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Related Manuals for Fayat Group CP1200
Summary of Contents for Fayat Group CP1200
- Page 1 Instruction Manual 4812325556EN Operation and Maintenance Pneumatic Tire Roller CP1200 / CP1200W Diesel Engine Cummins QSF 2.8 – Tier III e IV Serial number 100005x0xxB005427 - 10000515xxB005762 - It is reserved the right to make any changes Printed in Brazil...
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Page 3: Table Of Contents
TABLE OF CONTENTS OPERATION Page Introduction ..............................1 Safety - General instructions ........................3 Safety - When operating ..........................5 Safety – Option items ..........................7 Technical Specifications ..........................8 Technical specifications -Dimensions ......................9 Safety decals - description and location ....................11 Identification plates ..........................15 Instruments/controls .......................... - Page 4 4812325556EN 08/01/2023...
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Page 5: Introduction
Introduction CP1200/CP1200W Dynapac CP1200 is a 12 tones pneumatic tire roller with 5,77 ft. (1760 mm) width. CP1200 is also available on the wide base version (CP1200W), with larger tires and 6.857 ft (2,090 m) width. It has 5 front wheels, and four back wheels. The flexible ballast solution and the wide range of option equipment indicate that the machine has different settings available. - Page 6 Introduction General Information This manual contains instructions to operate and perform the maintenance of the machine. The machine's maintenance shall be made correctly in order to obtain the maximum performance and the equipment shall also be kept clean, so leakage, loosen bolts and connections can be found as soon as possible.
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Page 7: Safety - General Instructions
Safety - General instructions Safety - General instructions (You must also read the Safety Manual) Read and understand this Manual before starting and operating the machine. The operator must be familiar with the equipment contents before operating it. Observe and follow all the Maintenance Section instructions. Only experienced/trained operators are allowed to operate the machine. - Page 8 Safety - General instructions 19. For your own protection, always wear: Helmet; Working boots with steel toecaps; Ear protectors; Reflecting clothing; Working gloves. 20. If there is a cab in the machine, operate it always with the doors closed and with the seat belt.
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Page 9: Safety - When Operating
Safety Safety - When operating Avoid people entering at the danger area, that is, at a distance of at least 23 ft (7 m) in all the directions from the machine operating. The operator can allow one person to be at the danger area, but in this case, care must be taken and the machine can only be operated when this person is in a visible place or with clear indication of... - Page 10 Safety Transport on steep ground During the transport on steep ground (slope >5%), be careful to not exceed the roller's maximum speed. Selecting the low speed will increase the engine brake system efficacy and also the life of the braking system. >5% (2,8°) Fig.
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Page 11: Safety - Option Items
Safety - Option items Safety – Option items Air conditioning The system contains pressurized refrigerant. It is forbidden to release refrigerant to the atmosphere. The maintenance of the air conditioning system shall be carried out only by trained people and with the proper tools and equipment. -
Page 12: Technical Specifications
Technical specifications Technical Specifications Vibrations – Operator station (ISO 2631) The vibration levels are measured according to the operational cycle described in the EU directive 2000/14/EC on machines equipped for the EU market with the operator’s seat in the transport position. 1,75 The measured vibrations on the whole body are below the 0.5 m/s²... -
Page 13: Technical Specifications -Dimensions
Dimensions inches A – Between axles 2760 108,66 B – Total width (CP1200) 2057 80,98 B – Total width (CP1200 with cab) 2250 88,58 Bw – Total width (CP1200W) 2083 82,01 Bw – Total width (CP1200W with cab) 2260 88,98 H1 –... - Page 14 Technical specifications CP1200 Dimensions inches R – Outer radius 7090 279,13 r – Inner radius 4390 172,83 X – Tire width 8,54 T – Tire overlap 0,94 CP1200W Dimensions inches R – Outer radius 7090 279,13 r – Inner radius...
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Page 15: Safety Decals - Description And Location
Safety decals - description and location Safety decals - description and location 08/01/2023 4812325556EN... - Page 16 Safety decals - description and location Safety decals - Description and location (cont.) Always make sure that all the safety decals are completely legible and remove the dirt or request for new ones if they are illegible. Use the part number indicated on each decal.
