Dynapac CP1200 User manual

Instruction Manual
4812325556EN
Operation and Maintenance
Pneumatic Tire Roller
CP1200
Diesel Engine
Cummins QSF 2.8 –Tier III e IV
Serial number
100005x0xxB005427
It is reserved the right to make any changes
Printed in Brazil

2017-11-22 4812325556EN
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.................................................................................................. 10
Identification plates.................................................................................................................................. 14
Instruments/controls................................................................................................................................ 16
Instruments and Controls - Cab .............................................................................................................. 28
A/C –System operation .......................................................................................................................... 29
Starting.................................................................................................................................................... 34
Operating the roller.................................................................................................................................. 37
Ballast box............................................................................................................................................... 39
Interlock/Emergency Stop/Parking Brake ............................................................................................... 42
Long-term storage................................................................................................................................... 45
Lifting....................................................................................................................................................... 47
Towing..................................................................................................................................................... 48
Operation instructions - Overview........................................................................................................... 51
Preventive maintenance.......................................................................................................................... 52
Preventive maintenance - Symbols and lubricants ................................................................................. 53
Specifications .......................................................................................................................................... 56
Maintenance and lubrication points......................................................................................................... 60
Scheduled maintenance and lubrication ................................................................................................. 61
Scheduled maintenance.......................................................................................................................... 62
Electrical system...................................................................................................................................... 75

4812325556EN 2017-11-22

Introduction
2017-11-22 4812325556EN 1
Introduction
CP1200
Dynapac CP1200 is a 12 tones pneumatic tire roller with
5,77 ft. (1760 mm) 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.
CP1200 is mainly used together with other asphalt rollers to
seal surfaces. Thanks to its weight, it also serves as a roller
for other types of ground.
Warning 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 safety instructions
and keep the Manual inside the machine.
It is recommended to at least train the
operators on daily handling and
maintenance of the machine, according to
the Instruction Manual. Passengers are
not allowed on the machine, and the
operator must be on the seat whenever he
operates the equipment.
Read throughout the manual before
starting the machine and before
performing any maintenance.
Request immediately new manuals if the
old ones are lost damaged or become
illegible.
Make sure there is a good vent (air
exhaust) when the engine is turned on in
closed facilities.

Introduction
2 4812325556EN 2017-11-22
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.
Perform a daily inspection in the machine before
starting, so you can find possible leakage or other
failures.
Verify the machine's floor. Leakages are easier detected
on the floor than on the equipment itself.
THINK ABOUT THE ENVIRONMENT! Do
not dispose oil, fuel or other hazard
substances to the environment. Always
dispose correctly used filters, draining oil
and fuel residues.
This manual contains instructions for periodic
maintenance, which is usually performed by the
operator.
Other engine instructions can be found at the
manufacturer's manual.
CE Marking and Statement of Compliance
(APPLIED TO MACHINES SOLD WITHIN THE
EUROPEAN COMMUNITY)
This machine has a CE Marking. It shows that at its
delivery, it meets all the applicable health and safety
basic directives, according to 2006/42/EC Machinery
Directive, besides attending other directives applicable
on machinery.
Following the machine there is a "Statement of
Compliance" specifying the directive and supplement
applicable, as well as the harmonized norms and other
regulations relevant to the case.

