FachausschussInformation leaflet no.
Fachausschuss
Maschinenbau,
Fertigungssysteme,
Stahlbau
015
Testing and replacement of
hydraulic hose assemblies
Edition 10/2006
Hydraulic hose assemblies are used in
almost all machinery and plants applying
hydraulically controlled component groups,
in particular, where rigid pipes for power
transmission cannot be used.
Due to defective binding, ageing, wear,
damage and for other reasons, hydraulic
hose assemblies represent a particular
hazard. Therefore, the user has to check
hydraulic hose assemblies prior to their first
use and at regular intervals and to replacing
them in case of failure or aging.
__
Those requirements result from the industrial
safety regulations.
Table of contents:
1
Required tests
2
Test for proper assembly and safe
function (formerly called: initial
test)
3
Test for proper provision and
proper use
(formerly called: recurrent test)
4
Legal basis for the tests
5
Summary and limits of application
Annex (Tables 1 - 8)
This check for “proper assembly and safe
function” has to be arranged by the user after
assembly and prior to the initial setting into
operation or prior to putting the machine back
into operation; this check was formerly referred
to as “initial test”. (see chapter 2).
__
Fig.: Hydraulic hose assemblies
1
__
Required tests
For reasons of warranty and safe function, work
equipment (machinery and plants) which
includes hydraulic hose assemblies within
hydraulic plants shall be tested. The legal
guidelines for the tests are specified in the
Betriebssicherheitsverordnung BetrSichV [1],
which puts the provisions of the Industrial Safety
Act ArbSchG [2] in concrete terms for users of
equipment.
New machinery shall comply with European
directives which are certified by the declaration
of conformity and the CE-mark. However, this
does not mean that new machinery bearing this
mark has no safety deficiencies. In addition, work
equipment may be damaged by transportation,
after relocation or due to improper mounting.
Therefore, machines and their hydraulic hose
assemblies shall be checked after proper
mounting.
In addition, machines and their hydraulic hose
assemblies are exposed to „damage causing
influences“ or wear. Nevertheless, work equipment shall be safe at the beginning of each work
cycle.
Therefore, the user has to identify potential
hazards, assess the relevant risks, specify safety
measures for safe provision and use and ensure
that they are met. Those safety measures
include the testing and replacement of hydraulic
hose assemblies.
Work equipment has to be checked at regular
intervals for „safe provision and use“; formerly
called “recurrent test” (see chapter 3). These
tests have to be arranged by the user as well.
The kind of test (see above) as well as the test
scope and the test periods according to § 3
BetrSichV have to be specified by the user and
form part of the documentation of his hazard
analysis according to § 6 ArbSchG, (Employment
Protection Act), as do the results of the
performed tests.
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015
edition 10/2006
Testing and replacement of hydraulic hose assemblies
2
Test for proper assembly and safe
function (formerly called: initial
test)
The test for „proper assembly and safe function“
is intended to evaluate criteria related to the
assembly and which can only be evaluated on
the completely assembled machine. Besides the
testing of safeguards, e.g. emergency stop, the
installed hydraulic hose assemblies have to be
checked as well.
Some test criteria can be evaluated by „visual
inspection“ in the Off-state condition. Other
criteria require a “functional test” with power on.
Attention has to be drawn to the machinery
movements and the related risks.
A survey of the recommended test scope for a
„visual inspection“ (for the hydraulic hoses) is
given in Table 1 (see annex).
A survey concerning the recommended test
scope for “functional testing” (concerning the
hydraulic hose assemblies) is given in Table 2.
3
Test for safe provision and use
(formerly called: recurrent test)
Since hydraulic hose assemblies are exposed to
influences causing damage, they have to be
checked at regular intervals for „safe provision
and use“.
However, testing shall also be carried out as
“extraordinary testing” after accidents, modifications (rebuilding) at the machine, remounting
at a different location without modification of the
old machine, after longer periods of non-use and
after maintenance measures as a result of
damages (collision, natural phenomena).
All tests are intended, to detect and eliminate
damages at hydraulic hose assemblies as soon
as possible.
