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Maintenance

Maintenance Schedules

9831/7750-1

Item

Operation

10 h

50 h

100 h

(1)

500 h

1,000 h 2,000 h

Exhaust system security Check
Air Inlet system security Check
Throttle system and

control cables

Check

Transmission and steering.

Forward/ Reverse oper-

ation

Check

Vibration operation

Check

Steer circuit pressure

Check

Sprinkler system opera-

tion.

Check

Hydraulics

Charge pressure

Check

Operation all services.

Check

Brakes

Drive brake-operation

Check

Park brake -operation

Check

Electrics

Starter Motor

Check

Alternator- Output

Check

All electrical equipments

operation(e.g. warning

lights, beacon, alarm,

horn etc

Check

Operation of stop con-

trols/E.S.O.S.)

Check

Body and Framework

Drum scrapers

Check

Operator's seat safety

switch (if installed)

Check

Neutral start operation

Check

(1) Jobs which should only be done by a specialist.

Summary of Contents for CT160

Page 1: ...OPERATOR S MANUAL TANDEM ROLLER CT160 CT260 EN 9831 7750 ISSUE 1 06 2018 THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE...

Page 2: ......

Page 3: ...anual 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 understa...

Page 4: ...9831 7750 1 Notes...

Page 5: ...ame and Address of the Manufacturer 7 Product Compliance 7 Description General 8 Intended Use 8 Danger Zone 9 Main Component Locations 9 Product and Component Identification Machine 11 Engine 11 Opera...

Page 6: ...Belt 36 Starting the Engine General 38 Stopping and Parking General 40 Safety Equipment Articulation Lock 42 Drive Controls Steering Wheel 44 Hand Throttle Control 44 Transmission Drive Lever 44 Inst...

Page 7: ...Storage 73 Security General 74 Construction Equipment Security and Registration Scheme CESAR 74 LiveLink 74 Maintenance Introduction General 75 Owner Operator Support 75 Service Maintenance Agreement...

Page 8: ...Valve 102 Fuel System General 103 Tank 104 Pre Filter Element 105 Fuel Filter 106 Water Separator 107 Cooling System General 109 Coolant 109 Cooling Pack 110 Brakes Park Brake 112 Drum Scraper 113 Spr...

Page 9: ...sions General 133 Vibration Data 133 Fluids Lubricants and Capacities General 135 Fuel 135 Coolant 139 Torque Values General 141 Electrical System General 142 Fuses 142 Relays 144 Engine General 146 D...

Page 10: ...uipment Security and Registration ESOS Engine Shut Off Solenoid FEAD Front End Accessory Drive ISO International Organization for Standardization LED Light Emitting Diode MECU Machine Electronic Contr...

Page 11: ...general and specific warnings in this section are repeated throughout the manual Read all the safety statements regularly so you do not forget them Remember that the best operators are the safest ope...

Page 12: ...ross References In this manual cross references are made by presenting the subject title in blue electronic copy only The number of the page upon which the subject begins is indicated within the brack...

Page 13: ...ntil you are sure that you and those around you will be safe If you are not sure of anything about the machine or the work ask someone who knows Do not assume anything Remember Be careful Be alert Be...

Page 14: ...can cause drowsiness Feeling Unwell Do not attempt to operate the machine if you are feeling unwell By doing so you could be a danger to yourself and those you work with Mobile Phones Switch off your...

Page 15: ...otective Equipment PPE Do not wear loose clothing or jewellery that can get caught on controls or moving parts Wear protective clothing and personal safety equipment issued or called for by the job co...

Page 16: ...Notes 6 9831 7750 1 6...

Page 17: ...d some of its components may bear approval numbers and marking s and may have been supplied with a Declaration Certificate of Conformity These marking s and documents are relevant only for the country...

Page 18: ...vibration These compacting material include soil types ranging from stones to silty sand and having water contents ranging from 40 to 110 of the optimum water content These figures are in accordance...

Page 19: ...zards additional protective measures such as the use of PPE may be required The machine should not be operated by any person who does not have an appropriate level of qualification training or experie...

