CBS C-1070 Operating instructions

CBS Products Ltd, Pillings Road, Oakham, Rutland, LE15 6QF, UK Tel: [phone]
Fax: [phone] E-mail: [e-mail] Website: www.cbsproducts.com
C-1070 HYDRAULIC WINCH
OPERATING AND MAINTENANCE
MANUAL
MODELS C-1070
Copyright 2008 by CBS Products Limited
All rights reserved. No part of this publication may be copied, reproduced or transmitted in any
form whatsoever without the written permission of CBS ProductsLtd.

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REVISION HISTORY:
Rel.no
Date
Details
Author
01
01-2008
Original issue
A. Miller
02
03-2012
Hydraulic Oil changed from Tellus 37 to
Tellus 32
L.Kilpin
03
03-2012
Responsible Person Updated
L.Kilpin
04
05-2014
Manual up-dated
A. Miller
05
03-2107
Canister type suction filter added
A. Miller

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CONTENTS
1. Introduction
2. Safety Instructions
3. General Description
4. Specification
5. Operating Procedures
6. Maintenance
7. Towing Instructions
8. Equipment Layout
9. Recommended Spares List
APPENDICES
Appendix 1 Hydraulic Circuit Drawing A2-1070-139
Appendix 2 General arrangement drawing C-1070-AS1001-R1
Appendix 3 Certificate of Conformity

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1.0 INTRODUCTION
CBS Products Ltd is a long established U.K company situated in ruralOakham, Rutland. From
its 4-acre site, CBS design, manufacture, test and market a comprehensive range of quality
products for the electricity, telecommunication and CATV industries. Products include overhead
line and underground winches, cable drum trailers and stands, stringing equipment, in fact
everything required for the installation or erection of conductors and cables.
With a long history of designing standard and specialised equipment to meet the needs of
customers worldwide, CBS has invested in the latest computer aided design and analysis
systems and an integrated manufacturing plant.
The CBS Design Facility is available to discuss specific customer requirements for any product /
project, existing or new. Please contact CBS Products for further information.
CBS Products Ltd operate stringent quality controls throughout the organisation and has a quality
assurance system certificated to ISO 9001 : 2008. Our total commitment to providing quality
products and service is reflected in the high standard of the finish, use and long life of all our
products.
There are certain controls and control functions, included in the
winch, which are critical to the safe operation of the winch. These
safety critical controls are clearlymarked in the manual with the
following symbol. It is imperative that these operating and
maintenance procedures are followed exactly, to ensure safe
operation.

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2.0 SAFETY INSTRUCTIONS
THIS EQUIPMENT MUST ONLY BE USED BY AUTHORISED PERSONNEL,
WHO HAVE BEEN SUITABLY TRAINED AND COMPETENT TO DO SO.
THESE INSTRUCTIONS ARE TO BE MADE AVAILABLE TO
OPERATORS OF THIS EQUIPMENT AT ALL TIMES, FAILURE TO
OBSERVE THESE SAFETY INSTRUCTIONS COULD RESULT IN
SERIOUS PERSONAL INJURY AND / OR PROPERTY DAMAGE.
1) Read and understand the operation and maintenance manual supplied with this equipment.
Keep it in a convenient place for future reference.
2) Keep children and untrained personnel awayfrom this equipment whilst in operation.
3) Keep all guards and safety devices in place. Do not operate this equipment with guards
removed or damaged.
4) Keep hands, feet and loose clothing away from moving parts.
5) Always stop the machine to carry out lubrication and servicing.
6) Check machine before starting for worn or damaged parts. Check that all nuts and bolts are
tight.
7) If machine is left unattended, ensure that unauthorised use isprevented.
8) Never leave the machine unattended whilst in use.
9) Use safety barriers to create an exclusion zone and prohibit access by any person(s) to the
winch except the operator, this is especially important when used in public places.
10) Beware of pinch points involved with rotating components, e.g. rope/cable drums. Capstans,
bullwheels, shafts and chain drives.
11) Beware of hot surfaces, especially around the engine and exhaust pipe and hydraulic oil
tank.
12) Some component and assembly parts are in excess of 25kg (55lb). When lifting care must
be taken, ensure sufficient man power/lifting gear is available, to prevent personal injury and
damage to the machine.
13) Beware of exposed electrical contacts. Do not touch. Or allow metal objects to come into
contact.
14) Keep feet away from hydraulically operated props, (if applicable).
15) When draining the engine oil or the hydraulic oil tank always ensure that no fluid is spilt, and
that waste engine oiland hydraulic oil are to be disposed of via an environmentally
acceptable method e.g. passed on for re-cycling.