3.1 Recommended test scope
Table 3 provides a detailed survey with regard to
the recommended extent of test scope for the
„safe provision and use“. (concerning hydraulic
hose assemblies, see Table 3).
3.2 Test criteria for hydraulic hose
assemblies
The recommended test criteria for the testing of
individual hydraulic hose assemblies with regard
to their safety condition, can be found in Table 4.
page 2 / 10
3.3 Recommended test periods
The employer has to specify the periods for
required tests, according to § 3 BetrSichV within
the scope of their risk assessment and the
determination of measures for the safe provision
and use of work equipment.
The time intervals between recurrent tests have
to be chosen in such a way that deviations from
the proper state of work equipment can be
identified in time to prevent incidents.
The provisions stated in the rules and regulations
of accident insurers with regard to tests and test
periods have to be regarded as definite
description of the requirements of the
Betriebssicherheitsverordnung and should be
taken as a basic source of information for
specifying test periods.
The test periods of machinery or their safety
relevant components, such as hydraulic hose
assemblies, can be influenced by the criteria
listed in Table 5. Those criteria should also be
considered for checking or verifying the test
periods, given in the BG-rules which have been
proven up to now (to prolong or reduce the
periods as far as this is necessary).
With reservation of company-specific or
machinery related determinations of test periods
by the user of the work equipment and with the
reservation of specific provisions by the machine
manufacturer or the manufacturer of the hoses or
hose assemblies, the test periods summarized in
Table 6 are recommended for the testing of
hydraulic hose assemblies.
Notes:
It is possible that the user may specify the same
test periods according to the „Betriebssicherheitsverordnung“ as he did before the Betriebssicherheitsverordnung came into effect, e.g, to
have the hydraulic hose assembly tested prior to
the initial setting into operation and afterwards at
least once a year or according to the defined
provisions given by the manufacturer in the
operating instructions of the machine (e.g. 1x/
2x/ 4x per year) with regard to their safe
operational state.
Depending on the location of use or the
existence and types of secondary safeguards of
the hydraulic hose assemblies and the relevant
risk assessment, different test intervals (as well
as for replacement) can possibly be specified for
different hydraulic hose assemblies for one and
the same machine.
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015
edition 10/2006
Testing and replacement of hydraulic hose assemblies
page 3 / 10
3.4 Defective hydraulic hose
assemblies
replacement
companies.
Defective hydraulic hose assemblies shall be
replaced. Defects of the safe operational state
which have been detected at the testing of the
hydraulic hose assemblies have to be eliminated
immediately or suitable measures have to be
taken so that the machine cannot be used until
the hydraulic hose assembly has been replaced.
A maximum period of use for hydraulic hose
assemblies of 6 years including a storage period
of max 2 years is generally recommended as a
reference value. (BGR 237 [3]). At the production
of the hydraulic hose assembly (of the machine
respectively), the hose should not be older than
4 years.
Hydraulic hose assemblies shall neither be
repaired nor reassembled by old parts.
Deviations from the recommended maximum
period of use are possible if relevant test values
and empirical values are available which permit a
safe prolonged use beyond the maximum period
of use. An extended period of use of the
hydraulic hose assembly is even possible if there
is no risk from hydraulic fluids, the hose itself or
a hazardous motion of the machine or the load,
caused by damage or a hose fracture.
If several hydraulic hose assemblies are
replaced at the same time, ensure that only
those hydraulic hose assemblies are used which
are sufficiently dimensioned for the load to be
expected in the relevant connection (pressure-,
tank-, leakage pipe, etc.) and that mixing of the
connections is prevented.
intervals
in
the
individual
For further information concerning the selection
of the new hydraulic hose assembly to be
installed, see chapter 3.7.
For hoses consisting of thermoplastic or metallic
hydraulic hose assemblies, other reference
values besides those mentioned above may
apply.
NB:
Defective hydraulic
have to be replaced!
Deviations from the recommended reference
values for the period of use have to be included
in the operating instructions of the machine or
plant.
hose
assemblies
3.5 Replacement of hydraulic hose
assemblies
Even if no safety relevant defects can be
detected of the outside of the hydraulic hose
assembly during the visual inspection, the
compound of the inner and outer rubber layer
and one pressure support consisting of a singleor multi layer steel mesh or fabric ply can be
damaged inside.
