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jcb CT160 Operator's Manual

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OPERATOR'S MANUAL
TANDEM ROLLER
CT160, CT260
EN - 9831/7750 ISSUE 1 - 06/2018
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE

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  • 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 3 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. OPERATOR'S Do not operate the machine without an Operator's...
  • Page 4 Notes: 9831/7750-1...

  • Page 5: Table Of Contents

    Table of Contents Contents Page No. Acronyms Glossary ............................Introduction About this Manual Model and Serial Number ........................1 Using the Manual ..........................1 Left-Hand Side, Right-Hand Side ......................1 Cab/Canopy ............................1 Cross References ..........................2 Safety Safety - Yours and Others ........................3 Safety Warnings ............................
  • Page 6 Table of Contents Operation Introduction General ..............................23 Operating Safety General ..............................24 Worksite Safety ........................... 26 Risk Assessment ..........................27 Walk-Around Inspection General ..............................29 Entering and Leaving the Operator Station General ..............................30 Battery Isolator General ..............................32 Before Starting the Engine General ..............................
  • Page 7 Table of Contents Transporting the Machine General ..............................62 Loading the Machine onto the Transporting Vehicle/Trailer ............... 62 Operating Environment General ..............................66 Operating in Low Temperatures ......................66 Operating in High Temperatures ......................67 Refuelling General ..............................68 Filling the Tank ............................ 68 Preservation and Storage Cleaning General ..............................
  • Page 8 Table of Contents Body and Framework General ............................... 93 Operator Station Operator Protective Structure ......................94 Seat ..............................94 Seat Belt ............................. 94 Controls ............................... 94 Safety Equipment Check (Operation) ..........................95 Engine General ............................... 96 Oil ................................ 96 Drive Belt ............................98 Exhaust .............................
  • Page 9 Table of Contents Noise Emissions General .............................. 132 Noise Data ............................132 Vibration Emissions General .............................. 133 Vibration Data ........................... 133 Fluids, Lubricants and Capacities General .............................. 135 Fuel ..............................135 Coolant .............................. 139 Torque Values General .............................. 141 Electrical System General ..............................

  • Page 10: Acronyms Glossary

    Table of Contents Acronyms Glossary CECE Committee for European Construction Equipment CESAR Construction Equipment Security and Registration ESOS Engine Shut-Off Solenoid FEAD Front End Accessory Drive International Organization for Standardization Light Emitting Diode MECU Machine Electronic Control Unit Product Identification Number Root Mean Square ROPS Roll-Over Protective Structure...

  • Page 11: Introduction

    Particular attention must be given to all the safety aspects of operating and maintaining the machine. If there is anything you are not sure about, ask your JCB dealer or employer. Do not guess, you or others could be killed or seriously injured.

  • Page 12: Cross References

    Introduction About this Manual Cross 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 brackets. For example: Refer to: Cross References (Page 2).

  • Page 13: Safety

    If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking of what hazards there might be and how to avoid them.

  • Page 14: General Safety

    Lightning can kill you. Do not use the machine if there is lightning in your area. Machine Modifications This machine is manufactured in compliance with prevailing legislative requirements. It must not be altered in any way which could affect or invalidate its compliance. For advice consult your JCB dealer. 9831/7750-1...

  • Page 15: Clothing And Personal Protective Equipment (Ppe)

    Introduction Safety Clothing and Personal Protective 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 conditions, local regulations or as specified by your employer.
  • Page 16 Notes: 9831/7750-1...

  • Page 17: About The Product

    Product Compliance Your JCB product was designed to comply with the laws and regulations applicable at the time of its manufacture for the market in which it was first sold. In many markets, laws and regulations exist that require the owner to maintain the product at a level of compliance relevant to the product when first produced.

  • Page 18: Description

    The hydrostatic drive system allows for infinitely variable travel speeds. The drive motors (one motor mounted on the left side of each drum) are connected in series on the CT160 and parallel on the CT260. The machines is always driven with all drum drive. Each motor incorporates a spring on, pressure off brake system which engages when the machine is in neutral.

  • Page 19: Danger Zone

    Prior to use of the machine, its suitability (size, performance, specification etc.) should be considered with regards to the intended application and any relevant hazards that may exist. Contact your JCB dealer for support in determining the appropriate JCB machine, attachment and any optional equipment that is suitable for the application and environment.
  • Page 20 About the Product Description Figure 3. 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 Hydraulic tank oil indicator K Drum drive motor (front) L Smooth drum (front)

  • Page 21: Product And Component Identification

    About the Product Product and Component Identification Product and Component Identification Machine Your machine has an identification plate. The PIN (Product Identification Number), weight, engine power, year of manufacture and serial number of the machine are shown on the identification plate. The identification plate can be found on the front face of the seat platform.

  • Page 22: Operator Protective Structure

    About the Product Product and Component Identification The engine serial number is stamped on the cylinder block. Refer to Figure 5. The engine data label and emission label are located on the engine top cover. Refer to Figure 5. Figure 5. A Stamped engine serial number B Engine data label C Engine emission label...
  • Page 23 About the Product Product and Component Identification Figure 6. A Data plate Figure 7. Typical Data Plate 9831/7750-1...

