Jcb 100C-1 Bedienungsanleitung

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).

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.

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.

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

ACrankshaft drive pulley

BDrive belt

CCoolant pump drive pulley

DAlternator drive pulley

Figure 146. Poly-V Belt Configuration

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.

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.

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.

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.

CScrew

DTensioning screw

ENut

FPlate

6. Measure the tension of the belt at the point

shown.

Figure 151.

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.

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.

FTensioner pulley

2. Insert the new drive belt on the pulleys. Refer to

Figure 154.

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.

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.

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.

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.

AOil Filter

BElement

Figure 159.

ACartridge holder cover

BOil filter support

COil returning into the circuit

DOil returning to the crankcase

Figure 160.

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.

ADipstick

BMaximum level mark

CMinimum level mark

5. If necessary, add recommended oil through one

of the filler points.

Figure 162.

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.

DClamps

EPipes

FOil cooler

2. Use a suitable container to recover any residual

oil.

3. Loosen the element holder cap.

Figure 164.

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.

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