In general, hoses and hose assemblies are
subject to natural aging which reduces the
performance of the hydraulic hose assemblies
even if they are properly stored and used within
the admissible loads.
Consequently, the period of use of a hydraulic
hose assembly is limited. The user has to take
care that hydraulic hose assemblies are replaced
at appropriate intervals. This constitutes a
protective measure according to § 6 ArbSchG.
The period of use of hydraulic hose assemblies
highly depends on the conditions of use and
environment. Due to the broad range of
application of hydraulic hose assemblies, it is not
possible for technical reasons to indicate a
maximum permissible period of use which
applies to all different applications.
Specific statements or instructions by the
manufacturer of the hose assembly shall be kept,
and the recommendations of the machinery
manufacturer concerning the period of use
should be considered when specifying the
Notes:
When
specifying
the
company-specific
replacement intervals or the duration of use for
the individual hydraulic hose assemblies being
used on a machine, the user has to refer
primarily to the above mentioned replacement
intervals recommended by the manufacturer, but
also to experience gained from the individual
application conditions. This applies especially if
the recommended duration of six years is
exceeded.
A prolongation of the recommended duration of
use of six years is possible if:
-
relevant test results or empirical values are
available from the machinery manufacturer
and / or the machinery user or from the
manufacturer of the hose / hose assembly,
and
- a risk assessment has been carried out and
protective measures have been specified by
the user that consider also secondary
protective measures against risks due to
failure of hydraulic hose assemblies (e.g.
hose break protection) and an increased risk
does not occur. and
- the testing of the safe operational state is
carried out in adequately specified time
intervals – if necessary shortened – by a
competent person.
A prolongation of the replacement intervals is not
permissible without written documentation of the
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015
edition 10/2006
Testing and replacement of hydraulic hose assemblies
risk assessment and the specified protective
measures.
NB:
A prolongation of the replacement
intervals shall not result in a hazardous
situation which can lead to injuries to
employees or other persons!
If it is intended to extend the duration of use of
the hydraulic hose assemblies beyond the
recommended six years, shortened testing
intervals are recommended for safety reasons.
Some machinery manufacturers have specified
shorter test and replacement intervals in their
operating instructions resulting from the hazard
analysis and the protection concept of particular
hydraulic hose assemblies with increased
requirements (such as e.g. particular gravityloaded axes) (e.g. testing every six months and
replacement after two years).
The user has to take these aspects into account
when specifying their replacement intervals.
Table 7 shows a summary of the most important
factors influencing the replacement intervals.
For further information concerning the selection
of the new hydraulic hose assembly to be
installed, see chapter 3.7.
Reference:
Further explanations to the relevant standards and
regulations, to examples of applications and the
procedure for the risk evaluation concerning the
hydraulic hose assemblies are also included in the
publication [4].
3.6 Recommended replacement
intervals
With reservation of company specific and
machinery related specifications of test and
replacement periods by the user of the work
equipment and with the reservation of specific
provisions by the machine manufacturer or the
manufacturer of the hoses or hose assemblies,
and under the assumption that the necessary
test periods are kept (see chapter 3.3), the
intervals summarized in Table 8 are
recommended as reference values for the
replacement of hydraulic hose assemblies.
3.7 Selection and storage of hydraulic
hose assemblies
Basically, the replacement of hoses shall be
carried out according to the specifications of the
manufacturer. If, however, operating instructions
are not available and support by the
manufacturer is no longer possible, the
procedure should be as follows:
page 4 / 10
The hose, fitting and hose assembly have to be
selected in such a way, that
- the requirements with respect to the hose
assembly marking are fulfilled,
- the admissible stress of the components will
not be exceeded with the operating pressures
to be expected.
