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Fayat Group CP1200, Instruction Manual, Page: 1 / 86

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Fayat Group CP1200 Instruction Manual Download 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 

 

 

Summary of Contents for CP1200

Page 1: ...556EN 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...

Page 2: ......

Page 3: ...s controls 17 A C System Operation Cab 30 A C System operation 31 Starting 36 Operating the roller 38 Ballast box 40 Interlock Emergency Stop Parking Brake 44 Long term storage 49 Lifting 51 Towing 52...

Page 4: ...4812325556EN 08 01 2023...

Page 5: ...symbols WARNING Damage to the machine or its parts CAUTION Risk of death or injures Safety information The Safety Manual delivered with the machine shall be read by the operator Always follows the saf...

Page 6: ...onment Always dispose correctly used filters draining oil and fuel residues Is prohibited dispose of tires in the environment Dispose of waste tires at authorized collection points This manual contain...

Page 7: ...during the travel Always look up and down during the travel Make sure there are no obstacles in the direction of travel on the ground in front or behind the roller 11 Drive particularly carefully on...

Page 8: ...N 08 01 2023 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...

Page 9: ...with the machine in a stationary position The steering angle is zero the tires pressure is normal and all the tanks are full Always remember that loosen ground the steering of the machine different t...

Page 10: ...e the substrate might not have full bearing strength or the edge is close to a slope Keep in mind that the machine s center of gravity moves outwards when steering For example the center of gravity mo...

Page 11: ...em shall be carried out only by trained people and with the proper tools and equipment The air conditioning system is pressurized The incorrect handling can result in serious personal injury Do not lo...

Page 12: ...so below the 2 5 m s aren action value as specified in the same abovementioned directive The limit is 5 m s aren Noise level The sound levels are measured according to the operational cycle described...

Page 13: ...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 Total heigh...

Page 14: ...r radius 7090 279 13 r Inner radius 4390 172 83 X Tire width 217 8 54 T Tire overlap 24 0 94 CP1200W Dimensions mm inches R Outer radius 7090 279 13 r Inner radius 4390 172 83 X Tire width 275 10 83 T...

Page 15: ...Safety decals description and location 08 01 2023 4812325556EN 11 Safety decals description and location...

Page 16: ...NG Rotating engine components be careful Keep your hands off the danger zone 3 WARNING Hot surface Keep your hands off the surface 4 WARNING Read carefully the towing chapter before releasing the brak...

Page 17: ...scription and location 08 01 2023 4812325556EN 13 Safety decals Description and location cont 9 Emergency exit Cab 10 Hoisting plate 11 Tire pressure 12 Diesel oil 13 Securing point 14 Lifting point 1...

Page 18: ...d location 14 4812325556EN 08 01 2023 Safety decals Description and location cont 16 Handbook compartment 17 Battery switch 18 Battery voltage 19 Sound power level 20 Water tank 21 Hydraulic oil level...

Page 19: ...ngine 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 NOTE State the machine plate s serial n...

Page 20: ...ction s unit code B Sorocaba Brazil F Serial number de 000001 to 999999 Engine plate The engine plate 1 is on the cylinder head cover 1 and it can be accessible when the hood is open The plate is also...

Page 21: ...k 11 Brake test 12 Horn 13 increase of the sprinkler interval timer 14 decrease of the sprinkler interval timer 15 AWC automatic sprinkler 16 MAN manual sprinkler 17 Night working lights OPTION 18 Dec...

Page 22: ...her away from neutral the higher the speed 3 Command keyboard 4 Direction lights It shows that the direction lights are activated activation via switch at the steering column 5 Attention lights Indica...

Page 23: ...turned on off 17 Night work lights Press to turn on off the night work lights if equipped 18 Engine speed reduction Press to decrease engine speed three stages 19 Increase engine speed Press to incre...

Page 24: ...tton Press it to turn off the machine and the engine All the power supply is also turned off 26 Hazard warning lights Press the switch to activate the hazard warning lights 27 Rotating beacon Press th...

Page 25: ...specified in percentage The screen remains visible until the Diesel engine is turned on or if one of the function buttons below the screen is pressed If the engine starts before you choose the screen...

Page 26: ...tions Alarm log button to show the alarms of the engine and machine Settings menu selection button which opens the main menu Settings can be changed in the main menu Exit return button returns 1 step...

Page 27: ...en 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 To erase the message press OK When...

Page 28: ...ning symbol engine temperature If this symbol appears the engine is too hot Stop immediately the engine and find the fault Refer also to the engine manual Warning symbol hydraulic oil temperature This...

Page 29: ...y X X Machine Power Supply Main Control Unit power supply is greater than 18V or less than 4 5V Power Supply X X X Sensor Power Supply Fault Sensor Power Supply is out of range 5000mV 125mV Sensor Sup...

Page 30: ...mode is active as long as the fault remains SAFE Mode The machine stops and cannot be used before the fault is corrected Engine Coolant Temperature Alarm Engine Coolant Temperature is greater than 10...

Page 31: ...rol panel Alarms cont Alarms received are stored logged and can be seen by selecting Display Alarms ENGINE ALARM Stored logged engine alarms MACHINE ALARM Stored logged machine alarms They come from o...