  • Page 24: Safety Labels

    Keep all of the safety labels clean and readable. Replace a lost or damaged safety label. Make sure the replacement parts include the safety labels where necessary. Each safety label has a part number printed on it, use this number to order a new safety label from your JCB dealer. Safety Label Identification...
  • Page 25 About the Product Safety Labels Figure 8. 9831/7750-1...
  • Page 26 About the Product Safety Labels Figure 9. Table 3. Safety Labels Item Part No. Description Qty. 817/70028 Crushing of whole body. Insert the articulated frame lock during maintenance and shipping. 9831/7750-1...
  • Page 27 About the Product Safety Labels Item Part No. Description Qty. 817/70027 Warning. Crushing of whole body. Keep a safe distance. 332/U9190 Warning. Engine exhaust. Burn to fingers and hands. Stay a safe distance away. 332/W8904 Burns to fingers and hands. Stay a safe distance away. 817/70012 Run over hazard.

  • Page 28: Operator Station

    About the Product Operator Station Operator Station Component Locations Figure 10. A Steering wheel Refer to: Steering Wheel B Front console switches and instrument panel (Page 44). Refer to: Console Switches (Page 20). C Ignition switch Refer to: Ignition Switch D Auxiliary power socket Refer to: Auxiliary Power (Page 19).

  • Page 29: Interior Switches

    About the Product Interior Switches Interior Switches Ignition Switch Notice: Do not operate the starter motor for more than 20 s at one time. Let the starter motor cool for at least 2 min. The ignition key operates the three-position ignition switch. The ignition key can only be inserted or removed in position 0.

  • Page 30: Console Switches

    About the Product Console Switches Console Switches General The installed switches and their positions can change according to the specification of the machine. Each switch has a graphic symbol to show the function of the switch. Before you operate a switch, make sure that you understand its function.

  • Page 31: Front Work Lights

    About the Product Console Switches Front Work Lights Two position rocker switch. The switch functions operate when the ignition switch is in the on position. Position : 1 = Off Position : 2 = Front work light on (LED work light option). Rear Work Lights Two position rocker switch.
  • Page 32 Notes: 9831/7750-1...

  • Page 33: Operation Introduction General

    Operation Introduction Operation Introduction General The aim of this part of the manual is to guide the operator step-by-step through the task of learning how to operate the machine efficiently and safely. Read the Operation section through from beginning to end. The operator must always be aware of events happening in or around the machine.

  • Page 34: Operating Safety

    On a busy site, use a signalman. Before doing any job not covered in this manual, find out the correct procedure. Your local JCB distributor will be glad to advise you.
  • Page 35 This machine is designed for use in normal out door atmospheric conditions. It must not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB dealer. Regulations Obey all laws, worksite and local regulations which affect you and your machine.

  • Page 36: Worksite Safety

    Operation Operating Safety Visibility Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights, windows, mirrors and cameras clean (when fitted). Do not operate the machine if you cannot see clearly. Modification of the machine's configuration by the user (e.g.

  • Page 37: Risk Assessment

    It is essential that a risk assessment of the work to be done is completed and that the operator obeys any safety precautions that the assessment identifies. If you are unsure of the suitability of the machine for a specific task, contact your JCB dealer who will be pleased to advise you.
  • Page 38 Operation Operating Safety • Is supervision needed? Is the supervisor sufficiently trained and experienced? • As well as the machine operator, are any assistants or lookouts needed? The Machine • Is it in good working order? • Have any reported defects been corrected? •...

  • Page 39: Walk-Around Inspection

    Operation Walk-Around Inspection Walk-Around Inspection General WARNING Walking or working under raised attachments can be hazardous. You could be crushed by the attachments or get caught in the linkages. Lower the attachments to the ground before doing these checks. Also make sure that the park brake is engaged before doing these checks. The following checks must be made each time you return to the machine after leaving it for any period of time.

  • Page 40: Entering And Leaving The Operator Station

    Operation Entering and Leaving the Operator Station Entering and Leaving the Operator Station General CAUTION Entering or leaving the operator station must only be made where steps and handrails are provided. Always face the machine when entering and leaving. Make sure the steps, handrails and your boot soles are clean and dry.
  • Page 41 Operation Entering and Leaving the Operator Station Figure 13. 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 the steps to climb down backwards from the cab onto the ground. 9831/7750-1...

  • Page 42: Battery Isolator

    Operation Battery Isolator Battery Isolator General Notice: Before carrying out arc welding on the machine, disconnect the battery and alternator to protect the circuits and components. The battery must still be disconnected even if a battery isolator is installed. Notice: Do not isolate the machine electrics when the engine is running, this may cause damage to the machine electrics.

  • Page 43: Before Starting The Engine

    1.5. Remove or secure all loose articles on the machine- such as lunch boxes, tools etc. 1.6. Inspect the ROPS (Roll-Over Protective Structure) structure for damage. Get your JCB distributor to repair any damage. Make sure all the securing bolts are fitted and correctly tightened. Make sure the fold down ROPS frame locking pins are fitted and secure.

  • Page 44: Operator Seat

    Operation Operator Seat Operator Seat General CAUTION Position the seat so that you can comfortably reach the machine controls. Do not adjust the seat while the machine is moving. You could have an accident if you operate the machine with the seat in the wrong position.
  • Page 45 Operation Operator Seat Figure 15. A Weight adjustment lever B Fore and aft adjustment lever C Back rest adjustment control knob D Seat cushion tilt control 9831/7750-1...