- operating pressures are considered, the
control or the hydraulic pump have been
designed for, and which are indicated on the
type plates of such hydraulic plant
components,
- the cross sections or nominal diameters
respectively are sufficiently dimensioned so
that there will be no inadmissible
accumulation pressures which, for example,
obstruct the free backflow to the tank,
- the compatibility of hose materials and
sealing materials with the hydraulic fluid being
used is ensured,
- types of hose fittings consisting of a (turned)
connecting pipe socket with cutting ring are
not used since they represent a serious risk of
accident (due to slipping).
In summary, the replaced hose assembly has to
be suitable for the intended use with regard to
pressure, volume flow, possible pressure
impacts and resistance towards the hydraulic
fluid being used.
NB:
It has to be checked whether the selected
hydraulic hose assembly is suitable for
the intended use.
Basically, hydraulic hose assemblies should be
purchased in a ready-made condition only.
Preference should be given – if not already
stated by the manufacturer – to standardized
hoses/hose assemblies, e.g. according to DIN
EN 853 [5]. If a hydraulic hose assembly is selfassembled, care should be taken that the
components selected (hose and fittings) are
mutually adjusted with regard to dimensions,
shape and pressure level. Therefore, it is
essential to take into account the specifications
of the hose and fitting manufacturers.
The installed hydraulic hose assemblies shall not
consist of hoses which have already been used
as part of a hose assembly before!
A self-assembly shall only be carried out by a
competent person (TRBS 1203 [6]), and only
appliances and equipment shall be used which
are approved by the fitting manufacturer. A safe
implementation of hydraulic hoses also requires
specified knowledge about the relevant
procedure, the appliances and the components.
The storage period should not exceed four years
for hoses and two years for hydraulic hose
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015
edition 10/2006
Testing and replacement of hydraulic hose assemblies
assemblies. Storage should be at a cool, dry and
dust-free place; direct solar or ultraviolet
radiation has to be avoided; nearby heat sources
have to be shielded. Storage temperatures below
-10°C have to be avoided; for thermoplastic
material, other reference values may apply. For
further information, see BGR 237.
Remark:
Further information concerning pipeworks and the
connections is given in DIN 20066 [7].
page 5 / 10
4.1 Competent person
A competent person, as defined by the
Betriebssicherheitsverordnung, is a person
possessing the required expert knowledge for
the testing of hydraulic hose assemblies
acquired by professional training, professional
experience and contemporary professional
activities. For the testing, this person shall act
fully independent and shall not be committed to
any other instructions (BetrSichV § 2 clause 7
and TRBS 1203).
NB:
Hydraulic hose assemblies should be
purchased from a hose assembly
manufacturer in a ready-made condition
only.
A specific job profile for „competent persons“ in
view of the particular testing tasks in connection
with hydraulic hose assemblies does not exist,
however, the general requirements according to
TRBS 1203 shall be fulfilled by the competent
persons:
4
-
Professional training
The competent person shall have completed
a professional training regimen which enables
demonstration of their professional skills. The
proof should be based on professional
certificates or comparable evidence.
-
Professional experience
Professional experience assumes that the
competent person has been working with
equipment (i.e. hydraulic hose assemblies) for
a sufficient time, and including opportunities
to initiate the tests, e.g. as a result of the
hazard evaluation or from daily observation.
-
Contemporary professional activities
A contemporary professional activity in the
field of the particular test to be done (i.e. the
hydraulic hose assembly) and an up to date
knowledge of the State of the Art are
indispensable. The competent person shall
demonstrate experience in the execution of
the pending test or similar ones, and shall
have knowledge as to the State-of-the Art
concerning the work equipment to be tested
and the risks which have to be taken into
account.
Legal basis for the tests
The legal regulations for the testing of work
equipment (machinery, plants and consequently
hydraulic hose assemblies) are specified in the
Betriebssicherheitsverordnung which put the
provisions of the Employment Protection Act into
concrete terms.
The user of the work equipment shall specify the
method, the scope and the periods of testing for
their individual conditions of use within the scope
of a hazard evaluation (Betr SichV § 3) and carry
out the tests accordingly (BetrSichV § 10) by
taking the provisions and recommendations of
the manufacturer into account.