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16) Wear ear defenders if noise levels are considered high to prevent ear damage.
17) Suitable protective clothing, footwear, gloves, eye protection and hard hat must be used by
the operator when using, servicing or maintaining the winch.
18) Machine may cause additional fire hazard if involved in an existing fire due to petrol/diesel, oil
and hydraulic oils involved, suitable precautions against possiblefire mustbe taken before
the winch is used.
19) No personnel are to be in manholes or ducts when the Machine is being operated, (if
applicable).
20)Be aware of hot exhaust gases expelled from the engine exhaust silencer, no personnel to be
in the vicinity of the engine exhaust outlet when the engine is running.
21) The machine must be operated on firm ground in a level and stable condition
suitably anchored down for the pulling operation to be undertaken.
22)Always ensure that the winch is in line with the direction of the pull, failure to
do so may result in permanent damage to the chassis or drum frame.
23) Stay clear of cables or lines under tension.
24)Never try to release the hydraulic hoses when the hoses are pressurised.
25) Escaping fluids underpressure can penetrate the skin and cause serious personal injury.
26) Check for leaks with a piece of cardboard. Donot use your hands.
27) Check for leaks with a piece of cardboard. Donot use your hands.
28) When towing ensure that the rope drum is fixed securely.
29)Do not allow the hoses to come in to contact with any harmful substances that may cause
damage.
30)Ensure all hydraulic connections are securely tightened before operating the machine.
31)Never re-fuel the engine mounted fuel tank whilst the engine is running, the engine must be
stopped and allowed to cool down.
32)When re-fuelling always ensure that the correct grade of fuel is used and that no fuel is spilt.
33)During draining/filling of hydraulic oil, engine oil andfuel always ensure that none of the liquid
is spilt.
34)Do not use the winch if lighting levels are poor, such that make operation hazardous.
35)When topping up or re-filling the hydraulic oil tank always ensure that the correct grade of
hydraulic oil is used and that no hydraulic oil is spilt.
36)When topping up or re-filling with engine oil always ensure that that the correct grade is used
and that no engine oil is spilt.

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37)Do not operate the winch with any component parts removed, missing or damaged.
38)Do not use or manoeuvre the winch on surfaces or in a position that isunstable and/or
inclined that could result in the winch rolling, sliding or turning over.
39)Do not allow the engine on the winch to run for long periods while the hydraulic circuit is not is
use.
40)The winch must be used in a position that allows good circulation of cooling air around the
engine and winch, do not used in confined spaces.
41)Avoid unnecessary contact with the winch when running, as the engine causes vibration.
42)Avoid using the winch in thunderstorm conditions and/or where there is a risk of lightning,
snow / ice or high winds.
43)The winch must not be used in a potentially explosive atmosphere.
44)The operator must take care not to trip of fall when moving the winch.
45)The operator should monitor the winch for potential problems and hazards when the winch is
in use, these may arise slowly, quickly or suddenly.
46)Stay clear of cables or lines under tension.
47)Only use the machine for its intended purpose.
48)Do not tamper with pressure relief valves or pressure reducing valves.
49)Never operate the winch with the wire rope attached to the anchor hook.
50)When towing always ensure that the rope is fixed securely, this to prevent
uncoiling during transit.
51)If additional front mounted prop is fitted, ensure it is correctly stowed and
secured when towing.
52)Prior to Transit always ensure that the trailer has a positive NoseWeight at the
towing couplingand does not exceed the maximum limit as specified in Section
4.
53)Ensure the nose weight is within the limit of thetowing vehicle.
54)Before towing the trailer, connect breakaway cable to towing attachment on
towing vehicle, ensure that is passes through the hole in the front chassis support bracket,
check the condition, if frayed, kinked or damaged, replace immediately
55)The winch must not be operated until full training and compliance with the directives of this
Operator Instruction Manual and the Operator Instruction Manual for any the equipment to be
used in conjunction with has been fully completed.

