Lukas SHR 20 User manual

(Translation of the original instruction manual)
Hose reels
Instruction manual for rescue equipment
176250085 EN
replaces 10.2014
Edition 07.2017

2
1. Hazard classes 4
2. Product safety 5
3. Intended use 8
4. Description 9
4.1 General information 9
4.2 Single hose reel 9
4.3 Double hose reel 10
5. Connecting the equipment 11
5.1 On the side of the hydraulic unit 11
5.2 On the side of the equipment 11
5.3 Coupling the mono-couplings 12
6. Operation 13
6.1 Safety notes 13
6.2 Start-up 14
6.3 Parking brake 14
6.4 Unrolling 16
6.5 Coiling 16
7. Dismantling the equipment / deactivation following operation 16
7.1 Equipment 16
7.2 Hydraulic unit 16
7.3 Hoses 16
7.4 Hose reel 17
8. Maintenance and service 17
9. Repairs 18
9.1 General information 18
9.2 Preventative service 19
9.3 Repairs 20
Content Page

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Content Page
10. Troubleshooting 25
11. Technical Data 28
 11.1 Generalreelidentication 28
11.2 Maximum operating pressure 28
11.3 Technical data for the hose reels 29
 11.4 Hydraulicuidrecommendation 33
11.5 Operating and storage temperature range 33
12. EC Declarations of conformity 34
13. Notes 37

4
Wear helmet with face protection
Wear safety gloves
Wear safety shoes
Proper recycling
Observe principles of environmental protection
Read and observe operating instructions
We distinguish between various categories of safety notes. The table below gives you an
overview of the assignment of symbols (pictograms) and key words to the specic hazard
and possible consequences.
1. Hazard classes
Pictogram Damage /
injury to Key word Denition Consequences
human
DANGER! Immediate danger Death or major
injury
WARNING!
Potentially
dangerous
situation
Potential death or
major injury
CAUTION! Less dangerous
situation
Minor or slight
injury
device
CAUTION!
Danger of damage
to device /
environment
Damage to the
equipment,
damage to the
environment,
damage to
surrounding
materials
- REMARK
Advice for
application and
other important /
useful information
and advice
No injury /
damage to
persons /
environment /
equipment

5
2. Product safety
Wear protective clothing, safety
helmet with visor, protective
gloves
Inspect the equipment before
and after use for visible defects
or damage.
The responsible department
is to be informed immediately
of any changes (including to
the operating behavior). If
necessary, the equipment is
to be deactivated immediately
and secured!
Inspect all cables, hoses and
screwed connections for leaks
and externally visible damage.
Repair them immediately!
Squirting hydraulic liquids can
result in injuries and res.
In the event of malfunctions,
immediately deactivate 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.
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 help the safe use of LUKAS products.
The generally applicable, legal and other binding regulations pertaining to the prevention of
accidents and protection of the environment apply and are to be implemented 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 carefully the operating instructions
and the instructions contained therein before they use the equipment, and that they should
carefully follow such.
We further recommend that a qualied trainer 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 the following safety notes through again.
WARNING / CAUTION!
Ensure that the accessories and connected equipment used are suitable for
the max. operating pressure!

6
Observe all safety and danger
notes on the equipment and in
the operating instructions.
All safety and danger notes
on the device are to be kept
complete and in a legible
condition.
Any mode of operation which
impairs safety and/or stability
of the equipment is forbidden!
Comply with all specied
dates or dates specied in
the operating instructions
pertaining to regular controls /
inspections on the equipment.
Safety devices may never be
deactivated!
The maximum permitted
operating pressure noted on
the equipment may not be
exceeded.
Only original LUKAS
accessories and spare parts
may be used for repairs.
Please ensure that, when
working with this equipment
or during transportation of
such, you don’t get stuck in the
looped hoses and trip.
When working close to live
components and cables,
suitable measures must be
taken to avoid current transfers
or high-voltage transfers to the
equipment.
The formation of electrostatic
charging with the potential
consequence of spark
formation associated with
handling this equipment is to
be avoided.
The equipment is lled with a
hydraulic uid. These hydraulic
uids can be dangerous to
health if swallowed or their
vapors inhaled. Direct contact
with the skin is to be avoided
for the same reason. Please
also note that hydraulic uids
can have a negative e󰀨ect 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 e󰀨ects of stark
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.
Ensure adequate lighting when
you are working.
Before transporting the
equipment, always ensure that
the accessories are positioned
such that they cannot cause an
accident.
Always keep these operating
instructions within reach where
the equipment is used.
Ensure the proper disposal of
all removed parts, left-over oil,
left-over hydraulic uid and
packaging materials.

