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darda BP2 Product Manual

Hydraulic aggregate 2
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Product Manual
Hydraulic Aggregate 2
Translation of the original product manual

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  • Page 1 Product Manual Hydraulic Aggregate 2 Translation of the original product manual...
  • Page 2  by Darda GmbH Darda GmbH, Blumberg, retains the copyright to this documentation. This documentation is solely intended for the operator and his personnel. The content of this documentation (text, figures, drawings, graphics, plans, etc.) may not be copied or distributed in part or in full without our consent in writing, nor can it be used without authorisation for competitive purposes or given or made accessible to third parties.
  • Page 3 Information Manual Hydraulic Aggregate 2 Translation of the original information manual...
  • Page 4  by Darda GmbH Darda GmbH, Blumberg, retains the copyright to this documentation. This documentation is solely intended for the operator and his personnel. The content of this documentation (text, figures, drawings, graphics, plans, etc.) may not be copied or distributed in part or in full without our consent in writing, nor can it be used without authorisation for competitive purposes or given or made accessible to third parties.

  • Page 5: Table Of Contents

    Outline of Product Manual Outline of Product Manual The entire documentation of the hydraulic aggregate includes: Product Manual – Information Manual (IM) – for the operator of the device – Operating Manual (OM) – for the operator and – for the technical supervisor of the device Outlined Overview of the Entire Documentation Outlined Overview of the Information Manual (for the operator) Information Manual (IM)
  • Page 6 Table of Contents (IM) Table of Contents (IM) Chapter Subject Page Introduction Preface Product Identification / Product Information Storage Definition of Terms Responsibility of the Operator 1.5.1 Definition of specialists / authorised personnel Intended Use Limited Service Life Complaints Guarantee and Liability 1.10 Declaration of Conformity Device Data Sheet...

  • Page 7: Introduction Preface

    Dear – Customer, – Operator, By acquiring a hydraulic aggregate from Darda GmbH, you are the owner of one of the latest generation of hydraulic devices. The hydraulic aggregates are setting new standards for performance, quality and use in the proven Darda tradition.

  • Page 8: Product Identification / Product Information

    When making complaints or queries, please cite the data entered in the device da- ta sheet. Product information The hydraulic aggregates from Darda GmbH are designed to supply hydraulic stone and concrete splitters and combination shears from Darda GmbH. The engines/motors are available in various variants –...

  • Page 9: Responsibility Of The Operator

    1 Introduction Responsibility of the Operator The operator is required to allow work with the device only by experts who – were sufficiently trained in accordance with the activities to be carried out. – know the fundamental requirements for work safety and the prevention of acci- dents and have been familiarised with the handling of the device by qualified staff.

  • Page 10: Definition Of Specialists / Authorised Personnel

    1 Introduction 1.5.1 Definition of specialists / authorised personnel Physical or material damage can result from unqualified intervention in the device. Only qualified personnel may operate, clean and maintain the device for this rea- son. Qualified personnel in this sense are persons who ...

  • Page 11: Intended Use

    1 Introduction Intended Use The hydraulic aggregate from Darda GmbH with pressure relief valve is designed solely for driving the Darda GmbH devices specified for it. The hydraulic aggregate is only intended – for use within fixed buildings, – for use outdoors, –...

  • Page 12: Limited Service Life

    1 Introduction Limited Service Life The service life of the hydraulic hoses is limited. Regardless of the number of operating hours, have the hydraulic hoses replaced by the manufacturer or a person authorised by the manufacturer every 6 years. The date of manufacture is printed on the hoses. Before using the device, always check its overall condition, safety and ability to operate.

  • Page 13: Guarantee And Liability

    To ensure the functional safety, only original replacement parts from the manufac- turer may be used. 1.10 Declaration of Conformity You will find the Declaration of Conformity at our homepage under http: //www.darda.de IM Hydraulic Aggregate 2, Version 1.0 01/2013...

  • Page 14: Device Data Sheet

    2 Device Data Sheet Device Data Sheet This product manual refers to the following device: Hydraulic Aggregates from Darda GmbH 1 Position of the name plate Fig. 2-1 Name plate Please enter the name plate data of your device into the above illustration, if the manufacturer has not already done this.

