OPERATING AND MAINTENANCE MANUAL

Transcription

1 CBS Products Ltd, Pillings Road, Oakham, Rutland, LE15 6QF. UK Telephone: +44(0) Fax: +44(0) Website: OPERATING AND MAINTENANCE MANUAL CBS C-1265 FIBRE CABLE FLEETING DEVICE MODELS:- C R5 Cable Fleeting Device 3000M X 13mm Dia Copyright 2009 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 Products Limited.

2 REVISION HISTORY: Rev No. Date Details Author Original issue A. Miller 2

3 CONTENTS 1.0 Introduction 2.0 Safety Instructions 3.0 General Description 4.0 Specification 5.0 Cable Installation and Operating Procedure 6.0 Maintenance and Servicing 7.0 Towing Instructions 8.0 Equipment layout 9.0 Spares APPENDIX 1. General Arrangement Drawing 2. Certificate of Conformity 3

4 1.0 INTRODUCTION CBS Products Ltd is a long established U.K company situated in rural Oakham, 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 fibre cable fleeting device, which are critical to the safe operation of the fleeter. These safety critical controls are clearly marked in the manual with the following symbol. It is imperative that these operating and maintenance procedures are followed exactly, to ensure safe operation. 4

5 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 away from 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 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 is prevented. 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 fleeter 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, rollers and shafts. 5

6 11. Keep feet away from manually operated props. 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. Wear ear defenders if an engine is running nearby to prevent ear damage. 14. Machine may cause additional fire hazard if involved in an existing fire due to petrol/diesel, oil and hydraulic oils involved, suitable precautions against possible fire must be taken before the fleeter is used. 15. No personnel are to be in manholes or ducts when the fleeter is being operated, (if applicable). 16. The machine must be operated on firm ground in a level and stable condition. 17. Suitable protective clothing, footwear, gloves, eye protection and hard hat must be used by the operator when using, servicing or maintaining the fleeter. 18. Do not use the Fleeter if lighting levels are poor, such that make operation hazardous. 19. Do not operate the fleeter with any component parts removed, missing or damaged. 20. Do not use or manoeuvre the fleeter on surfaces or in a position that is unstable and/or inclined that could result in the fleeter rolling, sliding or turning over. 21. Avoid using the fleeter in thunderstorm conditions and/or where there is a risk of lightning, snow / ice or high winds. 22. The fleeter must not be used in a potentially explosive atmosphere. 23. The operator must take care not to trip of fall when moving the fleeter. 6

7 24. The operator should monitor the fleeter for potential problems and hazards when the fleeter is in use, these may arise slowly, quickly or suddenly. 25. Stay clear of cables or lines under tension. 26. Only use the machine for its intended purpose. 27. If additional front mounted prop is fitted, ensure it is correctly stowed and secured when towing. 28. Prior to transit always ensure that the trailer has a positive Nose Weight at the towing coupling and does not exceed the maximum specified in Section Ensure the nose weight is within the limit of the towing vehicle. 30. Before towing the trailer, connect the breakaway cable to the towing attachment on the towing vehicle, ensure that it passes through the cable guide on the hydratow coupling, check the condition, if frayed or damaged, replace immediately. 31. The trailer should be in a level position when towing (Chassis side members in a horizontal attitude) 32. The fleeter must not be towed with cable in the basket. 33. Ensure that the retaining clip on both rear prop stands is fitted and the handle is positioned inline with the main chassis side member when in the raised position. 34. When towing always ensure that the jockey wheel is facing to the rear, fully retracted such that the wheel is no longer free to rotate and is fully raised into the chassis and secured. 35. The rotating carousel must always be secured to prevent rotation prior to travelling with trailer. 36. The fleeter 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. 7

8 3.0 GENERAL DESCRIPTION The C-1265 Cable Fleeting Device has been developed to enable longer lengths of fibre optical cable to be laid from a single drum. With the increasing trend of longer cable installations with either pull and assist winching systems or cable blowing techniques there is a need for a C-1265 cable fleeting device. The need arises following the initial installation of the first half of the fibre optic cable from the drum. The balance of the cable on the drum needs to be removed, stored safely, with the inner end of the cable ready to be placed in the cable duct. See diagram section 5.0. The traditional method to achieve this operation is to employ manual labour to rotate the drum whilst the members of the team form the cable being removed into a gauge of 8 configuration on the ground. By using the C-1265 fleeter this operation can be achieved in less time with less manual labour and with the cable safely stored in the 8