The BG rule BGR 237 represents the practical
instruction of the Betriebssicherheitsverordnung
with regard to hydraulic hose assemblies. The
BGR 237 currently includes the contents of the
safety rule ZH 1/74 [8] which has been in force
until now and which is presently under revision.
The test periods as well as the replacement
intervals for replacement have to be documented
in writing together with other protective measures
according to § 6 ArbSchG. The test results have
to be added to this documentation as well.
The test results have to recorded (e.g. with the
test protocol of the appliance) and kept (at least
until the next test) in situ.
The tests shall only be carried out by competent
personnel who has been instructed accordingly
by the employer (see chapter 4.1).
Competent persons who have carried out the
tests of hydraulic hose assemblies so far, who
fulfil the three requirements mentioned above
and who are familiar with the contents of the
Betriebssicherheitsverordnung
and
the
modifications related to them may still be
charged with the tests.
The competent person is in no way bound by
directives while performing testing, and
therefore, shall not be put at a disadvantage.
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015
edition 10/2006
Testing and replacement of hydraulic hose assemblies
5
Summary and limits of application
The committee of experts “Mechanical
engineering, manufacturing systems, steel
construction” Fachausschuss Maschinenbau,
Fertigungssysteme, Stahlbau (FA MFS) is
composed of representatives of the German
institutions for statutory accident insurance and
prevention (Berufsgenossenschaften), federal
authorities, social partners, manufacturers and
users.
This leaflet is based on experience gathered by
the FA MFS in the field of hydraulic equipment of
machinery and plants.
It is particularly intended to assist the user in
specifying the:
- kinds of tests;
- test periods;
- test scope; and
- test criteria.
It should help to specify the replacement
intervals of hydraulic hose assemblies which are
used in machinery and plants, and which are
included in the scope of the European Machinery
Directive [9].
This leaflet refers to hydraulic hose assemblies
that have been excluded from the scope of the
Pressure Equipment Directive [10]. For hydraulic
hose assemblies which have not been excluded
from the scope of that directive, further
requirements according to the Pressure
Equipment Directive and the Betriebssicherheitsverordnung shall be considered additionally.
The particular provisions for different applications
(e.g. in the mining industry or similar) have to be
considered.
The provisions according to individual national
laws and decrees remain unaffected by this
German information leaflet. The requirements of
the legal rules apply without reservation. In order
to get detailed information it is necessary to read
the relevant wording of the rules.
page 6 / 10
German Bibliography
[1] Verordnung über Sicherheit und Gesundheitsschutz
bei der Bereitstellung von Arbeitsmitteln und deren
Benutzung bei der Arbeit, über die Sicherheit beim
Betrieb überwachungsbedürftiger Anlagen und über
die Organisation des Betrieblichen Arbeitschutzes
(Betriebssicherheitsverordnung – BetrSichV). BGBl. I
S. 3777 - 27. September 2002.
[2] Gesetz über die Durchführung von Maßnahmen des
Arbeitsschutzes zur Verbesserung der Sicherheit und
des Gesundheitsschutzes der Beschäftigten bei der
Arbeit (Arbeitsschutzgesetz - ArbSchG) vom
07.08.1996, zuletzt geändert am 19.12.1998, BGBl I
S. 2843
[3] BGR 237, Berufsgenossenschaftliche Regel 237,
„Hydraulik-Schlauchleitungen“,
Berufsgenossenschaft der Chemischen Industrie,
April 2005 (in Bearbeitung)
[4] Hydraulik-Schlauchleitungen – Sicherheit der Umgebung bei Versagen und Verwendungsdauer,
Sonderdruck aus o + p „Ölhydraulik und Pneumatik“
41 (1997), Nr. 11 – 12.
[5] DIN EN 853, Gummischläuche und –schlauchleitungen - Hydraulikschläuche mit Drahtgeflechteinlage - Spezifikation, 1996, Beuth Verlag GmbH,
Berlin
[6] Technische Regel für Betriebssicherheit TRBS 1203
„Befähigte Personen“ - Allgemeine Anforderungen vom 18.11.2004, (BAnz. S. 23 797).