Page 20: ...D A Engine compartment cover B Instrument panel and switches C Sunroof D Water tank filler cap E ROPS Roll Over Protective Structure F Smooth drum rear G Drum drive motor rear H Fuel filler cap J Hydr...

Page 21: ...eat platform Figure 4 B A A Machine data plate B Stamped PIN The machine model and build specification are indicated by the PIN The PIN has 17 digits and must be read from left to right Table 1 Typica...

Page 22: ...or missing ROPS If the ROPS has been in an accident do not use the machine until the structure has been renewed Modifications and repairs that are not approved by the manufacturer may be dangerous and...

Page 23: ...About the Product Product and Component Identification 13 9831 7750 1 13 Figure 6 A A Data plate Figure 7 Typical Data Plate...

Page 24: ...sure you wear them when reading the safety labels Do not over stretch or put yourself in dangerous positions to read the safety labels If you do not understand the hazard shown on the safety label th...

Page 25: ...About the Product Safety Labels 15 9831 7750 1 15 Figure 8 C F G E B A D...

Page 26: ...oduct Safety Labels 16 9831 7750 1 16 Figure 9 K F B D H J Table 3 Safety Labels Item Part No Description Qty A 817 70028 Crushing of whole body Insert the articulated frame lock during maintenance an...

Page 27: ...afe distance away 2 E 817 70012 Run over hazard Start the engine from the operator s seat only Do not short across the terminals 1 F 332 P4581 Warning Severing of hands and fingers Keep clear of do no...

Page 28: ...witches Page 20 C Ignition switch Refer to Ignition Switch Page 19 D Auxiliary power socket Refer to Auxiliary Power Socket Page 53 E Drive lever Refer to Transmission Drive Lever Page 44 F Fire extin...

Page 29: ...t the starter motor cool for at least 2 min between Figure 11 B A A Ignition switch B Ignition key Table 4 Switch Positions Position Function 0 Off Stop the Engine Turn the ignition key to this positi...

Page 30: ...s to show that the switch function is active Figure 12 1 3 2 A B A Graphic symbol B Light bar Road Lights Two position rocker switch The switch functions to operate when the ignition is in the on posi...

Page 31: ...rate the horn Position 1 On Beacon Two position rocker switch The switch functions operate when the ignition switch is in the on and off positions Position 1 Off Position 2 Beacon on Automatic Vibrati...

Page 32: ...Notes 22 9831 7750 1 22...

Page 33: ...e aware of events happening in or around the machine Safety must always be the most important factor when you operate the machine When you understand the operating controls gauges and switches practic...

Page 34: ...hine beyond its design limits can damage the machine it can also be dangerous Do not operate the machine outside its limits Do not try to upgrade the machine performance with unapproved modifications...

Page 35: ...to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near electric power lines Before you start using the machine check with your electricity su...

Page 36: ...as quickly as possible Roll Over Protection If the machine starts to roll over you can be crushed if you try to leave the cab If the machine starts to roll over do not try and jump from the cab Stay...

Page 37: ...Do not look into the end of it your eyes could be permanently damaged An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility The worksit...

Page 38: ...s Are there any obstacles or hazards in the area for example debris excavations manhole covers power lines Is the space sufficient for safe manoeuvring Are any other machines or persons likely to be i...

Page 39: ...an the windows light lenses and the rear view mirrors where applicable 1 2 Remove dirt and debris especially from around the linkages rams pivot points and radiator 1 3 Make sure the cab step and hand...

Page 40: ...ne Do not use the machine controls as handholds only use the handrails Operator can enter and leave the operator station from both side of the machine Make sure the machine is stopped and correctly pa...

Page 41: ...0 1 31 Figure 13 A A B A Handrails B Step Leaving the Canopy 1 Park the machine on solid level ground 2 Stop the engine 3 Turn the ignition key to the off position 4 Hold both of the handrails and use...

Page 42: ...Notice Do not isolate the machine electrics when the engine is running this may cause damage to the machine electrics Disconnect the Machine Electrics 1 Turn the ignition key to the off position 2 Ge...

Page 43: ...ing the engine 1 1 If you haven t already done it do a walk round inspection of the outside of the machine Also complete the daily checks as detailed in the service schedules 1 2 Remove dirt and rubbi...

