Lukas CT7 User Manual
Operating instructions
Rerailing Equipment
Control desks (model CT7)
84072134485 GB
Edition 08.2009
(Translation of the original operating instructions)
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Content Page
1. Hazard classes 4
2. Product safety 5
3. Proper use 8
4. Functions and performance 9
4.1 Description 9
4.2 Hydraulic supply 9
4.3 Overview 10
4.4 Hydraulic circuit diagrams for standard control desks 11
4.5 Optional accessories 14
5. Connection of hydraulic devices 14
5.1 Basic information 14
5.2 Connection of quick-connect couplings 15
6. Operation 16
6.1 Setting up the control desk 16
6.2 Start-up 16
6.3 Control desk controls 17
7. Dismantling the equipment / deactivation following operation 18
8. Maintenance and service 19
9. Repairs 19
9.1 General 19
9.2 Preventive service 20
9.3 Repairs 21
10. Troubleshooting 22
11. Technical data 24
11.1 Control unit 24
11.2 Pedestal 24
11.3 Control desk (control unit + pedestal) 25
11.4 Recommendedhydraulicuids 25
11.5 Operating temperature and storage temperature ranges 25
12. EC Declaration of Conformity 26
13. Notes 27
4
Hazard classes1.
We distinguish between various categories of safety instructions. The table below gives you
an overview of the assignment of symbols (pictograms) and key words to the specic hazard
and possible consequences.
Pictogram
Damage / injury
to
human
device
- REMARK
Key word Denition Consequences
DANGER! Immediate danger
WARNING!
CAUTION!
CAUTION!
Potentially
dangerous
situation
Less dangerous
situation
Danger of damage
to device /
environment
Advice for
application and
other important /
useful information
and advice
Death or major
injury
Potential death or
major injury
Minor or slight
injury
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
No injury /
damage to
persons /
environment /
equipment
Wear helmet with face protection
Wear safety gloves
Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
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Product safety2.
LUKAS products are developed and manufactured in order to guarantee the best performance
and quality when used properly.
Operator safety is the most important aspect of the product design. Moreover, the operating
instructions are intended to ensure LUKAS products are used 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 may only be operated by persons with appropriate training in the safety
aspects of such equipment – otherwise, there is a danger of injury occurring.
We would like to point out to all users that they should read the operating instructions carefully
before using the equipment and comply with the instructions there without restriction.
We further recommend that a qualied instructor train you in the use of the product.
WARNING / CAUTION!
The operating instructions for the hoses, the accessories and the connected
hydraulic equipment must also be observed.
Even if you have already received instructions on how to use the equipment, you should still
read through the following safety instructions once again.
WARNING / CAUTION!
Ensure that the accessories and connected equipment used 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, safety
helmet with visor, safety shoes
and protective gloves
The department responsible
is to be informed immediately
of any changes (including to
the operating behaviour). If
necessary, the equipment is to
be shut down immediately and
secured.
It is prohibited to work under
load if this load is lifted
exclusively by hydraulic
equipment. If this work
is absolutely imperative,
additional mechanical supports
must be used.
Inspect the equipment before
and after use for visible defects
or damage.
Inspect all lines, hoses and
screwed connections for
leaks and externally visible
damage. If necessary,
repair immediately. Squirting
hydraulic liquids can result in
injuries and res.
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In the event of malfunctions,
immediately shut down the
equipment and secure it. The
malfunction is to be repaired
immediately.
Do not carry out any changes
(additions or conversions)
to the equipment without
obtaining the prior approval of
LUKAS.
Comply with all the instructions
regarding safety and danger
on the equipment and in the
operating instructions.
Any method of operation which
impairs safety and/or stability
of the equipment is prohibited.
Safety devices may never be
deactivated.
Before the equipment is
switched on / started up, and
during its operation, it must
be ensured that nobody is
endangered by the operation of
the equipment.
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 the instructions regarding
safety and danger on the
equipment are to be kept
complete and in a legible
condition.
Comply with all specied
dates or dates specied in
the operating instructions
pertaining to regular checks /
inspections of the equipment.
