The operating manual is the central document for the safe and efficient use of hydraulic tools and attachments. For applications such as concrete demolition and deconstruction, building gutting and cutting, rock demolition and tunnel construction, natural stone extraction as well as special operations, it describes the correct handling of devices from Darda GmbH – from concrete pulverizers and hydraulic wedge splitters for rock and concrete through to hydraulic power packs, hydraulic demolition shears, Multi Cutters, steel shears and tank cutters. It combines fundamental knowledge with practical, hands-on instructions, thereby creating a reliable basis for work planning, commissioning, operation, maintenance operations and documentation.
Definition: What is meant by operating manual
An operating manual is the structured, device-specific documentation provided by a manufacturer that describes the safe and intended use of a product. It typically contains information on operating limits, technical data, assembly and commissioning steps, safety instructions, work procedures, maintenance and inspection plans, troubleshooting as well as spare parts information. For hydraulic tools from Darda GmbH – such as concrete pulverizers or hydraulic wedge splitters for rock and concrete – it is essential for using splitting or cutting forces correctly, setting the hydraulic power pack properly and minimizing risks. Legal requirements may vary by region; the operating manual serves as a practical guide document but does not replace a project-specific hazard analysis or company training/inductions.
Contents and structure of an operating manual
A well-structured operating manual follows a logical layout ranging from general information to specific work instructions. For devices such as concrete pulverizers, splitter cylinders and hydraulic wedge splitters for rock and concrete, a clear structure is crucial so that users can quickly find the correct steps and limits in daily work. Typical chapters include:
- General safety instructions, intended use, residual hazards
- Technical data (e.g., weight, dimensions, hydraulic pressure, flow rate, splitting and cutting performance)
- Device overview and designation of controls
- Assembly, connection and commissioning (incl. hydraulic power packs, hose bundles, couplings)
- Work procedures in typical application areas (concrete demolition, building gutting, rock excavation, natural stone extraction)
- Maintenance, inspection, lubrication, intervals and wear limits
- Troubleshooting and fault rectification
- Transport, storage, decommissioning
- Spare and wear parts, ordering and identification information
- Documentation, test records and traceability
Safety: Intended use, residual risks and protective measures
The operating manual defines what a device is intended for and the applicable operating limits. Protective measures are derived from this. For hydraulic tools from Darda GmbH, the interaction between the tool (e.g., concrete pulverizer, hydraulic wedge splitter for rock and concrete) and the hydraulic power pack is central: pressure, flow rate and coupling systems must match to avoid risks such as overload, leaks or uncontrolled movements. Warning notices and symbols structure the priority of hazards and indicate safety equipment, safety distance and crushing hazard zones.
Typical hazards with concrete pulverizers
- Pinch and shear points in the area of the moving jaws
- Spalling concrete and reinforcing steel pieces with throw distance; risk to eyes and bystanders
- Hydraulic pressure spikes and leaking oil; burn and slip hazards
- Load support and component stability during deconstruction; risk of uncontrolled component movements
Typical hazards with hydraulic wedge splitters for rock and concrete
- Energy input into boreholes and sudden material rupture
- Stone/concrete splinters, noise emission and vibration exposure
- Misalignment of splitter cylinders; uncontrolled crack propagation
- Hydraulic connections under pressure; hazard when disconnecting and connecting
Commissioning and functional test
Commissioning begins with a visual inspection and reconciliation of technical data. For devices from Darda GmbH, the hydraulic power pack, hose lines and the tool are regarded as a single unit. Before starting work, check all connections, verify operating supplies and perform a no-load functional test.
Hydraulic power packs: check pressure and flow rate
- Compare labeling and nameplates: maximum pressure and required flow rate of the tool.
- Check hydraulic oil level and oil condition; check filter condition.
- Clean quick couplings, inspect for damage, connect without tension.
- Depressurize the system, then ramp up slowly; compare pressure gauge readings with target values.
Preparations on the tool
- Check wear parts (e.g., cutting edges, jaws, wedge inserts) for condition and secure fastening.
- Test control functions: open/close the jaws, retract and extend the splitter wedges.
- No-load trial run, then a brief load test on a test piece within the operating limits.
Operation: work procedures and application areas
The operating manual describes concrete procedures for typical tasks. In concrete demolition and special demolition, components are separated in a controlled manner; in building gutting, lines and fixtures are removed. In rock excavation and tunnel construction as well as in natural stone extraction, the focus is on controlled crack guidance and splitting. The choice of tool – concrete pulverizer, splitter cylinders, hydraulic demolition shear, Multi Cutter, steel shear or tank cutter – depends on the material, component geometry and safety requirements.