Page 44: ...is moving You could have an accident if you operate the machine with the seat in the wrong position The seat is installed with a neutral start switch The engine cannot be started unless the operator i...

Page 45: ...Operation Operator Seat 35 9831 7750 1 35 Figure 15 B A D C A Weight adjustment lever B Fore and aft adjustment lever C Back rest adjustment control knob D Seat cushion tilt control...

Page 46: ...ne 1 Sit correctly in the seat 2 Pull the seat belt and the tongue from the inertia reel holder in one continuous movement 3 Push the tongue into the latch Make sure the seat belt worn is snug and pro...

Page 47: ...lease the Seat Belt WARNING Release the seat belt only after safely stopping the machine switching off the engine and engaging the park brake if applicable 1 Push the button and pull the tongue from t...

Page 48: ...ition This feature will also stop the engine from running and bring the machine to a safe standstill after 2 s when it detects that the operator seat is vacant and drive lever is not in park brake pos...

Page 49: ...ng revs be available Do not operate the starter motor for more than the time specified Duration 30 s 10 If the engine does not start turn the ignition key to the off position 11 Let the starter motor...

Page 50: ...e all rams if possible to reduce the risk of weather corrosion Notice Do not suddenly stop the engine when it is running under a operating load Instead allow it to idle for a short period with no load...

Page 51: ...ke Operational Limits The machine park brakes can hold the machine at gradients up to 25 Emergency Stop of the Engine Press the emergency stop switch on the steering column and the engine will be stop...

Page 52: ...ulation lock to its drive position 3 Put the locking pin and clips in position to secure the articulation lock in the drive position Figure 19 A C B A Articulation lock drive position B Locking pin C...

Page 53: ...articulation cylinder from the front chassis 5 Loosen the centre joint front plate bolts from both side of the machine 6 Adjust the centre joint front plate as required 7 Tighten the centre joint fron...

Page 54: ...positions 1 Push the lever downward into the operation position during normal machine operation 2 Pull the lever upwards into the idle position after operation of the machine Figure 22 D C B A A Hand...

Page 55: ...utral position Move the lever forward to drive the machine forward and move the lever backward to reverse The control is proportional i e the further the lever is moved from the neutral position the f...

Page 56: ...the condition The only way to cancel the alarm is to set the ignition switch to position 0 The problem can then be rectified Do not use the machine if it has a fault condition or you may damage the en...

Page 57: ...minate with the direction indicators Use the di rection indicators to signal before you turn the machine E Hazard warning indicator Visual only Flashes with the hazard warning lights Turn the flashers...

Page 58: ...ion position Refer to Hand Throttle Control Page 44 5 Disengage the park brake light goes out by pulling the drive lever to the left 6 Use the drive lever to move the machine in the forward or backwar...

Page 59: ...by means of it s own propulsion and then travel further for a short period Definition of Permissible Gradient The permissible gradient when the machine is being used as intended is that gradient of a...

Page 60: ...4 Put the drive lever into the neutral position in order to stop the machine Figure 27 F R N P A A Drive lever F Forward position R Reverse position N Neutral position P Parkbrake position Working wit...

Page 61: ...ss the vibration switch to turn on vibration Do not vibrate when the machine is stationary Only switch the vibration on when the machine is driving Press the vibration switch again to switch off the v...

Page 62: ...position 100 0 Operating the Sprinklers and Scrapers 1 Make sure that ignition switch is turn to on position 2 Set the sprinkler control switch to the required position Refer to Figure 29 3 To stop th...

Page 63: ...or mobile phone chargers or other 12 V powered devices Refer to Component Locations Page 18 Only connect items which are compatible with the power rating of the socket and have the correct plug Always...

Page 64: ...fter any use the extinguisher must be replaced or serviced Make sure that you understand how to use the fire extinguisher If necessary refer to the instructions found on the fire extinguisher Only try...

Page 65: ...ts of the hydraulic system If possible repair the disabled machine where it stands In the event that towing the machine to a safe location is unavoidable follow the procedure given Apply the minimum f...

Page 66: ...supply 6 2 Disconnect the positive booster cable from the positive terminal on the battery Then disconnect it from the booster supply Retrieval It is not recommended to tow a disabled machine Permane...