[7] DIN 20066 „Fluidtechnik; Schlauchleitungen; Maße,
Anforderungen“, Oktober 2002, Beuth-Verlag GmbH,
Berlin
[8] ZH 1/74 „Sicherheitsregeln für Hydraulik-Schlauchleitungen“, Ausgabe April 1988, (ersetzt durch
BGR 237)
[9] Richtlinie 98/37/EG (Maschinenrichtlinie, MRL).
Amtsblatt
der
Europäischen
Gemeinschaften
Nr. L 207.
[10] Richtlinie 97/23/EG des Europäischen Parlaments
und des Rates vom 29. Mai 1997 zur Angleichung
der Rechtsvorschriften der Mitgliedstaaten über
Druckgeräte (Druckgeräte-Richtlinie, DG-RL).
Amtsblatt
der
Europäischen
Gemeinschaften
Nr. L 181 vom 09.07.1997, S. 0001 – 0055..
[11] Fachausschuss MFS, FA-Informationsblätter siehe
http://www.bgmetallsued.de/fachausschuss
[12] DIN EN 982, Sicherheit von Maschinen,
– Sicherheitstechnische Anforderungen an fluidtechnische Anlagen und deren Bauteile – Hydraulik;
1996, Beuth Verlag GmbH, Berlin
The present document is the English translation
of the German information leaflet 015, edition
05/2006.
Further information leaflets published by the
committee of experts FA MFS may be
downloaded from the Internet [11].
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015
edition 10/2006
Testing and replacement of hydraulic hose assemblies
Annex: Tables 1 - 8
page 7 / 10
Annex
Table 1: Recommended test scope „Visual inspection“ (prior to initial setting into operation or
putting back into operation)
- Is all information for use available which is required for the safe operation of the hydraulic plant (e.g.
hydraulic plan, parts list, description of the plant, drawings, operating / maintenance instructions,
hydrostore documents, safety data sheets for the hydraulic fluid being used etc.)?
- Do the hydraulic hose assemblies correspond to the hydraulic plan and to the parts list and the
description of the plant (including the hydraulic fluid being used)?
- Have safety measures been taken for the case of exceptionally high pressure impacts or pressure
increases, such as for example, pressure control valves?
- Are the individual hoses of the hydraulic hose assembly marked with the name or a short
designation of manufacturer, EN-number and type (pressure level), nominal diameter, quarter/year
of manufacture? (s. DIN EN 982, [12])
- Are hydraulic hose assemblies individually marked on the fittings with the name or a short
designation of the manufacturer, the max. admissible operating pressure, month and year of
manufacture?
- Are hydraulic hose assemblies installed in such a way, that according to DIN 20066 [7]:
ΠThe natural position does not obstruct the movement;
ΠA torsion of the hose, a tensile load due to a line which is too short, or a bending radius which
is too low are all avoided;
ΠThe hose is led by buckling protection (if applicable at the connection element);
ΠExternal mechanical influences or abrasion at the edges are avoided by sufficient distance;
ΠDamage by running over is avoided by means of hose bridges;
ΠLoosely installed hose assemblies are protected by hose guiding devices (such as hose
brackets and fixtures;
ΠA thermal protection (shielding) protects from high temperatures?
- With regard to their installation location, are the hydraulic hose assemblies designed and arranged
in such a way, that they:
ΠCannot be mixed-up and are unambiguously and durably marked;
ΠAre protected against any foreseeable damage, e.g. mechanical or due to environmental
influences such as cooling lubricants; and
ΠDo not impair maintenance of the work equipment?
- Are hydraulic hose assemblies which are used in areas of high-level requirements, (e.g. holding up a
load) protected against hose break?
- Are hydraulic hose assemblies which in case of failure may generate hazards due to whiplash or
escape of hydraulic fluid provided with suitable protective measures, such as fastening, capturing
device or shielding?
- Are the hydraulic hose assemblies installed in such a way that they cannot be used as a ladder or
means for access?
- Do the hydraulic hose assemblies of the initially operated or reoperated machines already show
damages (s. Table 4)? If damages have been detected, proceed according to chapter 3.4.
