Lukas Concrete crushers User Manual
Operating Instructions - Recycling Systems
Concrete Crusher
(Translation of the original operating instructions)
84150150085 GB
Edition 08.2011
replaces 05.2010
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
5.4 MechanicalxingtoabalancerfromtheLUKAS
rangeofaccessories 17
6. Operation 18
6.1 Preparatory measures 18
6.2 Operating the star grip 18
7. Cutting and crushing 19
7.1 Safetyinstructions 19
7.2 Cutting 20
7.3 Crushing 22
8. Dismantling the device / deactivation following operation 23
8.1 Recycling unit 23
8.2 Hydraulic unit 23
8.3 Hoses 23
9. Maintenance and service 24
2
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 Tighteningtorquesofthepivotbolt 44
12.3 Hydraulicuidrecommendations 44
12.4 Operating and storage temperature ranges 44
13. EC Declarations of Conformity 45
14. Notes 46
3
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 specic danger and the
possible consequences.
Pictogram
Damage /
injury to
human
device
- NOTE
Key word Denition 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 protective 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 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.
The device must only be operated by appropriately educated, safety-trained persons, since
otherwise there is a risk of injury.
We would like to point out to all users that they should read the operating instructions carefully
before using the equipment and comply with the instructions there without reservation.
We further recommend that a qualied instructor train you in the use of the product.
WARNING / CAUTION!
The operating instructions for the hoses, the accessories and the connected
devices must also be heeded!
Even if you have already received instructions on how to use the equipment, you should still
read the following safety notes again.
WARNING / CAUTION!
Ensure that the accessories and connected equipment used are suitable for
the maximum operating pressure!
Please ensure that no body
parts or clothing are caught
between the visibly moving
parts (e.g. crusher arms).
Wear protective clothing,
safety helmet with visor, and
protective gloves.
The responsible department
must be informed immediately
of any changes (including to
the operating behaviour)! If
necessary, the device must
be deactivated immediately
and secured!
It is prohibited to work under
loads if the load is lifted
exclusively by hydraulic
equipment. If this work
is absolutely imperative,
additional mechanical
supports must be used.
Inspect the equipment before
and after use for visible
defects or damage.
Check all lines, hoses and
screwed connections for
leaks and externally visible
damage. Rectify any damage
immediately. Squirting
hydraulic uid can result in
injuries and res.
5
In the event of malfunctions,
immediately deactivate the
device and secure it. The
malfunction must be repaired
immediately.
Observe all safety and danger
notes on the equipment and
in the operating instructions.
Do not carry out any changes
(additions or conversions) to
the device without obtaining
the prior approval of LUKAS.
All safety instructions and
hazard warnings on the
device must be kept intact
and in a legible condition.
Any method of operation
which impairs safety and/or
stability of the equipment is
prohibited!
Safety devices must never be
deactivated!
Before the equipment is
switched on/started up, and
during its operation, it must
be ensured that nobody is
endangered by the operation
of the equipment.
When working close to live
components and cables,
suitable measures must
be taken to avoid current
transfers or high-voltage
transfers to the equipment.
Prevent electrostatic
discharge, which has the
possible consequence of
spark generation, when
handling the device.
Comply with all specied
dates or dates specied in
the operating instructions
pertaining to regular checks /
inspections of the equipment.
The maximum permitted
operating pressure noted on
the equipment must not be
exceeded.
Only original LUKAS
accessories and spare parts
may be used for repairs.
Make sure that you do not
get caught in the hose loops
and trip when working with or
transporting the device.
Please note that, when
crushing or cutting, tearing
or breaking can cause
falling material, or sudden
removal of such can cause
it to suddenly catapult off:
necessary precautions must
be taken.
Only touch any broken-off
parts or the cut-off parts while
wearing protective gloves,
since the torn / cut edges can
be very sharp.
6
The device is lled with
hydraulic uid. These
hydraulic uids 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 uids can
also have an adverse effect
on biological systems.
Ensure adequate lighting
when you are working.
Always keep these operating
instructions easily accessible
at the location where the
device is used.
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 safety information in these operating instructions.
When working with or storing
the equipment, ensure
that the function and the
safety of the equipment
are not impaired by the
effects of extreme external
temperatures and that the
equipment is not damaged in
any way. Please note that the
device 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.
Ensure the proper disposal of
all removed parts, left-over oil
and hydraulic uid as well as
packaging materials!
WARNING / CAUTION!
The device is specied exclusively for the purpose described in the operating
instructions (see Chapter “Intended use”). Any use for purposes other than or over and
above this is deemed not to be in accordance with its designated use. The manufacturer/
supplier refuses to accept liability for damage resulting from such misuse. The user bears
sole responsibility for such.