Page 67: ...with the articulation lock installed 3 Make sure that the articulation lock is in the drive position Refer to Articulation Lock Page 42 Manual Mechanical Brake Deactivation Machine installed with MSE...

Page 68: ...nut until the motor shaft turns freely while holding the screw Figure 34 Drive Motor Installed with Danfoss Pump Make sure that the loop bypass valve pin is pressed in on the pump to loop the neutral...

Page 69: ...is 28 kN 1 Remove the mechanical stopper Figure 36 A A A Mechanical stopper 2 Press the screw spring to engage the park brake piston internal thread Figure 37 B B Spring 3 Tighten the screw until the...

Page 70: ...e on solid level ground Refer to Stopping and Parking Page 40 2 Turn the ignition key to the off position 3 Stop the engine 4 Install the articulation lock Refer to Articulation Lock Page 42 5 Make su...

Page 71: ...tified on the machine by a label 10 Lift the machine slightly to check the balance of the machine and the installation of the lifting equipment If the machine does not lift horizontally adjust the len...

Page 72: ...red WARNING Make sure the articulation lock is in the transport position before you transport the machine The articulation lock must also be in the transport position if you are carrying out daily che...

Page 73: ...ulation lock Refer to Articulation Lock Page 42 3 Using suitable lifting equipment lift the machine onto the trailer Refer to General Page 60 4 Put blocks at the front and rear of the machine Using th...

Page 74: ...truck driver knows the clearance height before he drives away 6 If necessary fold down the ROPS Roll Over Protective Structure frame as follow 6 1 Two people are required to fold the ROPS frame 6 2 F...

Page 75: ...4 B A A Cotter pin B ROPS lock pin 6 5 Make sure that area is clear of people Carefully fold down the ROPS frame Refer to Figure 45 Figure 45 6 6 After transporting the machine unfold the ROPS frame M...

Page 76: ...e it easier to start and prevent possible damage to your machine Operating in Low Temperatures Notice Do not connect two batteries in series to give 24 V for starting as this can cause damage to the e...

Page 77: ...olant mixture 3 Check the coolant system regularly keep the coolant at the correct level Make sure there are no leaks 4 Keep the radiator oil cooler clean regularly remove dirt and debris from the rad...

Page 78: ...f fuel injection equipment where the failure is attributed to the quality and grade of the fuel used If you use the incorrect type of fuel or fuel which is contaminated then damage to the fuel injecti...

Page 79: ...that require components to be removed The cleaning must be done either in the area of components to be removed or in the case of major work or work on the fuel system the whole engine and the surround...

Page 80: ...intenance Positions Page 87 2 Stop the engine and let it cool for at least one hour Do not try to clean any part of the engine while it is running 3 Make sure that all of the electrical connectors are...

Page 81: ...servation and Storage Checking For Damage 71 9831 7750 1 71 Checking For Damage General Refer to the individual condition checks throughout the Maintenance section Refer to Maintenance Schedules Page...

Page 82: ...condensation in the tank if applicable 7 Examine the coolant condition Replace if necessary 8 Examine all fluid levels Top up if necessary Put into Storage 1 Park the machine on solid level ground 1 1...

Page 83: ...e Take out of Storage 1 Examine the coolant condition Replace if necessary 2 Examine all fluid levels If necessary replace the fluid or add more fluid 3 Clean the machine to remove all unwanted materi...

Page 84: ...machinery and recovering it The Construction Equipment Association is managing the scheme and Datatag are providing the security material and support JCB is fully supportive of the CESAR initiative a...

Page 85: ...ications and procedures Therefore only a JCB dealer is fully able which makes them best placed to maintain and service your machine A service record sheet or book is provided at the back of this publi...

Page 86: ...of operation whichever occurs first You should notify your distributor in advance to allow the necessary arrangements to be made Obtaining Spare Parts If you use non genuine JCB parts or consumables t...

Page 87: ...system pressure can injure you Before connecting or removing any hydraulic hose residual hydraulic pressure trapped in the service hose line must be vented Make sure the hose service line has been ve...

Page 88: ...s greater than 300 C 571 6 F e g engine fire must be treated using the following safety procedure Make sure that heavy duty gloves and special safety glasses are worn Thoroughly wash contaminated area...

