JCB 100C-1, 85Z-1, 86C-1, 90Z-1 Mini Excavator Service Repair Manual Instant Download

1
Foreword
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
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 Conditioning (HVAC) 15
- Engine
and Air-
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
2
15 - Engine 18 - Engine Belt 03 - Drive Belt
03 - Drive Belt
Introduction
Introduction .....................................
............... 15-79 Health and Safety
..........................................
15-80 Component Identification ...................
............ 15-80 Check (Condition)
..........................................
15-81 Adjust .....................................
....................... 15-81 Remove and Install
....................................... 15-83
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

• Alternator
• Adjusting 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.
• B
• A

1. Tightening pulley
2. Tensioning screw

15 - 79
15 - 79
3
15 - Engine 18 - Engine Belt 03 - Drive Belt
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
D
C

• B
• A
• Crankshaft drive pulley
• Drive belt
• Coolant pump drive pulley
• Alternator drive pulley
• Figure 146. Poly-V Belt Configuration
• D
• C

B

• A
• Crankshaft drive pulley
• Tensioner pulley
• Coolant pump drive pulley
• Alternator drive pulley
• Poly-V belt

E
15 - 80
15 - 79
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5
15 - Engine 18 - Engine Belt 03 - Drive Belt
Check (Condition)
Adjust
At the recommended service interval, visually
inspect the drive belt for damage.
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.

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.

A
B
D

• C
• Alternator
• Top mounting bolt
• Bottom mounting bolt
• Drive belt
• Tighten the top mounting bolt to the correct
  torque value.
• Torque 25Nm
• Tighten the bottom mounting bolt to the correct
  torque value.
• Torque 40Nm
• While tensioning the alternator, first install
  the top mounting screw and then the bottom
  mounting screw.
• Measure the tension of the belt at the point
  shown.
• Figure 148.

E E Tension measuring point
6
15 - Engine 18 - Engine Belt 03 - Drive Belt

• The tension of the belt should between the
  specified values.
• Weight/Force 350450N
• If the tension values do not match the specified,
  tighten the screws, then repeat the steps 1 to 6.

Figure 150.
D
E
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.
C
F
1. Make sure that the ribs of the belt are
engaged correctly into the grooves of the
pulleys. Figure 149.

• Screw
• Tensioning screw
• Nut
• Plate
• 6. Measure the tension of the belt at the point
  shown.
• Figure 151.

A
B
G

• Drive belt
• Pulley pin
• Make sure that the pulley pin is at the bottom of
  the guide groove.
• Tighten the screw, that attaches the pulley, to
  the correct torque value.
• Torque 45Nm
• Hold the tensioning screw with an Allen key.
• Tighten the nut on the plate to secure the
  tightening screw.
• Torque 45Nm

• G Tension measuring point
• The tension of the belt should between the
  specified values.
• Frequency 149196Hz
• Run the engine for the specified duration.
  Duration 1520min
• 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.
7
15 - Engine 18 - Engine Belt 03 - Drive Belt
Remove and Install
Figure 153.
Remove

• Make the machine safe. Refer to (PIL 01-03).
• Get access to the drive belt. Refer to (PIL
  15-18).
• Disconnect the battery. Refer to (PIL 33-03).
• Loosen the nut and tighten the screw until it
  touches the pulley shaft. Refer to Figure 152.
• Loosen the bolt that attaches the pulley to the
  pulley shaft, up to the specified distance. Refer
  to Figure 152.
• Distance 32mm
• Loosen the screw, the belt tensioner pulley will
  move up. Refer to Figure 152.
• If the pulley will not move, pull the belt
  tensioner pulley up.
• Remove the drive belt. Refer to Figure 152.
• Figure 152.
• A

F
F Tensioner pulley 2. Insert the new drive belt
on the pulleys. Refer to Figure 154. Figure 154.
J
H
J
B
E

• H New drive belt
• J Pulleys
• Make sure that the ribs of the drive belt are
  engaged correctly into the grooves of the
  pulleys.
• Tighten the screw until the pulley shaft reaches
  the bottom of the guide groove. Refer to Figure
  155.

C
F
D
G

1. Nut
2. Screw
3. Pulley shaft
4. Bolt
5. 32mm
6. Tensioner pulley
7. Existing drive belt

Install 1. Pull the belt tensioner pulley up.
Refer to Figure 153.
8
15 - Engine 18 - Engine Belt 03 - Drive Belt
Figure 155. B

• C
• Screw
• Pulley shaft
• Tension the drive belt.
• Tighten the pulley bolt to the correct specified
  torque value.
• Torque 45Nm
• Tighten the nut.
• Connect the battery.
• Close the engine cover.
• Check the belt tension after the engine operation
  for the specified time.
• Duration 15min

9
15 - Engine 18 - Engine Belt 21 - Tensioner
21 - Tensioner Remove and Install
Figure 157.
A
E
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.
C
B
Remove

• D
• Tensioning screw
• Screw
• Tightening pulley
• Pulley pin
• 32mm

• Make the machine safe. Refer to (PIL 01-03).
• Remove the drive belt. Refer to (PIL 15-18).
• Remove the tensioning screw.
• Remove the screw that secures the tightening
  pulley.
• Remove the tightening pulley.
• Figure 156.