  • Page 46: Seat Belt

    Operation Seat Belt Seat Belt General WARNING Operating the machine without a seat belt can be dangerous. Before starting the engine, make sure your seat belt is fastened. Check the tightness and condition of the seat belt securing bolts regularly. WARNING When a seat belt is installed on your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident.
  • Page 47 Operation Seat Belt Figure 17. C Seat belt D Button Release 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 the latch. 2.

  • Page 48: Starting The Engine

    The machine is fitted with an operator seat occupancy switch and lever position switch designed to prevent inadvertent activations of the controls. If either of the features malfunction stop using the machine immediately and contact your JCB dealer. This safety feature must be checked everytime before operating the machine. Operator Seat Occupancy Switch This feature prevents the machine from starting if it detects that the operator is not seated and drive lever is not in the park brake position.
  • Page 49 Operation Starting the Engine 9. Turn the ignition key to the start position and hold it there until the engine starts. An extended period of cranking will be required before the engine starts. An engine "warm up" period will follow and only then will operating revs be available.

  • Page 50: Stopping And Parking

    Operation Stopping and Parking Stopping and Parking General WARNING Do not dismount a moving machine. WARNING If the machine must temporarily be parked on a gradient, park the machine with the front pointing uphill. Ensure that the machine is blocked by a fixed object. WARNING An incorrectly parked machine can move without an operator.
  • Page 51 Operation Stopping and Parking Figure 18. If the machine is to be shutdown for long period, it must be prepared for long storage. Brake 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 stopped.

  • Page 52: Safety Equipment

    Operation Safety Equipment Safety Equipment Articulation Lock 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 checks or doing any maintenance work in the articulation danger zone.
  • Page 53 Operation Safety Equipment Figure 20. A Articulation lock- Transport position Centre Joint Adjustment (If Required) 1. Make the machine safe. 2. Remove the spilt pin from the cylinder pin. Refer to Figure 21. 3. Remove the articulation cylinder pin. 4. Disconnect the articulation cylinder from the front chassis. 5.

  • Page 54: Drive Controls

    Operation Drive Controls Drive Controls Steering Wheel Turn the steering wheel in the direction you want to go. Refer to: Component Locations (Page 18). The steering wheel incorporates an assister knob for single handed operation. Hand Throttle Control A hand operated throttle lever is located on the steering column. The hand throttle control lever has three positions.
  • Page 55 Operation Drive Controls Figure 23. A Drive lever F Forward drive position R Reverse drive position N Neutral position P Parkbrake position The neutral position is in the centre of the lever travel. To operate the machine, move the drive lever forwards or backwards from the neutral position. Move the lever forward to drive the machine forward and move the lever backward to reverse.

  • Page 56: Instrument Panel

    Operation Instruments Instruments Instrument Panel The instruments and warning lights are grouped together on an instrument panel. When a warning light comes on an alarm will sound (depending on severity of 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 engine and/or the transmission.
  • Page 57 Operation Instruments Table 5. Battery charging condition Audible/Visual. The lamp illuminates and buzzer will sound, if battery is not charging while engine is running. If battery is charging, the lamp and buzzer should go off a few seconds af- ter the engine is started. Engine low oil pressure Audible/Visual.

  • Page 58: Getting The Machine Moving

    Operation Getting the Machine Moving Getting the Machine Moving General DANGER Only reverse at slow speeds. Look behind while reversing and be aware of bystanders in the vicinity of the machine. WARNING If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected.

  • Page 59: General

    Loose ground, steering of the machine, vibration on, machine speed and changes to the centre of gravity could cause the machine to tip at smaller slope angles than those specified here. Figure 26. A Maximum Slope Angle Table 6. Model Maximum Slope Angle CT260-100 18 ° CT260-120 22 ° CT160-80 16 ° CT160-100 20 ° 9831/7750-1...

  • Page 60: Working With The Drum

    Operation Working with the Drum Working with the Drum Working without Vibration DANGER Only reverse at slow speeds. Look behind while reversing and be aware of bystanders in the vicinity of the machine. WARNING Before reversing, make sure the area behind the machine is clear of other persons. If this is not observed, injury or death can result.

  • Page 61: Sprinklers And Scrapers

    Operation Working with the Drum Make the first pass for pressing a bituminous layer without vibration. Make the last pass for smoothing the bituminous layer without vibration. 1. Set the throttle control lever to the maximum operation position. Do not adjust the speed of the machine with the throttle control lever but with the drive lever.
  • Page 62 Operation Working with the Drum Figure 29. Table 7. Item Switch Position On Time (sec) Off Time (sec) Off position 100 % Low position 33 % ( 4 s) 67 % ( 8 s) Medium position 50 % ( 6 s) 50 % ( 6 s) Maximum position 100 %...

  • Page 63: Power Sockets

    Operation Power Sockets Power Sockets Auxiliary Power Socket Your machine may be installed with one or more 12 V auxiliary power sockets, which can be used for 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.

  • Page 64: Fire Extinguisher

    Operation Fire Extinguisher Fire Extinguisher General The fire extinguisher cab be stowed in a bracket on the ROPS (Roll-Over Protective Structure) frame at the back of operator seat. Keep the fire extinguisher in the bracket until you need to use it. Refer to: Main Component Locations (Page 9).