Page 89: ...Whenever you are handling oil products you must maintain good standards of care and personal and plant hygiene For details of these precautions we advise you to read the relevant publications issued b...

Page 90: ...es Scrape up and remove to a chemical disposal area Fires WARNING Do not use water to put out an oil fire This will only spread it because oil floats on water Extinguish oil and lubricant fires with c...

Page 91: ...enance Maintenance Safety 81 9831 7750 1 81 Figure 47 A B C D E F A Keep away from children B Shield eyes C No smoking no naked flames no sparks D Explosive gas E Battery acid F Note operating instruc...

Page 92: ...Machine users that cannot find a suitable battery recycling facility should contact their JCB dealer for assistance First Aid Electrolyte Eyes In the case of eye contact flush with water for 15 min a...

Page 93: ...n the machine running hours Keep a regular check on the hourmeter readings to correctly gauge the service intervals When there is no hourmeter installed use the calendar equivalents to determine the s...

Page 94: ...Change Air filter dust valve Check Valve Clearances 5 Check and adjust Oil Filler and Dipstick O rings Change FEAD belt Change Injectors 5 Change Injector s Leak Off Rail 5 Change High Pressure Fuel...

Page 95: ...otes Check Cab Isolation Mounts Check ROPS Roll Over Protective Struc ture Check Condition Condition of Paintwork Check Seat Belt Condition and Security If fitted Check Machine Generally Check for Dam...

Page 96: ...ure Check Sprinkler system opera tion Check Hydraulics Charge pressure Check Operation all services Check Brakes Drive brake operation Check Park brake operation Check Electrics Starter Motor Check Al...

Page 97: ...and remove the ignition key 5 Wait for the specified time to dissipate any residual hydraulic pressure Duration 30 s 6 Disconnect the battery to prevent accidental operation of the machine 7 If necess...

Page 98: ...e 49 G F E C B A D J K L M H A Diesel fuel filler cap B Hydraulic oil level indicator C Hydraulic oil filler cap D Battery isolator E Battery F Engine oil dipstick G Air filter H Engine oil drain J Wa...

Page 99: ...Maintenance Service Points 89 9831 7750 1 89 Figure 50 A B C D E A Water tank filler cap B Water level indicator C Water filter D Hydraulic filter E Coolant recovery bottle...

Page 100: ...if installed 4 Engage the articulation lock 5 Stop the engine and turn the ignition key to the off position 6 Remove the ignition key 7 Unlock the latch connected to down left and right side of engine...

Page 101: ...Close 1 Remove the stay rod and put it back into the stowage position 2 Pull the cover down using the handle 3 Make sure that the cover is closed correctly 4 Lock the latch connected to down left and...

Page 102: ...e Tommy bar size 1 2 It is required for ROPS Roll Over Protective Structure folding and unfolding operation Refer to Loading the Machine onto the Transporting Vehicle Trailer Page 62 Double end spanne...

Page 103: ...of the pivot point welds 2 2 Examine the condition of all the pivot pins 2 3 Check that the pivot pins are correctly in position and secured by their locking devices 3 Check the steps and handrails a...

Page 104: ...to Torque Values Page 141 Seat Check Condition 1 Check that the seat adjustments operate correctly 2 Check the seat is undamaged 3 Check the seat mounting bolts are undamaged correctly installed and...

Page 105: ...hine 2 Sit on the operator seat 3 Put the drive lever in park brake and start the engine 4 Operator seat switch icon on the instrument panel should be extinguished 5 If the operator seat switch still...

Page 106: ...of engine oil in the sump If the maximum is exceeded the excess must be drained to the correct level An excess of engine oil could cause the engine speed to increase rapidly without control 1 Make the...

Page 107: ...your face away from the drain hole when removing the drain plug CAUTION It is illegal to pollute drains sewers or the ground Clean up all spilt fluids and or lubricants Used fluids and or lubricants...

Page 108: ...necessary Refer to Figure 53 5 Clean the seal face of the filter head 6 Install the filter canister Refer to Figure 53 6 1 Smear the seal on the new filter canister with clean engine oil 6 2 Screw th...