Safety - General instructions
2017-11-22 4812325556EN 3
Safety - General instructions
(you must also read the Safety Manual)
1. Read and understand this Manual before starting and operating the machine. The
operator must be familiar with the equipment contents before operating it.
2. Observe and follow all the Maintenance Section instructions.
3. Only experienced/trained operators are allowed to operate the machine. NEVER
allow the presence of passengers and ALWAYS remain seated while operating
the equipment.
4. Do not operate the equipment if adjustment or repairs are necessary.
5. Use ladders and rails to enter and leave the cab. NEVER enter or leave the
machine while it is moving.
6. The ROPS (Roll Over Protective Structure) should always be used when the
machine is operated on unsafe ground. Always use the seat belt when the ROPS
is on.
7. Use the first gear on sharp turns.
8. Avoid driving close to cliffs or sharp side slopes. Operate the machine on first
gear and always check the brakes.
9. When driving close to edges or holes, make sure at least 2/3 of the wheels are on
the previously compacted materials.
10. Make sure there are no obstacles over your head 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 uneven ground.
12. Follow all the safety rules and use the protection equipment proper to the work
to be performed.
13. Keep the roller clean. Clean immediately dirt, oil and grease accumulated on the
operator platform. Keep all the signs, lanterns, headlights and decals clean,
visible and legible.
14. Observe the following safety measures before refueling:
- Turn off the engine;
- Do not smoke;
- Do not allow sparks or flame next to the equipment;
- To avoid sparks, ground the filling nozzle.
15. Before performing any maintenance operation, chock the roller wheels and apply
the emergency/parking brakes.
16. Hearing protection is recommended if the machine's noise level exceeds 85 dB
(A). The noise level can vary depending on the work the machine performs.
17. Do not make any changes on the machine, under the risk of affecting the personal
safety as well the equipment's. Any change on the machine demands a previous
written approval by DYNAPAC.
18. Avoid using the machine before the hydraulic oil reaches the normal operating
temperature. The braking distance may be longer than normal if the oil is cold.
Refer to the operation instructions on "Stop", in the "Operation" section.

Safety - General instructions
4 4812325556EN 2017-11-22
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.

Safety
2017-11-22 4812325556EN 5
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 where he/she is.
Operating on slopes
The machine must never be operated from the
outside of the cab. The operator shall be seated
when operating.
Slopes
This angle was measured on a flat, hard surface and 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 tire pressures, the operation speed and the
gravity center raising may cause the machine to turn, even on
slopes smaller than the ones stated here.
If you need to leave the cab in emergency
situations, take off the hammer at the rear pillar on
the right and break the opening windows that are
also on the right.
It is recommended that ROPS (Roll Over Protective
Structure) is always used when driving on slopes
or unsafe ground.
Whenever possible, avoid driving across slopes.
On slopes, drive straight up and down.
The speed must always be slow when operating on
slopes.
Always operate the machine with the doors closed
and with the seat belt.
Fig.: Operação em declives.
Máx. 20°
ou 36%

Safety
6 4812325556EN 2017-11-22
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.
Operation and transport on steep ground
Always drive the machine in slow speed when operating or
during transport on steep ground.
(>15%).
To drive or stop the machine, the rear wheels shall always be
towards the slope, that is, the roller shall go up normally and
shall go down in reverse.
Make sure there are no obstacles both in front or
behind your work area.
Driving near edges
When driving close to edges or holes, make sure that at least
¼ of the tires is on the compacted ground.
>15% (8,5°)
Fig.: Steep slope
Low speed (up to 4.7 mph or 7.5 km/h)
>5% (2,8°)
Fig.: Steep ground
v < max. speed. (9.3 mph or 15 km/h).
No mínimo 1/4
Fig.: Position of wheel when driving near
edges.

Safety - Option items
2017-11-22 4812325556EN 7
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.
The air conditioning system is pressurized. The
incorrect handling can result in serious personal
injury. Do not loose or disconnect hoses and
connections with the system loaded.
The system must be refilled with approved coolant
when necessary. Refer to the safety decal next to the
replacement and filling place.
Fig. Air conditioning

Technical specifications
8 4812325556EN 2017-11-22
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.
The measured vibrations on the whole body are below the 0.5 m/s² action value, as specified in the
directive 2002/44/CE (the limit is 1.15 m/s²).
The measured vibrations on the hand/arm are also below the 2.5 m/s² action value, as specified in the
same abovementioned directive (the limit is 5 m/s²).
Noise level
The sound 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.
Guaranteed sound power level, LwA
101 dB (A)
Sound pressure level at the operator's ear (platform), LpA
85 ±3 dB (A)
Sound pressure level at the operator's ear (cab), LpA
80 ±3 dB (A)
During normal operations, the values abovementioned may differ, depending on the work specific
conditions.
Electrical system
The machines were tested for electromagnetic
compatibility (EMC) in accordance with EN 13309:2000:
"Construction machinery".

