Lukas 81-60-10, Instruction Manual

Page 1: ... Translation of the original instruction manual Hose reels Instruction manual for rescue equipment 176250085 EN replaces 10 2014 Edition 07 2017 ...

Page 2: ...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 ...

Page 3: ...ta 28 11 1 General reel identification 28 11 2 Maximum operating pressure 28 11 3 Technical data for the hose reels 29 11 4 Hydraulic fluid recommendation 33 11 5 Operating and storage temperature range 33 12 EC Declarations of conformity 34 13 Notes 37 ...

Page 4: ... and possible consequences 1 Hazard classes Pictogram Damage injury to Key word Definition 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 su...

Page 5: ...gn 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 s...

Page 6: ...uipment The formation of electrostatic charging with the potential consequence of spark formation associated with handling this equipment is to be avoided The equipment is filled with a hydraulic fluid These hydraulic fluids 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 fluids can ha...

Page 7: ... 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 ar...

Page 8: ...raulic 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 a...

Page 9: ...ction of a extension hose pair Delivery with carrier frame Parking brake fix mounted flap 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 fix connected with the hose drum Connection to the hydraulic pump or control unit is carri...

Page 10: ...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 cou...

Page 11: ... 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 t...

Page 12: ...eeve 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 CA...

Page 13: ...chen 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 endang...

Page 14: ...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 brak...

Page 15: ...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 ...

Page 16: ...ly 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 flapped 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 t...

Page 17: ...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 r...

Page 18: ... 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 different 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 ...

Page 19: ...ing 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 fluid 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 fluid out of the hose reel The period of pressurization ...

Page 20: ...N 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 ...

Page 21: ...lings 2 Loosen the connection nuts of the hose assembly and remove the coupling 3 Position the new coupling and tighten the connection nuts of the hose assemblies with a torque of MA 40 Nm 29 5 lbf ft and push the cover of the couplings back on WARNING CAUTION Never repair couplings they are to be replaced by original LUKAS parts CAUTION Take care that the port T T1 of the hose reel is always conn...

Page 22: ...n hose pairs 2 Loosen the elbow and remove it 3 Position the new ellbow and tighten it with a torqu of MA 40 Nm 29 5 lbf ft winding direction Coiling hose elbow CAUTION Take care that the elbows are always mounted in the correct oriented manner see illustration on the right protective covers Do not forget to push the protective covers back again over the screwed connections siehe illustration on t...

Page 23: ...he hose drum has been changed Find further details on disassembling and assembling in the spare parts list 9 3 6 Changing the hose drum on the double hose reel Damaged hose drums must be immediately replaced Before you can change the hose drums however you must dismantle the extension hose pairs Procedure 1 Remove both screws A and washer 2 Remove the shaft with both hose drums 3 Remove fixing bol...

Page 24: ...hers and nuts and tighten Find further details on disassembling and assembling in the spare parts list 9 3 8 Labels All damaged and or illegible labels safety notices type plate etc must be renewed Procedure 1 Remove damaged and or illegible labels 2 Clean the surfaces using acetone or industrial alcohol 3 Attach new labels Ensure that you attach the labels in the right position If you are no long...

Page 25: ...ydraulic pump to pressureless circulation Coupling defective Coupling needs to be replaced immediately It is frequently not possible to couple hose assemblies Control the degree of viscosity and application temperature of the used hydraulic fluid Hydraulic fluid not adapted to the application situation Hydraulic fluid must be replaced see chapter Recommended Hydraulic fluids Coupling defective Cou...

Page 26: ...LUKAS itself Leakage of hydraulic fluid on the connections between connection hoses and reel shaft Connection hoses defective Hoses defective Replace hoses Connections of the hoses tighten Hoses fittings not tightened properly Tighten the screwed connection of the hoses fittings Leakage between fitting and shaft Fittings not tightened properly Tighten the screwed connection Sealing between fitting...

Page 27: ...m an authorised LUKAS dealer or the LUKAS customer service department immediately The address for the LUKAS customer service department is LUKAS Hydraulik GmbH Weinstraße 39 D 91058 Erlangen Tel 0049 0 91 31 698 348 Fax 0049 0 91 31 698 353 http www lukas com ...

Page 28: ...re subject to tolerances minor differences may occur between the data on your equipment and the data listed here Type of hose reel SHR single hose reel DHR double hose reel Length of the extension hose pairs in m Length of the extension hose pairs in ft Length of the short supply hose pairs The max operating pressure of all STREAMLINE hose reels is ...

Page 29: ...1 x 12 9 x 19 3 in Operating pressure max 70 MPa 10000 psi Hose length m Reel without hose ft Number of connectable devices max 1 Streamline quick disconnect Number of hoses pump side 1 x 2 Connection hoses 1 5 m 4 9 ft long Number of connections pump side max 1 Streamline quick disconnect Weight 7 5 kg incl hydraulic fluid 16 5 lbs ...

Page 30: ... 3 in Operating pressure max 70 MPa 10000 psi Hose length 15 m 50 ft Number of connectable devices max 1 Streamline quick disconnect Number of hoses pump side 1 x 2 Connection hoses 1 5 m 4 9 ft long Number of connections pump side max 1 Streamline quick disconnect Weight 15 kg incl hydraulic fluid 33 1 lbs ...

Page 31: ... 3 in Operating pressure max 70 MPa 10000 psi Hose length 20 m 66 ft Number of connectable devices max 1 Streamline quick disconnect Number of hoses pump side 1 x 2 Connection hoses 1 5 m 4 9 ft long Number of connections pump side max 1 Streamline quick disconnect Weight 18 kg incl hydraulic fluid 38 6 lbs ...

Page 32: ... Operating pressure max 70 MPa 10000 psi Hose length 20 m 66 ft Number of connectable devices max 2 x 1 Streamline quick disconnect Number of hoses pump side 2 x 2 Connection hoses 1 5 m 4 9 ft long Number of connections pump side max 2 x 1 Streamline quick disconnect Weight 35 8 kg incl hydraulic fluid 78 9 lbs ...

Page 33: ...176 F HM 32 VG 32 E 17 6 158 F HF E15 VG 15 Bio oil recommended viscosity range 10 200 mm s 10 200 cSt Supplied with HM 22 DIN ISO 6743 4 11 5 Operating and storage temperature range Operating temperature C F 20 55 4 131 Storage temperature device not in operation C F 30 60 22 140 CAUTION Before using hydraulic fluids which do not correspond to the above mentioned specifications and or are not pur...

Page 34: ...34 12 EC Declarations of conformity ...

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Page 37: ...37 13 Notes ...

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Page 40: ...de in GERMANY Copyright 2017 LUKAS Hydraulik GmbH hose_reels_manual_176250085_en indd Subject to revision LUKAS Hydraulik GmbH A Unit of IDEX Corporation Weinstraße 39 D 91058 Erlangen Tel 49 0 91 31 698 0 Fax 49 0 91 31 698 394 e mail lukas info idexcorp com www lukas com ...