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3.0 GENERAL DESCRIPTION
The off-road / site use only C-1070 winch has been designed to provide a flexible winching
system capable of operating over a wide range of speeds, loads, and applications.
The winch has grooved double bullwheels to provide superior handling of the pulling bond, whilst
providing a constant tension capability. The pulling bond can be stored on a demountable drum
reel. The drive for this drum operates independently of the bullwheels and provides a nominal
back tension, which will always match the speed of the pulling bond. The winch isfitted with a
semi automatic layering arm, the operator monitors the pulling bond being wound on to the take
drum making manual adjustments when necessary.
This universal winch is ideally suited to ABC erection, 11/33 Kv stringing work, conductor
recovery and underground cable hauling.
The power source is from a petrol engine, which powers the triple mounted hydraulic pumps. These
pumps drive the hydraulic high torque, fixed displacement motor mounted onto the bullwheel drive
gearbox, drum overrun is controlled by the drum drive hydraulic motor and pressure relief valve, the
third hydraulic pump drives the hydraulic oil cooler.
The sealed hydraulic oil tank is fitted with an inlet filler/breather, return and suction filters as well as an
oil level sight glass.
The sturdy steel construction chassis is equipped with manually operated stabilising props to assist
when pulling. The towing equipment consists of braked axles, hydratow unit and jockeywheel.

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4.0 SPECIFICATION
Winch Serial Number …………………………………….
Capacity (Bullwheel Drive)
C-1070 1000 kg max.
Rope Speed
C-1070 40 metres/min (no load)
Chassis: All steel welded construction.
Axle: Single axle with independent torsional rubber suspension and
drum brakes.
Brakes: To EC standard for road going and fitted with an auto-reverse
facility.
Legs: TheWinch is fitted with manually operated rearlegs to give
support during operation.
Layering: Manual / semi-automatic.
Load indication: Calibrated gauge.
Main drive: Fixed displacement tandem pumps to fixed displacement
high torque motors.
Hydraulic circuit: Closed circuit system with full filtration and overload
protection
Hydraulic oil tank
Capacity 45 litres
Hydraulic Oil grade:
Moderate Climate Tellus 32
Very Hot Climate Tellus 68
Very Cold Climate Tellus T15
Environment friendly Alternative: Moderate Climate Bio 32 Ester Based Environment
Friendly
Hydratow coupling
Fixing nut torque 95 Nm (70 lb ft)
Nose Weight 100 kg Maximum
Tyres
Tyre size 185 R14 C 8PR
Tyre pressure 4.5 bar (65 P.S.I.)

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Wheel nut torque 110 Nm (80 lbft)
Max. speed 96 kph (60 mph)
Dimensions
Width 1375mm
Height –(without drum) 1450mm
Height –(with drum) 1600mm
Length 2765mm
Weights
Winch 580 kg (not including rope)
Rope drum (No rope) 22kg
8mm dia. x 400M Paraline rope 26.4kg
8mm dia. x 600m Paraline rope 39.6kg
Noise at operator workstation
Equivalent continuous A-weighted ……………….dB(A)
Peak instantaneous C weighted ……………….Pa
Sound Power Level ……………….Pa
1) dB(A) 2)Pa
LEQ (LP)
Noise at operator work Station
Noise at 1 metre 97.9 110.8
Noise at 2 metres 91.6 105.2
Noise at 3 metres 88.4 106.0
Noise at 7 metres 75.7 76.1

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5.0 OPERATING PROCEDURE
IT IS IMPERATIVE THAT ALL PERSONS USING, OPERATING OR
MAINTAINING THIS WINCH BE FULLY TRAINED AND COMPETENT TO DO
SO, AND HAVE READ THE ENTIRE OPERATING MANUAL.
CBS PRODUCTS LTD CANNOT BE HELD RESPONSIBLE FOR MIS-USE
OF THIS EQUIPMENT.
5.1. Controls
The operator controls have been designed to be safe and simple to use, with due
regard to ergonomic considerations. The operators control station is complete with
the following:
a) Control lever for winching in and paying out. This provides bi-directional
selection of bullwheel rotation. The valve spool has a soft start facility
allowing for a limited creep and inching movement.
b) Control lever for operation of the rear take-up drum. This lever should be in
its operating position before operating the bullwheels. If the winch is not
being used, this lever can be returned to its non-operating position, thus
saving on fuel and preventing the hydraulic oil from overheating.
c) Pressure gauge, which is also an indication of the pulling tension.
d) Tension control knob. This can be used to limit the actual pulling tension
applied to the pulling bond.
e) A safety ratchet mounted on the bullwheel can be used to hold the load.