  • Page 15: Technical Data

    3 Technical Data Technical Data Technical Data for Hydraulic Aggregates Perfor- σ Type Type of drive Weight Weight mance [dB(A)] 1,08  Petrol engine 2,1  40  88  101  Electric motor EP2 400 V 400 V 1,1  40  88  92  1,36  Electric motor EP2 230 V 230 V 1,1 ...

  • Page 16: Instructions For Servicing, Maintenance And Repair

    4 Instructions for Servicing, Maintenance and Repair Instructions for Servicing, Maintenance and Repair We call your attention expressly to the fact that servicing, maintenance and repair work may only be carried out by authorised and trained personnel! This implies they have read and must have understood this product manual and in particular Chapter 2 Safety Instructions, and in addition, have com- pleted occupational training which has provided them with the necessary technical background for their work!

  • Page 17: Information For Disposal

    5 Information for Disposal Information for Disposal General Information The operator is responsible for the proper disposal of the device. The sector- specific and local conditions for the disposal of the various materials must be followed. Disassembly and disposal of the device may only be handled by qualified personnel.

  • Page 18: Appendix A - Signature List

    Appendix A – Signature List Appendix A – Signature List Procedure / How to fill in the list of signatures  Copy the following signature list below.  Enter the address of your company / authority and confirm this by using the company stamp.
  • Page 19 Appendix A – Signature List Signature List of the following company / authority / operator: Address / Stamp The persons listed below confirm by their signature that  this product manual (IM and OM)  a training / instruction session carried out by the manufacturer has introduced them to ...
  • Page 20 Appendix A – Signature List IM Hydraulic Aggregate 2, Version 1.0 01/2013...
  • Page 21 Operation Manual Hydraulic Aggregate 2 Translation of the original operation manual...
  • Page 22  by Darda GmbH Darda GmbH, Blumberg, retains the copyright to this documentation. This documentation is solely intended for the operator and his personnel. The content of this documentation (text, figures, drawings, graphics, plans, etc.) may not be copied or distributed in part or in full without our consent in writing, nor can it be used without authorisation for competitive purposes or given or made accessible to third parties.

  • Page 23: Operating Manual (Om)

    Outline of Product Manual Outline of Product Manual The entire documentation of the hydraulic aggregate includes: Product Manual – Information Manual (IM) – for the operator of the device – Operating Manual (OM) – for the operator and – for the technical supervisor of the device Outlined Overview of the Entire Documentation Outlined Overview of the Information Manual (for the operator) Information Manual (IM)
  • Page 24 Safety Instructions for Commissioning Personal Protective Gear Description of Device and Operations Hydraulic Aggregate in General Hydraulic Aggregate BP2 (Petrol Engine) Hydraulic Aggregate EP2 (Electric Motor) Hydraulic Aggregate AP2 (Pneumatic Motor) Assembly / Disassembly Connecting a Hydraulically Driven Device to the...

  • Page 25: Introduction

    The descriptions in this operating manual refer solely to the Hydraulic Aggregates as defined in the device data sheet as a whole, or to modules, components and in- dividual parts that were developed and built by Darda GmbH.  IM, 2 Device Data Sheet Storage...

  • Page 26: Symbols In This Manual

    1 Introduction Symbols in this Manual 1.5.1 Danger Warning Levels Text that is marked with DANGER! provides a warning about exceptionally great, immediate dangers. If you do not take accident prevention measures, these hazards will lead with certainty to serious (irreversible) injuries or even death! Please heed this text and take accident prevention measures! Text that is marked with WARNING! provides a warning about exceptionally...
  • Page 27 1 Introduction 1.5.2 Danger Symbols 1.5.2.1 General Danger Symbols Warning about dangers that lead to serious (irreversible) injuries or even death! 1.5.2.2 Specific Danger Symbols Warning about dangerous voltage and/or dangerous electricity! Warning about dangerous hot surfaces! Warning about mechanical movements or hand injuries! Warning about crashing loads! Warning about explosions! Warning about lightning strikes!
  • Page 28 1 Introduction 1.5.3 Instruction Symbols  Heed the provided documentation and/or instructions!  Switch off the device (disconnect)!  Remove the plug from the electrical power supply!  Use ear protectors!  Wear protective gloves to protect against thermal risks according to EN 407. The gloves must offer protection against class 1 contact heat.
  • Page 29 1 Introduction 1.5.4 General Symbols This dot marks the descriptions of activities which you should carry out.  – This dash marks specifications. This arrow marks a cross reference.  If a cross reference to another chapter is necessary in the text, this is shortened for clarity.