- Page 17 Safety decals - description and location Safety decals - Description and location (cont.) Emergency exit - Cab. Hoisting plate Tire pressure Diesel oil Securing point Lifting point Hydraulic oil 08/01/2023 4812325556EN...
- Page 18 Safety decals - description and location Safety decals - Description and location (cont.) Handbook compartment Battery switch Battery voltage Sound power level Water tank Hydraulic oil level Do not spray with water 4812325556EN 08/01/2023...
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Page 19: Identification Plates
Identification plates Identification plates Machine plate The machine plate (1) is on the front, on the left side of the operator's platform. It specifies the manufacturer's name, the type of the machine, the serial number, the service weight, the engine power and the manufacturing year (machines delivered outside EU do not present CE marking and in some cases they also do not present the manufacturing year). - Page 20 00123 123456 Number) A - Manufacturer's code (100 = Dynapac) B - Family/model code (00500 = CP1200 Tier 3) (00510 = CP1200 Tier 4) C - Check code D - Year of manufacturing (E=2014, F=2015...) E - Production's unit code (B = Sorocaba, Brazil)
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Page 21: Instruments/Controls
Instrumentos e controles – Descrição e função Instruments/controls Control panel, side panel and command keyboard Fig. – Control panel, side panel and command keyboard. Ignition key Forward/reverse lever Command keyboard Direction lights (OPTION) Attention lights Warning lights High beam lights (OPTION) High/low speed Empty Emulsion Tank... - Page 22 Instrument/controls - Description and Function Instrument/Controls - Description and Function DESIGNATION SYMBOL FUNCTION The electric circuit is off. All instruments and electric controls are on. Ignition key The starter is activated. To turn on the machine, the lever must be in "Neutral ".
- Page 23 Instrument/controls - Description and Function DESIGNATION SYMBOL FUNCTION The sprinkling frequency increases each "+" increase of the sprinkler time the water volume on the wheels is also interval (timer) increased. The sprinkling frequency decreases each "-" decrease of the sprinkler time the water volume on the wheels is also interval (timer) decreased.
- Page 24 Instrument/controls - Description and Function DENOMINATION SYMBOL FUNCTION Press it to turn off the machine and the Emergency stop button engine. All the power supply is also turned off. Press the switch to activate the hazard Hazard warning lights warning lights. Rotating beacon Press the switch to activate the rotating beacon.
- Page 25 Instrument/controls - Description and Function Control panel – General Description When the ignition key is in the position "I", the start screen is visible on the display. It remains activated for a few seconds (1.5 seconds) then it switches to the status screen. Fig.
- Page 26 Instrument/controls - Description and function Control panel – General Description (cont.) A menu field is shown by pressing one of the selection buttons. It is visible for a short time, then it fades out if no selection is made. A menu field appears again by pressing one of the selection buttons (1).
- Page 27 Instrument/controls - Description and function Control panel – Alarms When an engine motor alarm is activated, it is shown in the screen. The alarm is sent from the engine's ECM, which tracks its functions. The message displays SPN and FMI codes and can be read via the engine supplier error code list.
- Page 28 Instrument/controls - Description and function Control panel – Alarms (cont.) SYMBOL DESCRIPTION FUNCTION If the symbol appears with the engine in Warning symbol, hydraulic oil filter. maximum rpm, it shall be necessary to replace the hydraulic oil. If the symbol appears with the engine in Warning symbol, air filter.
- Page 29 Instrument/controls - Description and function H1-AC Alarm DISPLAYED LIMITED SAFE YELLOW DESCRIPTION FUNCTION BUZZER MESSAGE MODE MODE ALARM ALARM Engine Engine Speed is greater Overspeed Overspeed than 3000 RPM No response from ECM (Tier 4/Stage V) or CAN J1939 Actuator (Tier 3) for more J1939 Fault than 5 seconds...
- Page 30 Instrument/controls - Description and function Engine Coolant Engine Coolant Temperature Temperature is greater Engine Temp Alarm than 107°C. Hydraulic Oil Hydraulic Oil Temperature Hydraulic Temperature is greater than 90°C. Temp LIMITED Mode Limits the speed to 50%. This mode is active as long as the fault remains. SAFE Mode The machine stops and cannot be used before the fault is corrected.
