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Related Manuals for Lukas SHR 1,5 Series
Summary of Contents for Lukas SHR 1,5 Series
- Page 1 Operating instructions for rescue equipment Hose reels 176250085 EN Edition 02/2025 replaces 03/2023 version (Translation of the original operating instructions)
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Page 2: Table Of Contents
Content Page 1. Danger classifications 2. Product safety 3. Proper use 4. Description 4.1 General 4.2 Single hose reel 4.3 Double hose reel 5. Connecting the device 5.1 On the power unit side 5.2 On the device side 5.3 Coupling the mono-couplings 6. Operation 6.1 Safety notes 6.2 Commissioning 6.3 Holding brake 6.4 Unrolling... - Page 3 Content Page 10. Troubleshooting 11. Technical data 11.1 General reel designation 11.2 Maximum operating pressure 11.3 Technical data of the hose reels 11.4 Hydraulic fluid recommendations 11.5 Operating and storage temperature ranges 12. Declarations of conformity 13. Notes...
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Page 4: Danger Classifications
1. Danger classifications We differentiate between various different categories of safety instructions. The table shown below provides an overview of the assignment of symbols (pictograms) and signal words to the specific danger and the possible consequences. Damage/ Pictogram Keyword Definition Consequences injury to Death or DANGER! Immediate danger severe injury Potentially Potential death or WARNING! dangerous serious injury situation Less dangerous Minor or CAUTION! situation slight injury Damage to the Risk of damage device, damage to ATTENTION! to property/ the environment, environment damage to surroundings Handling tips and No injury/damage other important/ to persons/ NOTE useful information... -
Page 5: Product Safety
2. Product safety LUKAS products are developed and manufactured to ensure the best performance and quality when used as intended. The operator’s safety is the most important consideration in product design. Furthermore, the operating instructions are intended to help you use LUKAS products safely. In addition to the safety information in these operating instructions, all generally applicable, statutory and other binding national and international accident prevention regulations must be observed and operators must be instructed accordingly. The device may only be operated by persons with appropriate training in the safety aspects of such equipment, otherwise, there is a risk of injury. We would like to point out to all users, they should carefully read, understand and follow all operating instructions before using the product. We further recommend that you have a qualified trainer show you how to use the product. WARNING / CAUTION! The operating instructions for the hoses, accessories and connected devices must also be observed! Even if you have already received instructions on how to use the device, you should still read through the following safety instructions again. WARNING / CAUTION! Make sure that the accessories used and the connected devices are suitable for the max. operating pressure! Wear protective clothing, Inspect the device before and... - Page 6 Any mode of operation which Observe all intervals compromises the safety for recurring tests and/or stability of the device and/or inspections that are is forbidden! prescribed or stated in the instruction manual. Safety devices must never be The maximum permissible disabled. operating pressure marked on the device must not be exceeded. Only genuine LUKAS Please ensure that you do accessories and spare parts not become entangled in are to be used for repairs. hose loops and trip when working with or transporting the device. When working close to live The build-up of static charges components and cables, and possible sparking must suitable measures must be avoided when handling be taken to avoid current the device. transfers or high-voltage transfers to the device. The device is filled with When working with or storing hydraulic fluid. This hydraulic...
- Page 7 Always keep this instruction Ensure proper disposal of manual easily accessible at all dismantled parts, oil and the place of operation. hydraulic fluid residues and packaging materials! In addition to the safety instructions in this instruction manual, all generally applicable, statutory and other binding national and international accident prevention regulations must be observed and operators must be instructed accordingly! WA RN ING / C AU TI ON / ATT ENTI ON! This device is intended exclusively for the purpose described in the instruction manual (see chapter "Proper use"). Any other use is not in accordance with its proper use. The manufacturer/supplier is not liable for any damage resulting from improper use.