Concrete demolition and special demolition
With concrete pulverizers, concrete components can be selectively broken and reinforcing steel exposed. For work close to structural elements, a step-by-step approach with small load packages is helpful, supported by shoring and controlled cutting sequences. Hydraulic demolition shears and steel shears assist in cutting profiles and reinforcement. Defined safety distance, load securing and a precise cut and break plan along the load path are essential.
Rock excavation and tunnel construction / natural stone extraction
Hydraulic wedge splitters act via controlled wedge forces in boreholes. The number, depth and grid spacing of the boreholes determine the crack direction. For massive blocks, preferred crack paths are used to trigger separations in a controlled manner. In tunnel heading or during rock excavation, edge-zone securing (e.g., against spalling) must be considered.
Special operations
Special conditions – such as work in ATEX zone environments, in contaminated sites or in confined spaces – require an adapted approach. The operating manual defines operating limits for this and refers to additional measures such as permits, exclusion zones and special equipment.
Maintenance, inspection and care
Regular maintenance extends service life and preserves performance. The operating manual contains intervals, checkpoints and wear limits. For hydraulic systems from Darda GmbH, this particularly concerns oil condition, filtration, seals, hoses, couplings, bearing points as well as cutting and splitting components.
- Daily: visual inspection for leaks, damage, loose fasteners; functional test.
- Weekly: cleaning, lubricate lubrication points, check protective caps and covers.
- Interval-based: oil and filter changes, seal replacement, check and document wear dimensions of cutting edges/jaws/wedges.
Hydraulics: fluids, filters and seals
Oil quality influences response speed and service life. Contamination leads to valve wear and performance loss. Seals must be checked for aging and mechanical damage; couplings must seal tightly and close cleanly. Spare parts are to be identified using the part numbers specified in the operating manual.
Testing, documentation and traceability
Traceable documentation of tests and maintenance supports safety and quality. The operating manual specifies forms or minimum information for this. Test reports and operating hour records facilitate planning of maintenance intervals and proof of proper operation.
- Equipment file with serial number, commissioning date, test data
- Maintenance and repair history with date, scope and parts used
- Test reports for pressure tests, functional tests and leakage test
- Operation reports for special operations or unusual environmental conditions
Spare and wear parts
The operating manual lists parts subject to replacement and wear-prone parts with limit dimensions. For concrete pulverizers, this includes, for example, cutting edges, pins and bushings; for hydraulic wedge splitters for rock and concrete, wedge inserts, tension anchor and seals. It is recommended to use original specified parts from Darda GmbH to ensure fit, performance and safety. Replacement must be carried out according to the described steps and documented.
Illustrations, pictograms and signaling elements
Graphics and pictograms increase comprehensibility. The operating manual explains the symbolism, warning levels and color codes. Signal words (e.g., Caution, Warning) are used consistently to clearly convey the importance of hazard notices. Exploded-view drawings and parts lists make it easier to identify components and follow the correct assembly sequence.
Troubleshooting: systematic diagnosis
Troubleshooting follows a structured sequence from simple to complex causes. First, operating supplies, connections and settings are checked, followed by wear and internal components. Measured values (pressure, flow rate) are compared with target values.
Typical symptoms and causes
- Concrete pulverizer closes slowly: flow rate too low, clogged filter, leak in the hose bundle, contaminated valve seat.
- Splitter does not build force: pressure below target, worn wedge insert, unsuitable borehole geometry, air in the system.
- Rough/uneven running: air or contamination ingress, unsuitable oil viscosity, coupling partially closed.
- Overheating: duty cycle too high, insufficient oil cooling, restricted return line.
Adapting to the operating environment
Environmental conditions influence the work procedure. In the presence of dust and dirt, protective caps and filters should be checked more frequently; at low temperatures, a warm-up phase is useful to stabilize oil viscosity and seal elasticity. Noise emission and vibration values are specified in the operating manual; appropriate safety equipment and work time limits should be observed in accordance with company regulations.
Decommissioning, transport and storage
Before transport, tools must be cleaned, depressurized and secured against damage. Fit protective covers and caps, relieve hose lines. Store in a dry, clean and temperature-controlled environment; regular visual inspections prevent corrosion and seal aging. For longer periods out of service, the operating manual provides guidance on preservation and on re-storing operating supplies.
Keep the operating manual up to date
Changes to devices, application procedures or operating supplies are documented in a traceable manner. Revision statuses must be indicated and communicated to the workforce. Translations and versions must be consistent in content. Training sessions should be conducted in clear language and refreshed regularly so that the specifications of the operating manual are followed in everyday work.