Page 109: ...ION Make sure the engine cannot be started Disconnect the battery before doing this job otherwise you could be injured Figure 54 A C B A Cracks B Fraying C Missing pieces 1 Make the machine safe Refer...

Page 110: ...ve the alternator drive belt adjustment bolt and the protective cover 5 Remove the alternator drive belt 6 Install the new drive belt around the pulleys Exhaust Check Condition Check that there are no...

Page 111: ...ilter must be replaced with a new one Do not attempt to clean or wash the old element Notice Clean the outer element when the air filter warning light illuminates on the instrument panel The outer ele...

Page 112: ...d 12 Insert a new outer element into the canister check seal is fully seated 13 Put the cover and assemble the scavenge hose 14 Push the cover firmly into position and make sure it is secured 15 Check...

Page 113: ...operation causes high fuel pressure High pressure fuel spray can cause serious injury or death Fuel Injection System 1 Make the machine safe Refer to General Page 87 2 Loosen the vent screw on the fue...

Page 114: ...roughly check again for air in the fuel system 4 2 If the fault persists contact your nearest JCB dealer Check Leaks 1 Make the machine safe 2 Get access to the engine compartment Refer to Access Ape...

Page 115: ...tank 5 Flush the fuel tank with diesel fuel 6 Install the drain plugs 7 Remove the filler screen clean the filler screen with diesel fuel Refer to Figure 59 8 Install the filler screen 9 Fill the fuel...

Page 116: ...pipe clips Do not overtighten the pipe clips 9 Make sure that any spilled fuel is cleaned up 10 Bleed the fuel system Refer to Bleed Page 103 11 Run the engine and make sure that there are no fuel lea...

Page 117: ...the filter head until the gasket contacts the head Hand tighten the filter an additional one half to three quarter of a turn 11 Install the bowl 12 Bleed the fuel system Refer to Bleed Page 103 13 Ru...

Page 118: ...Maintenance Fuel System 108 9831 7750 1 108 Figure 62 B A A Bowl B Tap...

Page 119: ...ng system 1 Make the machine safe 2 Let the engine cool 3 Get access to the top of the radiator Refer to Service Points Page 88 4 Check the coolant level in the coolant recovery bottle 4 1 Carefully l...

Page 120: ...6 Flush the system with clean water After flushing close the drain valve and install the radiator bottom hose 7 Use the necessary mix of clean soft water and antifreeze Fill the cooling system Refer...

Page 121: ...h or compressed air to remove all debris from the cooling pack Check Condition 1 Make the machine safe Refer to Maintenance Positions Page 87 2 Let the engine cool 3 Get access to the cooling pack Ref...

Page 122: ...be started when the drive lever is in park brake position Pushing the emergency stop switch will stop the engine causing the pressure in the braking system to fall and the brakes to be applied 1 Make...

Page 123: ...ed the scrapers should be released from the drum 1 Make the machine safe Refer to Maintenance Positions Page 87 2 Check the correct distance between the drum and the scraper 3 If necessary loosen the...

Page 124: ...e 87 Remove the dirt and debris with the clean water Sprinkler System Water Tank Check Level CAUTION Antifreeze can be harmful Obey the manufacturer s instructions when handling full strength or dilut...

Page 125: ...B Filler cap Clean The sprinkler system drain cap is located at the rear of the machine Refer to Figure 66 To drain the sprinkler system 1 Make the machine safe 2 Remove the water tank filler cap 3 O...

Page 126: ...sitions Page 87 2 Drain the water tank 3 Remove the water filter element Refer to Replace Page 118 4 Open the drain tap Refer to Figure 67 5 Insert a hose into the water tank and the spray pipes and f...

Page 127: ...nd cap C Sprinkler spray pipe D Drain tap Draining of Water at Pump 1 Make the machine safe Refer to General Page 87 2 Get access to the water pump Refer to Figure 68 Figure 68 A A Access panel 3 Push...

Page 128: ...l Page 87 2 Get access to the water sprinkler coupler Coupler is located between articulation joint Figure 70 A A Coupler 3 Open the coupler 4 Drain the trapped water from the hoses 5 Close the couple...