A C
B

• Tensioning screw
• Screw
• Tightening pulley
• Install
• Insert the screw in the tightening pulley.
• Manually tighten the screw on to the pulley pin
  up to the stop Loosen the screw again by one
  turn.
• The screw must be out by the specified distance
  from the surface of the tightening pulley.
• Distance 32mm
• Install the drive belt. Refer to (PIL 15-18).
• Install the tightening screw on to the plate, up
  to the stop on the pulley pin.
• Tension the drive belt.

10
15 - Engine 21 - Oil Filter 00 - General
Component Identification
Figure 160.
Figure 158.
H
A
B
B
E

• A
• Oil Filter
• Element
• Figure 159.
• A
• B

G
F

• Cartridge holder cover
• Oil filter support
• Oil filter cartridge
• Outgoing fitting from filter G Water/oil heat
  exchanger H Crankcase

C

• D
• Cartridge holder cover
• Oil filter support
• Oil returning into the circuit
• Oil returning to the crankcase

15 - 89
15 - 89
11
15 - Engine 21 - Oil Filter 00 - General
Check (Level)
Remove and Install
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.
Before Removal
1. Drain the engine oil, refer to Engine-General,
Drain and Fill (PIL 15-00). Refer to Engine gt
General gt General gt Drain and Fill (Page 15-17).

• Make the machine safe. Refer to (PIL 01-03).
• Park the machine on a hard level surface for
  accurate measurement of the oil level.
• Get access to the engine.
• Check that the oil level is between the two marks
  on the dipstick.
• Figure 161.

Remove and Install
1. Remove the clamps and remove the pipes from
the oil cooler unit. Figure 163.
F
A
E
B
D

• Clamps
• Pipes
• Oil cooler
• Use a suitable container to recover any residual
  oil.
• Loosen the element holder cap.
• Figure 164.

C

• Dipstick
• Maximum level mark
• Minimum level mark
• 5. If necessary, add recommended oil through one
  of the filler points.
• Figure 162.

G
D
J
H

• Element holder cap
• Oil filter support
• J Element
• Remove the cap and the oil filter element from
  the oil filter support.
• Remove the cartridge from the cap and discard.

D Oil filler caps
15 - 90
15 - 89
12
15 - Engine 21 - Oil Filter 00 - General
Figure 165.
17. When the oil has cooled, check the oil level
again, and if necessary top up with clean engine
oil.
G
Table 53. Torque Values
Item Nm
B 35
G 25
J
K

• G Element holder cap
• Element
• Seal
• Remove and replace the seals.
• Apply clean oil on the seals.
• Put the element on the cap.
• Install the cap on the oil filter support.
• Tighten the cap to the correct torque value.
• Install the pipes on the support.
• Secure the pipes with the clamps.
• Through one of the filler points, fill the engine
  with the recommended oil to the MAX mark on the
  dipstick.
• Figure 166.

L

• L Oil filler caps
• Wipe off any spilt oil, install the filler cap
  and make sure it is secure.
• Operate the engine, until the oil pressure low
  warning light has extinguished.
• Check for oil leakage.

15 - 91
15 - 89
13
15 - Engine 27 - Crankcase Ventilation Filter 03
- Separator
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.
Figure 172.
B
A
C

• Separator
• Screw
• Gasket
• 3. Remove the separator with the gasket.

Before removal

• Make the machine safe with the lift arm lowered.
• 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.
• Get access to the engine.
• Remove the crankcase ventilation filter
• Refer to Engine gt Crankcase Ventilation Filter
  (Page 15-97).

Install

• Check that the contact surfaces are free from
  impurities.
• Always examine the condition of the pipes, and
  replace them if there is any doubt regarding the
  integrity of their seal.
• Always replace the gasket after each assembly.
• Install the gasket on the separator.
• Figure 173.

Remove 1. Remove all the pipes from the
separator. Figure 171.
D
A
G
E
A
D

• E
• A Separator D Crankcase E Clamp
• Pipe
• Pipe1

F
C
B

• Separator
• Screw
• Gasket
• Crankcase
• Attach the holder on the crankcase with the
  screws.
• Tighten the screws to the correct torque value.