Page 32: ...n 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 between kPa...

Page 33: ...to do so the missing ones are shown in the display The missing conditions must be set before turning on the machine Conditions that must be set The parking brake shall be activated The forward revers...

Page 34: ...s the top to activate the front washers Press the bottom to activate the rear washers 4 Fuse box Contains fuses from the electric system in the cab 5 Automatic Climate Control Air conditioning automat...

Page 35: ...t point temperature will flash on the display press until reaches desired temperature Display The display shows set point value bar graph evaporator speed active function and other information It also...

Page 36: ...l 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 Ventila...

Page 37: ...r transverse travel raise the inner lever 1 The transverse travel brake will be released For rotation raise the outer lever 2 Make sure the control unit is in the correct position before operating the...

Page 38: ...to bottom to return to the initial position just move the selector until the end of the weight scale Comfort operator s seat option Adjustment Adjust the operator s seat so all the controls are withi...

Page 39: ...f the rubber elements 3 on the platform are in good condition Worn elements will impair the comfort Make sure that the anti slip protections 4 on the platform are in good condition Replace where anti...

Page 40: ...on When sitting on the operator s seat turn the ignition key 3 to the right the first position I and then to the start position Release the switch as soon as the engine starts Do not try to run the st...

Page 41: ...t with the engine in maximum rpm it shall be necessary to replace the hydraulic oil filter Warning lamp air filter If the lamp is lit with the engine in maximum rpm it shall be necessary to clean or r...

Page 42: ...Turtle Rabbit 6 Make sure the steering is working normally by turning the steering wheel to the left and to the right once with the roller stationary When compacting asphalts do not forget to activat...

Page 43: ...n the tire pressure is at the maximum level 620 kPa or at the minimum level 240 kPa it will not be possible to increase decrease the pressure Scrapers adjustment There are two models of scrapers with...

Page 44: ...water may leak when the ballast is filled with it Fill the ballast box when necessary with gravel sand and steel The water shall be added when it is filled with sand so it can fill all the spaces betw...

Page 45: ...he steel ballasts Remove the bedplate 4 off the ballasts assembly 3 Install or remove the ballasts according to the necessity using the forks from a standard forklift The ballasts grooves 5 were proje...

Page 46: ...rect pressure for the wheel according to the following table Low tire pressure 350 kPa 50 7 psi The lower the tire pressure the lower the pressure on the contact surface due to larger contact surface...

Page 47: ...9 905 380 410 420 905 55 59 61 1130 400 440 460 1130 58 64 67 1360 430 460 480 1360 62 67 70 CP1200W 10 5 80 16 Tire Inflation Pressure kPa 350 480 620 Wheel load kg Ground Contact Pressure kPa 600 28...

Page 48: ...he operator must hold the steering wheel firmly and be ready for a sudden stop The engine will be turned off and the brakes will be activated To check if the parking brake works correctly it shall be...

Page 49: ...n the neutral position and the parking brake shall be on Turning off the engine Allow the engine to cool down in low idle for a few minutes Check if the Display 1 shows any indication of faults Turn o...

Page 50: ...ystem automatically will change to transport mode See in Display 1 After the test enable the parking brake or press again the brake test button to end the Dynamic Brake test mode When the test ends th...

Page 51: ...e the joystick slowly to the maximum position forward or reverse and verify if the equipment moves In case the machine speed goes higher than 1km h within 3 seconds while executing the dynamic or park...

Page 52: ...eeze Drain the water tanks and pipings Battery switch At the end of the working shift turn off the battery switch 1 and remove the handle This will prevent the battery discharging and will also make i...

Page 53: ...manufacturer information in the engine instruction manual supplied with the roller Battery Remove the batteries from the roller clean their outside parts and recharge them once a month Air cleaner ex...

Page 54: ...over the instrument panel Cover the entire roller with a tarpaulin It shall have a gap between it and the ground If possible store the machine indoors and preferably in a place with regular temperatur...

Page 55: ...Check the machine gross weight and the compatibility of the lifting equipment Lifting the roller with a jack The machine s gross weight is specified in the hoisting plate 1 Refer also to the Technical...

Page 56: ...pump are freely connected to the pressure side This function allows the machine to be moved without the drive shaft rotating 4 Start the Diesel engine and run it in idle 5 Move the forward backward le...

Page 57: ...e release pump is at the right side of the engine compartment 5 Close the valve 2 by tightening clockwise with the knob to enable the manual brake release After towing release the knob anticlockwise t...

Page 58: ...pply the parking brake and make sure the machine is in the neutral position that is that the tires are pointing forwards Chock 1 the tires in an angle of 37 and at a minimum height of 9 9 inches 25 cm...

Page 59: ...ine and warm it Always check the brakes Before starting the working shift carry out a test in the system and remember that if the hydraulic oil is cold the brake distance will be longer When operating...

Page 60: ...eaving the plant The inspection shall happen in the moment it arrives to the client following the list in the warranty document Any transport damage shall be immediately reported to the carrier compan...

