The document provides service information for an excavator including: - An excavator service manual covering machine components, attachments, body framework, operator station, HVAC, engine, fuel/exhaust, cooling, driveline, hydraulic, and electrical systems. - The manual contains safety warnings and instructions for operating and maintaining the excavator. - Sections cover maintenance tasks like checking fluid levels, replacing belts, filters, and other wear items according to the maintenance schedule.

1. 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

2. 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
A Alternator
B 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.
A
B
A Tightening pulley
B Tensioning screw

3. 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
A Crankshaft drive pulley
B Drive belt
C Coolant pump drive pulley
D Alternator drive pulley
Figure 146. Poly-V Belt Configuration
B
A
D
C
E
A Crankshaft drive pulley
B Tensioner pulley
C Coolant pump drive pulley
D Alternator drive pulley
E Poly-V belt

4. 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
A Alternator
B Top mounting bolt
C Bottom mounting bolt
D Drive 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
E Tension measuring point

5. 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
A Drive belt
B Pulley 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
C Screw
D Tensioning screw
E Nut
F Plate
6. Measure the tension of the belt at the point
shown.
Figure 151.
G
G Tension 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.

6. 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
A Nut
B Screw
C Pulley shaft
D Bolt
E 32mm
F Tensioner pulley
G Existing drive belt
Install
1. Pull the belt tensioner pulley up. Refer to Figure
153.
Figure 153.
F
F Tensioner pulley
2. Insert the new drive belt on the pulleys. Refer to
Figure 154.
Figure 154.
J
H
J
H New drive belt
J Pulleys
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.

7. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 84 9813/2700-2 15 - 84
Figure 155.
B
C
B Screw
C Pulley 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

8. 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
A Tensioning screw
B Screw
C Tightening 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
A Tensioning screw
B Screw
C Tightening pulley
D Pulley pin
E 32mm

9. 15 - Engine
21 - Oil Filter
00 - General
15 - 89 9813/2700-2 15 - 89
Component Identification
Figure 158.
A
B
A Oil Filter
B Element
Figure 159.
C
D
B
A
A Cartridge holder cover
B Oil filter support
C Oil returning into the circuit
D Oil returning to the crankcase
Figure 160.
H
E
A
B
GF
A Cartridge holder cover
B Oil filter support
E Oil filter cartridge
F Outgoing fitting from filter
G Water/oil heat exchanger
H Crankcase

10. 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
A Dipstick
B Maximum level mark
C Minimum level mark
5. If necessary, add recommended oil through one
of the filler points.
Figure 162.
D
D Oil 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
D Clamps
E Pipes
F Oil cooler
2. Use a suitable container to recover any residual
oil.
3. Loosen the element holder cap.
Figure 164.
H
G
J
G Element holder cap
H Oil filter support
J Element
4. Remove the cap and the oil filter element from
the oil filter support.
5. Remove the cartridge from the cap and discard.

11. 15 - Engine
21 - Oil Filter
00 - General
15 - 91 9813/2700-2 15 - 91
Figure 165.
J
G
K
G Element holder cap
J Element
K Seal
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
L Oil 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

12. 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
A Separator
D Crankcase
E Clamp
F Pipe
G Pipe1
2. Remove the screws.
Figure 172.
A
C
B
A Separator
B Screw
C Gasket
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
CB
A Separator
B Screw
C Gasket
D Crankcase
5. Attach the holder on the crankcase with the
screws.
6. Tighten the screws to the correct torque value.

13. 15 - Engine
27 - Crankcase Ventilation Filter
03 - Separator
15 - 104 9813/2700-2 15 - 104
Figure 174.
AE G
F E
A Separator
E Clamp
F Pipe
G Pipe1
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

14. 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.

15. 15 - Engine
30 - Valve
00 - General
15 - 108 9813/2700-2 15 - 108
Technical Data
Table 55. Inlet and Exhaust Valve Data
Max lift Inlet 9.64mm @ 101° After
TDC (Top Dead Centre)
Max lift Exhaust 9.84mm @ 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 6.928–6.943mm
- Exhaust 6.918–6.933mm
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 131.9–132.4mm
Valve sealing Stem seal with sealing
washer
Valve head depth (below
cylinder head surface)
- Inlet 0.89–1.39mm
- Exhaust 0.95–1.45mm
Valve rim thickness 2.98–3.38mm
Valve Clearances (en-
gine cold)
- Inlet 0.19–0.27mm
(1)
- Exhaust 0.56–0.64mm
(1)
(1) The values refer to the tappet adjuster end of the
valve rockers.

