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Summary of Contents for darda C2S
- Page 1 Product Manual Hydraulic Stone and Concrete Splitter 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 Stone and Concrete Splitter 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 Outline of Product Manual Outline of Product Manual The entire documentation of the hydraulic stone and concrete splitter includes: Product Manual – Information Manual (IM) – for the operator of the device – Operating Manual (OM) – for the operator and –...
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Page 6: Table Of Contents
Table of Contents (IM) Table of Contents (IM) Chapter Subject Page Introduction Preface Product Identification / Product Information Receiving Inspection Definition of Terms Responsibility of the Operator Intended Use Limited Service Life Complaints Guarantee and Liability 1.10 Declaration of Conformity Device Data Sheet Technical Data Splitters... -
Page 7: Preface
Product Identification / Product Information The Darda type C splitters are used for splitting natural stone and concrete. The descriptions in this product manual relate to splitter types C2S, C4S, C9, C10S and C12 from Darda GbmH. The splitting devices are available in different designs that can be identified in the appendages to the names. -
Page 8: Definition Of Terms
1 Introduction Definition of Terms In this product manual, the hydraulic stone and concrete splitter is described as a device in the following sections. Responsibility of the Operator The operator is required to allow work with the device only by experts who –... -
Page 9: Intended Use
Intended Use The device from Darda GmbH is solely intended for the commercial splitting of concrete, rock and stone within fixed buildings and in freestanding structures. The following restrictions are to be regarded! -
Page 10: Complaints
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 website under http: //www.darda.de IM Hydraulic Stone and Concrete Splitter, Version 1.0 04/2010... - Page 11 2 Device Data Sheet Device Data Sheet This product manual is based on the device types C2S, C4S, C9, C10S and C12, which are defined in the following. Fig. 2-1 Name plate Please enter the name plate data of your device in the above illustration, if the manufacturer has not already done this.
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Page 12: Splitters
3 Technical Data Technical Data Splitters Required Minimum Theoretic Splitting Splitting Type borehole borehole splitting head distance diameter depth force kN/tonne 32-33 3490/355 35-36 10-40 4524/461 35-38 3267/333 35-38 3267/333 45-48 18-44 2995/305 45-48 18-40 2995/305 48-50 1080 18-40 2995/305 C10S 41-43 18-45... - Page 13 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!
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Page 14: 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 different materials must be followed. Disassembly and disposal of the device may only be handled by qualified personnel. -
Page 15: Appendix A - List Of Signatures
Appendix A – List of Signatures Appendix A – List of Signatures Procedure / How to fill in the list of signatures Copy the list of signatures below. Enter the address of your company / authority and confirm using the company stamp. - Page 16 Appendix A – List of Signatures List of Signatures of the following company / authority / operator: Address / Stamp The persons listed below confirm by their signature that they have been instructed, by means of this product manual (IM and OM) through special training / instructions given by the manufacturer, on the functions, the operations,...
- Page 17 Operating Manual Hydraulic Stone and Concrete Splitter Original Operating Manual...
- Page 18 © 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 19 Outline of Product Manual Outline of Product Manual The entire documentation of the hydraulic stone and concrete splitter includes: Product Manual – Information Manual (IM) – for the operator of the device – Operating Manual (OM) – for the operator and –...
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Page 20: Introduction
Table of Contents (OM) Table of Contents (OM) Chapter Subject Page Introduction Preface Validity Storage Definition of Terms Symbols in this Manual Responsibilities of the Personnel Limited Service Life Protection against Unauthorised Operation, Servicing and Repair Personal Protective Gear Safety Instructions Intended Use Safety Information for Certain Types of Use Safety Instructions for the Different Tasks... -
Page 21: Introduction
The descriptions in this operating manual refer solely to the Hydraulic Stone and Concrete Splitter as defined on the Device Data Sheet as a whole or they refer to modules, compo- nents and individual parts that were developed and built by Darda GmbH. IM, 2 Device Data Sheet Storage... -
Page 22: 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 the accident prevention measures! Text that is marked with WARNING! provides a warning about exceptionally... - Page 23 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 explosions! Provide lubrication every 2 hours! 1.5.3...
- Page 24 1 Introduction Wear an industrial hard hat in accordance with EN 397! Use ear protectors! Use a face mask for protection class 2 with a mechanical strength A! Use safety gloves with pulse protection and – an abrasion resistance of power level 4 –...
- Page 25 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.
