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 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 |