- Page 31 Instrument/controls - Description and function Control panel – Alarms (cont.) Alarms received are stored/logged and can be seen by selecting Display Alarms “ENGINE ALARM” Stored/logged engine alarms. Fig. – Engine alarm screen “MACHINE ALARM” Stored/logged machine alarms. They come from other systems on the machine.
- Page 32 Instrument/controls - Description and function “USER SETTINGS” Users can change lighting settings, choose between Metric or Imperial system and set warning sounds on/off. Unit system will be changed from METRIC to IMPERIAL, or IMPERIAL to METRIC. All the temperature values in the display should change between degrees Celsius and Fahrenheit, the speed value in the display should change between km/h to mph, and the AOR pressure value in the display should change...
- Page 33 Instrument/controls - Description and function Operators help when starting When trying to turn on the machine without having set up to three necessary conditions to do so, the missing ones are shown in the display. The missing conditions must be set before turning on the machine.
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Page 34: A/C System Operation - Cab
A/C – System operation A/C System Operation - Cab DESIGNATION SYMBOL FUNCTION Press to operate the front windshield Front wiper switch wiper. Press to operate the rear windshield Rear wiper switch wiper. Front and rear windshield Press the top to activate the front washers washers. -
Page 35: A/C - System Operation
A/C – System operation A/C – System operation Power/Enter By feeding the panel with 12VDC, the screen will be on, indicating that the product is in standby mode. Press to turn on the A/C, it will show the software version and then the temperature. - Page 36 A/C – System operation Ventilation The controller has two ventilation modes: manual and automatic ventilation. Manual ventilation The manual ventilation has three speeds. When some function (cooling, heating or automatic mode) is active, the ventilation function is always on. To change the fan speed, press the key (Ventilation mode) and after set the desired speed with the keys After press the key...
- Page 37 Operation - Before starting Operation - Before starting Daily maintenance Before starting your work shift and operating the equipment, make sure the daily maintenance was carried out. For further information, refer to the maintenance section in this manual. Battery switch Check if the Battery switch is on.
- Page 38 Operation - Before starting Standard operator's seat – adjustment Standard operator's seat Operator's seat (standard) - Adjustment Adjust the operator’s seat so that the position is comfortable and so that the controls are within easy reach. There is a scale (50-130 Kg) that can be changed according to the weight of the operator.
- Page 39 Operation - Before starting View Before starting the machine, make sure that the view forwards and backwards is unobstructed. All cab windows should be clean and the rear view mirrors should be correctly adjusted. Operator position If a ROPS (2) (Roll Over Protective Structure) or a cab is fitted to the roller, always wear the seat belt (1) provided and wear a protective helmet.
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Page 40: Starting
Operation Starting Screen - Control Sit down for all operations. Turn the ignition key (1) to the position I and the initial screen is shown in the Control panel (2). Fig.- Side panel Ignition key Control Panel Starting the engine Make sure the emergency stop system (2) is off (upper position) and the parking brake is on. - Page 41 Operation Display and button set The parking brake symbol is shown when the parking brake is activated. Automatic water control (AWC). The sprinkling is activated when the forward/backward lever is in the neutral position. Tire pressure displayed in position 3. Displayed in position 4.
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Page 42: Operating The Roller
Operation Operating the roller Under no circumstances the machine shall be operated away from the ground. The operator shall be seated inside the machine during the operation. Make sure the areas at the front and behind the machine are free. •... - Page 43 Operation Tire pressure adjustment (option) The operator can vary the pressure during the operation with the tire air pressure control. It can be variable adjusted with the keys (2) and (3) on the keypad, within the interval from 240 kPa to 620 kPa (35 to 90 PSI) and can be reduced with the key (3).
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Page 44: Ballast Box
Operation Ballast box Fig. – Ballast box cover Water and wet sand ballast Top forward covers Side covers Remove the top covers (1) and fill with water and sand through Draining plugs this opening. Keep the side covers (2) closed during the water filling. Do not remove the draining plugs (3) because the water may leak when the ballast is filled with it. - Page 45 Operation Removable steel ballasts The CP1200 roller uses an innovative and patented system of steel ballasts, which can be removed and installed easily and quickly: 1. With the ballast box drained (without water and/or sand), remove four side covers (1) from the ballast box.