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TENSION INDICATOR
TENSION CONTROL KNOB
WINCHING IN / PAYING OUT
CONTROL LEVER
TAKE-UP DRUM
CONTROL LEVER
SAFETY RATCHET

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5.2. Pre-winching procedure
Prior to using the winch for any hauling application, it is important to
ensure that the rear prop legs are lowered in order to level the winch,
and that the front prop stand / jockey wheel is also lowered to a
position where the winch is firm and stable. The winch should be
securely anchored to; either a suitable vehicle, ground anchors or other substantial
holding point. The winch should be in line with the direction of pull.
Check the hydraulic oil level, engine oil level and engine fuellevel.
5.3. Setting maximum line tension
This needs to be carried out with rope available on the take-up drum.
a) Attach the free end of the rope to the fixed hook situated below the rear
bullwheel.
b) Pass the rope over the rear guide roller, over the rear bullwheel and then
over the front bullwheel to occupy the first groove nearest the gearbox.
c) Pull the rope tight and pass it under the front bullwheel and back under the
rear bullwheel, occupying the first groove nearest to the gearbox.
d) Pass the rope over the bullwheel and continue threading the rope around
each groove on both bullwheels in turn until the bullwheel grooves are fully
occupied.
e) The rope should pass from the last groove on the rear bullwheel, over the
layering arm and onto the take-up drum.
f) Rotate the rope take-up drum until there is minimum slack in the rope from
the bullwheels to the drum and then re-engage the drum drive.
g) Start the engine. Refer to the engine manufacturers manual supplied with
the engine.
h) Operate the drum control lever to engage the drum drive. The rope should
tighten up between the bullwheels and the take-up drum.
i) Operate the control lever to winch in. The rope will tighten up between the
bullwheels and the rope hook securing the free end. The bullwheels will
stop rotating at the selected tension. This tension can now be adjusted by
rotating the tension adjustment knob clockwise to increase and counter-
clockwise to decrease the tension.
j) The maximum pulling tension is now set. Operate the winch control lever to
winch out. This will help release the tension in the rope. Reset the drum
control lever to its non-operating position. The rope may nowbe removed
from the fixed hook and from around the bullwheels if required.

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5.4. Pulling in
a) Thread the bullwheelsas described previously in section 5.3
ensuring that there is sufficient rope to pass over the layering
arm onto the rope take-up drum. Securely fasten the rope to
this take-up drum.
b) Start the engine, refer to the operator manual supplied with the engine.
c) Operate the drum control lever to engage the drum drive. This should be
left in its operating position at all times that the winch is working. At all other
times it is advantageous to return the drum control lever to its non-
operational position.
d) Operate the winch control lever by pulling gently towards the operator. The
rope will now be pulled in and be wound onto the rope take-up drum. It may
occasionally be necessary to assist the rope to layer evenly by moving the
layering arm in the appropriate direction. The speed of pulling can be
increased or decreased by adjusting the engine speed control.

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5.5. Pulling In (Extended Conductor Runs)
The C-1070 winch has been designed to enable the pulling of conductor over great
distances by using a series of winch ropes joined together with suitable
connectors. In order tomaintain tension when changing rope drums on the winch,
it is necessary to allowthe connector to travel around the bullwheels before
removing the connector, , tension needs to be applied to the rope and not allowed
to go stack around the bullwheels. The full rope drum may then be removed and
replaced with an empty drum. Attach the rope to the empty take-up drum, re-
engage the drum drive, and continue with the winching operation.
When the connector is passing around the bullwheels, the winch
should be run very slowly with the operator closely monitoring the
connector to ensure that it does not become derailed or tangled, the
rope keeper plate on the vertical layering arm may need to be opened to allowthe
connector to pass by.
Travelling
Ensure there is always a positive nose weight on the towing coupling, refer to
Section 4 for details of the maximum nose weight.

