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 01 - Machine

 06 - About this Manual

 06 - Using the Manual

01 - 18

9813/7750-1

01 - 18

06 - Using the Manual
Introduction

Information  in  this  manual  conforms  to  a  standard

JCB service manual format. The format uses section

headings  taken  from  a  PIL  (Parts  Identification

List).  These  headings  are  assigned  numerical

identification references.

Table 1.

Example

Section

Main Assembly / Head-

ing

Component / Sub-head-

ing

PIL reference

33

03

03

Heading

Electrical System

Battery

Isolator Switch

Information  within  each  PIL  reference  is  included

under  a  set  of  standard  headings  such  as

Introduction, Health and Safety, Technical Data and

Operation  for  example.  Where  additional  relevant

information is contained within another PIL reference

a cross reference is provided.

The  main  systems  information  is  contained  in  the

manual as follows.

Table 2.

System

PIL Reference

Heading

Hydraulic System

PIL 30-00-50

Schematic Circuit

Electrical System

PIL 33-03-03

Battery - Isolator Switch

PIL 33-09-00

Power Distribution (including fuses

and relays)

PIL 33-00-50

Schematic Circuit

Electronic Diagnostic

PIL 33-57-00

Electronic Diagnostic (including

Servicemaster)

Machine Variants

Where information is different depending on machine

variant, the applicable information sets are included

within  the  same  PIL  reference.  Headings  are

included  to  identify  which  information  is  for  which

variant. Make sure you use the correct information.

Diagnostics

Information  in  this  manual  can  help  you  diagnose

machine faults.

Before attempting to diagnose possible faults check

the following.

Make  sure  that  the  operator  understands  the

machine controls, functions and use. Refer to

the applicable Operator Manual.

Check  that  the  maintenance  record  complies

with the applicable schedule for the operating

environment.

Check  that  the  fluids  in  use  comply  with  the

standards specified.

Make sure that the machine electronic set-up

is applicable. Use the applicable Servicemaster

vehicle set-up tool.

Use the applicable Servicemaster diagnostics

tools.

Torque Tightening

When you replace components, always tighten the

applicable fixings to the correct torque value. Use the

torque tightening values contained in the individual

procedures (Remove and Install, Disassemble and

Assemble etc.). If no torque values are specified, use

the standard torque tightening values. For the torque

setting to be effective, do the following before you

install the fixings. Refer to PIL 72-00-00.

Make  sure  that  all  the  applicable  component

assemblies are correct.

Make sure that the applicable fixings are to the

correct  specification.  If  necessary  discard  the

original fixings and replace them with new ones.

The relevant procedures indicate when this is

necessary.

Make  sure  that  the  applicable  fixings  and

threaded  holes  are  free  from  contamination.

This  includes  dirt,  debris,  old  sealants  and

compounds, fluids and lubricants.

Summary of Contents for CT160

Page 1: ...achine 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 explai...

Page 2: ...9813 7750 1 Notes Find manuals at https best manuals com...

Page 3: ...CE MANUAL Volume 1 CT160 CT260 EN 9813 7750 SERVICE MANUAL Volume 2 CT160 CT260 EN 9813 7750 SERVICE MANUAL Volume 3 CT160 CT260 EN 9813 7750 SERVICE MANUAL Volume 4 CT160 CT260 EN 9813 7750 Find manu...

Page 4: ...Notes 9813 7750 1 Find manuals at https best manuals com...

Page 5: ...ety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 11 01 03 24 Risk Assessment 01 12 01 03 27 Maintenance Positions 01 13 01 06 About this Manual 01 06 03 Model and Serial Number 01 1...

Page 6: ...9813 7750 1 2018 06 15 Acronyms Glossary PIL Parts Identification List ROPS Roll Over Protective Structure Find manuals at https best manuals com...

Page 7: ...y Yours and Others 01 3 01 03 06 Safety Warnings 01 4 01 03 09 General Safety 01 5 01 03 12 Maintenance Safety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 11 01 03 24 Risk Assessme...

Page 8: ...Notes 01 2 9813 7750 1 01 2 Find manuals at https best manuals com...

Page 9: ...ial 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...

Page 10: ...dous 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 si...

Page 11: ...e 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 Ph...

Page 12: ...started while the hoses are open O rings Seals and Gaskets Badly installed damaged or rotted O rings seals and gaskets can cause leakages and possible accidents Renew whenever disturbed unless otherwi...

Page 13: ...o not touch component or surrounding area Used fluoroelastomeric components subjected to temperatures greater than 300 C 571 6 F e g engine fire must be treated using the following safety procedure Ma...