7
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.
WARNING / CAUTION!
The equipment is to be used exclusively for the purpose stated in the operating
instructions (see chapter “Proper Use”). Any other or further use 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.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are part of the proper use.
Never work when you are overtired or intoxicated!

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3. Intended use
Spare parts and accessories for the rescue tool can be ordered from your authorized
LUKAS-dealer!
The LUKAS hose reels are used for mounting extension hose pairs between the hydraulic
supply and the working equipment. The extension hose pairs are connected to the hose reel
and coiled onto the drum.
The use of a LUKAS hose reel with extension hose pairs enables a greater distance
between the hydraulic supply and the equipment. This allows the hydraulic unit to stay on
the emergency vehicle, for example.
When working with the units described here, make sure that participating and non-participating
persons in the vicinity of the work and during the lifting procedure are not endangered by the
connected hoses and equipment.
The hose reels can also be used under water at a depth of up to 40 m (131 ft).
CAUTION!
In this case, you must strictly observe any leaks in order to avoid threats to the
environment.
CAUTION!
Because of possible loss of pressure, only extension hose lines having a
maximum length of 20 m may be connected on the equipment side and on the
device side the length may also be no more than max. 30 m!

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4. Description
4.1 General information
4.2 Single hose reel
The single hose reel comprises one carrier frame and one shaft with hose drum. One
extension hose pair can be connected to the equipment side of the reel.
Connection to the hydraulic pump or control unit is made by connecting the “short” supply
hose pair to the pump or the control unit via mono-coupling.
3
Basically, a reel comprises a carrier, shaft and hose drum.
We distinguish between:
Single hose reel: - Connection of a extension hose pair
- Delivery with carrier frame
- Parking brake, x mounted, ap-in crank handle
Double hose reel: - Connection of two extension hose pairs
- Delivery with carrier frame
- Parking brake
Coiling / unrolling of all models is being carried out by a hand crank, which can either be
plugged in or is x connected with the hose drum.
Connection to the hydraulic pump or control unit is carried out by connecting the connection
hose pairs with the pump or control unit using mono-couplings.
1 Hose drum
2 Carrier
3 Extension hose pair
4 Supply hose pair
5 Mono-coupling (male)
6 Mono-coupling (female)
7 Crank
8 Reel locking
9 hose retaining strap
1
2
3
4
5
6
7
8
9

10
4.3 Double hose reel
The double hose reel comprises one carrier frame and one shaft with two hose drums. Two
extension hose pairs or extension hoses can be connected to the reel on the device side
(one extension hose per drum). Depending on the connector version, connection on the
equipment side is made by one or two short return hoses and one short extension hose
per extension hose or extension hose pair. These connecting hoses are attached to the
hydraulic pump or a control unit by means of couplings. The double hose reel also has a
parking brake for simultaneously securing both hose drums in their positions.
1 Hose drum
2 Carrier
3 Extension hose pair 1
4 Extension hose pair 2
5 Supply hose A
6 Supply hose A1
7 Return hose T
8 Return hose T1
9 Mono-coupling (female) 1
10 Mono-coupling (female) 2
11 Parking brake
12 Crank
13 Carrying
14 Mono-coupling (male) 1
15 Mono-coupling (male) 2
1
2
3
4
5
6
7
9
8
10
12
11
13
14
15

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5. Connecting the equipment
5.1 On the side of the hydraulic unit
5.2 On the side of the equipment
REMARK:
Di󰀨erent couplings than mono-couplings, like quick-disconnect-couplings, are
possible when using available adapter kits. Also the direct screw connection
into the pump connection block of the power unit is possible. The adapter kits
can be ordered via the LUKAS optional equipment.
There are “short” hoses on the side of the unit: they are connected to the pump unit.
The extension hose pairs are on the side of the equipment: they are connected with the
equipment by means of couplings. The combination female and male coupling ensures an
unmistakable connection.
WARNING / CAUTION!
Before connecting the equipment you have to pay attention that all
used components are suitable to the max operation pressure
of the pump unit! In the case of doubt you have to inquire
LUKAS directly!