The maximum operating
pressure marked on the
equipment must not be
exceeded.
Only original LUKAS
accessories and spare parts
may be used for repairs.
During all work and transport
operations involving the
equipment, take care not to trip
and become caught in hose
loops.
The build-up of static charge
with the potential consequence
of spark formation is to be
avoided when handling the
equipment.
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The equipment is lled with
hydraulic uid. These hydraulic
uids can be harmful to your
health if swallowed or if their
vapours inhaled. Direct contact
with the skin is to be avoided
for the same reason. Please
also note that hydraulic uids
can also have a negative effect
on 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 extreme external
temperatures and that the
equipment is not damaged in
any way. Please note that the
equipment can also heat up
over a long period of use.
Ensure adequate lighting when
you are working.
Always keep these operating
instructions within reach where
the equipment is used.
The generally applicable, legal and other binding national and international regulations
pertaining to the prevention of accidents and protection of the environment apply and are to
be implemented in addition to the operating instructions.
Before transporting the
equipment, always ensure that
the accessories are positioned
in such a way that they cannot
cause an accident.
Ensure the proper disposal
of all removed parts, leftover
oil and uid, and packaging
materials.
WARNING / DANGER / CAUTION!
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter "Proper use"). Any form of use beyond this is not considered
proper use. The manufacturer / supplier is not liable for any damages resulting from improper
use. The user bears sole responsibility for such use.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are covered by the denition of proper use.
Never work when you are overtired or intoxicated.
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Proper use3.
LUKAS control desks have been developed specically for rerailing operations. They are
intended to control the hydraulic jacks and pushers used in the event of a railway vehicle
derailment.
The accessories required for the derailment incident concerned must be used (depending
on the variant, e.g. pedestal).
CAUTION!
To minimise the risk to the environment, remedy leaks as soon as possible.
Accessories and spare parts for the control desks are available from your authorised LUKAS
dealer.
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Functions and performance4.
4.1 Description
The control desks in the CT7 model series comprise a number of valves housed in a control
block. The valves are controlled by means of control levers.
Depending on the version, up to 6 double-acting and 2 single-acting hydraulic devices can
be connected and controlled without the need for a separate controller.
The attached, manually operated pressure shut-off valve opens and closes the supply to the
control valves. With the manual pressure shut-off valve in the “closed” position, the ow to
WARNING / DANGER / CAUTION!
The manual pressure shut-off valve closes only the connection to the hydraulic
unit to be supplied.
It is NOT provided as an “emergency stop” function. This means that the
connected hydraulic devices could still move if one of the control levers were
operated. This could happen if residual pressure in the system or external loads
were to act on the connected hydraulic devices.
the hydraulic pump is automatically depressurised.
The control desks are usually mounted on a separate pedestal or secured directly to the unit
frame. LUKAS control desks are normally always delivered mounted on a pedestal or tted
to a frame. To nd out more, please contact your authorised LUKAS dealer.
The control desk also features a pressure gauge on the inlet block as standard. This pressure
gauge indicates the pressure acting on the control desk from the unit.
4.2 Hydraulic supply
Only LUKAS motor pumps are permitted to be used to drive the devices.
If an other-make pump power pack is used, it is important to ensure that it complies with
LUKAS specications, as otherwise dangerous situations beyond the control of LUKAS
could arise. Particular care must be taken to ensure that the maximum permissible operating
pressure of the connected LUKAS devices is not exceeded.
REMARK:
Before you use pumps of a different manufacturer, you must contact LUKAS or
an authorised dealer.
The connection to the supplied hydraulic pump and to the implements is established by
means of hose lines, which are connected to each other by couplings.
CAUTION!
Due to ram pressures in the hose lines, the maximum overall length of the hose
lines, from the unit to the control desk to the hydraulic device, is limited to 40 m
(131.2 ft.).
Long hose lines between the implement and control desk or unit and control desk
may result in delayed movement of the hydraulic implements (particularly in the
event of the automatic return of single-acting implements).
For work involving long hose lines at low ambient temperature, we recommend
theuseofahydraulicuidwithalowviscosity.
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