- Page 46 Operation Ground pressure (driving) The tire contact surface can be changed by means of tire pressure. The high pressure on the tires provides a smaller contact surface (1) and the low pressure on the tire provides a larger contact surface (2). The contact surface with the ground is very important for the compaction result.
- Page 47 Operation Ground pressure CP1200 Tire Inflation Pressure (kPa) Tire Inflation Pressure (psi) 7.50-15 7.50-15 Wheel load Ground Contact Pressure Wheel load Ground Contact Pressure (kg) (kPa) (kg) (kPa) 1130 1130 1360 1360 CP1200W Tire Inflation Pressure (kPa) Tire Inflation Pressure (psi) 10.5/80-16...
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Page 48: Interlock/Emergency Stop/Parking Brake
Operation Interlock/Emergency Stop/Parking Brake The interlock, emergency stop and parking brake shall be checked daily before starting the machine. To check if the emergency stop and interlock are working correctly, it is necessary to turn on and off the machine. To check if the Interlock works correctly, the operator shall rise from the seat with the roller moving forwards and backwards (perform the... - Page 49 Operation Emergency braking For emergency braking, press the emergency stop button (1), hold the steering wheel and be ready for a sudden stop. The engine stops. The diesel engine is turned off and must be turned on again if necessary. When starting the engine after an emergency stop, the forward/backward lever shall be in the neutral position and the parking brake shall be on.
- Page 50 Operation Dynamic Brake Test The dynamic brake test must be done with parking brake switch button (3) released. Press the brake test button (2) the accumulators will start to fill and a sound effect will activate on the machine and the test button light will begin to flash (the sound effect and flash in test button occurs until the accumulator reaches 90 bars - 1305 Psi).
- Page 51 Operation Parking Brake Test 1-) The parking brake test must be done with the parking brake switch button (1) engaged. 2-) Increase the engine to maximum rpm manually (2); 3-) Press and hold the Brake Test Button (3) and move the joystick slowly to the maximum position forward or reverse and verify if the equipment moves.
- Page 52 Operation Chocking the wheels Never leave the roller and let it with the engine running unless the parking brake is activated. In extremely cold weather, some components may freeze. Drain the water tanks and pipings. Fig. – Choking the wheels 1.
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Page 53: Long-Term Storage
Long-term storage Long-term storage For long-term storage (more than a month) follow the instructions below: These measures are valid for storage for a period of up to 6 months. Before starting the machine again, the points stated below shall be performed before parking and store the roller. Wash the machine and touch up the painting finishing to prevent rusting. - Page 54 Long-term storage Hydraulic oil reservoir Fill the hydraulic reservoir until the uppermost level. Tires Make sure the tires pressure is at least 345kPa (50 PSI). Jack up the frame, so that the tires do not take any load. Steering cylinder, hinges, etc. Grease the steering cylinder plunger spindle to preserve it.
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Page 55: Lifting
Lifting Lifting Lifting the roller Make sure the front wheels are parallel with the frame before lifting the roller. Make sure the hooks are safely placed in the lifting eyes. The equipment shall only be lifted by the proper lifting eyes. Always use cables and steel chains according to the safety norms and make sure there are no worn components and that parts are not damaged during... -
Page 56: Towing
Towing Towing Short distance towing with the engine running The roller can be moved up to 984 feet (300 meters), according to the following instructions: To tow the machine, use the same lifting points. 1. Park the roller on a flat and safe place. If necessary, chock the tires. - Page 57 Towing Short distance towing with engine inoperative As a safety measure, chock the wheels to prevent the machine to move when the brakes are hydraulically disengaged. The roller can be moved up to 984 feet (300 meters), according to the following instructions: Fig.
- Page 58 Refer to the table below to know the maximum pulling force allowed for this machine model: Fig. – Towing direction MODEL CP1200 40.465 Transport Preparing the roller for transport Apply the parking brake and make sure the machine is in the neutral position, that is, that the tires are pointing forwards.