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5.3 Coupling the mono-couplings
The equipment is connected to the hydraulic pump via mono-coupling halves (male and
female).
Before coupling, remove dust protection caps, then connect male and female, and turn
the locking sleeve of the female to direction „1“ until the locking sleeve locks into place.
The connection is now in place and secure. Decoupling is by turning the locking sleeve to
direction „0“.
The equipment can also be coupled under pressure provided the connected equipment is
not activated.
REMARK:
We recommend coupling the coupling halves in a pressureless state, when
working in areas with low ambient temperature otherwise decoupling could need
very high expenditure of force.
To protect them from dust, the accompanying dust protection caps must be put back on.
WARNING / CAUTION!
The mono-couplings may not be screwed o󰀨 the hose assemblies and / or the
hose assemblies be confused!
mono-coupling
halve (male)
mono-coupling
halve (female)
dust protection caps

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6. Operation
6.1 Safety notes
World-wide, safety guidelines pertaining to the specic country are to be observed and
complied with. In the Federal Republic of Germany, regular safety inspections according
to the regulations of the Gesetzlichen Unfallversicherung (GUV; connoted ‘Legal accident
insurance’) are mandatory.
The following are to be worn when working with the hose reel:
- protective clothing,
- safety helmet with visor or protective goggles,
- protective gloves
- and, if necessary, ear protection
WARNING / CAUTION!
When working with the hose reel, those not involved must maintain an appropriate,
suitable safe distance, so that they are not endangered in the event of failure
of the hose.

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6.3 Parking brake
A
B
C
A
B
C
C
6.2 Start-up
Before start-up and following repairs, the hose assemblies of the hose reel must be deaerated:
- Connect the hose reel to the hydraulic pump (see chapter “Connecting the equipment”).
- Switch on the hydraulic unit and pressurize the supply hoses for some time.
- Switch the hydraulic unit to depressurized circulation or switch it. If necessary, you have
to top-up hydraulic uid.
After the deaeration the working equipment can be reconnected to the hose reel.
CAUTION!
The working equipment has to be disconnected!
REMARK when using mono-couplings:
We recommend coupling the coupling halves in a pressureless state, when
working in areas with low ambient temperature otherwise decoupling could
need very high expenditure of force.
The parking brake prevents the extension hose pairs from unrolling during transport!
In order to release the parking brake, turn the knob A anti-clockwise until there is a distance
of approx. 5 mm / 0.2 in. between the brake shaft B and the hose drums C.
In order to activate the parking brake, turn the knob A clockwise until brake shaft B is nger-
tight with the hose drums C.
g. 9
6.3.1 Parking break DHR

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6.3.2 Parking break SHR
The parking break shall prevent that the extension hose pairs unroll during transport! To
unlock or release the break pull at the knob and turn it about 90°.
To activate the break turn the knob again about approx. 90° until it engages automatically.
The crank is supposed to make coiling easier! To make the curl ready for use, pull at the
crank handle, turn it about 90° outwards until it engages.
To put the crank into storing position, pull at the crank handle and turn it approx. about 90°
inwards until it engages again.
6.3.3 Crank SHR
90° 90°

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6.4 Unrolling
6.5 Coiling
To unroll, pull at the extension hoses until the required length has been unrolled from the
hose reel.
CAUTION!
For unrolling the hose from the hose reels, the parking brake must rst of all be
released. This prevents damage to the reel and the hoses.
REMARK:
We recommend the use of the hand crank for coiling the hose!
- First of all, put the hand crank onto the shaft of the hose reel.
- Release the parking break.
- Aligning the hose simplies the coiling of the hose.
- Now, you can turn the hand crank to coil the extension hose pair.
Ensure that the extension hose pair is always properly coiled on the hose drum.
This is usually guaranteed by guiding the extension hose pair with your hand during the
coiling process.
- Finally, you must activate the parking brake of the hose reels again and remove the crank
handle.
- In the case of the single hose reel the crank should be apped in again for safety reasons.
7. Dismantling the equipment / deactivation following
operation
7.1 Equipment
7.2 Hydraulic unit
7.3 Hoses
If the hose reel is to be disconnected from the unit and the equipment, please proceed as
follows:
On the side of the equipment:
Decouple the hoses as described in chapter “Connecting the equipment”.
Ensure that you put the dust protection caps back on to the mono-couplings.
On the side of the hydraulic unit :
Decouple the hoses as described in chapter “Connecting the equipment”.
Ensure that you put the dust protection caps back on to the mono-couplings.
Basically, all used equipment must be safely stored following deactivation.
Once work has been completed, the equipment is to be reset to its basic position.
Upon completion of work, the unit must be deactivated.