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Page 8: Proper Use
3. Proper use The LUKAS hose reels are used to hold pairs of extension hoses between the hydraulic supply and the work equipment. The pairs of extension hoses are connected to the hose reel and rolled up on the drum. Using a LUKAS hose reel with pairs of extension hoses allows for a greater distance between the hydraulic supply and the work equipment, meaning that e.g. the hydraulic power unit can remain on the vehicle. When carrying out any work with the hose reels described here, make sure that persons in the working environment, whether involved or uninvolved, are not endangered. ATTENTION! Due to possible pressure losses, only extension hose lines with a maximum length of 20 m may be connected on the power unit side, and the maximum length on the device side may not exceed 30 m! The hose reels can also be used under water at a depth of up to 40 m (131 ft). -
Page 9: Description
4. Description 4.1 General The reels basically consist of the carrier, shaft and hose drum. A distinction is made between the: - Connection of one pair of extension hoses Single hose reel: - Supplied with a carrying frame - Holding brake, permanently mounted, folding hand crank - Connection of two pairs of extension hoses Double hose reel: - Supplied with a carrying frame - Holding brake - Removable hand crank All variants are equipped with a hand crank to roll up and unroll the hoses. This is either inserted as required or permanently attached to the hose drum. Connection to the hydraulic pump or control unit is provided by connecting the pair of connection hoses to the pump or control unit via mono-couplings. -
Page 10: Double Hose Reel
4.3 Double hose reel The double hose reel consists of a carrying frame and a shaft with two hose drums. Two pairs of extension hoses or extension hoses can be connected to the reel on the device side (one extension hose per hose drum). Depending on the connection version, the connection on the power unit side is provided by one or two short return hoses and a short supply hose or pair of extension hoses per extension hose. These connecting hoses are connected to the connecting block of the hydraulic pump or a control unit by means of... -
Page 11: Connecting The Device
The adapter sets can be ordered via the optional LUKAS accessories. WARNING / CAUTION / ATTENTION! Prior to connecting the devices, ensure that all the components being used are suitable for the maximum operating pressure of the pump unit. In case of doubt, you must contact LUKAS directly! 5.1 On the power unit side Two "short" hoses are fitted on the power unit side and connected to the pump unit. 5.2 On the device side The pairs of extension hoses are provided for connection on the device side. They are connected to the work equipment via couplings. The combination of sleeve and nipple... -
Page 12: Coupling The Mono-Couplings
5.3 Coupling the mono-couplings The device is connected to the hydraulic pump via quick-disconnect coupling halves (sleeve and nipple) to prevent mix-ups. Dust caps Nipple Sleeve (male coupling) (female coupling) Before coupling, remove the dust caps, then connect the nipple and sleeve and turn the locking sleeve of the female coupling in direction "1" until the locking sleeve latches. The connection is now established and secured. Decoupling is accomplished by turning the locking sleeve in direction "0". -
Page 13: Operation
6. Operation 6.1 Safety notes Worldwide safety guidelines pertaining to the specific country must be observed and complied with. In the Federal Republic of Germany, regular safety inspections according to the legal accident insurance regulations (GUV - Gesetzliche Unfallversicherung) are mandatory. The following are to be worn when working with the rescue equipment: - protective clothing, - safety helmet with visor or protective goggles, - protective gloves - and, if necessary, ear protection WARNING / CAUTION When carrying out work with the hose reel, those not involved in the operation must maintain a safe distance appropriate to the situation, so that they are not exposed to danger if there is a hose failure (e.g. as a result of damage)! -
Page 14: Commissioning
6.2 Commissioning The hose lines on the hose reel must be bled as follows before commissioning and after repair: - C onnect the hose reel to the hydraulic pump (see chapter "Connecting the device"). - S witch on the hydraulic power unit and pressurize the supply lines for a short period. ATTENTION! The work equipment must be decoupled! - S et the hydraulic power unit to unpressurized circulation or switch off. Top up the hydraulic fluid if required. The work equipment can be connected to the hose reel after bleeding has been completed. NOTE Mono-couplings: When ambient temperatures are low and extension hoses are used, we recommend connecting the coupling halves in a depressurized state because decoupling may otherwise require a very large exertion of force. - Page 15 6.3.2 Holding brake SHR The holding brake is designed to prevent the pairs of extension hoses from unrolling during transport! To release the holding brake, pull the knob and turn it by 90°. To apply the holding brake, turn the knob again by approx. 90° until it engages automatically. 90° 90° 6.3.3 Hand crank SHR The hand crank is designed to make the hoses easier to roll up! To move the hand crank to the operating position, pull the lever, turn outward by 90° and release again so that it clicks into position. To move the hand crank back into storage position, pull the lever, turn inward 90° and release again so that it clicks into position.