9 cassette (basket) ensuring that the cable will not be damaged by passing vehicles or pedestrians. The C-1265 has been designed to fleet fibre optic cable safely without over tensioning, excessive bending or kinking of the cable. 3.1 The C-1265 has been designed to fleet fibre optical cable safely. It has a nominal capacity to store up to Ø13mm diameter cable having an approximate length of 3000 metres. WARNING The principle of operation and storage rate has been designed for major cable types. However, account should be made for miscellaneous cables, which have characteristics that do not always meet this standard. This may affect the volume of cable stored or the machine may have to be run at lower speeds. This could be curved cables, extremely soft cables or none symmetrical cables. The operator must establish the correct speed of operation and loading for the cable types being employed. It is recommended that this should be assessed by trial on your particular cable prior to site operation. The C-1265 Cable Fleeting device consists of the following major assemblies:- 3.2 TRAILER CHASSIS Cable storage cassette Rotating Cable Guide Carousel Fixed Cable Guide Quadrant 9

10 4.0 SPECIFICATION Fleeter VIN Vehicle Identification Number. Cable capacity 3000 Metres x 13mm Diameter 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. Props The fleeter is fitted with manually operated rear props to provide stability during operation. Towing Ball: 50mm diameter (Eye options are available) Tyres: Tyre size Tyre pressure: Max. speed Wheel nut torque 145 R BAR (35 P.S.I.) 96 kph (60 mph) 90 Nm (66 lbft) Hydratow coupling Fixing nut torque Nose Weight Coupling Height Towing Vehicles 80 Nm (59 Lb ft) 75 kg Maximum 430mm +/-35mm Categories M1, M2 and N1 10

11 Dimensions Width Height 2260mm 2350mm Lengths Overall Coupling centre to rear of trailer Trailer excluding the coupling device Centre of rearmost axle to back of trailer 3508mm 3466mm 2821mm 856mm Unladen weight Payload 380kg 0kg Lighting A 13 pin 12 volt lighting plug is fitted to the trailer and wired to current E.U. regulations. A 13 pin socket should be fitted to the towing vehicle. (A 7 pin vehicle to 13 pin trailer conversion adaptor is available to suit 7 pin vehicles, Note:- the reversing lamp will not work with this adaptor as there is not a wire available for the reverse lamp function, to obtain this function the vehicle should be changed to a 13 pin socket). 11

12 Statutory Plate Information A B C D E F G Name of Manufacturer Vehicle Identification Number (VIN) Maximum Permitted Laden Mass of the Trailer Maximum Permitted Coupling Nose Weight Maximum Permitted Laden Road Mass for the 1st Axle from the front Maximum Permitted Laden Road Mass for the 2nd Axle from the front (If applicable) Year of Manufacture 12

13 5.0 CABLE INSTALLATION AND OPERATING PROCEDURE MID POINT INSTALLATION IT IS IMPERATIVE THAT ALL PERSONS USING, OPERATING OR MAINTAINING THIS FIBRE CABLE FLEETING DEVICE 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 IMPORTANT:- Prior to installation of the first stage of cable as in Fig 1.0 a suitable length of Sub Duct (A) should be connected between the Tornado Blowing unit and the Sub Duct in the ground using a suitable connector. Ensure the length of Sub Duct (A) is long enough to allow connection to the Duct Clamps of the Fleeting basket Fig 2.0, on completion of the first stage of installation. Continue with first stage installation. a) The C-1265 Cable Fleeter should be positioned in line and adjacent to the manhole Fig 2.0 and levelled up by adjusting the rear props and the jockey wheel until the level bubble is centred. On soft ground it may be necessary to place wooden battens under the rear prop stands to spread the load, the trailer must be stable. Apply the handbrake to prevent movement. Note: Sufficient cable should be left between the manhole and the fleeting device to allow for any subsequent repositioning of the fleeting device. When loaded with cable. b) Release Cable Drive Clamp of Tornado Blowing unit and disconnect the Sub Duct connector. Push Fibre cable through machine by hand at the same time lifting sub duct (A) up ready to connect to the Duct Clamp of the Fleeting Basket Fig 2.0. c) IMPORTANT! Ensure sufficient cable is pulled through and placed in a loop on the ground beside the Fleeting Basket Fig 2.0 to allow the Fleeting Basket to be pushed back following installation of the remaining cable. Fig

