jcb 100C-1 User manual

SERVICE MANUAL
EXCAVATOR
100 C-1, 85 Z-1, 86 C-1, 90 Z-1
EN - 9813/2700 - ISSUE 2 - 2016-09-28
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 6-09-28 © 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, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 79 9813/2700-2 15 - 79
03 - Drive Belt
Introduction .................................................... 15-79
Health and Safety .......................................... 15-80
Component Identification ............................... 15-80
Check (Condition) .......................................... 15-81
Adjust ............................................................ 15-81
Remove and Install ....................................... 15-83
Introduction
Original Belt Configuration
The alternator adjusting lever makes sure that the
front end accessory drive belt (FEAD) is kept at the
correct tension.
Figure 143.
B
A
AAlternator
BAdjusting lever
Alternate Belt Configuration
A tensioning screw, which adjusts the tightening
pulley travel, makes sure that the front end accessory
drive belt (FEAD) is kept at the correct tension.
Figure 144.
A
B
ATightening pulley
BTensioning screw

15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 80 9813/2700-2 15 - 80
Health and Safety
Notice: A drive belt that is loose can cause
damage to itself and/or other engine parts.
Component Identification
Figure 145. Original Belt Configuration
C
A
D
B
ACrankshaft drive pulley
BDrive belt
CCoolant pump drive pulley
DAlternator drive pulley
Figure 146. Poly-V Belt Configuration
B
A
D
C
E
ACrankshaft drive pulley
BTensioner pulley
CCoolant pump drive pulley
DAlternator drive pulley
EPoly-V belt

15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 81 9813/2700-2 15 - 81
Check (Condition)
At the recommended service interval, visually inspect
the drive belt for damage.
1. Make the machine safe. Refer to (PIL 01-03).
2. Stop the engine and let it cool down.
3. Replace the drive belt if it has cracks or if it is
frayed or has pieces of material missing.
Adjust
Original Belt Configuration
The belt must always be replaced every time it is
removed, even if it has not reached the scheduled
hours for replacement.
1. Pull the alternator in the direction of the arrow.
Figure 147.
A
C
B
D
AAlternator
BTop mounting bolt
CBottom mounting bolt
DDrive belt
2. Tighten the top mounting bolt to the correct
torque value.
Torque: 25N·m
3. Tighten the bottom mounting bolt to the correct
torque value.
Torque: 40N·m
4. While tensioning the alternator, first install the top
mounting screw and then the bottom mounting
screw.
5. Measure the tension of the belt at the point
shown.
Figure 148.
E
ETension measuring point

15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 82 9813/2700-2 15 - 82
6. The tension of the belt should between the
specified values.
Weight/Force: 350–450N
7. If the tension values do not match the specified,
tighten the screws, then repeat the steps 1 to 6.
Alternate Belt Configuration
The belt must always be replaced every time it is
removed, even if it has not reached the scheduled
hours for replacement.
1. Make sure that the ribs of the belt are engaged
correctly into the grooves of the pulleys.
Figure 149.
B
A
ADrive belt
BPulley pin
2. Make sure that the pulley pin is at the bottom of
the guide groove.
3. Tighten the screw, that attaches the pulley, to the
correct torque value.
Torque: 45N·m
4. Hold the tensioning screw with an Allen key.
5. Tighten the nut on the plate to secure the
tightening screw.
Torque: 45N·m
Figure 150.
D
E
C
F
CScrew
DTensioning screw
ENut
FPlate
6. Measure the tension of the belt at the point
shown.
Figure 151.
G
GTension measuring point
7. The tension of the belt should between the
specified values.
Frequency: 149–196Hz
8. Run the engine for the specified duration.
Duration: 15–20min
9. Repeat the step 6 to 7.
10. The Poly-v drive belt is not adjustable. If the
tension value is not within the specified range
replace the drive belt.