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7.4 Hose reel
8. Maintenance and service
Coil the extension hose pairs onto the hose reel.
Apply the parking brake on double hose reels.
Apply the parking brake and ap in the crank handle on single hose reels.
Visual inspection
Hose reel
• General tightness (leaks),
• Operability of the hose drums,
• All fastening screws are in place and tightened,
• Carrier, frame and drum are undamaged,
• Hand crank in place and undamaged,
• Parking brake in place and in working order,
• Labels completely existent and legibly,
Hoses
• Visual control for visible damage,
• Control for leaks.
• The hose connection must be tightly attached to the mounted reel, and not leak,
• Couplings must be easy to couple,
• Dust protection caps must be available.
Function test
• Undisturbed coiling and unrolling of the extension hose pairs.
• no unusual noises.
A visual inspection is to be carried out after every use: however, at least one visual inspection
is to be carried out annually. A function test is also to be carried out every three years or
should there be any doubt regarding the safety or reliability of the equipment.
(Please also observe the relevant valid national and international regulations pertaining to
service intervals of rescue equipment). In the Federal Republic of Germany, regular safety
inspections according to the regulations of the Gesetzlichen Unfallversicherung (GUV;
connoted ‘Legal accident insurance’) are mandatory.
CAUTION!
Clean o󰀨 any dirt before controlling the equipment!
WARNING / CAUTION!
In order to carry out maintenance and repair works, tools appropriate for the job
and personal protecting equipment are essential.

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Servicing may only be carried out by the manufacturer or personnel trained by the
manufacturer and by authorised LUKAS dealers.
Only LUKAS spare parts may be used to replace all components (see spare parts list) since
special tools, assembly advice, safety aspects, inspections might have to complied with (see
also chapter “Maintenance and Service”).
During assembly, ensure the complete cleanliness of all components, since dirt can
damage the rescue equipment!
9. Repairs
WARNING / CAUTION!
Protective clothes must be worn when repairs are being carried out, since parts
of the units can also be pressurised in an idle state.
REMARK:
Always register your tool on the LUKAS Hydraulik GmbH internet site. This is the
only way to guarantee extended warranty cover.
REMARK:
Before you use couplings from a di󰀨erent company, you must contact LUKAS or
an authorised dealer.
9.1 General information
CAUTION!
Because LUKAS of rescue equipment are appropriate for highest achievements,
only components may be exchanged, which are specied in the spare parts list
of the appropriate equipment.
Further components of the equipment may only be exchanged, when:
- you have participated on a appropriate LUKAS service training.
- you have the explicit permission of the LUKAS Service department (After inquiry,
examination for the distribution of permission. Examination in each individual
case necessarily!)

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9.2.1 Care regulations
The exterior of the equipment is to be cleaned from time to time in order to protect it from
external corrosion. Oil is to be applied to the metallic surfaces.
9.2.2 Function and load test
If there is any doubt regarding the safety or reliability of the equipment, a function and load
test must also be performed.
9.2.3 Changing the hydraulic uid
- The hydraulic uid must be changed after after three years at the latest.
- It must always be changed whenever the hydraulic uid for the accompanying pump
(motor / hand pump) is changed. This is to prevent the fresh hydraulic uid from becoming
contaminated by the used uid from the rescue equipment.
Procedure:
1. Change the hydraulic uid of the pump. Please observe the separate operating instructions
for the pump being used!
2. Screw o󰀨 the return hose on the pump:
- remove the cover from the mono-coupling (male).
- completely unscrew the connection nut of the blue return hose on the mono-
coupling (male).
3. Put the return hose into a separate collecting basin for the hydraulic uid still in the
equipment.
4. Activate the hydraulic pump and pressurize the supply hose. Pressurize the supply hose
as long as it needs to scavenge the whole used hydraulic uid out of the hose reel.
The period of pressurization depends on the length of the hose assemblies (Fluid volume
in the hose reel) and the ow rate of the pump. You will nd the uid volume of the hose
reel in the chapter ‘technical data’.
5. Switch the pump o󰀨 (motor pump) / no longer activate it (e.g. hand pump) and dispose the
collected hydraulic uid properly and according to the legal specications.
6. Reconnect the return hose to the pump:
screw the connection nut of the blue return hose back onto the mono-coupling (male).
(Observe the necessary torque of MA = 35 Nm/25.8 lbf∙ft!)
Pull back the cover on the couplings as far as the limit stop.
7. Check and top up the hydraulic uid level in the hydraulic pump.
9.2 Preventative service

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9.3 Repairs
9.3.1 Changing or tightening connection hoses
Hose assembly of the supply and/or return hose leaks or hoses are defective. Tighten the
hose connections on the shaft.
(CAUTION! Observe torque of MA = 40 Nm/29.5 lbf∙ft!)
9.3.2 Changing or tightening extension hose pairs
Hose assembly of the supply and/or return hose leaks or hose pairs are defective. Pull back
the protective cover and tighten the hose connections on the elbows.
(CAUTION! Observe torque of MA = 40 Nm/29.5 lbf∙ft!)
elbow
protective cover
hose
CAUTION!
Set of protectiv covers must be assembled on the reel!