  • Page 30: Responsibilities Of The Personnel

    1 Introduction Responsibilities of the Personnel Before beginning work, all persons entrusted with jobs using the devices are re- quired – to heed the fundamental regulations on industrial safety and accident preven- tion. – to read the safety and the warning information contained in this product manual and to confirm with their signature that they have understood them.

  • Page 31: Limited Service Life

    1 Introduction Limited Service Life The service life of the hydraulic hoses is limited. Regardless of the number of operating hours, have the hydraulic hoses replaced by the manufacturer or a person authorised by the manufacturer every 6 years. The date of manufacture is printed on the hoses. Before using the device, always check its overall condition, safety and ability to operate.

  • Page 32: Safety Instructions

    2 Safety Instructions Safety instructions The device is a quality product manufactured according to state-of-the-art technol- ogy rules and was released from the manufacturing plant in perfect condition in re- spect of safety technology! In spite of this, there are residual risks –...

  • Page 33: Danger Symbols / Signs On The Device

    2 Safety Instructions Danger Symbols / Signs on the Device All safety signs, such as warnings, instructions and prohibitions, must be checked at least once a year. Missing, damaged, illegible or loose signs must be replaced. Please refer to replacement parts list for their location. Safety sign sticker Airborne noise sticker The airborne noise depends on the drive motor.

  • Page 34: Intended Use

    2 Safety Instructions Intended Use The hydraulic aggregate from Darda GmbH with pressure relief valve is designed solely for driving Darda GmbH devices specified for this purpose. The hydraulic aggregate is only intended for use within fixed buildings, for use outdoors,...

  • Page 35: Safety Information For Certain Types Of Use

    2 Safety Instructions Safety Information for Certain Types of Use 2.3.1 Hazards caused by hot surfaces Even after a short operation time or after longer idle times, the device parts may become or still be hot. In case of skin contact, serious burns may be incurred! ...
  • Page 36 2 Safety Instructions 2.3.5 Hazards caused by insufficient securing of place of work The operator in charge is solely responsible for securing the place of work and its surroundings. 2.3.6 Hazards caused by electric shock Touching live components may cause a life-threatening electric shock. Work on electric device parts or operating equipment may only be undertaken by an authorised electrician according to recognised electrical regulations.
  • Page 37 2 Safety Instructions 2.3.7 Hazards caused by pneumatic / hydraulic pressurised device parts Pneumatic / hydraulic oil escaping at high pressure can permeate the skin and may cause poisoning, infections and other serious injuries to the eyes or other organs. ...
  • Page 38  Use a carrier to help carry the device. This accessory is available from Darda GmbH.  At least two or four people should carry the device, depending on the em- ployees' assessment threshold.
  • Page 39 2 Safety Instructions 2.3.13 Hazards caused by noise There is an immediate risk of airborne noise when the device is started up.  Use ear protectors! 2.3.14 Hazards caused by the surroundings There are dangers from the surroundings. Surrounding dangers are dangers that can emerge at the site where the de- vices are being used, but are not caused by the devices.

  • Page 40: Safety Instructions For The Different Tasks

    2 Safety Instructions Safety Instructions for the Different Tasks 2.4.1 Failure or Malfunctioning If the device fails or malfunctions, it is to be taken out of operation immedi- ately.  Block off the work area of the device.  Secure the device against accidental start-up. ...