15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 83 9813/2700-2 15 - 83
Remove and Install
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Get access to the drive belt. Refer to (PIL 15-18).
3. Disconnect the battery. Refer to (PIL 33-03).
4. Loosen the nut and tighten the screw until it
touches the pulley shaft. Refer to Figure 152.
5. Loosen the bolt that attaches the pulley to the
pulley shaft, up to the specified distance. Refer
to Figure 152.
Distance: 32mm
6. Loosen the screw, the belt tensioner pulley will
move up. Refer to Figure 152.
6.1. If the pulley will not move, pull the belt
tensioner pulley up.
7. Remove the drive belt. Refer to Figure 152.
Figure 152.
A
B
C
F
D
G
E
ANut
BScrew
CPulley shaft
DBolt
E32mm
FTensioner pulley
GExisting drive belt
Install
1. Pull the belt tensioner pulley up. Refer to Figure
153.
Figure 153.
F
FTensioner pulley
2. Insert the new drive belt on the pulleys. Refer to
Figure 154.
Figure 154.
J
H
J
HNew drive belt
JPulleys
3. Make sure that the ribs of the drive belt are
engaged correctly into the grooves of the pulleys.
4. Tighten the screw until the pulley shaft reaches
the bottom of the guide groove. Refer to Figure
155.

15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 84 9813/2700-2 15 - 84
Figure 155.
B
C
BScrew
CPulley shaft
5. Tension the drive belt.
6. Tighten the pulley bolt to the correct specified
torque value.
Torque: 45N·m
7. Tighten the nut.
8. Connect the battery.
9. Close the engine cover.
10. Check the belt tension after the engine operation
for the specified time.
Duration: 15min

15 - Engine
18 - Engine Belt
21 - Tensioner
15 - 85 9813/2700-2 15 - 85
21 - Tensioner
Remove and Install
This procedure is applicable for machines installed
with Poly-V drive belt.
Important: The drive belt must always be replaced
every time it is removed, even if it has not reached
the scheduled hours for replacement.
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Remove the drive belt. Refer to (PIL 15-18).
3. Remove the tensioning screw.
4. Remove the screw that secures the tightening
pulley.
5. Remove the tightening pulley.
Figure 156.
A
B
C
ATensioning screw
BScrew
CTightening pulley
Install
1. Insert the screw in the tightening pulley.
2. Manually tighten the screw on to the pulley pin up
to the stop; Loosen the screw again by one turn.
3. The screw must be out by the specified distance
from the surface of the tightening pulley.
Distance: 32mm
4. Install the drive belt. Refer to (PIL 15-18).
5. Install the tightening screw on to the plate, up to
the stop on the pulley pin.
6. Tension the drive belt.
Figure 157.
A
B
E
D
C
ATensioning screw
BScrew
CTightening pulley
DPulley pin
E32mm

15 - Engine
21 - Oil Filter
00 - General
15 - 89 9813/2700-2 15 - 89
Component Identification
Figure 158.
A
B
AOil Filter
BElement
Figure 159.
C
D
B
A
ACartridge holder cover
BOil filter support
COil returning into the circuit
DOil returning to the crankcase
Figure 160.
H
E
A
B
G
F
ACartridge holder cover
BOil filter support
EOil filter cartridge
FOutgoing fitting from filter
GWater/oil heat exchanger
HCrankcase

15 - Engine
21 - Oil Filter
00 - General
15 - 90 9813/2700-2 15 - 90
Check (Level)
Engine oil and oil filter replacement must be
completed in accordance with the service schedules.
Failure to replace the oil and filter at the
recommended interval could cause serious engine
failure.
1. Make the machine safe. Refer to (PIL 01-03).
2. Park the machine on a hard level surface for
accurate measurement of the oil level.
3. Get access to the engine.
4. Check that the oil level is between the two marks
on the dipstick.
Figure 161.
B
A
C
ADipstick
BMaximum level mark
CMinimum level mark
5. If necessary, add recommended oil through one
of the filler points.
Figure 162.
D
DOil filler caps
Remove and Install
Before Removal
1. Drain the engine oil, refer to Engine-General,
Drain and Fill (PIL 15-00).
Refer to: Engine > General > General > Drain and
Fill (Page 15-17).
Remove and Install
1. Remove the clamps and remove the pipes from
the oil cooler unit.
Figure 163.
D
E
F
DClamps
EPipes
FOil cooler
2. Use a suitable container to recover any residual
oil.
3. Loosen the element holder cap.
Figure 164.
H
G
J
GElement holder cap
HOil filter support
JElement
4. Remove the cap and the oil filter element from
the oil filter support.
5. Remove the cartridge from the cap and discard.

