Lukas CU 4DVV User Manual
Instruction Manual Rerailing Equipment
90000085 EN
Control tables CU 2DV and CU 4DVV
CU 2DV
CU 4DVV
(Translation of the original instruction manual)
1490000085 EN
14
Edition 09.2014
Edition 09.2014
2
Content Page
1. Danger classifi cations 4
2. Product safety 5
3. Proper use 8
4. Components and functions 9
4.1 Description 9
4.2 Hydraulic supply 9
4.3 Installation of the control table 10
4.4 Functions and controls available at the control desk 11
5. Erection and start-up 13
5.1 Folding out the support frame 14
5.2 Connection of the working equipment 15
5.3 Coupling the quick-disconnect couplings 15
6. Dismantling the equipment / deactivation following operation 16
7. Maintenance and service 17
7.1 General information 17
7.2 Repairs 18
8. Troubleshooting 19
9. Technical data 21
9.1 Control unit CU 2DV 21
9.2 Control unit CU 4 DVV 22
9.3 Operating and storage temperature ranges 22
10. EC Declaration of Conformity 23
11. Notes 24
3
1. Danger classifi cations
We differentiate between various different categories of safety instructions. The table shown
below provides an overview of the assignment of symbols (pictograms) and signal words to
the specifi c danger and the possible consequences.
Pictogram
Damage /
injury to
Persons
Property
- NOTE
Key word Defi nition Consequences
DANGER! Immediate danger
WARNING!
CAUTION!
ATTENTION!
Potentially
dangerous
situation
Less dangerous
situation
Danger of damage
to property/
environment
Handling tips and
other important/
useful information
and advice
Death or severe
injury
Potential death or
serious injury
Minor or slight
injury
Damage to the
equipment,
damage to the
environment,
damage to
surroundings
No injury/damage
to persons/
environment/
device
Wear a helmet with a face guard
Wear protective gloves
Wear safety shoes
Proper recycling
Protect the environment
Read and follow the operating instructions
4
2. Product safety
LUKAS products are developed and manufactured to ensure the best performance and
quality when used as intended.
The safety of the operator is the most important consideration in product design. Furthermore,
the operating instructions are intended to help in using LUKAS products safely.
The generally applicable legal and other binding regulations pertaining to the prevention of
accidents and protection of the environment apply and are to be complied with in addition to
the operating instructions.
The equipment must only be operated by persons with appropriate training in the safety
aspects of such equipment – otherwise, there is a danger of injury.
We would like to point out to all users that they should read carefully the operating instructions
and the instructions contained therein before they use the equipment, and that they should
carefully follow such.
We also recommend that you have a qualifi ed trainer show you how to use the product.
WARNING / CAUTION!
You must also observe the operating instructions for the hoses, the
accessories and the connected devices!
Even if you have already received instruction on how to use the equipment, you should still
read through the following safety instructions again.
WARNING / CAUTION!
Ensure that the accessories and connected equipment are suitable for the
maximum operating pressure!
Please ensure that no body
parts or clothing get stuck
between the visibly moving
parts.
Wear protective clothing,
a safety helmet with visor,
protective footwear and gloves
Immediately report any
changes that occur (including
changes in operating
behaviour) to the appropriate
persons/departments! If
necessary, the equipment is to
be shut down immediately and
secured!
Working under suspended
loads is not permitted where
such loads are being lifted
only using hydraulic devices.
If working under suspended
loads is unavoidable, suitable
mechanical props are also
required.
Inspect the device before and
after use for visible defects or
damage.
Check all lines, hoses and
screwed connections for leaks
and externally visible damage,
and repair immediately!
Escaping hydraulic fl uid can
cause injuries and fi res.
5
In the event of malfunctions,
immediately deactivate the
equipment and secure it.
Repair the fault immediately.
Do not carry out any changes
(additions or conversions)
to the equipment without
obtaining the approval of
LUKAS beforehand.
Observe all safety and danger
information on the device and
in the operating instructions.
Any mode of operation which
compromises the safety and/
or stability of the device is
forbidden!
Safety devices must never be
disabled!
Make sure before switching
on/starting up the device and
during its operation, that this
will put no one in danger.
When working close to live
components and cables,
suitable measures must be
taken to avoid current transfers
or high-voltage transfers to the
equipment.
All safety and danger
instructions on the device must
always be complete and in a
legible condition
Observe all intervals for
recurring tests and/or
inspections that are prescribed
or stated in the operating
instructions.
The maximum permitted
operating pressure noted on
the equipment must not be
exceeded.
Only genuine LUKAS
accessories and spare parts
are to be used for repairs.