  • Page 41: Safety Information For Maintenance

    2 Safety Instructions Safety Information for Maintenance We would like to draw your attention to the fact that device maintenance may only be carried out by trained personnel with sound mechanical, hydraulic / pneumatic and if necessary electrical knowledge.  Depressurise all pneumatic / hydraulic device parts and disconnect these before working on the device.
  • Page 42 2 Safety Instructions 2.5.3 Safety risk resulting from defective hydraulic hose maintenance The hydraulic hoses must be replaced when the specified service life is reached. Regardless of the number of operating hours, have the hydraulic hoses re- placed with new ones by the manufacturer or a person authorised by the manufacturer every 6 years.

  • Page 43: Hazards Caused By Operating Materials

    2 Safety Instructions 2.5.6 Hazards caused by concealed dangers / residual risks When working with the device, there are unforeseeable residual risks that can only be prevented by systematic work planning, working methods that take account of possible risks, experience, etc. The following list is intended to draw your attention to some possible risks: –...
  • Page 44 2 Safety Instructions 2.6.1.1 Hazards caused by hydraulic oil, engine oil and petrol When working in the area of hydraulic supply lines, danger can result from – suddenly escaping hydraulic oil, – contact with harmful hydraulic oil.  Only perform work on the hydraulics –...

  • Page 45: Safety Instructions For Transport

    2 Safety Instructions Safety Instructions for Transport When transporting the device, the applicable work protection measures should be observed.  Switch off the device before transport.  Secure the device in accordance with the requirements for transport (e.g. with lashing straps) to prevent slippage. ...

  • Page 46: Safety Instructions For Commissioning

    2 Safety Instructions Safety Instructions for Commissioning We would like to draw your attention to the fact that the conversion and the hydraulic installation of the device may only be carried out by trained per- sonnel and authorised persons with profound mechanical, hydraulic / pneu- matic and if necessary electric knowledge.

  • Page 47: Personal Protective Gear

    2 Safety Instructions Personal Protective Gear When working on / with the device, wear the personal protective gear that the relevant safety instructions require. You may not work with the device without personal protective gear. The recommendations for personal protective gear only apply to the de- scribed product.

  • Page 48: Description Of Device And Operations

    3 Description of Device and Operations Description of Device and Operations The hydraulic aggregates fall into three variants: – Hydraulic aggregate BP2 (petrol engine) – Hydraulic aggregate EP2 (electric motor) – Hydraulic aggregate AP2 (pneumatic motor) These variants are explained in the following chapters.

  • Page 49: Hydraulic Aggregate In General

    3 Description of Device and Operations Hydraulic Aggregate in General 1 Oil tank 2 Pressure gauge 3 Oil level indicator 4 Transport roller 5 Frame 6 Handle bar 7 Motor/engine (example: petrol engine) 8 Distributor block with pressure relief valve 9 High pressure connection 10 Oil filler neck 11 Low pressure connection...
  • Page 50 3 Description of Device and Operations Flow chart for hydraulic aggregate 1 Return 2 Pressure relief valve 3 Feed 4 Drive motor 5 Low pressure pump 6 High pressure pump 7 Bypass valve 8 Return filter Fig. 3-2 Flow chart for hydraulic aggregate OM Hydraulic aggregate, Version 1.0 01/2013...
  • Page 51 3 Description of Device and Operations 3.1.1 Functional description of the general assemblies The main components of each hydraulic aggregate are: – Oil tank – Engine/motor – Pump – Frame – Distributor block with pressure relief valve and pressure gauge –...

  • Page 52: Hydraulic Aggregate Bp2 (Petrol Engine)

    3 Description of Device and Operations Hydraulic Aggregate BP2 (Petrol Engine) 1 Combustion engine Fig. 3-3 Hydraulic aggregate BP2 (petrol engine) 3.2.1 Functional description of petrol engine Please refer to the enclosed manufacturer's documentation for information on the petrol engine.

