Operating Instructions - Recycling Systems Concrete Crusher 84150150085 GB Edition 08.2011 replaces 05.
Contents Page 1. Hazard classes 4 2. Product safety 5 3. Intended use 8 4. Functional description 10 4.1 Description10 4.2 Unit in detail 10 4.3 Circuit diagram 11 4.4 Controlling the operating movements 11 4.5 Hydraulic supply 11 4.6 Hoses 12 4.7 Replaceable tips 12 4.8 Detachable guard 13 5. Connecting the equipment 14 5.1 General points 14 5.2 Coupling Monocouplings 14 5.3 Coupling Quick-disconnect Couplings 16 5.
10. Repairs 25 10.1 General points 25 10.2 Preventive maintenance 27 10.3 Repairs 31 11. Troubleshooting 40 12. Technical Data 43 12.1 Concrete Crusher 43 12.2 44 Tightening torques of the pivot bolt 12.3 Hydraulic fluid recommendations 44 12.4 Operating and storage temperature ranges 44 13. EC Declarations of Conformity 45 14.
1. Hazard classes We distinguish between various categories of safety instructions. The table below provides an overview, using symbols (pictograms) and signal words, of the specific danger and the possible consequences.
2. Product safety LUKAS products are developed and manufactured to ensure the best performance and quality for the intended use. The safety of the operator is the most important consideration in the design of the product. Furthermore, the operating instructions are intended to help in using LUKAS products safely. In addition to the operating instructions, all generally applicable, statutory and other binding rules for accident prevention and for environmental protection must be heeded and disseminated.
In the event of malfunctions, immediately deactivate the device and secure it. The malfunction must be repaired immediately. Do not carry out any changes (additions or conversions) to the device without obtaining the prior approval of LUKAS. Observe all safety and danger notes on the equipment and in the operating instructions. All safety instructions and hazard warnings on the device must be kept intact and in a legible condition.
The device is filled with hydraulic fluid. These hydraulic fluids can be harmful to your health if swallowed or if their vapours inhaled. Direct contact with the skin must be avoided for the same reason. Please note also that hydraulic fluids can also have an adverse effect on biological systems.
3. Intended use The Concrete Crushers are designed for continuous industrial deployment in demolition work. The Concrete Crushers can be used, in particular, for the crushing of walls, concrete and reinforced concrete components and for the cutting up of reinforcement. You do not need to change tools between crushing and cutting work. The low-vibration method of working not only reduces the physical load on the body of the user but also facilitates working in vibration-sensitive areas.
The Concrete Crushers need a hydraulic source for their operation and this is connected to the unit with hoses. A LUKAS hydraulic pump is used as the hydraulic source. The use of other hydraulic sources is possible, but this will require approval from LUKAS in each individual case. Because the connection between the unit and the power pack is via hoses, the hydraulic power packs can be located outside sensitive areas.
4.1 Description 4. Functional description The units are designed in such a way that a hydraulically actuated piston symmetrically opens and closes two identical opposing crusher arms via a mechanical linkage system. This allows stones or concrete parts to be broken up or reinforcing bars and reinforcing mesh to be cut. All Concrete Crushers guarantee full load-holding function when disconnected from the hydraulic supply (e. g. when unintentionally decoupled; defective hose, and so on).
4.3 Circuit diagram To facilitate understanding of the function, a simplified circuit diagram (hydraulic cylinder of the Concrete Crusher (A) + hand valve (B)) is shown here. cutting / crushing / closing A B opening 4.4 Controlling the operating movements The piston movement is controlled by the star grip on the attached valve (see illustration). Star grip 4.5 Hydraulic supply A LUKAS motor pump or hand pump only may be used to drive the equipment.