Technical specifications
2017-11-22 4812325556EN 9
Technical specifications -Dimensions
Dimensions
Dimensions
mm
inches
A –Between axles
2760
108,6
B –Total width
2057
81
H1 –Total height
2576
101,4
H2 –Total height (Platform)
1875
73,8
K –Height from the ground
237
9,33
L –Total length
3650
143,7
A
L
H1
B
K
H2

Safety decals - description and location
10 4812325556EN 2017-11-22
Safety decals - description and location
9
11
1
20
15
5
10
4,6
2,3
12
8
7
17
5
1
10
13
11
13
16
11
11
13
13
21
14
14
18
19

Safety decals - description and location
2017-11-22 4812325556EN 11
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.
1
WARNING:
Crush zone, wheel.
Keep a safe distance from the crush zone.
2
WARNING:
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 brakes. Crushing injury danger.
5
WARNING:
The operator must read the Safety and Engine
Manuals, as well as the Operation and Maintenance
instructions.
6
WARNING:
High pressure fluid.
Make sure to release the pressure from the
accumulators before opening the hydraulic system.
7
WARNING:
Gas shall not be used to start the machine.
8
WARNING:
Toxic gas danger.
Refer to the Instruction Manual.

Safety decals - description and location
12 4812325556EN 2017-11-22
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
15
Hydraulic oil

Safety decals - description and location
2017-11-22 4812325556EN 13
Safety decals - Description and
location (cont.)
16
Handbook compartment
17
Master switch
18
Battery voltage
19
Sound power level
20
Water tank
21
Hydraulic oil level
22
Do not spray with water

Identification plates
14 4812325556EN 2017-11-22
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).
NOTE: State the machine plate's serial number when ordering
spare parts.
PIN (Product Identification Number) at the frame
The PIN - product identification number (1) is punched on the
right side of the right frame. It is the same number of the
machine plate (serial number).
Fig. Frame
1 –PIN
1
Fig.: Frame
1 –Machine plate

Identification plates
2017-11-22 4812325556EN 15
Explanation of the 17PIN (Product Identification
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)
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 on the top step of the operator's platform.
It contains information like the serial number and the engine
specifications.
NOTE: State the engine plate's serial number when ordering
spare parts.
100
00123
V
E
B
123456
A
B
C
D
E
F
1
Fig. Engine
1. Engine plate
1

Instruments/controls
16 4812325556EN 2017-11-22
Instruments/controls
Control panel, side panel and command keyboard
1. Ignition key
2. Forward/reverse lever
3. Command keyboard
4. Direction lights (OPTION)
5. Attention lights
6. Warning lights
7. High beam lights (OPTION)
8. High/low speed
9. Enable the regeneration (Tier 4 Engine)
10.Disable the regeneration (Tier 4 Engine)
11.Brake test
12.Horn
13."+" increase of the sprinkler interval (timer) - OPTION
14."-" decrease of the sprinkler interval (timer) - OPTION
15."AWC" automatic sprinkler (OPTION)
16."MAN" manual sprinkler (OPTION)
17.Night working lights (OPTION)
18.Decrease engine rotation
19.Increase engine rotation
20."+" increase in the tire pressure (OPTION)
21."-" decrease in the tire pressure (OPTION)
22.Working lights (OPTION)
23.Display
24.Parking brake
25.Emergency stop button
26.Warning light switch
27.Rotate beacon lights
4
Fig. Control panel, side panel and command keyboard.
6
5
7
19
18
17
16
20
9
10
11
12
14
21
22
13
15
1
2
3
23
24
25
26
27
8