Page 129: ...er to Figure 71 4 Remove the water filter bowl 5 Remove and discard the filter element 6 Install the new filter element 7 Check the seal on the filter element bowl If necessary replace the seal 8 Inst...

Page 130: ...l in grease lubricated shaft drums These drums are installed with lifetime grease only from the factory and it is maintenance free The lifetime grease need only be replaced following dismantling and r...

Page 131: ...nd then examine the cardboard for signs of fluid If fluid penetrates your skin get medical help immediately Examine the hoses for Damaged hose ends Worn outer covers Ballooned outer covers Kinked or c...

Page 132: ...Page 88 4 3 Use a suitable container to add the hydraulic fluid through the filler port 4 4 Check the level of hydraulic fluid Replace Notice Ensure that dirt etc does not enter the hydraulic system...

Page 133: ...r screen 7 Fill the tank with recommended oil through the filler Refer to Fluids Lubricants and Capacities Page 135 7 1 Add oil until the oil level is above the filler screen 8 Check the O ring on the...

Page 134: ...g circuit off before connecting or disconnecting the battery When you have installed the battery in the machine wait 5 min before connecting it up When reconnecting attach the positive lead first DANG...

Page 135: ...s clear of the positive battery terminal Such items can short between the terminal and nearby metal work If it happens you can get burned CAUTION The machine is negatively earthed Always connect the n...

Page 136: ...ttery Isolator Page 32 4 Disconnect the battery leads Disconnect the earth terminal first Battery Isolator Check Operation Notice Do not isolate the machine electrics when the engine is running this m...

Page 137: ...nt cover Open the engine compartment cover to get access to the primary fuses Refer to Engine Compartment Cover Page 90 Relays Replace The relays are situated in the back side of steering column panel...

Page 138: ...Maintenance Electrical System 128 9831 7750 1 128 Figure 76 A B B A Panel B Screws...

Page 139: ...60 80 CT160 100 A Wheelbase 1 560 mm 1 560 mm B Overall width 960 mm 1 090 mm C Drum diameter 580 mm 580 mm D Height to the top of seat 1 650 mm 1 650 mm E Height with ROPS Roll Over Protective Struct...

Page 140: ...mm K Drum width 1 000 mm 1 200 mm Weights For CT160 Page 130 For CT260 Page 130 For CT160 Table 16 Description CT160 80 CT160 100 Nominal weight 1 630 kg 1 710 kg Operating weight CECE Committee for...

Page 141: ...T160 80 CT160 100 Vibration stage 1 2 1 2 Vibration frequency 50 Hz 66 Hz 50 Hz 66 Hz Amplitude 0 47 mm 0 41 mm Centrifugal force 12 8 kN 22 2 kN 12 8 kN 22 2 kN For CT260 Table 20 Description CT260 1...

Page 142: ...chments Table 22 Definition of terms Term Definition Notes LpA A weighted sound pressure level mea sured at the operator s station Determined in accordance with the test method defined in ISO 6396 and...

Page 143: ...ting duties see dominant axis X Y or Z Figure 78 Z X Y Exposure to Vibration Exposure to vibration can be minimised through Selection of the correct size and capacity of machine equipment and attachme...

Page 144: ...termined in accordance with ISO 2631 1 1997 for this machine type is 0 69 m s normalised to an 8 h reference period A 8 and based upon a test cycle defined in SAE J116 Hand arm vibration determined in...

Page 145: ...1 1805 20 L API CH 4 Engine Coolant 5 5 L JCB Antifreeze HP Coolant Concentrate 4006 1120 20 L ASTM D6210 Hydraulic tank 60 L JCB HP Hy draulic Fluid 46 4002 0805 20 L Vibration system JCB Special HP...

Page 146: ...en 3 Low sulfur content 3 1 The sulfur content of fuel must be as low as possible since it contributes to wear of parts and deterioration of oil When a sulfuric compound is burned it changes to sulfur...

Page 147: ...tandard fuel is a mixture of n cetane and alpha methylnaphthalene The former indicates the lowest knocking point its cetane number is defined as 100 The latter has the greatest knocking points its cet...

Page 148: ...s represent products which have a higher boiling range than gasoline and are obtained from fractional distillation of the crude oil or from streams from other refining processes Finished diesel fuels...