4.6 Hoses The pump unit and the recycling unit are connected by hoses. Please observe all safety instructions in the separate operating instructions for the hoses! 4.7 Replaceable tips The Concrete Crusher has optional replaceable breaker tips. When they are worn out they can easily be replaced by new ones. Replacing the tips: 1. Remove pin “A” 2. Pull out the breaker tips “B” and replace them. 3. Refit the pin “A”.
4.8 Detachable guard The Concrete Crusher has an optional removable guard. This means that the unit can also be used in inaccessible locations. A 1. Remove the split-pin “A” A B 2. Pull the guard “B” away upwards. 3. The guard is refitted in the reverse sequence. Make sure that the split pins engage fully.
5. Connecting the equipment 5.1 General points There are two short hoses on the side of the equipment: they are connected to the pump unit via two hoses. All hose assemblies are marked with a colour and have couplings to enable non-interchangeable connection. NOTE: The devices can be equipped with different coupling systems. They differ only by the article number and not by the designation. It goes without saying that the coupling systems can also be converted at a later time.
Before coupling, remove dust protection caps, then connect male and female, and turn the locking sleeve of the female in direction “1” until the locking sleeve locks into place. The connection is then made and secured. Decoupling is accomplished by turning the locking sleeve in direction “0”. The equipment can also be coupled under pressure provided the connected equipment is not activated.
5.3 Coupling Quick-disconnect Couplings The device is connected to the hose lines to the hydraulic pump using non-interchangeable quick disconnect coupling halves (female and male coupling). X Y Before coupling, remove the dust caps then pull back and hold the locking sleeve on the female connector (position X). Plug the male and female connectors together and release the locking sleeve. Then turn the locking sleeve to position Y. The connection is then made and secured.
5.4 Mechanical fixing to a balancer from the LUKAS range of accessories First set the weight of the recycling unit on the green rotating ring on the back of the balancer (see arrow on illustration at left); this ensures that the cutting unit later stays at any height position at a later time. Fix the balancer using the attached hook (see illustration at right hand side, Item 1) onto the suspension device provided (e.g.
6. Operation 6.1 Preparatory measures 6.1.1 Initial start-up Before commissioning and following repairs, the equipment must be de-aerated. - Connect the equipment to the hydraulic pump (see chapter “Connecting the equipment”). - Open / close the crusher arms of the equipment without any load at least twice (see chapter “Operation of the star grip”).
7. Cutting and crushing 7.1 Safety instructions Before starting work, the object to be processed must be stabilised and secured in its position. This in ensured by adequate supports and / or props. Comply with the safety regulations in force in the country of use. The units must not be used in explosion-risk areas.
7.2 Cutting The blades must be positioned at a 90° angle to the object to be cut. 15° 15° 12 90° 9 3 WRONG RIGHT 6 Higher cutting capacities can be achieved by cutting as close as possible to the crusher arm’s pivot point.
Cutting area Crusher arm pivot point CAUTION! Avoid cutting particularly high-strength parts (e.g.
7.3 Crushing The crusher arms must be applied at right angles to the material to be crushed. 90° WRONG RIGHT When the two crusher arms are moved together, the tip penetrates the concrete component and this leads to the fracture of this part. If the concrete component does not break by the time the crusher arm internal faces are in contact with the goods to be crushed, you need to open the crusher arms again and apply them again.
8. Dismantling the equipment / deactivation following operation 8.1 Recycling unit Once work has been completed, the crusher arms must be closed so that there is a tip distance of just a few mm. This relieves the hydraulic and mechanical stresses on the device. NOTE: Never store the Concrete Crusher with fully-closed blade arms! The complete closure of the crusher arms can cause hydraulic and mechanical stress to build up again.
9. Care and Maintenance The equipment is subject to very high mechanical stresses. A visual inspection must be carried out after every use: however, at least one visual inspection must be carried out every six months. These inspections enable the early detection of wear and tear, which means that breakages can be prevented by punctual replacement of these wearing parts. Also regularly check the torque of the pivot bolt.