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6.0 MAINTENANCE
IT IS IMPERATIVE THAT ALL PERSONS USING, OPERATING OR
MAINTAINING THIS WINCH BE FULLY TRAINED AND COMPETENT TO DO
SO, AND HAVE READ THE ENTIRE OPERATING MANUAL.
CBS PRODUCTS LTD CANNOT BE HELD RESPONSIBLE FOR MIS-USE OF
THIS EQUIPMENT.
It is recommended that this winch is serviced every 12 months, regardless of its condition orthe
number of operating hours used. This will help to ensure reliable, trouble free service.
a) PRE-WINCHING MAINTENANCE CHECK
This should be carried out each day prior to the start of winching.
Check hydraulic oil level. Oil should be visible within the black lines marked on the
oil level sight gauge. Replenish if necessary with the following hydraulic oil –
Summer (ambient temperature above +10°C) Hydraulic oil shell Tellus 32 or
equivalent. (For very hot climate Hydraulic oil shell Tellus 68 or equivalent)
Winter (ambient temperature -20°C to +20°C)
Hydraulic oil shell Tellus T15 or equivalent.
For further information refer to specification Section 4
Check the engine oil level as indicated in the engine manufacturers manual
supplied with the engine. Replenish if necessary with the correct grade of engine
oil.
Check the condition of the hydraulic hoses, replace if damaged, check the
hydraulic oil system for leaks, rectify before proceeding.
Check that all screw fasteners are tight.
Check that sufficient engine fuel is available for the days winching operations.
Clean the bullwheel grooves, removing as much oil, grease, dirt and debris as
possible.
Check that the oil cooleris free from dirt and debris, clean if necessary.
b) MONTHLY MAINTENANCE
This should be carried out at intervals not exceeding 12 weeks. These
intervals will depend upon the degree of use of the winch.
Carry out all the pre-winching checks as detailed above.
Apply a generalpurpose, medium grade grease to the towing hitch grease nipples
(if applicable) and also to the towing ball up if fitted.

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Remove the top plate of the bullwheel gearbox. Apply a single stroke of the grease
gun to the four grease nipples mounted on the bearing units. Apply grease the
bullwheel chain drive. Replace the gearbox cover.
Grease all bearings and grease points (using the grease nipples fitted).
For example (where applicable)
The rope drum shaft bearing
The hydratow coupling
The jockey wheel bearing
Apply oil to all oilite bushes, eg on the layering arm.
Apply oil to any linkages.
Check and adjust the tyre pressures, refer to Section 4 for tyre pressures. Check
the tread depth of the tyres, replace if worn or damaged.
With the engine and bullwheels running, check the returnfilter condition indicator.
This is a red/green indicator mounted on the hydraulic oil tank return filter. If the
indicator is well over into the red area, replace the filter.
c) ANNUAL SERVICING
This service should be carried out at approximately 12 monthly intervals
by a qualified and experienced workshop team.
Carry out all the work as specified above in section b).
Drain the hydraulic circuit of oil. Clean thefiller/breather and replace. Renewthe
suction filter element and the return filter element. Refill with fresh oil, refer to
specification Section 4 for further details. Check and reset all relief valves.
Service the engine asper the engine manufacturers manualsupplied as part of this
manual.
Check the condition of the brakes, tyres and running gear. Adjust and reset if
necessary.
Check the condition of the towing breakaway cable. If frayed, kinked or damaged,
replace immediately.
Clean and re-grease the transmission chain inside the bullwheel gearbox.