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Page 16: Unrolling
6.4 Unrolling To prepare for operation, pull on the extension hose package until the required length is unrolled from the hose reel. ATTENTION! In order to avoid damage to the reel and the hose package, release the holding brake on the hose reel first! 6.5 Rolling up NOTE: We recommend using the hand crank to roll up the hoses! - First of all, insert the hand crank in the shaft of the hose reel. - Release the holding brake. - Aligning the hose makes rolling up easier. - Now roll up the pair of extension hoses by turning the hand crank. Make sure that the pairs of extension hoses are always rolled up correctly onto the hose drum by guiding the pair of extension hoses with your hand when rolling up. -
Page 17: Hose Reel
7.4 Hose reel Roll up pairs of extension hoses on the hose reel. In the case of double hose reels, apply the holding brake afterwards. In the case of single hose reels, apply the holding brake and fold up the handle. 8. Maintenance and service A visual inspection must be carried out after each use, but at least once a year. Every three years – or if you have any doubts about safety or reliability – an additional functional check must be carried out. (Comply with the applicable national and international regulations regarding the maintenance intervals of hydraulic devices). In the Federal Republic of Germany, regular safety inspections according to the legal accident insurance... -
Page 18: Repairs
9. Repairs 9.1 General information Service work may only be performed by the device manufacturer or by personnel trained by the device manufacturer and authorized LUKAS dealers. Only LUKAS spare parts may be used to replace all components (see spare parts list), as special tools and compliance with, assembly instructions, safety aspects and inspections are required (see also chapter "Maintenance and Servicing"). During assembly, ensure that all components are particularly clean, as dirt can damage the rescue equipment! -
Page 19: Preventive Service
9.2 Preventive service 9.2.1 Care instructions The device must be cleaned externally from time to time to protect it from corrosion, and the metal surfaces must be rubbed with oil. 9.2.2 Function and load test If you have any doubts about safety or reliability, an additional function and load test must be carried out. 9.2.3 Changing the hydraulic fluid (for longer storage periods) - Replace the hydraulic fluid after three years at the latest. - It must always be changed whenever the hydraulic fluid for the accompanying pump (motor/hand pump) is replaced. This prevents the fresh hydraulic fluid from becoming contaminated by the used fluid in the rescue equipment. Procedure: 1. Change the hydraulic fluid at the hydraulic pump. Observe the separate operating instructions for the pump being used. 2. Detach the return hose from the pump: - Remove the dust protection cap from the mono-coupling nipple - C ompletely unscrew the connection nut on the blue return hose of the mono-coupling nipple. -
Page 20: Repairs
9.3 Repairs 9.3.1 Replacing or tightening up connection hoses The hose connection of the supply and/or return hose is leaking or defective. Tighten up the hose connections on the shaft (Warning! Ensure torque M = 40 Nm!) 9.3.2 Replacing or tightening up pairs of extension hoses The hose connection of the supply and/or return hose is leaking or pairs of hoses are defective. Pull back the protective hose and tighten up the hose connections at the manifolds. (Warning! Ensure torque M = 40 Nm!) Manifold Pair of hoses Protective hose ATTENTION! The protective hose set must be mounted on the reel! - Page 21 9.3.3 Replacing the hose lines (mono-hose with connecting nipple and union screw) Unroll the hose lines "A". Then unscrew the hoses from the relevant connection slot "B". Size 36 2. Screw the new hose lines into the connection slot "B" with a torque of = 120 Nm 3. Roll up the hose line.
- Page 22 9.3.4 Mono-couplings The mono-couplings must be replaced if: - there is external damage, - the lock does not work, - hydraulic fluid is constantly escaping in the coupled and/or uncoupled state. WARNING / CAUTION / ATTENTION! The repairing of couplings is not permitted, they must be replaced by original LUKAS parts! Procedure: 1. Pull the cover back from the couplings. 2. Loosen the union nuts on the hose line and remove the coupling. 3. Position the new coupling and tighten the union nuts on the hose lines to a torque of = 40 Nm and push the coupling cover back on. ATTENTION! Make sure that connection "T" / "T1" of the hose reel is always connected to...
- Page 23 Procedure for hose line couplings (mono-hose): 1. Undo the hose line union screw. Remove the coupling and O-ring. If required, remove any remnants of threadlocker from the thread of the union screw. 2. Fit a new O-ring, apply threadlocker to the new coupling and tighten with a torque of = 80 Nm.