Hoses • Visual check for visible damage • Check for leaks Functional test • perfect opening and closing when star grip activated, • no suspicious noises. • no further movement of the crusher arms when valve actuation interrupted during the process (“dead-man’s” function) 10.1 General points 10. Repairs Service work may only be performed by the device manufacturer or by personnel trained by the device manufacturer and authorised LUKAS dealers.
NOTE when using the quick-disconnect coupling system: Over-pressure safety device of the recycling unit (model with yellow coupling nipple on the return hose) Pressure can build up in the device as a result of temperature rises if the device's short hoses are not connected to a power pack. Hence, the return hose of the equipment is equipped with a safety coupling (quick-disconnect coupling male, yellow). Undesired overpressure (approx. 1.
10.2 Preventive maintenance 10.2.1 Care instructions The exterior of the equipment must be cleaned from time to time in order to protect it from external corrosion. Oil must be applied to the metallic surfaces. 10.2.2 Routine checks Regularly check the torque of the pivot bolt. For torques, see Chapter “Technical Data”. Check the cutting faces and repair if possible. Refer to the Chapter “Regrinding the Crusher Arms”.
Unscrew the hand grip and pull back the protective sleeve as shown in the illustration below. Remove contamination and swarf from the mechanical section of the unit (as shown in the illustration below) and blow out carefully with compressed air. If the sections of the protective sleeve that seal against the crusher arms are clearly worn or torn, you should replace the entire sleeve. 10.2.
10.2.4 Function and load test Perform a stress test if there is doubt about safety or reliability. For the load test, the recycling unit must be surrounded by a sturdy screen. The screen must be capable of protecting all involved and uninvolved persons from mechanical failure of the unit during the test. Mechanical failure includes e.g. the fracture of the crusher arm or the failure of the hose. In the load test the maximum operating pressure is applied to the Concrete Crusher.
10.2.5 Replacing the hydraulic fluid - Change the hydraulic fluid after approximately 500 operating hours, and every two years at the latest. - It must always be changed whenever the hydraulic fluid for the accompanying pump (motor / hand pump) is changed. This prevents the fresh fluid from being contaminated by the used fluid from the recycling unit. Procedure: 1. Close crusher arms (until the tips are almost touching). 2. Change the hydraulic fluid of the pump.
10.3 Repairs 10.3.1 Repairs to the unit (without replacement of guard, hose or coupling ) Components to be replaced Required work steps Guard 1. - 5. and 14. Handle 1. - 6. and 14. Pivot bolt 1., 2., 8. and 14. Crusher arms 1. - 10. and 14. Tips 1., 11. and 14. Protective sleeve 1. - 10. and 12. - 14. Procedure: 1. First of all, carefully clean the rescue equipment. 2. Next, close the blade arms so that the tips are almost touching.
B 4. Pull the guard “B” away upwards. 5. Release screws “C” and remove them together with the washers “D” and fixing elements “E” with the associated split pins “A”. You can now replace the guard “F” and the posts “G”. The plugs “H” can be levered out using a screwdriver, for example.
K 6. Remove the screws “J”. Then, the handle “K” can be removed in the direction of the connecting hoses of the device. J M 7. Push the protective sleeve “L” in the depicted direction until the securing bolts “M” are easily accessible. L M N O 8. Remove the locknuts “N” and the washer “O” and push out the pivot pin “P”. R P 9. Remove the safety rings “Q” and push out the bolt “R”.
10. Now, you can remove the crusher arm “S” and slide plates “T”. The seals “U” on the crusher arms can be removed and replaced. U S T S U 11. By removing the pins “V”, you can also replace the tips “W”. X V W 12. Fold in the lever elements “X”. X 13. Finally, remove the protective sleeve “L” from the equipment as shown. L 14. In order to assemble the new parts, points 2 -13 should be carried out in reverse order.