- Have the installed hydraulic hose assemblies or hoses exceeded the period of storage or use,
recommended by the individual manufacturer (s. chap. 3.6)?
- Are the hydraulic hose assemblies over-lacquered (over painted)?
- Does the operating manual state testing intervals? If so, what?
Note:
The hydraulic hose assemblies being installed shall not consist of hoses which have already been used as part
of a hose assembly before! (s. DIN EN 982, no. 5.3.4.3)
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015
edition 10/2006
Testing and replacement of hydraulic hose assemblies
Annex: Tables 1 - 8
page 8 / 10
Table 2: Recommended test scope „functional testing“ (prior to initial setting into operation or
putting back into operation)
-
Does the hydraulic control system fulfil the intended function and comply with the plant description?
-
Is there an indication by acoustic signals or similar indicating extremely high pressure impact or
pressure increase for the hydraulic hose assembly for all required machine functions during the
intended machine operation?
-
All parts of the hydraulic plant shall be tested with the intended maximum operating pressure which
can be reached in all intended applications:
ΠHave measurable leakages been detected at the hydraulic hose assembly and connection
elements?
ΠDid all hydraulic hose assemblies withstand the pressure?
ΠAre there spots of abrasion due to hydraulic hose assemblies moving under operation
conditions?
Table 3: Recommend test scope „for safe provision and use“
(recurrent or extraordinary test)
- Is the information for use (operating instructions, hydraulic plan, parts list etc.) from the
manufacturer still complete and available?
- Do the conditions of use and environmental conditions of the machine still comply with the initial
intended use of the machine?
(This requires consideration of for example: kind of product, cycle times, number of pieces
produced, hydraulic pressures and volume / flows temperatures, hydraulic fluid(s) used, speeds/
stopping times of hazardous movements, moved/ upheld masses, loading and unloading method of
workpieces, place of installation, external influences (e.g. vibration, humidity, pollution by oil, UVradiation, mechanical influences, ambient temperature etc.), position of transport ways and kind of
transport means being used (hazards of damage), location and access for operation and
maintenance, arrangement and assembly of additional equipment, interaction/ link with other
machinery).
- Have the above mentioned preconditions changed, which previously formed the basis for specifying
a defined duration of use of the hydraulic hose assembly? If so, have the testing periods and
replacement intervals been considered accordingly and if necessary, been changed?
- Are the markings at the hydraulic hose assemblies still existent and legible?
- Do the hydraulic hose assemblies show any deficiencies indicated in table 4? If deficiencies are
detected, proceed according to chapter 3.4.
- Are the safety measures against whiplash hazard and/or escape of hydraulic fluid at the relevant
hydraulic hose assemblies still existent respectively installed?
- Have the periods for recurrent tests at the hydraulic hose assemblies been specified and kept? If
required, the periods have to be specified by the user and the required tests have to be carried out
or arranged for.
- Have the intervals for replacement recommended by the manufacturer respectively the maximum
duration of use specified by the user for hydraulic hose assemblies been taken into account (s.
chapter 3.5)?
- Have shortened test intervals been established, e.g. to biannually or quarterly (instead of yearly or
biannually) in case of intended prolonged duration of use of hydraulic hose assemblies?
- In case of modifications at the machine and in the hydraulic plant (control and equipment) as well as
after extensive maintenance work, in particular if this involves the new installation of hydraulic hose
assemblies, a relevant test for „proper assembly and safe function“, s. chapter 2 table 1 and 2 has
to be carried out.
- Have those modifications been recorded and have they been considered in the machine
documentation?
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015
edition 10/2006
Testing and replacement of hydraulic hose assemblies
Annex: Tables 1 - 8
page 9 / 10
Table 4: Recommended test criteria for hydraulic hose assemblies
- Damage at the outer layer to the reinforcement? (abrasion spots, cuts, cracks);
- Embrittlement of outer layer (crack formation of the hose material);
- Deformations, which do not correspond to the original shape of the hydraulic hose assembly, in the
non-pressure state or in the pressurized state or in case of bending e.g. separation of layers,
formation of bubbles, squeeze points, buckling points;
- Leakages at the hose, hose assembly or fittings;
- Disentanglement of the hose out of the fittings;
- Damaging or deformation of fittings which reduces the function and strength of the fittings or the
connection of hose-fittings;
- Corrosion of fittings, reducing the function and strength;
- Do hydraulic hose assemblies have freedom of movement, or has there been formation of squeeze,
shearing or abrasion points due to the assembly of new plant parts or aggregates?