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7.0 TOWING INSTRUCTIONS
BEFORE TOWING
a) Check the ball head cup is well greased (if fitted).
b) Handbrake is fully applied.
c) Raise the coupling head above height of ball bracket by use of jockey wheel
provided.
d) Reverse towing vehicle until ball bracket is directly below ball head on coupling.
e) Grasp locking handle on top of coupling and press trigger backwards with thumb.
Then lift handle (you can now release trigger). With handle still raised wind up
jockey wheel until ball on towing vehicle enters ball cup on coupling. Now release
handle and continue winding up jockey wheel until locking handle automatically
drops down and trigger snaps shut. If this doesnot occur lift handle again and
check if ball seatsthis time and trigger snaps shut. If there is still no success,
check if ball or head is worn.
f) If ball seats properly, then continue winding up jockey wheel until it is fully
retracted.
g) If a towing eye is fitted instead of ball head, remove the pin from towing jaw and
reverse the towing vehicle until the eye enters the jaw. Then replace pin and
locking pigtail or other securing device.
h) Continue to wind up jockey wheel until fully retracted and wheel is no longer free to
rotate. Loosen jockey clamp and raise jockey wheel up into chassis with wheel
facing rearwards and re-tighten clamp firmly ensuring wheel is well clear of brake
linkage, ensure that the rear prop stands are raised.
i) Check condition of breakaway cable. If frayed or kinked at all replace immediately
before use. Then connect breakaway cable to towing attachment on towing
vehicle. The cable must be free of knots.
j) Check the load is distributed to give the correct nose weight for the coupling, refer
to Section 4 for information on the hydratow coupling, a positive nose weight is
required to ensure stable towing. Also ensure nose weight is within limit of towing
vehicle.
k) If towing with a car transporter vehicle or any other vehicle, which has a long rear
overhang, extra forces can be applied to the coupling and towing device causing
rapid wear and damage. Please consult our Sales Department.

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WHEN ON THE ROAD
REVERSING –AUTO REVERSING BRAKES
a) Simply reverse with towing vehicle having checked all is clear around you. Initial
resistance will be felt as brakes are applied on trailer and then automatically ‘roll-
off’, allowing reversing to continue. If reversing a heavy trailer up an incline, or on
grass or otherslippery surfaces, wheel spin on the towing vehicle may occur, as
brakes initially come on.
b) If so, simply pullforward on to flat surface and recommence reversing operation
from there.
c) If trailer regularly has tobe reversed up a steep incline, then an optional manual
override for such conditions can be offered.

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PARKING
AUTO REVERSING BRAKED TRAILERS
a) Apply handbrake fully (if energy stores is fitted to rear of coupling then apply further
pressure to the handbrake to compress the spring which is fitted within the energy
store component). This ensures that should brake roll-off occur when a trailer is
parked with the rear facing down an incline that the brakes will automatically be re-
applied. If the unit is fitted with a power assisted handbrake, then no further action
is required as the handbrake will automatically take up anyfurther movement
should roll-off start to occur when parked on a slope.
b) If towing eye is fitted instead of ball head, remove pin from towing jaw and reverse
towing vehicle until eye enters jaw. Then replace pin and locking pigtail or other
securing device.
c) Continue to wind up jockey wheel until fully retracted and wheel is no longer free to
rotate. Loosen jockey clamp and raise jockey wheel up into chassis with wheel
facing rearwards and re-tighten clamp firmly ensuring wheel is well clear of brake
linkage.
Please remember brake linkage must be free to move fully during overrun braking
when on the road. Also handbrake so that breakaway cable can apply brakes if
trailer should part company with towing vehicle.
d) Check condition of breakaway cable. If frayed or kinked at all replace immediately
before use. Then connect breakaway cable to towing attachment on towing
vehicle. The cable must be free of knots.
e) Check the load is distributed to give the correct nose weight forthe coupling (max
allowable HU2 –75kg, all HU3 units –100kg, HU12 –120kg) a positive nose
weight is strongly recommended to ensure stable towing. Also ensure nose weight
is within limit of towing vehicle.
f) If towing with a car transporter vehicle or any other vehicle, which has a long rear
overhang, extra forces can be applied to the coupling and towing device causing
rapid wear and damage. Please consult our Sales Department.
g) Loosen jockey clamp and lower jockey wheel to ground. Firmly re-tighten clamp
(by hand). Press back trigger with thumb and lift handle on coupling head. At the
same time raisefront of trailer by use of jockey wheel until head is fully clear of ball
on towing vehicle.
h) Disconnect breakaway cable from towing vehicle.
i) Drive towing vehicle clear of trailer. (In the case of a couplingfitted with an eye
follow above instructions except in respect of the final disconnecting of the towing
vehicle in which case the instructions suppliedwith the towing jawof hook should
be used accordingly).
j) As extra security it is strongly recommended that the wheels of the trailer should be
chocked as an additional safeguard.