15 - Engine
21 - Oil Filter
00 - General
15 - 91 9813/2700-2 15 - 91
Figure 165.
J
G
K
GElement holder cap
JElement
KSeal
6. Remove and replace the seals.
7. Apply clean oil on the seals.
8. Put the element on the cap.
9. Install the cap on the oil filter support.
10. Tighten the cap to the correct torque value.
11. Install the pipes on the support.
12. Secure the pipes with the clamps.
13. Through one of the filler points, fill the engine with
the recommended oil to the MAX mark on the
dipstick.
Figure 166.
L
LOil filler caps
14. Wipe off any spilt oil, install the filler cap and
make sure it is secure.
15. Operate the engine, until the oil pressure low
warning light has extinguished.
16. Check for oil leakage.
17. When the oil has cooled, check the oil level
again, and if necessary top up with clean engine
oil.
Table 53. Torque Values
Item Nm
B 35
G 25

15 - Engine
27 - Crankcase Ventilation Filter
03 - Separator
15 - 103 9813/2700-2 15 - 103
03 - Separator
Remove and Install
Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves
to prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
Before removal
1. Make the machine safe with the lift arm lowered.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Get access to the engine.
4. Remove the crankcase ventilation filter
Refer to: Engine > Crankcase Ventilation Filter
(Page 15-97).
Remove
1. Remove all the pipes from the separator.
Figure 171.
E
F
A
E
G
D
ASeparator
DCrankcase
EClamp
FPipe
GPipe1
2. Remove the screws.
Figure 172.
A
C
B
ASeparator
BScrew
CGasket
3. Remove the separator with the gasket.
Install
1. Check that the contact surfaces are free from
impurities.
2. Always examine the condition of the pipes, and
replace them if there is any doubt regarding the
integrity of their seal.
3. Always replace the gasket after each assembly.
4. Install the gasket on the separator.
Figure 173.
A
D
C
B
ASeparator
BScrew
CGasket
DCrankcase
5. Attach the holder on the crankcase with the
screws.
6. Tighten the screws to the correct torque value.

15 - Engine
27 - Crankcase Ventilation Filter
03 - Separator
15 - 104 9813/2700-2 15 - 104
Figure 174.
A
E
G
F
E
ASeparator
EClamp
FPipe
GPipe1
7. Attach the pipes on the separator with the clamp.
After installation
1. Install the crankcase ventilation filter
Refer to: Engine > Crankcase Ventilation Filter
(Page 15-97).
2. Start the engine and check for leaks.
Table 54. Torque Values
Item Nm
B 10

15 - Engine
30 - Valve
00 - General
15 - 107 9813/2700-2 15 - 107
00 - General
Introduction .................................................. 15-107
Technical Data ............................................. 15-108
Component Identification ............................. 15-109
Operation ..................................................... 15-111
Adjust .......................................................... 15-113
Calibrate ...................................................... 15-113
Remove and Install ..................................... 15-115
Introduction
The valve train system opens and closes the
valves with correct timing in relation to the piston
movements.
Each push rod has one end in a valve tappet and
the other end under a rocker arm, or as applicable.
Hydraulic tappets are used which automatically
adjust the clearance between the valve and push
rods.
The valves extend through the cylinder head. The
valves are made from a special metal to provide a
long service life. Damaged or worn valves cannot be
lapped or reground and must be replaced with new
ones. Each valve stem has an oil seal.
The Valve seat inserts are pressed into the cylinder
head. The seat inserts are also made from a special
metal to provide for a long service life. Damaged or
worn seat inserts can be removed and replaced with
new ones.

Our support email:
[e-mail]