2. Remove the screws.
15 - 103
14
15 - Engine 27 - Crankcase Ventilation Filter 03
- Separator
Figure 174.
A
G
E
F
E A Separator E Clamp F Pipe G Pipe1

• 7. Attach the pipes on the separator with the
  clamp.
• After installation
• Install the crankcase ventilation filter
• Refer to Engine gt Crankcase Ventilation Filter
  (Page 15-97).
• Start the engine and check for leaks.
• Table 54. Torque Values

Item Nm
B 10
15 - 103
15
15 - Engine 30 - Valve 00 - General
00 - General
Introduction
Introduction .....................................
............. 15-107 Technical Data
.............................................
15-108 Component Identification
............................. 15-109 Operation
..................................................
... 15-111 Adjust ................................
.......................... 15-113
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.
Calibrate ...................................................... 15-113 Hydraulic tappets are used which automatically
Remove and Install ..................................... 15-115 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.
15 - 107
16
15 - Engine 30 - Valve 00 - General
Technical Data Table 55. Inlet and Exhaust Valve
Data
Max lift Inlet 9.64mm _at_ 101 After TDC (Top Dead Centre)
Max lift Exhaust 9.84mm _at_ 115 Before TDC
Inlet opens (top of ramp) 6 Before TDC
Inlet closes 28 After TDC
Exhaust opens 41 Before TDC
Exhaust closes 6 After TDC
Valve stem diameter
- Inlet 6.9286.943mm
- Exhaust 6.9186.933mm
Valve spring free length 51.1mm
Valve guide bore diame- ter
- min 6.958mm
- max 6.973mm
Valve face angle
- Inlet 60.5
- Exhaust 45.17
Valve length 131.9132.4mm
Valve sealing Stem seal with sealing washer
Valve head depth (below cylinder head surface)
- Inlet 0.891.39mm
- Exhaust 0.951.45mm
Valve rim thickness 2.983.38mm
Valve Clearances (en- gine cold)
- Inlet 0.190.27mm(1)
- Exhaust 0.560.64mm(1)
(1) The values refer to the tappet adjuster end
of the valve rockers.
15 - 107
17
15 - Engine 30 - Valve 00 - General
Component Identification
Figure 175.
H
D
G
F E
C B
A
A Crankshaft C Intermediate gear E Camshaft G
Rocker arm push rod
B Crankshaft gear D Camshaft control gear F
Camshaft tappet H Valve
15 - 107
18
15 - Engine 30 - Valve 00 - General
Figure 176. C
D
L
K

• J
• A B
• Crankshaft
• Crankshaft gear
• Intermediate gear
• Camshaft control gear J Camshaft phonic wheel K
  Intermediate gear pin
• L Phonic wheel positioning reference pin on
  camshaft
• Figure 177.
• M
• Q
• N
• P
• H
• G

15 - 107
19
15 - Engine 30 - Valve 00 - General
Operation
The camshaft drive gear is driven by the
crankshaft gear at half the speed of the
crankshaft. Camshaft lobes, two for each
cylinder, (operating exhaust and inlet valves)
actuate the valve tappets.
keep the rockers in their correct positions along
the camshaft and prevent them contacting one
another. The rockers incorporate a swivel tip to
ensure alignment with the bridge piece. This
prevents excessive wear.
When the camshaft rotates the cam lobes act on
the tappets. The push rods act on the rockers
which pivot on the camshaft, depressing two
valves at the same time via the bridge piece.
Each valve has a compression spring. The function
of the spring is to close the valve and at the
same time return the rocker arm and push rod to
ensure that the tappets follow the camshaft
lobes. The spring is located on the valve stem
by a retainer and split collets.
The screw is self locking in the rocker by means
of a tapered thread. Springs and holders are
used to
Figure 178.
H
D
G
F E
C B
A
A Crankshaft C Intermediate gear E Camshaft G
Rocker arm control rod
B Crankshaft gear D Camshaft control gear F
Camshaft tappet H Valve stem
15 - 107
20
15 - Engine 30 - Valve 00 - General
Figure 179.
H
V
N
M
U
P W
Q
J
L
T
S
K
R
H Valve stem K Hydraulic tappet M Rocker arm pin
holder P Collets R Valve seat inserts T Valve
tappet V Suction rocker arm
J Rocker arm body L Rocker arm distancing
spring N Retainer Q Oil seal - valve stems S Oil
flow line U Discharge rocker arm W Spring
15 - 107
21
15 - Engine 30 - Valve 00 - General
Adjust
Calibrate
There is no valve adjustment possible on this
engine.
Valve Seat check

• Thoroughly clean the valves and their seats with
  suitable degreasing agent.
• Measure the seal width of each valve and the
  valve recess from the cylinder head.
• Table 56.