Please ensure that, when
working with this equipment or
during transportation of such,
you don’t get caught up in the
looped hoses and trip.
The build-up of static charge
and therefore possible
sparking must be avoided
when handling the device.
6
The equipment is fi lled with
hydraulic fl uid. This hydraulic
fl uid can be detrimental to
health if it is swallowed or
its vapour is inhaled. Direct
contact with the skin must be
avoided for the same reason.
Also, when handling hydraulic
fl uid, note that it can negatively
affect biological systems.
When working with or storing
the equipment, ensure that the
function and the safety of the
equipment are not impaired
by the effects of severe
external temperatures or that
the equipment is damaged in
any way. Please note that the
equipment can also heat up
over a long period of use.
Make sure there is adequate
lighting while working.
Always keep these operating
instructions easily accessible
at the place of operation.
In addition to the safety instructions in this operating manual, all generally applicable,
statutory and otherwise binding national and international regulations for accident prevention
must be heeded and disseminated!
Before transporting the
equipment, always ensure that
the accessories are positioned
in such a way that they cannot
cause an accident.
Dispose properly of all
disassembled parts, oil and
left-over fl uid, as well as
packaging materials.
WARNING / CAUTION / ATTENTION!
The device is intended exclusively for the purpose stated in the operating instructions
(see chapter "Proper Use"). Any other use is not considered to be as intended. The
manufacturer/supplier is not liable for any damage resulting from use not as intended. The
user bears sole responsibility for such use.
Proper use includes observance of the operating instructions and compliance with the
inspection and maintenance conditions.
Never work in a fatigued or intoxicated state!
WARNING / CAUTION / ATTENTION!
However, if you do injure yourself on the hydraulic unit, clean the wound
immediately and consult a doctor to have it attended to!
If you get hydraulic fl uid in your eye, rinse it immediately several times with clear,
clean water and consult a doctor!
Also, if you swallow hydraulic fl uid you should consult a doctor!
7
3. Proper use
LUKAS control tables are especially designed for rerailing technology. They serve to
control the deployed hydraulic lifting and traversing equipment for rerailing, erection and
maintenance work on rail-bound vehicles.
When carrying out any work, use the control tables described here and the connected hoses
and equipment to ensure that you yourself, the involved and uninvolved persons in the
proximity of the work and objects in closer proximity during the lifting and traversing process
are not endangered.
Y ou can obtain accessories and replacement parts for the control tables from your authorised
LUKAS dealer!
System overview
Rail-bound vehicle erection
WARNING / CAUTION / ATTENTION!
The safety instructions in this operating instruction manual concerning the site of
erection and type of erection must always be observed!
The Type CU LUKAS control tables are not explosion-protected!
ATTENTION!
Watch out vigilantly for any leaks in order to avoid threats to the environment.
lifting cylinders and the
LUKAS traversing system
8
Control table
UnitLifting and rerailing with
4. Components and functions
4.1 Description
The CU range of control tables consist of a control desk with support frame and a large
number of valves. The valves are actuated by control levers. The control levers automatically
return to the neutral or middle position when released (dead man's handle - depressurised
circulation with hydraulic load holding).
The control table has been developed for connection of double-acting cylinders, but singleacting cylinders can also be connected and controlled to a limited extent. If necessary you
may need to consult LUKAS or one of their authorised dealers.
The control tables are rigidly mounted on a support frame that can be folded fl at for space-
saving storage.
Pressure gauges are mounted on the control tables as standard. Each pressure gauge
shows the pressure generated by each individual pump circuit and which is present at the
control table via the power unit.
The hydraulic power packs developed for the single control table are 2POWER packs with
two circuits, and the power packs developed for the double control table are 4POWER packs
with four circuits.
4.2 Hydraulic supply
Only LUKAS hydraulic power packs may be used to drive the equipment.
If the pump unit supplying the pressure is from a different manufacturer you need to make
sure that it is made in accordance with the stipulations laid down by LUKAS. If this is not the
case, dangers can arise that cannot be attributed to LUKAS.
Ensure in particular that the maximum permissible operating pressure for the connected
LUKAS equipment is not exceeded.
NOTE:
Before using pumps and power packs from a different manufacturer, you must
always contact LUKAS or an authorised dealer.
The connection to the hydraulic pump providing the supply and to the hydraulic working
equipment is by hoses that are connected by couplings.
ATTENTION!
Because of the back-pressure in the hoses, the maximum overall length of
the hoses from the power pack via the control table to the working equipment
must be 20 m (66 ft.). If necessary, it is, however, possible to use longer hoses.
However, each individual case must be agreed with LUKAS or with an authorised
dealer, in order to take account of the local conditions if necessary.
9
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