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Page 26: 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 instructions and the warning information contained in this product manual and to confirm with their signature that they have understood them. -
Page 27: Limited Service Life
1 Introduction Limited Service Life The service life of the devices 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. Before using the device, check its overall condition, safety and ability to operate each time. -
Page 28: Intended Use
Intended Use The Darda type C splitters are suited for splitting concrete, rocks and stones within fixed buildings and in freestanding structures. All other materials such as metal cannot be handled with this method. -
Page 29: Safety Information For Certain Types Of Use
2 Safety Instructions Safety Information for Certain Types of Use 2.2.1 Hazards caused by hot surfaces Even after a short operation time or after longer idle times, the hydraulic hose assemblies or other device parts can already or still be hot! In case of skin contact, serious burns may be incurred! Note that during normal operation the hydraulic oil may reach a tempera- ture of up to 80 °C! - Page 30 2 Safety Instructions 2.2.4 Hazards caused by pressurised device parts 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! For all work at hydraulic hose assemblies or device parts, wear appropri- ate personal protective gear (e.g.
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Page 31: Safety Instructions For The Different Tasks
2 Safety Instructions Safety Instructions for the Different Tasks 2.3.1 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 commissioning. Inform the operator immediately. - Page 32 2 Safety Instructions 2.4.2 Safety risk from contaminated hydraulic oil Before starting up the devices, check the hydraulic oil for contamination. Contaminated hydraulic oil can lead to malfunctioning. 2.4.3 Hazards from a loss of power With a loss of power, dangers for people and the environment can result from the device.
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Page 33: Danger From Operating Material / Splitting Material
2 Safety Instructions 2.4.5 Hazards from concealed dangers / residual risks When concrete, rocks and stone are split, there are fundamentally unfore- seeable residual risks that can only be prevented by systematic work plan- ning, working methods taking into account possible risks, experience, etc.! The following list is intended to draw your attention to some possible risks: ... -
Page 34: Safety Instructions For Conversion
2 Safety Instructions 2.5.2 Hazards from operating material 2.5.2.1 Hazards from hydraulic oil When working in the area of hydraulic supply lines, danger can result from – – suddenly escaping hydraulic oil, – – contact with hydraulic oil that damages your health. Only perform work on the hydraulics –... -
Page 35: Safety Instructions For Transport
2 Safety Instructions Safety Instructions for Transport When transporting the device, the applicable work protection measures are to be considered! Secure the device in accordance with the requirements for transport (e.g. with lashing straps) to prevent slippage. Safety Instructions for Commissioning We call your attention expressly to the fact that the conversion and the hy- draulic installation of the device may only be carried out by trained and authorised personnel with a profound mechanical and hydraulic knowledge! -
Page 36: Protective Gear
2 Safety Instructions Protective Gear When working on / with the device, wear the personal protective gear that the relevant safety instructions require! Work with the device is not allowed without personal protective gear! 2.9.1 Class S1 safety shoes When performing tasks such as –... -
Page 37: Information About Off-Limits Area
2 Safety Instructions 2.9.4 Industrial protective hard hat When performing tasks such as – transport – commissioning – operation – maintenance, cleaning, servicing, wear a hard hat according to EN 397. 2.10 Information about Off-limits Area The operator or the construction management team is solely responsible for securing the direct and indirect danger zones. -
Page 38: Device Protection
Lubricate the pressure surfaces at the latest after 3 to 5 splittings! Solely use the Darda special lubricant paste! Avoid frequent full capacity utilization of the splitter by using multiple splitters with the smallest possible borehole intervals! Constantly reach-... -
Page 39: Device Description
3 Device Description Device Description 1 Control valve 7 Operating lever 2 Cylinder 8 Bolt* 3 Piston 9 Screw (on the opposite side of the plastic cap) * 4 Handle 10 Built-in pot 5 Plastic cap * 11 Hooks (2 x, right and left) * 6 Splitting wedge 12 Pressure piece (2 x) * (only with C9, C10S and C12) -
Page 40: Work Preparation
4 Work Preparation Work Preparation Drilling Boreholes Fig. 4-1 - 1 Drilling boreholes To avoid damage to the splitter, the boreholes must be the correct size and cautiously drilled! Please heed the following instructions: – To protect the splitting head, the borehole should be drilled as straight as possi- ble. -
Page 41: Connection To Hydraulic Hoses
4 Work Preparation Connection to Hydraulic Hoses 1 Pressure limitation valve, complete 2 Hydraulic hose 3 Hydraulic hose 4 Distribution pieces, 1 to 3-point, complete 5 Hydraulic hose 6 Hydraulic hose 7 Quick-release coupling, low pressure, complete 8 Quick-release coupling, high pressure, complete 9 Quick-release coupling, low pressure, complete 10 Quick-release coupling, high pressure, complete 11 Control valve, complete... -