14 d) Open the detachable segments of the quadrant rollers by releasing the toggle clamps on the fixed quadrant roller and the rotating quadrant roller. e) Having pulled a suitable length of cable off the drum and placed on the ground beside the Fleeting Basket insert the loop through the gap in the cable storage cassette and clockwise around the central frame. Fig 2.0. f) The cable loop should now be placed into the rollers of the rotating carousel. This will direct the cable loop vertically upwards to the fixed quadrant roller mounted on the frame. Assemble the detachable segments by ensuring the locating lugs seat properly and secure with retaining toggle clamps. g) The cable loop should then be directed over the rollers on the fixed quadrant and through the Sub Duct clamp on the frame. Re assemble the quadrant ensuring the locating lugs seat properly and secure the retaining toggle clamps. h) Ensure the Sub Duct is securely clamped in the clamping device and that the Sub Duct is pushed right through and is touching the Fixed Quadrant. Fig 2.0 (To eliminate possible cable flex) I) Clamp the cable into the Tornado Blowing unit as normal with 1full turn of the screw when the clamp washers cannot be turned by hand, refer to the Tornado Blowing Machine manual for details. Slowly start to push the cable into the Fleeting Basket (No Air required) ensuring it is rotating in a clockwise direction Slower speeds recommended for this application Care MUST be taken by the operator during this procedure When the remaining cable has been pulled from the cable drum and has passed completely through the Tornado Blowing unit the cable will stop. At this point remove Sub Duct (A) Fig

15 4.0 Push Fleeting Basket back and re-position Tornado Blowing unit as in Fig 3.0. Re connect using a suitable length of sub duct (B) and joint connector. a) Leaving a short length of sub duct in the Fleeting Basket clamp (to protect the cable when running though) pass the cable through the Tornado Blowing unit and continue to Blow cable as normal. At the end of the cable installation it will be necessary to open both the Rotating and Fixed Quadrants to allow complete removal of the cable from the Fleeting Basket. It will be necessary to cut and remove sub duct (B) from the cable, care must be taken not to damage the cable. A small loop of cable will remain which should be looped and placed in the Manhole Fig

16 CONNECTOR SUB DUCT (A) SUB DUCT (A) CONNECTOR CABLE ONLY (NO SUB DUCT) SUB DUCT (B) 16

17 6.0 MAINTENANCE AND SERVICING The trailer unit is fitted with towing equipment to comply with European Standards. This consists of overrun inertia type brakes with auto reverse facility. The axles have torsional rubber suspension. The towing bracket has hand operated parking brake, together with adjustable height jockey wheel and security wire facility. 6.1 MAINTENANCE Brakes and Tyres The brakes fitted are the auto reverse type to make towing easier. The maintenance of the drum brakes should be undertaken by trained personnel only, and adjusted when necessary to ensure the drums just run clear when the wheel is rotated in a forward direction only. It is important to keep these adjusted every 6 months, as too large a drum movement can affect the performance of the auto reverse facility and parking brake. An indication of worn brakes will be given by increased handbrake travel. After adjusting the drum brakes, remove any slack in the operating system by loosening the lock nut and tightening the pull rod (Fig 5), but without pre loading brakes (check this again by rotating each wheel in a forward direction). The linkage mechanism should be oiled weekly to ensure smooth operation and to protect from moisture. Check the condition of the brake cables weekly, replace if frayed or damaged. Apply a light oil as required to ensure cables move freely. Follow brake manufacturers appropriate instructions in this respect. DO NOT ADJUST FOR BRAKEWEAR ANYWHERE OTHER THAN AT THE WHEEL BRAKE THEMSELVES. The tyre pressure should be checked daily, refer to Section 4 for tyre pressures and details of the tyres. 17

18 Check the condition of the brake away cable each time the Cable Fleeter is used, replace if kinked or damaged. Cable Storage Cassette This assembly will not require any maintenance. Make sure it is kept free of materials which may cause damage to fibre cables during operation. Rotating Cable Guide Carousel This assembly must always be secured to prevent rotation prior to travelling with trailer. Alternatively the securing device should always be removed prior to use, and freedom to rotate checked. Ensure rollers are free to rotate and are kept free of materials which may cause damage to fibre cables during operation. Ensure the guide retaining toggle clamps operate freely and are adjusted such that the 2 guide halves are securely held together. 18

19 Fixed Cable Guide Quadrant Ensure the rollers are free to rotate and are kept free from materials which may cause damage to fibre optic cables during operation. Ensure the guide retaining toggle clamps operate freely and are adjusted such that the 2 halves are securely held together. The main spindle bearings and the nylon roller bearings are all sealed for life and maintenance should not be required. If however rollers become damaged or do not run freely, it is essential the roller is replaced. The concept of operation requires that the rollers are free running, otherwise friction can be induced into the cable. This friction could potentially build up to cause the cable to be damaged. 6.2 SERVICING Apply grease to ball and to cup of ball head after cleaning each item. (Alternatively towing eye and jaw are fitted). This to be carried out each time the trailer is to be towed. Oil all moving parts weekly having wiped away all corrosion and dirt deposits. 19