- Page 24 9.3.5 Manifolds on the single and double hose reels The manifolds must be replaced if: - there is external damage, - hydraulic fluid escapes at the manifold pipes. Procedure: 1. Disassemble pairs of extension hoses. 2. Undo manifold and remove. 3. Attach the new manifold and tighten to a torque of M = 40 Nm. ATTENTION! "Roll up" Ensure that the manifolds are direction always correctly aligned when they are mounted (see Fig. on the right). Manifold Hose Remember to push the protective hoses back over the screw connections (see Fig. on the left). Protective hose...
- Page 25 9.3.6 Replacing the hose drum on a single hose reel Damaged hose drums should be replaced without delay. You must disassemble the pairs of extension hoses before replacing the hose drums. Procedure: 1. Remove the two attachment screws and washers of the holding brake. 2. Remove the three attachment screws and washers of the hand crank. 3. Remove the hose drum and replace it with a new one. 4. Assembly is carried out in the reverse order. Ensure that all screws are tightened up after the hose drum has been replaced. See the spare parts list for more details on disassembly and assembly. 9.3.7 Replacing the hose drum on a double hose reel Damaged hose drums should be replaced without delay. You must disassemble the pairs of extension hoses before replacing the hose drums.
- Page 26 9.3.8 Holding brake on the double hose reel If the holding brake of the double hose reel is damaged or inoperative, it must be replaced. Procedure: 1. Remove the two screws, washers, spring washers and nuts. 2. Remove the damaged holding brake and replace it with a new one. 3. Assemble the holding brake in the reverse order and tighten the screw connections. See the spare parts list for more details on disassembly and assembly. 9.3.9 Labels All damaged and/or illegible labels (safety notices, type plate, etc.) must be replaced. Procedure: 1. Remove damaged and/or illegible labels. 2. Clean surfaces with acetone or industrial alcohol. 3. Affix new labels. Make sure to affix the labels in the correct position. If this is no longer known, you should contact your authorized LUKAS dealer or LUKAS directly.
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Page 27: Troubleshooting
10. Troubleshooting Fault Check Cause Solution The work equipment Hose lines properly Hose lines not Reconnect or does not move when connected? connected. recouple the hose operated. lines. Pump unit running? Work equipment See separate or hydraulic power operating instructions unit defective. for hydraulic power unit or work equipment. Work equipment Hose lines properly Air in the hydraulic Bleed the hydraulic moves slowly or jerkily connected? system. system. when operated. Pump unit running? Hose lines cannot be Pressure too Set hydraulic pump coupled. high (e.g. due to to unpressurized excessive ambient circulation... - Page 28 Hoses not Tighten the hose tight? tightened properly connections at the at the manifold. manifolds. Leaks from the Defect on manifold Replace the manifold screw connection or the seal or seal. between the underneath it manifold and shaft? Shaft defect Repair by an authorized dealer, by personnel specially trained by LUKAS, or by LUKAS itself. Hydraulic fluid leak Connection hoses Hoses defective. Replace hoses. from the connections damaged? between the connecting hoses and the reel shaft. Hose connections Hose connections Tighten the screw tight? or connecting connections on the nipples not hose lines or the tightened correctly.
- Page 29 Fault Check Cause Solution Leak at connection Seal between hub Repair by an between hub and and shaft defective. authorized dealer, by shaft. personnel specially trained by LUKAS, or by LUKAS itself. Contact an authorized LUKAS dealer or the LUKAS Customer Service Department directly if the malfunctions cannot be rectified. 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...
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Page 30: Technical Data
11. Technical data As all values are subject to tolerances, there may be minor differences between the data on your device and the data stated here. 11.1 General reel designation DHR 20 - 66 - 1,5 Type of hose reel Length of the short pairs of SHR =Single hose reel supply hoses DHR =Double hose reel MDHR =Double hose reel with mono-hose Length of the pairs of Length of the pairs of extension hoses in [m] extension hoses in [ft.] 11.2 Maximum operating pressure The maximum operating pressure of all STREAMLINE hose reels is: 70 [MPa]* = 10000 [psi.] * 1 [MPa] = 10 [bar]... -
Page 31: Technical Data Of The Hose Reels
11.3 Technical data of the hose reels Device type SHR xx-xx-1,5 Item number 81-60-10 L x W x H 434 x 327 x 490 Dimensions 17.1 x 12.9 x 19.3 Operating max. pressure 10000 Hose length Reel without hose Number of connectable max. devices Streamline® quick connector Number of hoses, on the 1 x 2 Connection hoses, pump side 1.5 m long Number of connections, on... - Page 32 Device type SHR 15-50-1,5 Item number 81-60-15 L x W x H 434 x 327 x 490 Dimensions 17.1 x 12.9 x 19.3 Operating max. pressure 10000 Hose length Number of connectable max. devices Streamline® quick connector Number of hoses, on the 1 x 2 Connection hoses, pump side 1.5 m long Number of connections, on max. Streamline® quick the pump side connector Weight incl. hydraulic fluid...