Observance of the operating instructions and compliance with the inspection and maintenance
conditions are part of the Intended use.
Never work when you are overtired or intoxicated!
7
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. An additional advantage of the virtually
zero vibrations is the dust-free demolition work which permits working in an enclosed space.
The noise level is also very low as a result of the purely hydraulic method of operation.
This means that the units can also be used in locations that are sensitive to noise. The main
source of noise is the unit required for the generation of hydraulic pressure.
LUKAS Concrete Crushers can also be used under water at a depth of up to 40m (131ft).
CAUTION!
In this case, you must strictly observe any leaks in order to avoid threats to the
environment.
WARNING / CAUTION!
All objects to be worked on must be secured using stable supports or substructures.
CAUTION!
When cutting with the Concrete Crusher, make sure that you do not cut directly
into the concrete with the blade area. This can lead to increased wear in the
blade area.
The Concrete Crushers must not be used in explosion-risk areas. Sparks can be created
when crushing and cutting from the friction at the crusher arms, and these can ignite explosive
atmospheres.
8
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.
You must never use equipment with internal combustion engines in enclosed spaces!
The use of electrical equipment in wet areas is prohibited if it is not specically designed for
this purpose.
LUKAS offers a wide range of the most varied of units for driving the Concrete Crushers.
Contact your authorised LUKAS dealer or LUKAS directly!
WARNING / CAUTION!
The following may not be cut / crushed:
- live cables
- pre-tensioned and hardened parts such as springs, spring steels,
- - pipes / hoses under gas or liquid pressure,
- explosive objects such as gas cartridges
NEVER operate the recycling unit at a higher operating pressure than that stated
in the chapter “Technical data”. A higher setting may cause property damage and/
or injuries.
The Concrete Crushers must not be used in explosion-risk areas. Sparks can be
created when crushing and cutting from the friction at the crusher arms, and these
can ignite explosive atmospheres.
Replacement parts and accessories for the recycling unit can be ordered from your authorised
LUKAS dealer!
9
4. Functional description
4.1 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). In addition,
the guard can be removed from the unit. In this case, the operator must, however, take other
measures to protect from aking or breaking parts, e.g. by sturdy protective clothing and a
safety helmet with a face-protecting visor
4.2 Unit in detail
1 Star grip
2 Control valve
3 Device body
4 Handle with removable guard
5 Protective sleeve
6 Crusher arm
7 Central pin with self-locking nut
and grease nipple
8 Grip tube
9 Replaceable breaker tips
10 Pressure hose
11 Return hose
12 Quick-disconnect coupling,
male
13 Quick-disconnect coupling,
female
14 Mono-coupling half,
male
3
8
10
14
11
1
2
7
6
5
9
6
10
4
Quick-disconnect coupling system:
12
13
4.3 Circuit diagram
To facilitate understanding of the function, a simplied 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.
If the pump unit is a different make, you must make sure that it complies with LUKAS
specications, otherwise potential dangers may occur which are not the responsibility of
LUKAS. Ensure in particular that the authorised operating pressure for LUKAS equipment
is not exceeded.
NOTE:
Before you use pumps from a different manufacturer, you must contact LUKAS
or an authorised dealer.
11
4.6 Hoses
The pump unit and the recycling unit are connected by hoses.
Pleaseobserveallsafetyinstructionsintheseparateoperatinginstructionsforthehoses!
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. Ret the pin “A”.
A
B
12
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 retted in the reverse sequence. Make sure that the split pins engage
fully.
13
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.
WARNING / DANGER / CAUTION!
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 consult LUKAS
directly.
5.2 Coupling Mono-couplings
The device is connected to the hose line to the hydraulic pump using non-interchangeable
monocoupling halves (female and male coupling).
Dust protection caps
Mono-coupling
half (male)
Mono-coupling
half (female)
14
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.
NOTE:
We recommend coupling the coupling halves in a depressurised state when
working in areas with low ambient temperature and extension hose assemblies /
hose reels are used, otherwise coupling could need very high expenditure of
force.
For dust protection, the supplied dust caps must be reattached.
Using the dust protection caps:
The “A” dust protection caps have two internal pins “B”. The dust protection caps must be
placed on the coupling unions in such a way that the pins are guided into the “C” grooves.
Fasten the screw up to the limit stop to x the dust protection caps on the coupling unions.
A
C
B
WARNING / CAUTION!
The mono-couplings may not be screwed off the hose assemblies and / or the
hose assemblies be mixed up!
15
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