20 7.0 TOWING INSTRUCTIONS Attaching to Vehicle The CBS C-1265 Cable Fleeter Trailer is designed for towing behind a categories M1, M2 or N1 vehicle, therefore ensure that the towing vehicle has the correct towing arrangement to match the trailer. It should also be at a height which enables the trailer to travel in a horizontal position, and not leaning up or down, (Ensure that there is a positive nose weight). If the latter is the case, the vehicle towing arrangement should be adjusted to suit. The towing facility on the trailer is to E.U. specification and is of the inertiatype (i.e. overrun). The towing bracket is fitted with a handbrake for holding the trailer in the stationary condition. It is essential to apply the handbrake when the trailer is separated from the towing vehicle. The adjustable height jockey wheel allows the towing eye to be adjusted to ease the operation of attaching the trailer to the vehicle. Once attached the safety wire should be applied around the towing pin of the vehicle. The 13 pin lighting plug is wired to current E.U. regulations. The plug should be connected to the vehicle socket before towing commences. To avoid problems with the electrics it is advisable to ensure the plug is kept dry and free from dirt. When fitting and removing the plug do not pull on the connecting cables. BEFORE TOWING a. Check the ball head cup is well greased (if fitted). b. The handbrake is fully applied. c. Raise the coupling head above height of the ball bracket by use of the jockey wheel provided. d. Reverse the towing vehicle until the ball bracket is directly below ball head on coupling. e. Grasp the locking handle on top of coupling and press the trigger backward with the thumb. Then lift the handle (you can now release the trigger). With the handle still raised, wind up the prop stand until the ball on the towing vehicle enters the ball cup on coupling. Now 20

21 release the handle and continue winding up the prop stand until locking handle automatically drops down and the trigger snaps shut. If this does not occur, lift the handle again and check if ball seats this 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 the prop stand 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 and that the retaining clip on both rear prop stands are fitted and the handles are positioned inline with the main chassis side member. If an additional front mounted prop is fitted, ensure it is correctly stowed and secured for towing. Please remember brake linkage and handbrake must be free to move fully during overrun braking when on the road so that breakaway cable can apply brakes if trailer should part company with towing vehicle. 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. i. Connect electrical plug to socket on rear of towing vehicle and check all lights are fully operational. 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. When fitting the number plate ensure that if is fitted centrally beneath the number plate lamp. 21

22 l. Do not travel with any cable in the trailer basket. m. Ensure that the retaining clip on both rear prop stands is fitted and the handle is positioned inline with the main chassis side member when in the raised position. n. 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. 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 other slippery surfaces, wheel spin on the towing vehicle may occur, as brakes initially come on. b) If so, simply pull forward on to flat surface and recommence reversing operation from there. c) If trailer regularly has to be reversed up a steep incline, then an optional manual override for such conditions can be offered. 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. 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. If the unit is fitted with a power assisted handbrake, then no further action is required as the 22

23 handbrake will automatically take up any further movement should roll-off start to occur when parked on a slope. b) Disconnect electrical plug from socket and store in safe position. c) Loosen jockey clamp and lower jockey wheel to ground. Firmly rerighten clamp (by hand). Press back trigger with thumb and lift handle on coupling head. At the same time raise front of trailer by use of jockey wheel until head is fully clear of ball on towing vehicle, if additional front mounted prop is fitted, ensure it is correctly lowered and secured. d) Disconnect breakaway cable from towing vehicle. e) Drive towing vehicle clear of trailer. (in the case of a coupling fitted with an eye follow above instructions except in respect of the final disconnecting of the towing vehicle in which case the instructions supplied with the towing jaw or hook should be used accordingly). f) As extra security it is strongly recommended that the wheels of the trailer should be chocked as an additional safeguard. 23

24 8.0 EQUIPMENT LAYOUT Fleeter Basket 2 Fixed Quadrant Rollers 3 Rotating Carousel 4 Stabilising Rear Prop 5 Jockey Wheel 6 Sub-Duct Clamp Bracket 7 Hydratow Coupling 8 Level Indicator 24

25 9.0 SPARES For spare parts always quote the model type, VIN (Vehicle Identification Number, located on the chassis frame) and contact:- CBS PRODUCTS LIMITED PILLINGS ROAD OAKHAM RUTLAND LE15 6QF UK TEL: +44 (0) /6 FAX: +44 (0) Website: Model: C-1265 Fleeting Device VIN No: See Certificate of Conformity Typical Spares:- Rear Prop Jockey Wheel Mudguard Wheel and Tyre Roller Assembly Clamp Toggle Latch C-PROP-005-F C-J-WHL-005-F P-MUD-G-TC442 C-WHL-059-F C-1050-AS1002 R-CLAMP

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