jcb CT160 User manual

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

OPERATOR'S
MANUAL
TANDEM ROLLER
CT160, CT260
EN - 9831/7750 - ISSUE 1 - 06/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2018 © 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.
Machine Delivery and Installation
Even if you have operated this type of equipment
before, it is very important that your new machines
operations and functions are explained to you by
a JCB Dealer Representative following delivery of
your new machine.
Following the installation you will know how to gain
maximum productivity and performance from your
new product.
Please contact your local JCB dealer if the
Installation Form (included in this manual) has not
yet been completed with you.
Your local JCB Dealer is

9831/7750-1
Notes:

Table of Contents
i 9831/7750-1 i
Contents Page No.
Acronyms Glossary ........................................................................................................................................ vi
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 .................................................................................................................................... 3
General Safety ...................................................................................................................................... 4
Clothing and Personal Protective Equipment (PPE) ............................................................................ 5
About the Product
Introduction
General .................................................................................................................................................. 7
Name 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
Operator Protective Structure ............................................................................................................. 12
Safety Labels
General ................................................................................................................................................ 14
Safety Label Identification ................................................................................................................... 14
Operator Station
Component Locations ......................................................................................................................... 18
Interior Switches
Ignition Switch ..................................................................................................................................... 19
Console Switches
General ................................................................................................................................................ 20
Road Lights ......................................................................................................................................... 20
Direction Indicators ............................................................................................................................. 20
Hazard Warning Lights ....................................................................................................................... 20
Front Work Lights ............................................................................................................................... 21
Rear Work Lights ................................................................................................................................ 21
Horn .................................................................................................................................................... 21
Beacon ................................................................................................................................................ 21
Automatic Vibration ............................................................................................................................. 21
Front Vibration .................................................................................................................................... 21
Rear Vibration ..................................................................................................................................... 21

Table of Contents
ii 9831/7750-1 ii
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 ................................................................................................................................................ 33
Operator Seat
General ................................................................................................................................................ 34
Basic Seat ........................................................................................................................................... 34
Seat Belt
General ................................................................................................................................................ 36
Inertia Reel Seat 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
Instruments
Instrument Panel ................................................................................................................................. 46
Getting the Machine Moving
General ................................................................................................................................................ 48
Slopes
General ................................................................................................................................................ 49
Working with the Drum
Working without Vibration ................................................................................................................... 50
Working with Vibration ........................................................................................................................ 50
Sprinklers and Scrapers ..................................................................................................................... 51
Power Sockets
Auxiliary Power Socket ....................................................................................................................... 53
Fire Extinguisher
General ................................................................................................................................................ 54
Moving a Disabled Machine
General ................................................................................................................................................ 55
Jump-Starting the Engine ................................................................................................................... 55
Retrieval .............................................................................................................................................. 56
Lifting the Machine
General ................................................................................................................................................ 60

Table of Contents
iii 9831/7750-1 iii
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 ................................................................................................................................................ 69
Preparation .......................................................................................................................................... 70
Checking For Damage
General ................................................................................................................................................ 71
Storage
General ................................................................................................................................................ 72
Put into Storage .................................................................................................................................. 72
During Storage .................................................................................................................................... 72
Take out of 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 Agreements ...................................................................................................... 76
Initial Service and Inspection .............................................................................................................. 76
Obtaining Spare Parts ........................................................................................................................ 76
Maintenance Safety
General ................................................................................................................................................ 77
Fluids and Lubricants ......................................................................................................................... 78
Maintenance Schedules
General ................................................................................................................................................ 83
How to Use the Maintenance Schedules ........................................................................................... 83
Maintenance Intervals ......................................................................................................................... 83
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................... 84
Functional Tests and Final Inspection ................................................................................................ 85
Maintenance Positions
General ................................................................................................................................................ 87
Service Points
General ................................................................................................................................................ 88
Access Apertures
Engine Compartment Cover ............................................................................................................... 90
Tools
General ................................................................................................................................................ 92

Table of Contents
iv 9831/7750-1 iv
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 ............................................................................................................................................. 100
Air Filter
General ............................................................................................................................................. 101
Outer Element .................................................................................................................................. 101
Dust 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
Sprinkler System .............................................................................................................................. 114
Vibration System
General .............................................................................................................................................. 120
Hydraulic System
General ............................................................................................................................................. 121
Oil ...................................................................................................................................................... 121
Cylinders / Rams .............................................................................................................................. 123
Electrical System
General ............................................................................................................................................. 124
Battery ............................................................................................................................................... 125
Battery Isolator ................................................................................................................................. 126
Fuses ................................................................................................................................................ 126
Relays ............................................................................................................................................... 127
Technical Data
Static Dimensions
Dimensions ........................................................................................................................................ 129
Weights ............................................................................................................................................. 130
Performance Dimensions
General .............................................................................................................................................. 131