  • Page 65: Moving A Disabled Machine

    The booster (slave) supply must not be higher than that of the machine. Using a higher voltage supply will damage your machine's electrical system. If you do not know the voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump-start the 9831/7750-1...

  • Page 66: Retrieval

    Operation Moving a Disabled Machine engine until you are sure of the voltage of the booster (slave) supply. The negative (-) terminal on the battery is connected to frame earth. 1. Set all switches in the cab to their off positions. 2.
  • Page 67 Operation Moving a Disabled Machine Figure 31. A Front tow eye Figure 32. B Rear tow eye WARNING! Always make sure the articulation lock has been removed before attempting to drive the machine. The machine cannot be steered with the articulation lock installed. 3.
  • Page 68 Operation Moving a Disabled Machine Figure 33. 3. Tighten the 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 passages internally before towing the machine.
  • Page 69 Operation Moving a Disabled Machine Machine installed with MK04 Drive Motors- CT160 The maximum permissible towing force is 28 kN. 1. Remove the mechanical stopper. Figure 36. A Mechanical stopper 2. Press the screw spring to engage the park brake piston internal thread.

  • Page 70: Lifting The Machine

    7. Attach the lifting chain to the single lifting point on the machine. Refer to Figure 39. Figure 39. A Lifting label 8. Alternatively, machine can be lift using the lift points provided on the carrier plate. Contact your local JCB dealer for more information. Refer to Figure 40. 9831/7750-1...
  • Page 71 Operation Lifting the Machine Figure 40. A Lifting label 9. The correct lift-point position is identified 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 length of the slings.

  • Page 72: Transporting The Machine

    Operation Transporting the Machine Transporting the Machine General WARNING The safe transit of the load is the responsibility of the transport contractor and driver. Any machine, attachments or parts that may move during transit must be adequately secured. CAUTION Before moving the machine onto the trailer, make sure that the trailer and ramp are free from oil, grease and ice.
  • Page 73 Operation Transporting the Machine Figure 41. A Tie down decal 2. Install the articulation 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 the tie down points anchor the machine to the trailer with chains.
  • Page 74 Operation Transporting the Machine Figure 42. X 35 ° Y 45 ° 5. Measure the maximum height of the machine from the ground. Make sure the 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.
  • Page 75 Operation Transporting the Machine Figure 44. 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. Make sure that lock pin and cotter pin are installed correctly.

  • Page 76: Operating Environment

    7. Protect the machine when its not in use. Park the machine inside a building or cover it with a tarpaulin. 8. Install a cold weather starting aid. In very low temperatures as specified, additional starting aids may be needed. Examples are fuel, oil and coolant heaters. Ask your JCB dealer for advice. Temperature: -18 °C ( -0.4 °F) 9.

  • Page 77: Operating In High Temperatures

    Operation Operating Environment Operating in High Temperatures In high temperature situations, take the following precautions to prevent possible damage to the machine. 1. Use the correct viscosity engine lubricating oil. 2. Use the correct coolant mixture. 3. Check the coolant system regularly, keep the coolant at the correct level. Make sure there are no leaks. 4.

  • Page 78: Refuelling

    Do not use fuel to clean the machine. When filling with fuel, choose a well aired and ventilated area. Notice: Consult your fuel supplier or JCB dealer about the suitability of any fuel you are unsure of. Filling the Tank WARNING Do not use petrol in this machine.

  • Page 79: Preservation And Storage

    Preservation and Storage Cleaning Preservation and Storage Cleaning General WARNING When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions. WARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when installed).

  • Page 80: Preparation

    Preservation and Storage Cleaning Preparation 1. Make the machine safe. Refer to: Maintenance 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.

  • Page 81: Checking For Damage

    Preservation and Storage Checking For Damage Checking For Damage General Refer to the individual condition checks throughout the Maintenance section. Refer to: Maintenance Schedules (Page 83). 9831/7750-1...

  • Page 82: Storage

    Preservation and Storage Storage Storage General If the machine will not be used for an extended period, you must store the machine correctly. If you prepare the machine carefully and apply on-going care you can prevent deterioration and damage to the machine while it is in storage.

  • Page 83: Take Out Of Storage

    Preservation and Storage Storage 3. Examine all fluid levels. If necessary, add more fuel. 4. Install a charged battery. 5. Start the engine. 6. Operate the hydraulic controls. Make sure that the hydraulic functions operate correctly. 7. Prepare the machine for storage. Take out of Storage 1.

  • Page 84: Security

    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 and will offer it as a factory option across the range.

  • Page 85: Maintenance

    JCB trained specialist competent person. JCB dealer service engineers have been trained by JCB to do such specialist tasks, and are equipped with the necessary special tools and test equipment to do such tasks, thoroughly, safely, accurately and efficiently.

  • Page 86: Service/Maintenance Agreements

    If you use non-genuine JCB parts or consumables, then you can compromise the health and safety of the operator and cause machine failure. A parts book for your machine is available from your JCB dealer. The parts book will help you identify parts and order them from your JCB dealer.

  • Page 87: Maintenance Safety

    The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating accumulators, the system pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may cause serious injury or death.

