. 888 |
| Main hydraulic pump type | Rexroth. Tandem variable displacement axial piston. | p. 765 |
| Transmission oil capacity | 41L | p. 1254 |
| Front axle oil capacity | 35L | p. 1254 |
| Front and rear axle model | MT-L3095II | p. 594 |
| Service brake operating pressure | 70bar (1,014.5psi) | p. 519 |
| Park brake operating pressure | 80bar (1,159.4psi) | p. 519 |
| Electrical system voltage and polarity | 24V, negative earth | p. 928 |
| Front wheel nut torque | 620N·m | p. 738 |
| Rear wheel nut torque | 600 Nm | p. 740 |
| Standard | ||
| Standard gearbox model | 4WG-210 | p. 594 |
| Option | ||
| Optional gearbox model | 5WG-210 | p. 594 |
JCB 457 Common Problems This Manual Covers
Knocking or excess play at the articulation joint or lift arm pins
Grease first and see whether the knock changes. Then jack and lever-check each pivot for movement in the bushes. Body and Framework covers the articulated joint, pivot pins and lift arm. It also covers fitting the transportation lock and maintenance strut so the machine can't fold or the arms drop while you work. Replace worn pins and bushes before cracks start in the bosses.
Manual Section: Body and Framework: Articulated Joint, Pivot Pins, Lift Arm p. 118Repeated overheating or coolant warning under load
Let it cool fully before opening anything, then check the level in the expansion tank against the 42L system capacity. Blow out the coolers from the clean side. Then work through the fan motor, water pump, thermostat and hoses. All of these are in the Cooling System section. A slow fan motor on a hydraulic drive often looks like a radiator fault, so check it first.
Manual Section: Cooling System p. 466Weak braking or slow brake pressure recovery
Take the machine out of work until it's tested. Service brakes operate at 70bar and the park brake at 80bar. Gauge both before replacing parts. The Brake System section covers the service and park brakes. The Hydraulic System section covers the accumulator, which is a common reason pressure is slow to build after repeated pedal applications. Look for leaks at hoses and connectors at the same time.
Manual Section: Brake System: Service Brake, Park Brake p. 518Steering goes heavy, wanders or stops responding
Check hydraulic oil level and look for leaks around the articulation hoses first. Then work through the steering pump, steer unit/valve and column using the Steering System section. Heavy steering only at low revs points toward supply from the pump. Wander with a steady supply points toward the steer unit. Inspect the articulated joint too, because mechanical binding feels exactly like a hydraulic fault.
Manual Section: Steering System: Pump, Steer Unit/Valve, Column p. 549Frequently Asked Questions
What causes slow hydraulics on a JCB 457?
Start with the cheap checks: oil level in the 240L system, then the filter for restriction. Then work through the Rexroth tandem variable displacement pump and the lift arm control valve block, whose main relief sits at 280bar. If the lift arms are lazy but the bucket cylinders are fine, look at the valve block and that cylinder's seals before blaming the pump. The Hydraulic System section covers the tank, filter, pump, accumulator, cylinders, hoses and connectors. p. 769
What happens if the DEF system on a JCB 457 develops a fault?
The engine power will be reduced if a problem is detected within the Diesel Exhaust Fluid (DEF) system, including contamination. Use the DEF specification and the 42.7L tank (32L usable) listed in the Consumable Products section, and work through the Selective Catalytic Reduction (SCR) procedures in the Fuel and Exhaust System section. p. 1271
Why won't my JCB 457 select a gear or hold drive?
Check the transmission oil level and grade first. It takes 41L, and low or wrong oil causes slipping and lost drive. Confirm whether you have the standard 4WG-210 or the optional 5WG-210, because they are different units. The Driveline section covers the semi-automatic gearbox, torque converter, propshafts and axles. The Electrical System section covers the harness and power distribution if a solenoid or sensor feed is the problem. p. 602
How do I bleed the fuel system on a JCB 457?
Air usually gets in after a filter change, after running the 300L tank dry, or through a loose fuel pipe joint. The Fuel and Exhaust System section covers the filter, water separator, fuel pump, injection and fuel pipes. Follow those procedures in order and don't crank the starter in long bursts hoping it clears itself. A healthy MTU will start once the supply side is full and sealed. p. 271
What are the torque specs for a JCB 457?
Wheel nuts are 620 N·m on the front and 600 Nm on the rear. Don't swap them, and re-check after the first few hours on a refitted wheel. Component torques sit inside each system's procedures. The Fasteners and Fixings section covers screws, bolts, bearings, clips and threaded inserts, and Consumable Products lists the locking fluids and sealants that go with them. p. 738
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