Table of Contents
v 9831/7750-1 v
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 .............................................................................................................................................. 142
Fuses ................................................................................................................................................. 142
Relays ............................................................................................................................................... 144
Engine
General .............................................................................................................................................. 146
Declaration of Conformity
General .............................................................................................................................................. 147
Data ................................................................................................................................................... 148
Warranty Information
Service Record Sheet ....................................................................................................................... 150

Table of Contents
vi 9831/7750-1 vi
Acronyms Glossary
CECE Committee for European Construction Equipment
CESAR Construction Equipment 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 Control Unit
PIN Product Identification Number
RMS Root Mean Square
ROPS Roll-Over Protective Structure
RPM Revolutions Per Minute

Introduction
About this Manual
1 9831/7750-1 1
Introduction
About this Manual
Model and Serial Number
This manual provides information for the following model(s) in the JCB machine range:
Model From: To:
CT160 2556201
CT260 2556350
Using the Manual
This operator's manual is arranged to give you a good understanding of the machine and its safe operation.
It also contains maintenance and technical data.
Read this manual from the front to the back before you use the machine for the first time, even if you have used
machines of a similar/same type before as the technical specification, systems and controls of the machine
may have changed. 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.
The 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 operators.
The illustrations in this manual are for guidance only. Where the machines are different, the text and or the
illustration will specify.
The manufacturer's policy is one of continuous improvement. The right to change the specification of the
machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur
between specifications of the machine and the descriptions contained in this manual.
All of the optional equipment included in this manual may not be available in all territories
Left-Hand Side, Right-Hand Side
In this manual, 'left' and 'right' mean your left and right when you are seated correctly in the machine.
Figure 1.
A
B
ARight BLeft
Cab/Canopy
This manual frequently makes references to the cab. For example, 'do not operate the machine without an
operator's manual in the cab'. These statements also apply to canopy build machines.

Introduction
About this Manual
2 9831/7750-1 2
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).

Introduction
Safety
3 9831/7750-1 3
Safety
Safety - Yours and Others
All machinery can be hazardous. When a machine is correctly operated and maintained, it is a safe machine
to work with. When it is carelessly operated or poorly maintained it can become a danger to you (the operator)
and others.
In this manual and on the machine you will find warning messages, you must read and understand them. They
inform you of potential hazards and how to avoid them. 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.
Do not work with the machine until you are sure that you can control it.
Do not start any work until 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 safe.
Safety Warnings
In this manual there are safety notices. Each notice starts with a signal word. The signal word meanings are
given below.
The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
The signal word 'WARNING' indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
The signal word 'CAUTION' indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
The signal word 'Notice' indicates a hazardous situation which, if not avoided, could result in machine damage.
The safety alert system symbol (shown) also helps to identify important safety messages in this manual. When
you see this symbol your safety is involved, carefully read the message that follows.
Figure 2. The safety alert system symbol

Introduction
Safety
4 9831/7750-1 4
General Safety
Training
To operate the machine safely you must know the machine and have the skill to use it. You must abide by
all relevant laws, health and safety regulations that apply to the country you are operating in. The operator's
manual instructs you on the machine, its controls and its safe operation; it is not a training manual. Ensure that
you receive the correct training before operating any machinery. Failing to do so will result in incorrect operation
of the machine and you will be putting yourself and others at risk. In some markets, and for work on certain
jobsites, you may be required to have been trained and assessed in accordance with an operator competence
scheme. Make sure that you and your machine comply with relevant local laws and jobsite requirements – it
is your responsibility.
Care and Alertness
All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be
alert for hazards.
Clothing
You can be injured if you do not wear the correct clothing. Loose clothing can get caught in the machinery.
Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and
personal jewellery.
Alcohol and Drugs
It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume
alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines
which 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 mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such
an area could cause an explosion or fire resulting in death or serious injury.
Switch off and do not use your mobile phone when refuelling the machine.
Lifting Equipment
You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all local regulations.
Raised Equipment
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which
is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control
is operated (even with the engine stopped).
Make sure that no-one goes near the machine while you install or remove the mechanical device.
Raised Machine
Never position yourself or any part of your body under a raised machine which is not correctly supported. If the
machine moves unexpectedly you could become trapped and suffer serious injury or be killed.
Lightning
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.

Introduction
Safety
5 9831/7750-1 5
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.

Notes:
6 9831/7750-1 6

About the Product
Introduction
7 9831/7750-1 7
About the Product
Introduction
General
Before you start using the machine, you must know how the machine operates. Use this part of the manual
to identify each control lever, switch, gauge, button and pedal. Do not guess, if there is anything you do not
understand, ask your JCB dealer.
Name and Address of the Manufacturer
JCB India Limited, Heavyline - India Business Unit, Talegaon, Pune - 410507, India.
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. Even in the absence
of defined requirements for the product owner, JCB recommend that the product compliance be maintained
to ensure safety of the operator and exposed persons and to ensure the correct environmental performance.
Your product must not be altered in any way which could affect or invalidate any of these requirements. For
advice consult your JCB dealer.
For its compliance as a new product, your JCB and 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/region in which the product was first sold to the extent that the
laws and regulations required them.
Re-sales and import/export of products across territories with different laws and regulations can cause new
requirements to become relevant for which the product was not originally designed or specified. In some cases,
pre owned products irrespective of their age are considered new for the purposes of compliance and may be
required to meet the latest requirements which could present an insurmountable barrier to their sale/use.
Despite the presence of any compliance related marking's on the product and components, you should not
assume that compliance in a new market will be possible. In many cases it is the person responsible for import
of a pre owned product into a market that becomes responsible for compliance and who is also considered
the manufacturer.
JCB may be unable to support any product compliance related enquiry for a product which has been moved out
of the legislative country/region where it was first sold, and in particular where a product specification change
or additional certification would have been required in order for the product to be in compliance.