- Do hydraulic hose assemblies protrude into traffic routes, even if the aggregates being coupled with
the hydraulic hose assemblies are operated to the final position?
- Have hydraulic hose assemblies been over-lacquered (over painted (explanation: no detection of
marks and cracks)?
- Have storage periods and durations of use been exceeded (s. chapter. 3.5)?
- Have all coverings been re-installed and are they active (after testing, relocation, rearrangement)?
- Are there additional tear-off protections existent or required?
Table 5: Factors influencing the test periods
- Hazards which may occur when using the work equipment for all relevant operation procedures
(basis: hazard evaluation);
- Increased requirements for safety (such as holding of loads in particular gravity-loaded axes) e.g.
due to the protection concept of the machinery manufacturer and provisions for shortened periods
in the operation manual;
- Conditions of use of work equipment and hydraulic plant (e.g. particular loads, conditions with
defined overload, operating times, operation parameters, influence of the hydraulic fluid being
used);
- Environmental conditions (damaging external influences such as vibration, humidity, pollution,
mechanical influences, ozone generation by electric motors or welding transformers) and more, s.
table 3);
- Comparison, whether the actual operating conditions / conditions of use comply with those
conditions stated by the manufacturer at acquisition;
- General manufacturer’s information (of machinery manufacturer or the manufacturer of the
hydraulic hose assemblies) with regard to test intervals;
- Age respectively rate of wear of the work equipment or of the hydraulic hose assembly;
- Prolongation of replacement intervals;
- Kind and system by means of which the intended maintenance is carried out, in particular for safety
relevant components and wear parts;
- Experience made by the users / set-up/ maintenance personnel with the work equipment and the
hydraulic plant (with regard to failure behaviour, occurrence of defects, interruptions, increase of
such events);
- Evaluation of results from the visual and function inspection prior to the daily use of the machine;
- Any known accidents at comparable machines or hydraulic plants;
- Evaluation of test results of recurrent tests at those hydraulic hose assemblies or those being
operated under comparable conditions;
- Test results prior to commissioning.
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001
Fachausschuss- Information leaflet no. 015
edition 10/2006
Testing and replacement of hydraulic hose assemblies
Annex: Tables 1 - 8
page 10 / 10
Table 6: Recommended test periods
Requirements for hydraulic hose assembly
Recommended
period
Normal requirements
12 months
Increased requirements for safety, e.g. due to:
- increased operating times (e.g. multiple-shift operation)
- strong external influences
- intended prolonged duration of use
(replacement intervals, see. chapter 3.5) or
- provisions stated by the machine manufacturer for particular gravityloaded axes
6 months
test
Table 7: Influencing factors with regard to the replacement intervals
- Statements or instructions given by the manufacturer of the hydraulic hose assemblies or the
machinery manufacturer, particularly provisions given by the manufacturer for gravity-loaded axes;
- Conditions of use and environment;
- Hazards due to hydraulic fluid, the pipe itself or a hazardous machine or load movement in case of
damage or break of the hose assembly;
- Test and empirical values of the machinery manufacturer or the user;
- Secondary protective measures against hazards in case of failure of the hose assembly, e. g.
covering, line break protection;
- Proper execution of tests with regard to the safe operational state in adequately determined time
intervals, (if necessary shortened) by a competent person.
Table 8: Recommended replacement intervals
Requirements for the hydraulic hose assembly
Recommended
replacement intervals
Normal requirements
6 years
Increased requirements for safety, e.g. by:
- increased operating times (e. g. multiple-shift operation)
- strong external influences
- provisions stated by the machine manufacturer for particular gravityloaded axes
2 years
Information: As to the intention of the Fachausschuss-Information leaflets, see Fachausschuss Information leaflet No.: 001