Page 149: ...sion of the fuel Bsystem or too early clogging of the fuel filter 5 Pay careful attention to the following cautions because the fuel BDF during refueling and in the fuel tank tends to deteriorate by o...

Page 150: ...ion The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below Table 29 Concentration Level of protection 50 Standard Protects against damage down to 40 C 40 F 60 Extreme...

Page 151: ...le 30 Scrapers adjustment fasteners Refer to Scraper Page 113 22 N m Vulcollan scraper bolts 10 N m Retrieval Table 31 Bypass screws CT260 42 N m Bypass screws CT160 50 5 N m ROPS Table 32 ROPS Roll O...

Page 152: ...dimension length x width x height 240 mm x 175 mm x 175 mm Fuses Primary Fuses Figure 79 Table 34 Fuse No Circuits Protected Rating PF1 Buzzer Hazard and Diagnostic 40 A PF2 Horn Front and rear workl...

Page 153: ...ndary Fuses Figure 80 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 FA FB FC Table 35 Fuse No Circuits Protected Rating FA1 Ignition relay 3 A FA2 Emergency stop 7 5 A FA3 Alternator...

Page 154: ...rse alarm 3 A FB2 Hazard 3 A FB3 Diagnostic Livelink 5 A FB4 MECU 20 A FB5 Spare FB6 Horn 5 A FB7 Rear worklight 15 A FB8 Front worklight LED Light Emitting Diode 7 5 A FB9 Rear worklight LED 7 5 A FB...

Page 155: ...Data Electrical System 145 9831 7750 1 145 Figure 81 A B C D E Table 36 Relay No Description A Starter relay B 2 s timer relay C Ignition relay D Neutral relay Front worklight relay E Fuse relay Reve...

Page 156: ...avel motor Poclain motor MK01 408cc Service brake Hydrostatic propulsion system Secondary brake Hydraulically released multi discbrake on front and rear drum For CT260 Table 38 Data Description Make K...

Page 157: ...ompleted copy of the EC Declaration of Conformity is supplied with all machines manufactured according to EC type examination and or self certification requirements A sample copy of the EC Declaration...

Page 158: ...Technical Data Declaration of Conformity 148 9831 7750 1 148 Data Figure 82 Table 39 A JCB Vibromax GmbH Graf Zeppelin Str 16 51147 Cologne Germany B Compaction Machines...

Page 159: ...art 1 and part 2 2013 F Engineering Manager JCB Vibromax GmbH Graf Zeppelin Str 16 51147 Cologne Germany G Group NVH Specialist at JCB World Headquarters Rocester H Annex VI Procedure 1 J A V Technolo...

Page 160: ...Information 150 9831 7750 1 150 Warranty Information Service Record Sheet Table 40 Signature and stamp Date Annual Insurance Yes Hours Figure 83 Installation Checklist h Figure 84 500h 6 Month h Figu...

Page 161: ...Technical Data Warranty Information 151 9831 7750 1 151 Figure 86 1500h 18 Month h Figure 87 2000h 24 Month h Figure 88 2500h 30 Month h Figure 89 3000h 36 Month h...

Page 162: ...Technical Data Warranty Information 152 9831 7750 1 152 Figure 90 3500h 42 Month h Figure 91 4000h 48 Month h Figure 92 4500h 54 Month h Figure 93 5000h 60Month h...

Page 163: ...Technical Data Warranty Information 153 9831 7750 1 153 Figure 94 5500h 66 Month h Figure 95 6000h 72 Month h Figure 96 6500h 78 Month h Figure 97 7000h 84 Month h...

Page 164: ...Technical Data Warranty Information 154 9831 7750 1 154 Figure 98 7500h 90 Month h Figure 99 8000h 96 Month h Figure 100 8500h 102 Month h Figure 101 9000h 108 Month h...

Page 165: ...Technical Data Warranty Information 155 9831 7750 1 155 Figure 102 9500h 114 Month h Figure 103 10000h 120 Month h Figure 104 10500h 126 Month h Figure 105 11000h 132 Month h...

Page 166: ...Notes 156 9831 7750 1 156...

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jcb CT160, Operator'S Manual

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