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
10. Troubleshooting 25
2
11. Technical Data 28
11.1 General reel identifi cation 28
11.2 Maximum operating pressure 28
11.3 Technical data for the hose reels 29
11.4 Hydraulic fl uid recommendation 33
11.5 Operating and storage temperature range 33
12. EC Declarations of conformity 34
13. Notes 36
3
1. Hazard classes
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 specifi c hazard
and possible consequences.
Pictogram
Damage /
injury to
human
device
-REMARK
Key wordDefi nitionConsequences
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
4
2. Product safety
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 qualifi 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!
Wear protective clothing, safety
helmet with visor, protective
gloves
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!
In the event of malfunctions,
immediately deactivate the
equipment and secure it. The
malfunction is to be repaired
immediately.
5
Inspect the equipment before
and after use for visible defects
or damage.
Inspect all cables, hoses and
screwed connections for leaks
and externally visible damage.
Repair them immediately!
Squirting hydraulic liquids can
result in injuries and fi res.
Do not carry out any changes
(additions or conversions)
to the equipment without
obtaining the prior approval of
LUKAS.
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!
Safety devices may never be
deactivated!
Only original LUKAS
accessories and spare parts
may be used for repairs.
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 equipment is fi lled with a
hydraulic fl uid. These hydraulic fl 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 fl uids
can have a negative effect on
biological systems.
Ensure adequate lighting when
you are working.
Comply with all specifi ed
dates or dates specifi ed in
the operating instructions
pertaining to regular controls /
inspections on the equipment.
The maximum permitted
operating pressure noted on
the equipment may not be
exceeded.
Please ensure that, when
working with this equipment
or during transportation of
such, you don’t get stuck in the
looped hoses and trip.
The formation of electrostatic
charging with the potential
consequence of spark
formation associated with
handling this equipment is to
be avoided.
When working with or storing
the equipment, ensure that
the function and the safety
of the equipment are not
impaired by the effects 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.
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 fl uid and
packaging materials.
6
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!
7
3. Proper use
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.
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!
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.
Spare parts and accessories for the rescue tool can be ordered from your authorized
LUKAS-dealer!
8
4. Description
4.1 General information
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, fi x mounted, fl 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 fi 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.
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.
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.
Different 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.
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!
5.1 On the side of the hydraulic unit
There are “short” hoses on the side of the unit: they are connected to the pump unit.
5.2 On the side of the equipment
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.
11
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