  • Page 88: Fluids And Lubricants

    Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton®, FluorelTM and Technoflon®. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. This acid can severely burn. New fluoroelastomeric components at ambient temperature require no special safety precautions.
  • Page 89 If accidentally spilled on to skin, it must be washed off immediately. Protective clothing and eye protection must be worn when handling antifreeze. Hygiene JCB lubricants are not a health risk when used correctly for their intended purposes. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.
  • Page 90 Maintenance Maintenance Safety Here are precautions to protect your health when handling used engine oil: • Avoid prolonged, excessive or repeated skin contact with used oil • Apply a barrier cream to the skin before handling used oil. Note the following when removing engine oil from skin: •...
  • Page 91 Maintenance Maintenance Safety Figure 47. 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 instructions 9831/7750-1...
  • Page 92 When the battery reaches the end of its usual life it must be removed from the machine and recycled in an approved way in accordance with local environmental regulations. This service is usually operated by battery vendors. Machine users that cannot find a suitable battery recycling facility should contact their JCB dealer for assistance.

  • Page 93: Maintenance Schedules

    The 10 h and 50 h service tasks can be done by the operator. Details of how to do the service tasks are given in this manual and the schedules include a page reference. The remaining service tasks must be done by your JCB dealer. The services must be done at either the hourly interval or the calendar equivalent, whichever occurs first.

  • Page 94: Pre-Start Cold Checks, Service Points And Fluid Levels

    Maintenance Maintenance Schedules Interval ( h) Calendar Equivalent 1000 Yearly 1500 Eighteen months 2000 Two years Pre-start Cold Checks, Service Points and Fluid Levels Table 11. Component Task 1,000 2,000 Engine Oil Level Check Change Oil and Filter (1, 2, 3, 5) Coolant Quality/ level Check Coolant or Oil Leaks...

  • Page 95: Functional Tests And Final Inspection

    Maintenance Maintenance Schedules Component Task 500 1,000 2,000 Lubricate Drum bearing Check/ Change(if necessary) Drum Distance Spacers / Buffer Articulation Joint Check Steering Cylinder Bolts Check Hydraulics Hydraulic System Check (Leaks) Check (Level) Replace Oil Reservoir Clean Replace Oil Filter Hoses - Damage or Leaks Check Steering Rams - External Leaks...
  • Page 96 Maintenance Maintenance Schedules Item Operation 10 h 50 h 500 h 1,000 h 2,000 h 100 h Exhaust system security Check Air Inlet system security Check Throttle system and Check control cables Transmission and steering. Forward/ Reverse oper- Check ation Vibration operation Check Steer circuit pressure...

  • Page 97: Maintenance Positions

    Maintenance Maintenance Positions Maintenance Positions General 1. Park the machine on solid, level ground. 2. Install the articulation lock. 3. Move the drive lever to the neutral position. 4. Stop the engine and remove the ignition key. 5. Wait for the specified time to dissipate any residual hydraulic pressure. Duration: 30 s 6.

  • Page 98: Service Points

    Maintenance Service Points Service Points General Figure 49. 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 Water separator/fuel filter K Radiator L Primary fuses M Fuel filter (inline)
  • Page 99 Maintenance Service Points Figure 50. A Water tank filler cap B Water level indicator C Water filter D Hydraulic filter E Coolant recovery bottle 9831/7750-1...

  • Page 100: Access Apertures

    Maintenance Access Apertures Access Apertures Engine Compartment Cover Most of the service points can be access through the engine compartment cover. Open 1. Make the machine safe. 2. Park the machine on firm level ground. 3. Apply the parking brake (if installed). 4.
  • Page 101 Maintenance Access Apertures 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 right side of engine cover. Refer to Figure 51. 9831/7750-1...

  • Page 102: General

    Maintenance Tools Tools General All tools must be kept in the tool bag when not in use. Your tool bag contains allen keys, tommy bar, and spanner. Following tools are recommended for the routine maintenance: 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).

  • Page 103: Body And Framework

    Maintenance Body and Framework Body and Framework General Check (Condition) 1. Make sure that all of the guards and protective devices are in position, secured by their locking devices and free from damage. 2. Inspect all of the steelwork for damage. Include the following: 2.1.

  • Page 104: Operator Station

    Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS/FOGS certification. A failure to adhere to these precautions can cause death or injury to the operator. For assistance, contact your JCB dealer. 1. Make the machine safe. Refer to: Maintenance Positions (Page 87).

  • Page 105: Safety Equipment

    Press the emergency stop switch on the steering column and the engine will be stopped. If any controls are still functional, contact your local JCB dealer to rectify the faults immediately. Do not use the machine until the fault is rectified.

  • Page 106: Engine

    3. Check the engine and the area below for oil leaks. 4. Close the engine cover (if applicable). 5. If necessary, contact your JCB dealer. Check (Level) WARNING Never check the oil level or add oil with the engine running. Be careful of hot lubricating oil.
  • Page 107 Maintenance Engine Refer to: Fluids, Lubricants and Capacities (Page 135). 8.3. Replace the dipstick. 8.4. Remove the dipstick. 8.5. Check the oil level, if necessary add more oil. 8.6. Replace the dipstick 8.7. Replace the filler cap. 9. Close and secure the engine cover (if applicable). Replace WARNING Before draining the oil make sure you loosen the oil filler plug or the breather (if installed), and wait until the internal pressure is completely released.

