Lukas SHR 20 User Manual

Instruction manual for rescue equipment
Hose reels
(Translation of the original instruction manual)
176250085 EN
Edition 10.2014
Content Page
1. Hazard classes 4
2. Product safety 5
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
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 word Defi nition 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
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 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!
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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.
1 Hose drum
1
2
9
8
7
3
6
5
9
2 Carrier 3 Extension hose pair 4 Supply hose pair
4
5 Mono-coupling (male) 6 Mono-coupling (female) 7 Crank 8 Reel locking 9 hose retaining strap
3
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
13
3
5
7
4
9
10
8
6
14
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
10
15
2
12
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5. Connecting the equipment
REMARK:
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.
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