CAUTION! Don’t forget to apply LUKAS special grease to all sliding surfaces. CAUTION! The nut of the pivot bolt and the pivot bolt itself are matched by a special procedure, therefore they must only be changed as a set by using a new set! Because of the special procedure, any unscrewing of the nut while working will be minimised and a resulting crusher arm fracture will be prevented.
10.3.2 Replacing or tightening the hoses Hose connection on the pressure and/or return line is leaking or hoses are defective. Tighten the hoses on the control valve. (Please note! Observe torque of MA = 40 Nm!) NOTE when using mono-couplings: If you want to change the hoses, you must first dismantle the mono-couplings. CAUTION (when using the mono-coupling system)! Take care that the port ‘T’ of the recycling unit is always connected to the port ‘T’ of the mono-coupling.
10.3.3 Regrinding the crusher arms Only burrs may be removed and smoothed out! Chips or deep grooves cannot be ground away. The crusher arms must be replaced in these cases. CAUTION! Only grind in the grinding area (see illustration)! The sliding faces, in particular, must not be reground! Pivot point Crusher arm Slide surface plane Direction of movement Crusher arm Grinding area Tools required: 1. Clamping device (e.g. vice) with jaw protection in order not to damage the crusher arms. 2. Grinder (e.g.
10.3.4 Mono-couplings The mono-couplings on the connection hoses on the equipment must be replaced if: - there is external damage - the locking mechanism does not work - hydraulic fluid continues to leak in the coupled/uncoupled state. WARNING / CAUTION! Never repair couplings: they must be replaced by original LUKAS parts! During assembly, tighten the union nuts on the hose line to a torque of MA = 40 Nm. Procedure: 1. Remove the cover from the couplings. 2.
10.3.4 Quick-disconnect coupling The quick-disconnect-couplings must be replaced if: - there is external damage - the locking mechanism does not work - hydraulic fluid continues to leak in the coupled/uncoupled state. WARNING / CAUTION! Never repair couplings: they must be replaced by original LUKAS parts! During assembly, tighten the union nuts on the hose line to a torque of MA = 35 Nm. Procedure: 1. Loosen the union nuts on the hose line and remove the coupling. 2.
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Trouble Damage on the surface of the hydraulic hoses Check Hydraulic fluid leaks on the piston rod Cause Solution Replace hoses.
Trouble With quickdisconnect-couplingsystem: Leak in the couplings Check Is the coupling damaged? Cause Solution Coupling defective Coupling must be replaced immediately Is the leak only on the male coupling (in uncoupled status)? Safety valve responded After pressure release, there is no more leakage.
12. Technical data Because all values are subject to tolerances, there may be small differences between the data for your device and the data in the following tables! The values may also differ because of reading inaccuracies and/or tolerances in the measuring equipment used. NOTE: The following tables contain only the technical data required for standard acceptance. Additional data concerning your unit can be obtained from LUKAS on request. 12.1 Concrete Crusher Type LSI 531 CC Ref. No.
12.2 Tightening torques of the pivot bolt Type LSI 531 CC Pivot bolt M 27 x 1,5 Wrench size Torque [mm] 41 [in.] 1.61 [Nm] 130 +10 [lbf.in.] 1,151 + 89 12.3 Hydraulic fluid recommendations Mineral oil DIN ISO 6743-4 for LUKAS hydraulic equipment and others Oil temperature range -20 .... +55°C Oil code HM 10 Viscosity rating VG 10 Remarks A Oil temperature range -4.0 .... +131°F Oil code HM 10 Viscosity rating VG 10 Remarks A recommended viscosity range: 10...
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Please dispose all packaging materials and dismantled parts properly. LUKAS Hydraulik GmbH A unit of the IDEX Corporation Phone: (+49) 0 91 31 / 698 - 0 Fax.: (+49) 0 91 31 / 698 - 394 e-mail: lukas.info@idexcorp.com www.lukas.com Made in GERMANY Concrete_Crusher_BA_GB_84150150085_0811.