16. 15 - Engine
30 - Valve
00 - General
15 - 109 9813/2700-2 15 - 109
Component Identification
Figure 175.
H
E
F
G
A
D
C
B
A Crankshaft B Crankshaft gear
C Intermediate gear D Camshaft control gear
E Camshaft F Camshaft tappet
G Rocker arm push rod H Valve

17. 15 - Engine
30 - Valve
00 - General
15 - 110 9813/2700-2 15 - 110
Figure 176.
K
C D
A
L
J
B
A Crankshaft
B Crankshaft gear
C Intermediate gear
D Camshaft control gear
J Camshaft phonic wheel
K Intermediate gear pin
L Phonic wheel positioning reference pin on
camshaft
Figure 177.
H
G
N
M
Q
P
G Rocker arm push rod
H Valve
M Articulation control valve
N Valve control bridge
P Hydraulic tappet
Q Rocker arm

18. 15 - Engine
30 - Valve
00 - General
15 - 111 9813/2700-2 15 - 111
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.
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.
The screw is self locking in the rocker by means of
a tapered thread. Springs and holders are used to
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.
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.
Figure 178.
H
E
F
G
A
D
C
B
A Crankshaft B Crankshaft gear
C Intermediate gear D Camshaft control gear
E Camshaft F Camshaft tappet
G Rocker arm control rod H Valve stem

19. 15 - Engine
30 - Valve
00 - General
15 - 112 9813/2700-2 15 - 112
Figure 179.
L
H
N
R
Q
W
P
M
J
S
U
V
K
T
H Valve stem J Rocker arm body
K Hydraulic tappet L Rocker arm distancing spring
M Rocker arm pin holder N Retainer
P Collets Q Oil seal - valve stems
R Valve seat inserts S Oil flow line
T Valve tappet U Discharge rocker arm
V Suction rocker arm W Spring

20. 15 - Engine
30 - Valve
00 - General
15 - 113 9813/2700-2 15 - 113
Adjust
There is no valve adjustment possible on this engine.
Calibrate
Valve Seat check
1. Thoroughly clean the valves and their seats with
suitable degreasing agent.
2. 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.
B
A
D
C
A Valve Seat
B Cylinder head
C Valve recess
D Seal width

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22. 15 - Engine
30 - Valve
00 - General
15 - 114 9813/2700-2 15 - 114
Valve Springs
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.
Table 57.
Item Load (Kg) Length (mm)
Z Without load 48.35
Z1 20.4 30.00
Z2 34.8 22.00
Figure 181.
A Z1
Z
Z2
A Valve spring
Valve Guides Check
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.
Table 58.
Item Dimension
(mm)
Clearance
(mm)
Wear limit
(mm)
D 5.978 -
5.990
E 5.030 -
6.042
0.040 -
0.064
0.100
F 7.000 -
7.020
Figure 182.
F
E
D
C
B
A
A Valve guide
B Valve stem
C Rocker arm support surface
D Valve stem diameter
E Valve guide diameter
F Valve guide height
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.
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

23. 15 - Engine
30 - Valve
00 - General
15 - 115 9813/2700-2 15 - 115
Figure 183.
A
B
A Valve guide diameter
B Valve guide housing diameter
Remove and Install
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).
10. Remove the rocker assembly. Refer to (PIL
15-42).
11. Remove the cylinder head assembly. Refer to
(PIL 15-06).
12. Measure the valve recession as follows:
12.1.Clean the area around the valve heads to
remove the carbon deposits.
12.2.Measure the valve recession with a DTI
(Dial Test Indicator).
12.3.If the valve recession is more than the
specified limits, get a new or repaired
cylinder head assembly.
Remove
1. Install the spring compressor tool in one of the
bolt holes for the rocker arm cover.
2. Make sure you change the position of the spring
compressor tool according to the valves to be
removed.

24. 15 - Engine
30 - Valve
00 - General
15 - 116 9813/2700-2 15 - 116
Figure 184.
B
C
A
A Rocker arm cover attaching holes
B Spring compressor tool
C Valve stem
3. Use the spring compressor tool to compress the
valve spring equally.
Figure 185.
G
E
F
C
D
C Valve stem
D Retainer
E Spring
F Cotter
G Valve stem seal
4. Use a magnet to pull out the cotter.
5. Remove the spring compressor tool and lift off
the retainer and valve spring.
6. Turn the cylinder head and remove the valve.
Figure 186.
C
H
C Valve stem
H Cylinder head
7. When you remove the valves, record the position
of each valve.
8. Use a suitable valve stand to keep the valves
together and to identify them with their respective
cylinder.
Figure 187. Valve stand
EXHAUST
CYL. 1 CYL. 2 CYL. 3 CYL. 4
INLET
EXHAUST
INLET
EXHAUST
INLET
EXHAUST
INLET
9. Remove the valve stem seal. Discard the seal.
Figure 188.
G
G Valve stem seal
Inspection
1. Carefully clean the carbon deposits from the
valves, take care not to damage the valve seats.