Page 61: ...ydraulic 300 Shell Tellus T100 ou equivalente P N 4812161867 5L P N 4812161868 20L BYOLOGICAL HYDRAULIC OIL When leaving the plant the machine may be filled with biologically degradable oil When repla...

Page 62: ...Preventive maintenance Symbols and lubricants 58 4812325556EN 08 01 2023 Engine oil level Engine oil filter Hydraulic fluid level Air filter Hydraulic fluid filter Fuel filter Battery Coolant level...

Page 63: ...Preventive maintenance Symbols and lubricants 08 01 2023 4812325556EN 59 Lubricating oil Air pressure Sprinkler Sprinkler water Recycling...

Page 64: ...lbs 9135 kg 20139 lbs Operating Water 7805 kg 17207 lbs 7535 kg 16612 lbs FILLING VOLUMES Hydraulic oil reservoir 70 L 18 49 gal Hydraulic oil system 30 L 7 92 gal Diesel engine lubricating oil 8 2 L...

Page 65: ...lb ft 110 N m 81 1 lb ft 117 N m 86 3 lb ft 131 N m 96 6 lb ft M14 110 N m 81 1 lb ft 123 N m 90 7 lb ft 156 N m 115 lb ft 174 N m 128 3 lb ft 187 N m 138 lb ft 208 N m 153 4 lb ft M16 169 N m 124 6...

Page 66: ...N m 213 9 lb ft 360 N m 265 5 lb ft M20 470 N m 346 6 lb ft 585 N m 431 4 lb ft 560 N m 413 03 lb ft 698 N m 514 8 lb ft M22 626 N m 461 7 lb ft 786 N m 579 7 lb ft 752 N m 554 6 lb ft 944 N m 696 2 l...

Page 67: ...stem 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 Engines ENGINE Manu...

Page 68: ...ay to detect earlier leakages and possible damages Fig Service and lubrication points 1 Engine oil 9 Coolant 17 Cab air filter 2 Oil filter 10 Engine air filter 18 Cab air conditioning 3 Fuel filter 1...

Page 69: ...und the covers plugs grease nipples or hoods before open or apply grease to them Respect and follow the engine manufacturer instructions For further information refer to the Engine Manual Park the rol...

Page 70: ...e manual 11 Fill the fuel tank 68 Clean the dust ejection valve 68 Refer to the engine manual Replace the hydraulic oil filters 69 l l l Check the air tire pressure 69 Check the tightness of the w hee...

Page 71: ...and above the mark H Low performance or engine damage may occur Place the machine on a flat surface wait at least 15 minutes after switching off the machine and make sure the level is between the mar...

Page 72: ...nonstick tire DYNA GUARD In addition to protecting the tire is biodegradable Check the sprinkler system Make sure the sprinkler system runs smoothly The solenoid valves 5 shall issue a noise to show t...

Page 73: ...re two positions of work and rest Adjust the snap rings 2 of the scrapers to control the pressure applied on wheels Replace water separator filter 1 Remove the old water separator filter with a filter...

Page 74: ...and secure turn off the engine and ground the supply nozzle placing it in contact with the chassis not isolated spot before the start filling While refueling hold the pump nozzle in contact with the o...

Page 75: ...t with one more turn 5 Check the hydraulic oil level on the sight glass 2 and adjust if necessary 6 Turn on the engine and check if the filter is well sealed Check the tires air pressure To check the...

Page 76: ...age 3 When replacing the main filter 3 insert a new one in its place and fit the air filter components in the reverse order 4 Verify that the anti dust valve 6 is in good condition and replace if nece...

Page 77: ...ng compressed air use safety glasses Where possible clean the hives in the opposite direction to the fan airflow Every time you flush the hive cover the electrical and electronic components Change the...

Page 78: ...and before carrying out the operation let the engine in idle for a few minutes and turn it off Change the engine oil filter Diesel Never perform any maintenance work under the machine while the engine...

Page 79: ...tting 1 Lubricate the operator s seat rotation bearing with three strokes of a hand operated grease gun 2 Clean and lubricate the chain 3 with grease between the seat and the steering column 3 If the...

Page 80: ...ion on inspection and replacement belts refer to the engine manual Change the engine coolant Caution Risk of severe burns Wait until the engine temperature cools down to 122 F 50 C before removing the...

Page 81: ...ent 3 Unscrew the drain plug 2 and drain the remaining fuel inside the tank 4 Refit the drain plug and tighten it Using adulterated contaminated dirty or bad quality fuel damages the injection system...

Page 82: ...d the alternator when the engine is operating Fuses Fuse box 1 Ignition key main relay 5A 2 Main ECU hydraulic traction motor feed rotation sensor 5A 3 Main ECU PWR 1 10A 4 Main ECU PWR 2 10A 5 Main E...

Page 83: ...ty 8 Empty Main fuse box 9 Main fuse 50A 10 Empty 11 Cab 50A 12 Engine 30A Main fuses panel The main fuses panel is near the radiators on the left side of the machine 1 Main switch 2 Pre heating relay...

Page 84: ...N MODIFICATION 01 01 2023 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...

Page 85: ......

Page 86: ...Dynapac do Brasil Industria e Comercio de M quinas 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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