  • Page 108: Drive Belt

    Maintenance Engine Replace the Oil Filter Figure 53. A Filter canister 1. Make the machine safe. Refer to: Maintenance (Page 75). 2. Get the access to the engine compartment. Refer to: Engine Compartment Cover (Page 90). 3. Drain the oil. 3.1.
  • Page 109 Maintenance Engine WARNING Do not try to turn the engine by pulling the fan or fan belt. This could cause injury or premature component failure. CAUTION Make sure the engine cannot be started. Disconnect the battery before doing this job, otherwise you could be injured.

  • Page 110: Exhaust

    Maintenance Engine Figure 55. A Drive belt adjustment bolt 1. Make the machine safe. 2. Open the engine compartment cover. 3. Loosen the alternator mounting bolts. 4. Remove the alternator drive belt adjustment bolt and the protective cover. 5. Remove the alternator drive belt. 6.

  • Page 111: Air Filter

    Air Filter Air Filter General Check (Condition) Notice: Do not modify or install non JCB approved components to the engine induction system, otherwise the engine emissions will be compromised. 1. Make the machine safe. 2. Get access to induction system.

  • Page 112: Dust Valve

    14. Push the cover firmly into position and make sure it is secured. 15. Check all hoses for condition and tightness. 15.1. Never try to replace hose with any other pipe/ hose. The machine can catch fire if incorrect parts are fitted. Contact JCB service dealer for details. Dust Valve Check (Condition) •...

  • Page 113: Fuel System

    Maintenance Fuel System Fuel System General Bleed WARNING Do not open the high pressure fuel system with the engine running. Engine 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).

  • Page 114: Tank

    4.1. If the engine continues to run 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.

  • Page 115: Pre-Filter Element

    Maintenance Fuel System Draining Fuel Tank 1. Make the machine safe. Refer to: Maintenance Positions (Page 87). 2. Remove the fuel cap on the fuel tank. Refer to Figure 59. 3. Put a suitable container below the drain plug on the right hand side of the rear chassis. Do not confuse with the hydraulic tank drain plug.

  • Page 116: Fuel Filter

    Maintenance Fuel System 6. Replace the pre-filter. Refer to Figure 60. 7. Make sure that the filter is fitted the correct way round. There may be an arrow on the filter body to indicate the direction of flow. 8. Tighten the pipe clips. Do not overtighten the pipe clips. 9.

  • Page 117: Water Separator

    Maintenance Fuel System 4. Drain the trapped water from the bowl. 5. Remove the bowl and electrical connection (if any). 6. Place a suitable container to catch any fuel. Remove the filter element. Refer to Figure 61. 7. Clean around the filter base seal area. 8.
  • Page 118 Maintenance Fuel System Figure 62. A Bowl B Tap 9831/7750-1...

  • Page 119: Cooling System

    Refer to: Maintenance Positions (Page 87). 2. Get access to the cooling pack. Refer to: Access Apertures (Page 90). 3. Check the cooling system for leaks. 4. If necessary, contact your JCB dealer. Coolant Check (Condition) Refer to: Coolant (Page 139).

  • Page 120: Cooling Pack

    Maintenance Cooling System Figure 63. A Radiator cap B Bottom radiator hose C Drain valve 1. Make the machine safe. Refer to: Maintenance Positions (Page 87). 2. Open the engine compartment cover. 3. Carefully remove the radiator cap. Let any pressure escape before removing the cap. Refer to Figure 63. 4.
  • Page 121 Maintenance Cooling System 2. Let the engine cool. 3. Get access to the cooling pack. Refer to: Access Apertures (Page 90). 4. If necessary, use a soft bristle brush or compressed air to remove all debris from the cooling pack. Check (Condition) 1.

  • Page 122: Park Brake

    3. Engage the park brake. Machine should not move. If the machine moved during the test, drive the machine to a suitable flat location and contact your JCB dealer to inspect the park brake. Do not use the machine until the fault is rectified.

  • Page 123: Drum

    Maintenance Drum Drum Scraper Check (Condition) Smooth Drum Scraper The scrapers are designed for use when rolling asphalt and in conjunction with the sprinkler system. If earth is being compacted the scrapers should be released from the drum. 1. Make the machine safe. Refer to: Maintenance Positions (Page 87).

  • Page 124: Sprinkler System

    Maintenance Drum Figure 64. A Front side scraper B Rear side scraper C Bottom side scraper D Drum E Fasteners F Scraper Clean Clean Make the machine safe. Refer to: Maintenance Positions (Page 87). Remove the dirt and debris with the clean water. Sprinkler System Water Tank Check (Level)
  • Page 125 Maintenance Drum 1. Make the machine safe. 2. Check the water level indicator gauge, if necessary fill the tank through filler cap. Figure 65. A Water level indicator gauge 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.
  • Page 126 Maintenance Drum Figure 66. A Filler cap B Drain cap C O-ring Cleaning of Sprinkler Pipe and Nozzle To clean the sprinkler system, proceed as follows: 1. Make the machine safe. Refer to: Maintenance Positions (Page 87). 2. Drain the water tank. 3.
  • Page 127 Maintenance Drum Figure 67. A Nozzle B End 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.
  • Page 128 Maintenance Drum Figure 69. A Lever 4. Drain the trapped water from hoses. 5. Connect the hoses. Draining at Water Sprinkler Coupler 1. Make the machine safe. Refer to: General (Page 87). 2. Get access to the water sprinkler coupler. Coupler is located between articulation joint. Figure 70.
  • Page 129 Maintenance Drum 1. Make the machine safe. Refer to: Maintenance Positions (Page 87). 2. Drain the water tank. Refer to: Clean (Page 115). 3. Open the panel to get access to the filter element. Refer to Figure 71. 4. Remove the water filter bowl. 5.