Page 14: ...ses Machine exhaust gases can harm and possibly kill you or bystanders if they are inhaled Do not operate the machine in closed spaces without making sure there is good ventilation If possible install...

Page 15: ...ur 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 t...

Page 16: ...ating Safety 01 10 9813 7750 1 01 10 has passed Do not attempt to mount or enter the machine If the machine is struck by lightning do not use the machine until it has been checked for damage and malfu...

Page 17: ...leak is suspected contact the local gas company immediately and warn all personnel on the site Ban smoking make sure that all naked lights are extinguished and switch off any engines which may be runn...

Page 18: ...nd is there sufficient fuel to complete the job if applicable The Load How heavy is it Is it within the capabilities of the machine How bulky is it The greater the surface area the more affected it wi...

Page 19: ...e 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 Disconnect the battery to prevent accidental...

Page 20: ...on solid level ground To prevent anyone starting the engine remove the ignition key Disconnect the battery by means of the battery isolator if installed when you are not using electrical power If you...

Page 21: ...01 Machine 06 About this Manual 01 15 9813 7750 1 01 15 06 About this Manual Contents Page No 01 06 03 Model and Serial Number 01 17 01 06 06 Using the Manual 01 18...

Page 22: ...Notes 01 16 9813 7750 1 01 16...

Page 23: ...03 Model and Serial Number 01 17 9813 7750 1 01 17 03 Model and Serial Number Introduction This manual provides information for the following model s in the JCB machine range Model From To 2556201 CT1...

Page 24: ...information is for which variant Make sure you use the correct information Diagnostics Information in this manual can help you diagnose machine faults Before attempting to diagnose possible faults ch...

Page 25: ...01 Machine 09 Description 01 19 9813 7750 1 01 19 09 Description Contents Page No 01 09 12 Main Component Locations 01 21 01 09 15 Service Point Locations 01 23...

Page 26: ...Notes 01 20 9813 7750 1 01 20...

Page 27: ...Component Identification Figure 3 C E F J K L M H G A B D A Engine compartment cover B Instrument panel and switches C Sunroof D Water tank filler cap E ROPS Roll Over Protective Structure F Smooth dr...

Page 28: ...01 Machine 09 Description 12 Main Component Locations 01 22 9813 7750 1 01 22 L Smooth drum front M Scraper...

Page 29: ...ations Introduction Figure 4 G F E C B A D J K L M H A Diesel fuel filler cap B Hydraulic oil level indicator C Hydraulic oil filler cap D Battery isolator E Battery F Engine oil dipstick G Air filter...

Page 30: ...Machine 09 Description 15 Service Point Locations 01 24 9813 7750 1 01 24 Figure 5 A B C D E A Water tank filler cap B Water level indicator C Water filter D Hydraulic filter E Coolant recovery bottl...

Page 31: ...01 Machine 33 Cleaning 01 25 9813 7750 1 01 25 33 Cleaning Contents Page No 01 33 00 General 01 27...

Page 32: ...Notes 01 26 9813 7750 1 01 26...

Page 33: ...ender the machine inoperable Remove dirt using a brush or damp cloth Clean the product with water and or steam Do not let mud debris etc to collect on the product Before you do any service procedures...

Page 34: ...aim the water jet directly at bearings oil seals or the engine air induction system Use a low pressure water jet and brush to remove dried mud or dirt Use a pressure washer to remove soft dirt and oi...

Page 35: ...5 Articulated Joint 06 7 06 33 Articulated Joint 06 33 00 General 06 11 06 63 Identification Label 06 63 00 General 06 21 06 63 03 Machine 06 22 06 63 06 Engine 06 24 06 66 Tools 06 66 00 General 06 2...

Page 36: ...9813 7750 1 2018 05 25 Acronyms Glossary PIN Product Identification Number...

Page 37: ...06 Body and Framework 06 Moveable Panel and Cover 06 1 9813 7750 1 06 1 06 Moveable Panel and Cover Contents Page No 06 06 00 General 06 3 06 06 06 Engine Compartment 06 4...

Page 38: ...Notes 06 2 9813 7750 1 06 2...

Page 39: ...duction Access panels provide easy access to the machine major components test and service points and other parts which require routine testing servicing adjusting replacement or repair Before you ope...

Page 40: ...ply the parking brake if installed 4 Engage the articulation lock 5 Stop the engine and turn the ignition key to the off position 6 Remove the ignition key 7 Unlock the latch connected to down left an...

Page 41: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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