Valve Recess Wear Limit
0.110-0.150mm (0.0043-0.0059in) 1.100mm (0.0433in)
If the dimensions measured do not comply with the
above- mentioned values, replace the
valves. The seats must be replaced by a
rectification workshop. Make sure you always
lubricate the valve and valve seat contact
surfaces to prevent oxidation. Figure 180.
C
B
A
D

1. Valve Seat
2. Cylinder head C Valve recess D Seal width

15 - 107
22
15 - Engine 30 - Valve 00 - General
Valve Springs
Figure 182.

1. Use a vernier caliper to measure the free length
   of the spring.
2. With a dynamometer, subject the spring to two
   different loads and check that the length of the
   spring corresponds to the values given in the
   table below.

F
C
B
Table 57.
Item Load (Kg) Length (mm)
Z Without load 48.35
Z1 20.4 30.00
Z2 34.8 22.00
D
A
Figure 181.
E
Z
A
Z1
Z2

1. Valve guide
2. Valve stem
3. Rocker arm support surface
4. Valve stem diameter E Valve guide diameter F
   Valve guide height

A Valve spring
Valve Guides Check
Valve Guides Replacement The intake and exhaust
guides are both made out of grey iron with
pearlitic phosphoric matrix and they have the
same dimensions.

1. With a micrometer, measure the diameter of the
   valve stem.
2. With a internal dial gauge, measure the diameter
   of the valve guides.
3. After the guides are installed in the cylinder
   head, measure the height of the guides from the
   rocker arm support surface.
4. Make sure you take the measurements in different
   points to find any ovalisation and/or
   concentrated wear.

The guides are not pre-finished, so they must be
processed after press-fitting along with the
seats. Contact a workshop for these operations.
Table 59.
Item Dimensions (mm)
A 10.000 - 10.015
B 10.045 - 10.054
Table 58.
Item Dimension (mm) Clearance (mm) Wear limit (mm)
D 5.978 - 5.990 0.040 - 0.064 0.100
E 5.030 - 6.042 0.040 - 0.064 0.100
F 7.000 - 7.020
15 - 107
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15 - Engine 30 - Valve 00 - General
Remove and Install
Figure 183.
Before Removal

1. This procedure requires service parts. Make sure
   you have obtained the correct service parts
   before you start, refer to Parts Catalogue.
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 thermostat. Refer to (PIL 21-12).
5. Remove all of the fuel injector pipes. Refer to
   (PIL 18-96).
6. Remove the inlet manifold. Refer to (PIL
   18-24-03).
7. Remove the exhaust manifold. Refer to (PIL
   18-24-04).
8. Remove the fuel injectors. Refer to (PIL 18-18).
9. Remove the rocker cover. Refer to (PIL 15-42-06).

B
A

1. Valve guide diameter
2. Valve guide housing diameter

• Remove the rocker assembly. Refer to (PIL
  15-42).
• Remove the cylinder head assembly. Refer to (PIL
  15-06).
• Measure the valve recession as follows
  12.1.Clean the area around the valve heads to
• remove the carbon deposits.
• Measure the valve recession with a DTI (Dial
  Test Indicator).
• If the valve recession is more than the
  specified limits, get a new or repaired cylinder
  head assembly.
• Remove
• Install the spring compressor tool in one of the
  bolt holes for the rocker arm cover.
• Make sure you change the position of the spring
  compressor tool according to the valves to be
  removed.

15 - 115
25
15 - Engine 30 - Valve 00 - General
Figure 184.
Figure 186.
B
C
H
C
A

• Rocker arm cover attaching holes
• Spring compressor tool
• Valve stem
• 3. Use the spring compressor tool to compress the
  valve spring equally.
• Figure 185.

• C Valve stem
• H Cylinder head
• When you remove the valves, record the position
  of each valve.
• Use a suitable valve stand to keep the valves
  together and to identify them with their
  respective cylinder.
• Figure 187. Valve stand

EXHAUST INLET EXHAUST INLET
EXHAUST INLET EXHAUST INLET
CYL. 1 CYL. 2 CYL. 3 CYL. 4
C
E
D

• G
• Valve stem
• Retainer
• Spring
• Cotter
• Valve stem seal

F
9. Remove the valve stem seal. Discard the
seal. Figure 188.

1. Use a magnet to pull out the cotter.
2. Remove the spring compressor tool and lift off
   the retainer and valve spring.
3. Turn the cylinder head and remove the valve.

G G Valve stem seal
Inspection 1. Carefully clean the carbon deposits
from the valves, take care not to damage the
valve seats.
15 - 115
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the link into your browser. The full manual is
available for immediate download. https//www.eb
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