  • Page 53: Hydraulic Aggregate Ep2 (Electric Motor)

    3 Description of Device and Operations Hydraulic Aggregate EP2 (Electric Motor) 1 Switch 2 CEE device plug 3 Electric motor Fig. 3-4 Hydraulic aggregate EP2 (electric motor) 3.3.1 Functional description of electric motor Please refer to the enclosed manufacturer's documentation for information on the electric motor.
  • Page 54 3 Description of Device and Operations 3.3.2 400 V circuit diagram 1 Wall-mounted device plug 2 Motor protection switch Q1 3 Engine/motor Fig. 3-5 Circuit diagram The electric connection (5) takes the form of a (CEE17) device plug (516 / 6h). Please refer to the technical data for the mains voltage.
  • Page 55 3 Description of Device and Operations 3.3.3 230 V circuit diagram 1 Wall-mounted device plug 2 Motor protection switch Q1 3 Engine/motor Fig. 3-6 Circuit diagram The electric connection takes the form of a (CEE17) device plug (316 / 6 h). Please refer to the technical data for the mains voltage.

  • Page 56: Hydraulic Aggregate Ap2 (Pneumatic Motor)

    3 Description of Device and Operations Hydraulic Aggregate AP2 (Pneumatic Motor) 1 Claw coupling 2 Vacuum trigger 3 Compressed air filter 4 Silencer 5 Oil vaporiser 6 Ball cock 7 Pneumatic motor Fig. 3-8 Hydraulic aggregate AP2 (pneumatic motor) The maintenance unit consists of a vacuum trigger, compressed air filter and oil vaporiser.
  • Page 57 3 Description of Device and Operations 3.4.1 Functional description of pneumatic motor Please refer to the enclosed manufacturer's documentation for information on the pneumatic motor and associated components. 1 Vacuum trigger 2 Compressed air filter 3 Oil vaporiser 4 Ball cock 5 Pneumatic motor 6 Silencer Fig.

  • Page 58: Assembly / Disassembly

    4 Assembly / Disassembly Assembly / Disassembly We call your attention expressly to the fact that the conversion and the hydraulic installation of the device may only be carried out by trained per- sonnel with a profound mechanical and hydraulic knowledge! Connecting a Hydraulically Driven Device to the Hydraulic Aggregate When connecting devices without quick-release couplings to the hydraulic aggre-...

  • Page 59: Commissioning / Shut-Down Procedure

    5 Commissioning / Shut-down Procedure Commissioning / Shut-down Procedure Commissioning / Operation We call your attention expressly to the fact that the conversion and the hydraulic installation of the device may only be carried out by trained per- sonnel with a profound mechanical and hydraulic knowledge! (...
  • Page 60 5. Commissioning / Shut-down Procedure Hydraulic connection Direct connection  Once switched off and depressurised, remove the lock nuts and plugs from the screwed insert and fit the hose. 1 Distributor block 2 High pressure connection 3 Low pressure connection 4 Pressure gauge Fig.
  • Page 61 5 Commissioning / Shut-down Procedure Quick-release coupling  Once switched off and depressurised, remove the screwed inserts on the dis- tributor block.  Fit the screwed insert and/or quick-release coupling. Ensure that you use the right components for the high pressure circuit. Please refer to replacement parts list for the tightening torque.
  • Page 62 S-Box protection device and device must not exceed 2 m. Cable loops or windings are prohibited for distances of up to 2 m" The S-Box protective equipment is available from Darda GmbH as an accessory. OM Hydraulic aggregate, Version 1.0 01/2013...
  • Page 63 5 Commissioning / Shut-down Procedure Safety instructions Connections to sockets with rated currents in excess of 16 A are prohibited. Use of plug or cable adaptors, or connecting these in series (cascading) to reduce plug-in couplings, is strictly prohibited. Such equipment brings with it the risk of electric shock“ If extension cables, cable drums or other equipment are used for the connection, the user information provided with them must also be observed.