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Page 59: Operation Instructions - Overview
Operation instructions Operation instructions - Overview Follow the safety instructions specified in the Safety Manual. ● Make sure all the MAINTENANCE INSTRUCTIONS were carried out. For further information, refer to the Maintenance section in this manual. ● Turn on the battery switch. ●... -
Page 60: Preventive Maintenance
Preventive maintenance Preventive Maintenance Introduction It is necessary to carry out a complete maintenance so the machine can work satisfactorily and at the lowest possible costs. The Maintenance section includes the periodic maintenance that shall be carried out on the machine. The recommended maintenance intervals assume that the machine is being used in a normal environment and working conditions. -
Page 61: Preventive Maintenance - Symbols And Lubricants
Preventive maintenance - Symbols and lubricants Preventive maintenance - Symbols and lubricants Always use high quality lubricants and in the amounts required. Too much grease or lubricant oil can cause overheating and premature wear. P/N 4812161855 (5L) Air temperature -15°C +50°C (5°F- ENGINE OIL Dynapac Engine oil 200 P/N 4812161856 (20L) - Page 62 Preventive maintenance - Symbols and lubricants Engine, oil level Engine, oil filter Hydraulic fluid, level Air filter Hydraulic fluid, filter Fuel filter Battery Coolant level 4812325556EN 08/01/2023...
- Page 63 Preventive maintenance - Symbols and lubricants Lubricating oil Air pressure Sprinkler Sprinkler water Recycling 08/01/2023 4812325556EN...
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Page 64: Specifications
Specifications Specifications WEIGHTS ROPS Shipping Mass 5535 kg 12203 lbs 5265 kg 11607 lbs Operating: Empty 5825 kg 12842 lbs 5555 kg 12247 lbs Operating: 8 ballasts 9395 kg 20712 lbs 9125 kg 20117 lbs Operating: 8 ballasts + Water 10905 kg 24041 lbs 10635 kg... - Page 65 Specifications Torque Torque for oiled bolts tightened with a torque wrench. METRIC STRENGTH CLASS COARSE 8.8, oiled 10.9, oiled 10.9 12.9, oiled 12.9 SCREW THREAD, BRIGHT GALVANIZED (fzb) 13.4 N.m 14.6 N.m 16.3 N.m 8.4 N.m 9.4 N.m 12 N.m (9.9 lb.ft) (10.7 lb.ft) (12.02lb.ft)
- Page 66 Specifications Torque (cont.) METRIC COARSE STRENGTH CLASS THREAD, ZINC- 10.9 10.9 12.9 12.9 TREATED oiled oiled (Dacromet/GEOMET) 12 N.m 15 N.m 14.6 N.m 18.3 N.m (8.8 lb.ft) (11.06 lb.ft) (10.7 lb.ft) (13.4 lb.ft) 28 N.m 36 N.m 34 N.m 43 N.m (20.6 lb.ft) (26.5 lb.ft) (25.07 lb.ft)
- Page 67 Specifications Specifications (cont.) Air conditioning (option) The system described in this manual is the ACC (Automatic Climate Control), that is, a system which maintains the set temperature in the cab provided that all the windows and doors are kept closed. Coolant designation: HFC-R134:A Coolant weight when full: 1,350 g (2.98 lbs).
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Page 68: Maintenance And Lubrication Points
Maintenance and lubrication points Maintenance and lubrication points Read carefully this manual section before carrying out any maintenance or lubrication on the machine. Always check the areas around and under the equipment. It is an easy way to detect earlier leakages and possible damages. -
Page 69: Scheduled Maintenance And Lubrication
Scheduled maintenance and lubrication Scheduled maintenance and lubrication The maintenance and lubrication shall be carried out first based on the working hours. When they cannot be considered, use the periods, like daily, weekly, etc. Always clean around the covers, plugs, grease nipples or hoods before open or apply grease to them. -
Page 70: Scheduled Maintenance
Scheduled maintenance Scheduled maintenance Pos. Action Pag. Note Check operation of the emergency brake Check the engine oil level Refer to the engine manual Check the level of engine coolant Check the hydraulic oil level Fill the w ater tanks ... - Page 71 Revision History Check operation of the emergency brake Make the machine move slowly. Hold the steering wheel and brace yourself for a sudden stop. Press the emergency brake button (1). The roller will stop abruptly and the engine will shut down.