  • Page 130: Vibration System

    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 reassembly of the drum shaft. During re-assembly use only JCB Special Grease. The lifetime grease installed from the factory is brown in colour. JCB Special Grease is blue in colour. 9831/7750-1...

  • Page 131: Hydraulic System

    Contact your JCB dealer immediately. 1. Make the machine safe. 2. Open the access covers. 3. Check the hydraulic hoses for damage. 4. Close the access covers. 5. If necessary, contact your JCB dealer. Check (Level) 1. Make the machine safe. 9831/7750-1...
  • Page 132 2. Look at the hydraulic fluid in the sight tube. If the hydraulic fluid is cloudy, water or air is in the system. Water or air in the system can damage the hydraulic pump. Contact your JCB dealer if the hydraulic fluid is cloudy.

  • Page 133: Cylinders / Rams

    Extend each ram fully, one at a time and visually examine for score marks, dents, leaks or similar defects. Make the machine safe before inspecting each ram. If a ram piston appears defective, contact your service engineer or JCB dealer. 9831/7750-1...

  • Page 134: Electrical System

    Maintenance Electrical System Electrical System General Check (Operation) Make sure all of the electrical equipment operates correctly, for example: • Switches • Warning lights • Beacon • Alarms • Horn • Hourmeter/display • Battery • Lights All defective equipment must be repaired before the machine is used. Check (Condition) DANGER Batteries give off an explosive gas.

  • Page 135: Battery

    Maintenance Electrical System Battery Clean WARNING Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work. If it happens you can get burned.

  • Page 136: Battery Isolator

    Notice: Do not isolate the machine electrics when the engine is running, this may cause damage to the machine electrics. 1. Isolate the machine electrics. 2. Make sure that the machine electrics are isolated. A defective isolator must be repaired before the machine is used. For more information, contact your JCB dealer. Fuses Replace Secondary Fuses- Steering Column Notice: Always replace fuses with ones of correct ampere rating to avoid electrical system damage.

  • Page 137: Relays

    Maintenance Electrical System Figure 75. A Panel B Screws Primary Fuses- Engine Compartment 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. Refer to Figure 76. To get accesses to the relays: 1.
  • Page 138 Maintenance Electrical System Figure 76. A Panel B Screws 9831/7750-1...

  • Page 139: Technical Data

    Technical Data Static Dimensions Technical Data Static Dimensions Dimensions For: CT160 ..........................Page 129 For: CT260 ..........................Page 130 (For: CT160) Figure 77. Table 14. Item Description CT160-80 CT160-100 Wheelbase 1,560 mm 1,560 mm Overall width 960 mm 1,090 mm...

  • Page 140: Weights

    2,490 mm 2,490 mm Drum thickness 12 mm 12 mm 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...

  • Page 141: Performance Dimensions

    Technical Data Performance Dimensions Performance Dimensions General For: CT160 ..........................Page 131 For: CT260 ..........................Page 131 (For: CT160) Table 18. Description CT160-80 CT160-100 Steering angle 33 ° 33 ° Oscillation angle 8 ° 8 ° Inner turning radius 2,160 mm...

  • Page 142: Noise Emissions

    The noise data values shown only apply to CE marked machines. For information relating to this machine when used with other JCB approved attachments, please refer to the literature accompanying the attachments. Table 22. Definition of terms...

  • Page 143: Vibration Emissions

    Technical Data Vibration Emissions Vibration Emissions General To assist in compliance with the European Directive 2002/44/EC, the duty specific vibration emission values for this machine type have been provided on the following page(s) and may be used for the assessment of risks to exposure from vibration.
  • Page 144 Technical Data Vibration Emissions The whole-body vibration emission determined in accordance with ISO 2631-1:1997 for this machine type is 0.69 m/s² normalised to an 8 h reference period [A(8)] and based upon a test cycle defined in SAE J116. Hand-arm vibration determined in accordance with dynamic test conditions defined in ISO 5349-2: 2001 does not exceed 2.5 m/s².