  • Page 64: Shut-Down Procedure

    5. Commissioning / Shut-down Procedure 5.1.1 Starting up after a power cut Note the information provided in the product manual for the hydraulically driven device. Please refer to the enclosed manufacturer's documentation for information on starting up the petrol engine. The electric motor is started up by switching on the main switch.
  • Page 65 5 Commissioning / Shut-down Procedure Securing the petrol engine against accidental start-up 1 Lock Fig. 5-4 Securing the petrol engine When replacing the starter handle or motor, these must be drilled with a hole for the padlock to secure against accidental start-up. Fig.
  • Page 66 5. Commissioning / Shut-down Procedure Securing the electric motor against accidental start-up 1 Lock Fig. 5-6 Securing the electric motor Securing the pneumatic motor against accidental start-up 1 Lock Fig. 5-7 Securing the pneumatic motor OM Hydraulic aggregate, Version 1.0 01/2013...

  • Page 67: Hydraulic Aggregate Operation

    6 Hydraulic Aggregate Operation Operating the Hydraulic Aggregate Before work, follow the safety instructions in chapter 2. Connecting to the Supply 6.1.1 Fuelling the petrol engine Please refer to the enclosed manufacturer's documentation for information on fuelling the petrol engine. 6.1.2 Connecting the electric motor The rated energy supply value can be found on the motor type plate or in the tech-...

  • Page 68: Maintenance / Cleaning

    7 Maintenance / Cleaning Maintenance / Cleaning We would like to draw your attention to the fact that the conversion and hydraulic installation of the device may only be carried out by trained and authorised personnel with a profound mechanical, hydraulic / pneumatic and if necessary electric knowledge.
  • Page 69 7 Maintenance / Cleaning 7.1.2 Maintaining the petrol engine Please refer to the manufacturer's documentation for information on main- taining the petrol engine. 7.1.3 Maintaining the electric motor Please refer to the manufacturer's documentation for information on main- taining the electric motor. 7.1.4 Maintaining the pneumatic motor / maintenance unit Please refer to the manufacturer's documentation for information on main-...

  • Page 70: Cleaning

    7 Maintenance / Cleaning Cleaning Only clean the device after shutting it down beforehand! Before starting to clean, read the chapter about the shut-down procedure. ( 5.2 Shut-down Procedure) At the engine/motor end, the device must not be cleaned directly with a high- pressure jet of water.

  • Page 71: Repairs

    7 Maintenance / Cleaning Repairs We would like to draw your attention to the fact that repair work that is not described in the documentation is not allowed for reasons of safety. Please refer to replacement parts list for further information on repairs. The device must be disconnected from the energy supply before fault rectifi- cation, servicing and repair work.
  • Page 72 7 Maintenance / Cleaning Cause Error Error rectification Pneumatic motor shuts Energy supply failed. ● Check the energy down during operation. supply. Leaks in pneumatic line. ● Replace defective lines. Motor/engine defective. ● Replace motor/engine. Silencer iced over. Ambient temperature too ●...
  • Page 73 7 Maintenance / Cleaning Cause Error Error rectification The engine/motor is run- Too little oil in the tank. ● Top up oil. ning, the hydraulically  OM, 5.1. Commis- driven devices are not sioning / Operation moving to the limit posi- tion.

  • Page 74: Accessories

    8 Accessories Accessories Storage box The storage box has a load-bearing capacity of 20 kg. The ropes for fastening must be placed around the frame and the straps connected with a carabiner. Carrier The carriers may only be used to carry the device. OM Hydraulic aggregate, Version 1.0 01/2013...

  • Page 75: Disposal

    8 Accessories Disposal  After shutting down the device correctly ( 5.2 Shut-down Procedure) and re- moving the hydraulic oil, it can be disassembled and recycled according to the ma- terials used. If contaminated with radioactive, toxic or other substances hazardous to per- sons or the environment, the devices must be disposed of in accordance with the applicable regulations.

  • Page 76: Technical Data

    10 Technical Data Technical Data 10.1 Technical Data for Hydraulic Aggregates Perfor- σ Type Type of drive Weight Weight mance [dB(A)] Petrol engine 1,08  2,1  40  88  101  Electric motor EP2 400 V 400 V 1,1  40  88  92  1,36  Electric motor EP2 230 V 230 V...
  • Page 77 10 Technical Data Empty page OM Hydraulic Aggregate, Version 1.0 01/2013...

This manual is also suitable for:

Ep2 400 vEp2 230 vAp2

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