- Page 72 Scheduled maintenance Check the hydraulic oil level 1. Park the roller on a level ground and turn off the engine 2. Check the hydraulic oil reservoir sight glass (1) located on the right side of the machine. 3. If the oil level is 2 cm below the glass upper line, fill with the recommended hydraulic oil.
- Page 73 Revision History Nozzle - Disassembly / Cleaning Remove manually the clogged nozzle. Apply the nozzle (2) and fine filter (4) a compressed air jet. Alternatively, install replacement parts and clean the clogged later. After checking and cleaning possible, turn on the system and check its operation.
- Page 74 Scheduled maintenance Fill the fuel tank Never fill the engine when it is working. Do not smoke and avoid spilling fuel. The supply nozzle and the reservoir cap are located in front of the operator platform on the left side of the machine.
- Page 75 Revision History Replace the hydraulic oil filters Hydraulic filters are located on the right side of the engine compartment. TAKE CARE OF THE ENVIRONMENT: All the used oil shall be properly stored for subsequent disposal. Do not dispose of oil on the ground, sewage system or other place which can harm the environment.
- Page 76 Scheduled maintenance Check the tightness of the wheel nuts Confirm the tightening torque of the REAR wheel nuts (1) with 770 Nm (78kpm) / 550 Nm (56 kpm) and FRONT wheel with 494 Nm (50 kpm): Check all wheels and all nuts (this information is valid only for new machines or newly installed wheels).
- Page 77 Revision History Grease the lower and upper articulated bearings 1. Lubricate the fitting of the upper pivot bearing (1) and the lower pivot bearing (2) with five applications of the manual pump. Use the grease in accordance with the recommended lubricant specifications for Dynapac.
- Page 78 Scheduled maintenance Loosen the hex nut, pull the hose out and release the oil drain plug. 1. Let all the oil drain into the container and finish the operation attach the drain plug back and attach the hose. Then tighten the hex nut.
- Page 79 Revision History Check the hydraulic oil tank cover To check the hydraulic oil tank cap: Unscrew the tank cap and check if it’s obstructed. The air must flow freely throughout the cap in both ways. 2. If one way is obstructed, wash the filter with a small portion of Diesel oil and use compressed air until the obstruction is eliminated or replace the cap for a new one.
- Page 80 Scheduled maintenance 1 2 1 Replace the cab air filter Use a step ladder to reach the filter (1). The filter can also be accessed by the window at the right side of the cab. The filter is located at the front of the cab. Remove three bolts and the protective plastic.
- Page 81 Revision History 4. Unscrew the hexagon nut, remove the hose and unscrew the drain plug. Drain all the fluid to the container. 5. After the replacement, tighten the drain plug and fit back the hose and the hexagon nut. Empty and clean the fuel tank NEVER perform maintenance work under the machine when the engine is working.
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Page 82: Electrical System
Scheduled maintenance Electrical system The machine's main control box (1) is located on the rear of the operator platform. There is a plastic cap over it and the fuses. A 12V jack is available in the plastic cap. Fig. - Main control box 1. - Page 83 Revision History Cab fuse box 1. Indoors lighting (10A) 2. Windscreen wiper/washers, front/rear (10A) 3. Heating (15A) 4. Empty 5. Empty 6. Empty 7. Empty Fig. - Cab fuse box 8. Empty Main fuse box 9. Main fuse (50A) 10. Empty 11.
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Page 84: Revision
0 General. 02/11/2023 1 Change of hydraulic system pressure. 06/09/2020 2 Change of width with cab CP1200 and 1200W 06/16/2020 3 Update the PN of lubrication oils for roller 08/01/2023 4 General update, added decal 8 in the Safety Decals section. - Page 86 Dynapac do Brasil Industria e Comercio de Máquinas Ltda. Rua Georg Schaeffler, 430, Sorocaba/SP, Brasil Tel.: +55 (15) 3412-7500 Fax.: +55 (15) 3412-7522 www.dynapac.com...
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