  • Page 145: Fluids, Lubricants And Capacities

    Technical Data Fluids, Lubricants and Capacities Fluids, Lubricants and Capacities General For: CT160 ..........................Page 135 For: CT260 ..........................Page 135 (For: CT160) Table 25. Item Capacity Fluid/Lubricant JCB Part Num- Container Size International Specification Fuel Tank 33 L Diesel...
  • Page 146 Technical Data Fluids, Lubricants and Capacities • US EPA : United States Environmental Protection Agency • ASTEM : American Society of Testing and Materials • US EPA : United States Environmental Protection Agency Do not use kerosene in Kubota diesel engines. Requirements for Diesel Fuel 1.
  • Page 147 Technical Data Fluids, Lubricants and Capacities 5.2. Any unvaporized oil will cause soot and smoke, and eventually contaminate the oil. Fuel with good volatility burns more completely, minimizing fuel combustion, lowering the exhaust gas temperature and does not generate black smoke. 6.
  • Page 148 Technical Data Fluids, Lubricants and Capacities Table 27. Property Flash Point Distillation Pour Point Mass % of Kinemat- Sulfuric Cetane Class of (90% Distil- Residual ic Viscosi- Mass % Fuel lation Tem- Carbon in ty 30 °C (86 perature) 10% Resid- °F) mm2/s ual Oil (cSt)

  • Page 149: Coolant

    Technical Data Fluids, Lubricants and Capacities 1. Only the fuel that contains 5% or lower volume mixing ratio of 100% BDF (B100) in the mineral diesel fuel can be used. (B5) 2. The mineral diesel fuel shall be according to the newest edition of EN590 (Europe) or ASTMD975 (USA), while the B100 to be mixed shall be according to the newest edition of EN14214 (Europe) or ASTMD6751 (USA) standards.
  • Page 150 The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion. The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below. Table 29. Concentration...

  • Page 151: Torque Values

    22 N·m (Page 113). 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-Over Protective Structure) Mounting 259 N·m, 275 N·m (Loctite) bolts ROPS hinge bolts 100 N·m...

  • Page 152: Electrical System

    Technical Data Electrical System Electrical System General Table 33. Item Specification Battery voltage/system voltage 12 V Battery 62Ah and 610 CCA Battery dimension (length x width x height) 240 mm x 175 mm x 175 mm Fuses Primary Fuses Figure 79. Table 34.
  • Page 153 Technical Data Electrical System Secondary Fuses Figure 80. Table 35. Fuse No. Circuits Protected Rating Ignition relay Emergency stop 7.5 A Alternator Neutral parkbrake 7.5 A Instrument panel 9831/7750-1...

  • Page 154: Relays

    Technical Data Electrical System Fuse No. Circuits Protected Rating Beacon 15 A Front worklight Vibration MECU (Machine Electronic Control Unit)Ignition FA10 Livelink ignition Reverse alarm Hazard Diagnostic/Livelink MECU 20 A Spare Horn Rear worklight 15 A Front worklight LED (Light Emitting Diode) 7.5 A Rear worklight LED 7.5 A...
  • Page 155 Technical Data Electrical System Figure 81. Table 36. Relay No. Description Starter relay 2 s timer relay Ignition relay Neutral relay/Front worklight relay Fuse relay/Reverse relay 9831/7750-1...

  • Page 156: Engine

    Technical Data Engine Engine General For: CT160 ..........................Page 146 For: CT260 ..........................Page 146 (For: CT160) Table 37. Data Description Make Kubota Model D1005-E4B-EU Gross power rating at 2550 RPM (Revolu- 14.5 kW tions Per Minute) Engine management Mechanical...

  • Page 157: Declaration Of Conformity

    Technical Data Declaration of Conformity Declaration of Conformity General A completed 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 of Conformity and a summary of the information that can appear is provided.

  • Page 158: Data

    Technical Data Declaration of Conformity Data Figure 82. Table 39. JCB Vibromax GmbH, Graf-Zeppelin-Str. 16, 51147 Cologne, Germany. Compaction Machines. 9831/7750-1...
  • Page 159 Refer to: Model and Serial Number (Page 1). Refer to: Machine (Page 11). ISO (International Organization for Standardization) 20474 part 1 and part 2- 2013 Engineering Manager, JCB Vibromax GmbH, Graf-Zeppelin-Str. 16, 51147 Cologne, Germany. Group NVH Specialist at JCB World Headquarters Rocester. Annex VI Procedure 1.

  • Page 160: Warranty Information

    Technical Data Warranty Information Warranty Information Service Record Sheet Table 40. Signature and stamp Date Annual Insurance (Yes) Hours Figure 83. Installation Checklist Figure 84. 500h/6 Month Figure 85. 1000h/12 Month 9831/7750-1...
  • Page 161 Technical Data Warranty Information Figure 86. 1500h/18 Month Figure 87. 2000h/24 Month Figure 88. 2500h/30 Month Figure 89. 3000h/36 Month 9831/7750-1...
  • Page 162 Technical Data Warranty Information Figure 90. 3500h/42 Month Figure 91. 4000h/48 Month Figure 92. 4500h/54 Month Figure 93. 5000h/60Month 9831/7750-1...
  • Page 163 Technical Data Warranty Information Figure 94. 5500h/66 Month Figure 95. 6000h/72 Month Figure 96. 6500h/78 Month Figure 97. 7000h/84 Month 9831/7750-1...
  • Page 164 Technical Data Warranty Information Figure 98. 7500h/90 Month Figure 99. 8000h/96 Month Figure 100. 8500h/102 Month Figure 101. 9000h/108 Month 9831/7750-1...
  • Page 165 Technical Data Warranty Information Figure 102. 9500h/114 Month Figure 103. 10000h/120 Month Figure 104. 10500h/126 Month Figure 105. 11000h/132 Month 9831/7750-1...
  • Page 166 Notes: 9831/7750-1...

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