- Page 33 Device type SHR 20-66-1,5 Item number 81-60-20 L x W x H 434 x 327 x 490 Dimensions 17.1 x 12.9 x 19.3 Operating max. pressure 10000 Hose length Number of connectable max. devices Streamline® quick connector Number of hoses, on the 1 x 2 Connection hoses, pump side 1.5 m long Number of connections, on max. Streamline® quick the pump side connector Weight incl. hydraulic fluid...
- Page 34 Device type DHR 20-66-1,5 Item number 81-61-20 L x W x H 445 x 385 x 400 Dimensions 17.5 x 15.2 x 15.8 Operating max. pressure 10000 Hose length Number of connectable max. 2 x 1 devices Streamline® quick connector Number of hoses, on the 2 x 2 Connection hoses, pump side 1.5 m long Number of connections, on max. 2 x 1 Streamline® quick the pump side connector...
- Page 35 Device type MDHR 15-50-1,5 Item number 81-61-15 L x W x H 442 x 408 x 395 Dimensions 17.4 x 16.0 x 15.6 Operating max. pressure 10000 Hose length Number of connectable max. 2 x 1 devices Streamline® quick connector Number of hoses, on the 2 x 2 Connection hoses, pump side 1.5 m long Number of connections, on max. 2 x 1 Streamline® quick the pump side connector...
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Page 36: Hydraulic Fluid Recommendations
11.4 Hydraulic fluid recommendations Oil for LUKAS hydraulic devices, mineral oil DIN ISO 6743-4 and others Oil temperature range Oil designation Viscosity class Note -24 ..+30°C HL 5 VG 5 -18 ..+50°C HM 10 VG 10 -8 ..+75°C HM 22 VG 22 +5 ..+80°C HM 32 VG 32 -8 ..+70°C HF-E15 VG 15 Bio oil Oil temperature range Oil designation Viscosity class Note HL 5 VG 5 -11.2 ..+86°F HM 10 VG 10 -0.4 ..+122°F HM 22 VG 22 +17.6 .. -
Page 37: Declarations Of Conformity
12. Declarations of conformity... - Page 41 Hose reel Item number regulations. SHR xx-xx-1,5 81-60-10 Supply of Machinery (Safety) Regulations 2008 SHR 15-50-1,5 81-60-15 BS EN ISO 12100: 2010-12-31 LUKAS Hydraulik GmbH Weinstraße 39, 91058 Erlangen Deutschland LUKAS Hydraulik GmbH, 91058 Erlangen, Germany Erlangen, 01.09.2022 Seite/Page 1von/of1...
- Page 42 Hose reel Item number regulations. SHR 20-66-1,5 81-60-20 Supply of Machinery (Safety) Regulations 2008 BS EN ISO 12100: 2010-12-31 BS EN 13204: 2016-09-30 LUKAS Hydraulik GmbH Weinstraße 39, 91058 Erlangen Deutschland LUKAS Hydraulik GmbH, 91058 Erlangen, Germany Erlangen, 01.09.2022 Seite/Page 1von/of1...
- Page 43 Hose reel Item number regulations. DHR 20-66-1,5 81-61-20 Supply of Machinery (Safety) Regulations 2008 BS EN ISO 12100: 2010-12-31 LUKAS Hydraulik GmbH Weinstraße 39, 91058 Erlangen Deutschland LUKAS Hydraulik GmbH, 91058 Erlangen, Germany Erlangen, 01.09.2022 Seite/Page 1von/of1...
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Page 44: Notes
A unit of the IDEX Corporation Weinstrasse 39, 91058 Erlangen, Germany Tel.: (+49) 0 91 31 / 698 - 0 Fax.: (+49) 0 91 31 / 698 - 394 email: lukas.info@idexcorp.com www.lukas.com Made in GERMANY hose_reels_manual_176250085_en.indd © Copyright 2025 LUKAS Hydraulik GmbH...
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