Page 42: Lubrication
Procedure for lubrication: Spread the splitting head with a screw driver or similar instrument and use a spatula to apply a thin layer of Darda special lubricant paste on the pressure surfaces and pressure pieces and the splitting wedge. Advantages of the Darda special lubricant paste: –... -
Page 43: Commissioning / Operation / Shut-Down Procedure
5 Commissioning / Operation / Shut-down Procedure Commissioning / Operation / 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 and authorised personnel with a profound mechanical and hydraulic knowledge! 2.8 Safety Instructions for Commissioning OM Hydraulic Stone and Concrete Splitter, Version 1.0 04/2010... -
Page 44: Operation
R Wedge back: The wedge is retracted. As soon as the wedge has been completely retracted, the pressure limitation valve built into the Darda aggregate relieves the pressure cylinder (noticeable in the clearly audible bang from the aggregate). N Zero position: The wedge does not move. -
Page 45: Safety-Conscious Work
5 Commissioning / Operation / Shut-down Procedure Safety-conscious Work 1 Danger zone! If the pressure pieces break during the splitting process, this can lead to sudden lateral or axial deflections of the splitter. Fig. 5-3 - 1 Danger zones and correct handling Guide the splitter into the borehole by hand until it stops (operating lever posi- tion: N / R 5.2 Operation) -
Page 46: Expanding
5 Commissioning / Operation / Shut-down Procedure Expanding 5.4.1 Splitter types C2S, C4S 1 Built-in pot of splitter 2 Splitting wedge 3 Inner expander insert, 1st side 4 Outer expander insert, 1st side 5 Outer expander insert, 2nd side 6 Inner expander insert, 2nd side Fig. - Page 47 5 Commissioning / Operation / Shut-down Procedure 5.4.2 Splitter types C9, C10S, C12 Expanding with expander pressure pieces Fig. 5-4-2 - 1 Expanding with expander pressure pieces To expand a split with these spitter types, the normal pressure pieces are succes- sively replaced by thicker expansion pressure pieces.
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Page 48: Shut-Down Procedure
5 Commissioning / Operation / Shut-down Procedure Shut-down Procedure Switch off the hydraulic aggregate and protect it against accidental start-up. Avoid the pressure in the hydraulic circuit by moving the operating lever one or two times to its end position. OM Hydraulic Stone and Concrete Splitter, Version 1.0 04/2010... -
Page 49: Splitter Type C4S
6 Replacing Splitting Heads Replacing Splitting Heads We call your attention expressly to the fact that the conversion and the hy- draulic installation of the device may only be carried out by trained and authorised personnel with a profound mechanical and hydraulic knowledge! Splitter Type C4S 6.1.1 Expansion of the splitting wedge and / or pressure pieces... - Page 50 6 Replacing Splitting Heads 6.1.2 Assembly of the splitting wedge and / or pressure pieces 1 Built-in pot 6 Plastic cap 2 Pressure piece 7 Rubber disc 3 Screw 8 Guide pin 4 Bolt 9 Guide disc 5 Splitting wedge Fig.
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Page 51: Splitter Types C9, C10S, C12
6 Replacing Splitting Heads Splitter Type C9, C10S, C12 6.2.1 Exchanging the pressure pieces 1 Screwdriver 2 Hooks (2 x, right and left) 3 Splitting wedge 4 Pressure piece Fig. 6-2-1 - 1 Exchanging the pressure pieces Retract the splitting wedge (3) completely (operating lever in position R). Press both hooks (2), e.g. -
Page 52: Maintenance Every 6 Years
6 Replacing Splitting Heads 6.2.2 Replacing the splitting wedge 1 Screw 2 Splitting wedge 3 Plastic cap (not visible) 4 Bolt 5 Mandrel for pounding out the bolt Fig. 6-2-2 - 1 Replacing the splitting wedge Remove both pressure pieces as described on the previous page. Extend the splitting wedge (2) completely (operating lever in position F). -
Page 53: Cleaning
6 Replacing Splitting Heads Cleaning Only clean the device after shutting it down beforehand! Before starting to clean, read the chapter about the shut-down procedure. 5.5 Shut-down Procedure Remove – coarse splitting material which has settled on the device during work manu- ally at regular intervals. -
Page 54: Troubleshooting
7 Troubleshooting Troubleshooting Error: Error: Error: Error: Hydraulic aggre- Hydraulic aggre- Wedge does not Wedge moves in gate does not gate does not build extend or retract - one direction very achieve pressure of up pressure. Hydraulic aggre- slowly. 50 MPa - Pressure gate increases limitation valve pressure to... -
Page 55: Technical Data
8 Technical Data Technical Data Splitters Required Minimum Theoretic Splitting Splitting Type borehole borehole splitting head distance diameter depth force kN/tonne 32-33 3490/355 35-36 10-40 4524/461 35-38 3267/333 35-38 3267/333 45-48 18-44 2995/305 45-48 18-40 2995/305 48-50 1080 18-40 2995/305 C10S 41-43 18-45... -
Page 56: Disposal
9 Disposal Disposal After shutting down the devices correctly ( 5.5 Shut-down Procedure) , remov- ing the hydraulic oil and removing possible lubricating grease residues, the devices can be disassembled and recycled according to materials. If contaminated with radioactive, poisonous or other substances hazardous to persons or the environment, the devices must be disposed of in accor- dance with the regulations applicable! Disposal of Old Oil...