About the Product
Description
8 9831/7750-1 8
Description
General
The JCB Tandem roller machine is a self-propelled, vibratory tandem drum rollers which is powered by a 3
cylinder, diesel engine.
The machine is designed for compacting soil types ranging from stones to silty sand, or asphalt construction
materials when rolling over the subgrade in a forward or reverse direction (with or without vibration).
Four scrapers (two on each drum) are mounted on the machine and sprinkler bars are fitted to the front and
rear drums. The spray nozzles and the bar end caps are removable for easy cleaning.
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. The drive motor hoses are protected inside steel frame plates.
A hydraulic system is also used to turn the machine front and rear vibratory shafts. Designed with an overturning
weight system on the vibratory shafts, the machine has selectable front drum, rear drum or both drums vibration.
The machine operates at a vibratory frequency of between 50 and 66 Hz and a nominal amplitude of 0.5 mm.
The machine has an articulated steering system giving a tight turning radius.
Intended Use
The machine is intended to be used in normal environmental conditions as described in this manual. Normally
the machine is designed only for compacting beds of earth or bituminous construction when running over the
subgrade in the forward or reverse direction, with or without 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 to the standard Proctor test DIN 18127.
Application also include road and pavement construction, sub-soil compaction and similar applications.
Soil of fine-grained or soils having higher water contents require a qualified trial compaction.
Use for which it is not intended includes, in particular:
• It is not permissible to drive on a high gradient which is greater than the permissible gradient of the
machine. The permissible gradient is subgrade gradient .
• Before driving on a gradient, it is still necessary to check, at the start of the gradient as seen in the
intended driving direction, whether there is adequate frictional engagement between the drums and the
roadway, i.e. whether, on the gradient, the machine can be driven uphill with medium acceleration and
can be braked downhill.
• It is not permissible to drive on a gradient if the drums skid during braking.
• Vibration at standstill.
• Vibrating travel on blocks, rocks, concrete or frozen soil.
• Vibrating travel in the vicinity of buildings if this could damage parts or installations; This should normally
be assumed for vibrational speeds of 8 mm/s or more at the endangered parts.
• Earth-moving during forward driving with the pusher blade lowered.
• Operation in extraordinary applications (see below) without additional safety measures.
• Driving from above onto an untested gradient.
• Driving on a subgrade having a gradient greater than the permissible gradient in a direction other than
the incline direction.
• Use of the roller other than from the operator's seat.
The machine is intended to be used only on a subgrade gradient up to the permissible gradient. Refer to:
Slopes (Page 49). Refer to: Performance Dimensions (Page 131).
Extraordinary applications are, in particular:

About the Product
Description
9 9831/7750-1 9
• Work on a subgrade having a gradient greater than the permissible gradient.
• Work on the edges of hillsides or trenches.
• Work in regions having continuous construction site traffic.
Additional safety measures can be:
• Securing by means of ropes attached to winches or accompanying heavy construction vehicles.
• Adequate escape lanes.
• Appointment of guides.
• Testing the function of the brakes when first driving onto the gradient at the lower end of the gradient
• Correspondingly: testing the directional stability of the longitudinal axis of the roller when switching on
the vibration.
The manufacturer/supplier is not liable for damage resulting from such use. The user alone bears the risk.
If the machine is to be used in applications where there is a high silica concentration, risk due to materials
containing asbestos or similar environment based hazards, 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 experience of use of this type of machine.
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.
It is also intended that the instruction manual is observed and that the servicing and maintenance regulations
are followed.
Danger Zone
The danger zone is any zone within and/or around the machinery in which a person is subject to a risk to their
health or safety. During operation of the machine, keep all persons out of the danger zone. Persons in the
danger zone could be injured.
Before you do a maintenance task, make the product safe. Refer to: Maintenance Positions (Page 87).
Main Component Locations

About the Product
Description
10 9831/7750-1 10
Figure 3.
C
E
F
J
K
L
M
H
G
A
B
D
AEngine compartment cover BInstrument panel and switches
CSunroof DWater tank filler cap
EROPS (Roll-Over Protective Structure) FSmooth drum (rear)
GDrum drive motor (rear) HFuel filler cap
JHydraulic tank oil indicator KDrum drive motor (front)
LSmooth drum (front) MScraper